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Wide bandgap (WBG) and ultra-wide bandgap (UWBG)-based inverters are increasingly being adopted in More Electric Aircraft (MEA) and All Electric Aircraft (AEA) due to their ability to operate at higher switching frequencies with improved efficiency and power density. However, these advantages come with drawbacks, including increased electrical stress and exacerbation of AC losses, such as the skin effect and proximity effect. Litz wire, known for its effectiveness in mitigating these losses, is becoming a preferred conductor in highvoltage, high-frequency aerospace applications. This study investigates the breakdown voltage behavior of Litz wire insulation under square wave voltage stress across different frequencies. Twisted-pair Litz wire specimens were tested using a state-of-the-art high-voltage pulse generator with fixed rise times to emulate inverter-fed conditions. The resulting breakdown voltages were statistically analyzed using the Weibull distribution to evaluate insulation strength and failure predictability. The findings offer new insights into the insulation characteristics of Litz wire under realistic high-frequency converter stress and support the development of converter-resistant insulation systems for next-generation aerospace electrical power systems (EPS).
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This content will become publicly available on August 24, 2026
DC Dielectric Strength Evaluation of Motor Winding Insulation for Aerospace Applications
Insulation in electric machines is vital in determining system reliability and lifespan, especially under extreme environmental conditions. With the rapid shift toward More Electric Aircraft (MEA), All Electric Aircraft (AEA), and advanced space missions, electric motor components must perform reliably under low pressures, wide temperature ranges, and exposure to radiation. Magnet wires are central to motor operation, and their insulation must withstand high voltage stress in these demanding conditions. While prior research has predominantly focused on insulation performance under AC or pulse width modulated (PWM) waveforms and partial discharge (PD) behavior, there is a limited understanding of dielectric strength under direct current (DC) stress, particularly at reduced atmospheric pressures. This paper presents an experimental investigation into the DC dielectric strength of three magnet wire types (15 AWG, 18 AWG, and 20 AWG) tested at three pressure levels: 101kPa,80kPa, and 40 kPa. Using a voltage to breakdown with a constant ramp method, the study evaluates the insulation's withstand capacity across wire sizes and environmental pressures.
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- Award ID(s):
- 2306093
- PAR ID:
- 10652888
- Publisher / Repository:
- IEEE
- Date Published:
- Page Range / eLocation ID:
- 1 to 6
- Format(s):
- Medium: X
- Location:
- Dallas, TX, USA
- Sponsoring Org:
- National Science Foundation
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