高速扁线电机绝缘故障原因分析与优化
袁明珂1,2，王德成1,2，李嘉诚1,2，祁同晖1,2，贾小丽1,2，高文进1,2
1.内燃机与动力系统全国重点实验室，山东 潍坊 261061；2.潍柴动力股份有限公司，山东 潍坊 261061
摘要：为解决某款高速扁线电机应用过程中批量出现的由定子绕组烧蚀导致的绝缘失效故障，通过电镜扫描、光谱分析、绕组焊接端部焚烧试验等方法分析烧蚀故障原因，提出优化措施并进行市场应用验证。结果表明：绕组烧蚀的成因源于扁铜线漆膜与绝缘漆不兼容导致漆膜产生横向裂纹缺陷，变速箱内部高温环境下产生的气化油状物质通过密封失效的油封进入绕组区域，加剧漆膜损伤，最终导致绕组相间短路进而烧蚀。采取更换扁铜线漆膜绝缘漆和油封唇口材料，在变速箱底部增设泄压孔，在内外花键配合处增加密封胶圈等优化措施后，电机顺利通过了市场应用验证，有效解决了绕组绝缘失效故障。
关键词：绕组烧蚀；兼容试验；漆膜材质
Analysis of insulation fault causes for high-speed flat wire motors and its optimization
YUAN Mingke1,2, WANG Decheng1,2, LI Jiacheng1,2, QI Tonghui1,2, JIA Xiaoli1,2, GAO Wenjin1,2
1.State Key Laboratory of Engine and Powertrain System, Weifang 261061, China;
2.Weichai Power Co., Ltd., Weifang 261061, China
Abstract: To address the insulation failure caused by stator winding burnout that frequently occurs in the mass production of a certain type of high-speed flat wire motor, the root causes of the burnout are analyzed through methods such as electron microscopy scanning, spectral analysis, and winding terminal burning tests. Optimization measures are proposed and validated in the market. The results indicate that the burnout originated from the incompatibility between the flat copper wire paint film and the insulation varnish, leading to transverse crack defects in the paint film. Vaporized oily substances generated under high-temperature conditions inside the gearbox entered the winding area through failed oil seals, further exacerbating paint film damage and ultimately causing inter-phase short circuits and subsequent burnout. After implementing optimizations such as replacing the flat copper wire paint film, insulation varnish, and oil seal lip material, adding pressure relief holes at the gearbox bottom, and installing sealing gaskets at the internal and external spline interfaces, the motor successfully passed market validation, thereby effectively resolving the winding insulation failure issue.
Keywords: winding erosion; compatibility test; paint film material
