Ageing Analysis of Hairpin Windings in Inverter-Fed Motor Under PWM Voltage

The partial discharge (PD) measurement under pulse width modulation (PWM) voltage is a critical measurement of quality assessment for inverter-fed motors, as outlined in IEC 60034-18-41 and IEC 60034-18-42. One of the key parameters in PD measurement is the repetitive partial discharge inception voltage (RPDIV). This paper examines factors that influence the ageing process of hairpin windings in motors, with ageing tests designed using the Design of Experiment (DoE) method. The study focuses on the effects of electrical and thermal stresses on the ageing process. To achieve this, the failure rate, the RPDIV data, and the lifetime data are selected as the output responses. The findings highlights that RPDIV measurements alone cannot accurately predict the degree of ageing of hairpin windings. Specifically, RPDIV results are influenced not only by the quality of the hairpin windings under PWM voltage but also by other contributing factors. Furthermore, the change in RPDIV during the ageing process showed that the RPDIV measurement cannot predict the ageing degree of the hairpin winding. Experimental data on failure rates and lifetimes reveal that both electrical and thermal stresses significantly influence the ageing process, with a notable interaction between these factors. Among the three output responses, the failure rate provides a more accurate reflection of this interaction. To reliably estimate the lifetime of hairpin windings, more precise parameters are necessary. Further research is required to deepen the understanding of the underlying PD mechanisms under PWM voltage, which could enhance diagnostic and predictive capabilities for hairpin winding performance.