Insulation considerations and qualifications for form-wound air-core armature windings in high-frequency electrical machines

High specific power electrical machines are a key enabling technology in hybrid electric aircraft. Specific power can be increased by increasing the machine's electrical loading and operating frequency, which often increases the machine's operating temperature and requires a strong insulation scheme. This thesis will explore the insulation scheme implemented in a high specific power permanent magnet synchronous machine currently being developed by the Haran Research Group. The insulation, initially developed by other members of the group, will first be summarized. The machine and drive system will then be examined in a system context to determine the possibility of voltage overshoot at the motor terminals caused by a variable frequency drive along a transmission line. Based on simulation results, recommendations for future work in the insulation system are made. The remainder of the thesis will focus on developing a test plan for the existing insulation scheme through the use of dc hipot testing and impulse winding testing. The work concludes by appointing successors to continue winding validation and begin an exploration of accelerated aging behavior in the author's absence. Appendices provide a step-by-step guide to the impulse winding test and printed circuit board designs with photographs of windings under test