Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826177
D.W. Steinmeier, M. Becker
FlashSoldering was first developed in 1998 as a new innovative, non-contact, localized reflow soldering process for terminating fine insulated copper magnet wires to electronic contacts without first removing the wire insulation. Subsequent research in 1999 has extended FlashSoldering applications from miniature magnetic component packages to soldering insulated single and multiple magnet wires and Litz wire to high-speed data connectors and other forms of electronic contacts. Quality issues concerned with copper-tin intermetallic growth and what happens to the magnet wire insulation during FlashSoldering were successfully resolved. Applications for FlashSoldering have broadened to include: single and multiple toroidal transformer packaging; LAN filters; low power DC-DC converters; single or multiple form coils and inductors; woven or braided high speed data cables; and connecting a single wire to a Litz wire bundle.
{"title":"FlashSoldering update-extending fine magnet wire joining applications","authors":"D.W. Steinmeier, M. Becker","doi":"10.1109/EEIC.1999.826177","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826177","url":null,"abstract":"FlashSoldering was first developed in 1998 as a new innovative, non-contact, localized reflow soldering process for terminating fine insulated copper magnet wires to electronic contacts without first removing the wire insulation. Subsequent research in 1999 has extended FlashSoldering applications from miniature magnetic component packages to soldering insulated single and multiple magnet wires and Litz wire to high-speed data connectors and other forms of electronic contacts. Quality issues concerned with copper-tin intermetallic growth and what happens to the magnet wire insulation during FlashSoldering were successfully resolved. Applications for FlashSoldering have broadened to include: single and multiple toroidal transformer packaging; LAN filters; low power DC-DC converters; single or multiple form coils and inductors; woven or braided high speed data cables; and connecting a single wire to a Litz wire bundle.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"22 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133877943","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826209
B. Burk, C. Peterson, N. Rotstein, B. Brentin
A new category of semi-crystalline engineering thermoplastics has been developed for electrical insulation systems. QUESTRA, crystalline polymers, are syndiotactic polystyrene (SPS) produced using metallocene catalyst technology. In addition to good heat and chemical resistance characteristic of semi-crystalline thermo-plastics, they also exhibit good electrical properties, dimensional stability and insensitivity to moisture. Injection molding processing is made easier with the low melt viscosity of SPS, which typically needs no pre-drying. Thin wall parts can be filled with modest injection pressure and runner diameters can be reduced. Electrical insulation systems testing according to IEEE 117 and IEC 61857 has been completed and this new thermoplastic is now recognized under UL 1446. This set of properties makes glass-reinforced SPS resin well suited for coil, transformer and motor applications.
{"title":"QUESTRA crystalline polymer: a new material option for electrical insulation systems","authors":"B. Burk, C. Peterson, N. Rotstein, B. Brentin","doi":"10.1109/EEIC.1999.826209","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826209","url":null,"abstract":"A new category of semi-crystalline engineering thermoplastics has been developed for electrical insulation systems. QUESTRA, crystalline polymers, are syndiotactic polystyrene (SPS) produced using metallocene catalyst technology. In addition to good heat and chemical resistance characteristic of semi-crystalline thermo-plastics, they also exhibit good electrical properties, dimensional stability and insensitivity to moisture. Injection molding processing is made easier with the low melt viscosity of SPS, which typically needs no pre-drying. Thin wall parts can be filled with modest injection pressure and runner diameters can be reduced. Electrical insulation systems testing according to IEEE 117 and IEC 61857 has been completed and this new thermoplastic is now recognized under UL 1446. This set of properties makes glass-reinforced SPS resin well suited for coil, transformer and motor applications.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"654 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133963061","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826219
C. Harrell
Simulation is a rapidly growing technology that is taking the risk out of design and management decisions for production systems of all types. This paper outlines the use of simulation and how it can benefit electrical and coil winding manufacturing. First, principles of process and facility design are presented. Then, simulation is described with an explanation of how it applies to the design and management of production systems.
{"title":"Simulation of coil winding manufacturing systems","authors":"C. Harrell","doi":"10.1109/EEIC.1999.826219","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826219","url":null,"abstract":"Simulation is a rapidly growing technology that is taking the risk out of design and management decisions for production systems of all types. This paper outlines the use of simulation and how it can benefit electrical and coil winding manufacturing. First, principles of process and facility design are presented. Then, simulation is described with an explanation of how it applies to the design and management of production systems.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"38 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114518052","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826236
F. Emery, J. Roach
Electrostatic field analysis was performed on generic electrodes for assessment of generator end turn electrical insulation design. A number of coil end turn configurations were analyzed near highly stressed electrode corners and along support block creep surfaces for various insulation thickness, and a range of air gap spacings. A finite element electrostatics code was employed to generate two dimensional equipotential plots for insulated electrodes with and without dielectric support blocks. Empirical theories based upon local stress enhancement were used to estimate corona onset, creep discharge, and spark breakdown as a function of insulation thickness and air gap spacing. The corona onset calculations were verified using actual test setups and monitoring the corona with the Corona Scope/sup TM/. Sparkover tests were also done to verify the calculations.
{"title":"Electrostatic field analysis and verification of air cooled generator end turn insulation models","authors":"F. Emery, J. Roach","doi":"10.1109/EEIC.1999.826236","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826236","url":null,"abstract":"Electrostatic field analysis was performed on generic electrodes for assessment of generator end turn electrical insulation design. A number of coil end turn configurations were analyzed near highly stressed electrode corners and along support block creep surfaces for various insulation thickness, and a range of air gap spacings. A finite element electrostatics code was employed to generate two dimensional equipotential plots for insulated electrodes with and without dielectric support blocks. Empirical theories based upon local stress enhancement were used to estimate corona onset, creep discharge, and spark breakdown as a function of insulation thickness and air gap spacing. The corona onset calculations were verified using actual test setups and monitoring the corona with the Corona Scope/sup TM/. Sparkover tests were also done to verify the calculations.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"307 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116195573","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826208
Z. Berler, I. Blokhintsev, A. Golubev, G. Paoletti, A. Romashkov
This paper presents the authors' practical experience in the on-line measurement of partial discharges in medium voltage motor and generator stator windings using the RTD as a partial discharge detector. Results of off-line calibration on several machines are also presented.
{"title":"RTD as the valuable tool in partial discharge measurements on rotating machines","authors":"Z. Berler, I. Blokhintsev, A. Golubev, G. Paoletti, A. Romashkov","doi":"10.1109/EEIC.1999.826208","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826208","url":null,"abstract":"This paper presents the authors' practical experience in the on-line measurement of partial discharges in medium voltage motor and generator stator windings using the RTD as a partial discharge detector. Results of off-line calibration on several machines are also presented.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"70 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116275908","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826288
W. McDermid, A. Glodjo, J. Bromley
In spite of periodic off-line electrical tests and on-line gas-in-oil analysis, three HVDC converter transformers have failed within a 12-month period. The possible causes of failure are reviewed together with changes in maintenance, monitoring and system operation that might prolong the life of similar transformers.
{"title":"Analysis of winding failures in HVDC converter transformers","authors":"W. McDermid, A. Glodjo, J. Bromley","doi":"10.1109/EEIC.1999.826288","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826288","url":null,"abstract":"In spite of periodic off-line electrical tests and on-line gas-in-oil analysis, three HVDC converter transformers have failed within a 12-month period. The possible causes of failure are reviewed together with changes in maintenance, monitoring and system operation that might prolong the life of similar transformers.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"101 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121303524","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826202
H. Zhu, V. Green, D. Huynh
Partial discharge testing can effectively diagnose insulation problems in the stator winding of high-voltage generators and motors, since partial discharges are a symptom of most insulation failure mechanisms. Partial discharge testing can be performed either when the machine is not operating (offline) or during normal machine operation (on-line). Off-line PD testing is a well-known method to assess the stator winding insulation. Over ten years, on-line PD testing has proven to be a successful technique of monitoring stator insulation condition to forewarn plant personnel of possible machine failures and to help them implement a predictive maintenance program. This paper presents an on-line and off-line PD test on a hydro-generator using the same test instrument and sensors. A comparison of the two tests indicates that the off-line test results are consistent with the on-line test results. Similarities and differences of the on-line and off-line PD tests are discussed.
{"title":"Application of on-line versus off-line PD testing for stator insulation monitoring","authors":"H. Zhu, V. Green, D. Huynh","doi":"10.1109/EEIC.1999.826202","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826202","url":null,"abstract":"Partial discharge testing can effectively diagnose insulation problems in the stator winding of high-voltage generators and motors, since partial discharges are a symptom of most insulation failure mechanisms. Partial discharge testing can be performed either when the machine is not operating (offline) or during normal machine operation (on-line). Off-line PD testing is a well-known method to assess the stator winding insulation. Over ten years, on-line PD testing has proven to be a successful technique of monitoring stator insulation condition to forewarn plant personnel of possible machine failures and to help them implement a predictive maintenance program. This paper presents an on-line and off-line PD test on a hydro-generator using the same test instrument and sensors. A comparison of the two tests indicates that the off-line test results are consistent with the on-line test results. Similarities and differences of the on-line and off-line PD tests are discussed.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124170856","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826222
H. Philips
This paper outlines the need for, and the basic principles of, vacuum casting. The primary objecting is the discuss the most productive equipment, materials and techniques. The use of these principles will result in consistently high-quality results, with shorter cycle times, lower scrap levels and substantial savings.
{"title":"The science of vacuum-casting high-voltage ignition coils","authors":"H. Philips","doi":"10.1109/EEIC.1999.826222","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826222","url":null,"abstract":"This paper outlines the need for, and the basic principles of, vacuum casting. The primary objecting is the discuss the most productive equipment, materials and techniques. The use of these principles will result in consistently high-quality results, with shorter cycle times, lower scrap levels and substantial savings.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129319074","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826257
R. Obika, Y. Tatematsu, M. Mesaki, A. Higashiura
For manufacturers of motors and transformers supplied to the home appliance industry or the automotive industry, developing higher performance products and reducing the cost have become more vital than before. These manufacturers have improved their winding process to be more automatic with higher winding speed. They also try to fill a slot of a coil with more volume of magnet wire to produce higher efficiency product. There is a strong possibility that the insulation coating of the wire is damaged in the winding process. Conventionally, to prevent insulation from damage, we have developed some unique Bell-lubricating enamel or new surface lubricant for magnet wire. In the circumstance, we have developed new enamel, which improved adhesion between bare wire conductor and enamel insulation film of magnet wire. This challenge successfully provided new magnet wire that significantly improves windability.
{"title":"Development of magnet wire having excellent windability","authors":"R. Obika, Y. Tatematsu, M. Mesaki, A. Higashiura","doi":"10.1109/EEIC.1999.826257","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826257","url":null,"abstract":"For manufacturers of motors and transformers supplied to the home appliance industry or the automotive industry, developing higher performance products and reducing the cost have become more vital than before. These manufacturers have improved their winding process to be more automatic with higher winding speed. They also try to fill a slot of a coil with more volume of magnet wire to produce higher efficiency product. There is a strong possibility that the insulation coating of the wire is damaged in the winding process. Conventionally, to prevent insulation from damage, we have developed some unique Bell-lubricating enamel or new surface lubricant for magnet wire. In the circumstance, we have developed new enamel, which improved adhesion between bare wire conductor and enamel insulation film of magnet wire. This challenge successfully provided new magnet wire that significantly improves windability.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"4 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132021370","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 1999-10-26DOI: 10.1109/EEIC.1999.826242
T. Kainmuller, R. Moser, R. Kultzow
Single-component epoxy resin-based systems can be used in a variety of applications including those for high voltage solventless electrical insulating varnishes as well as for casting systems for coils, insulators and bushings. Other important applications include those of reinforced composites and laminates for a wide variety of electrical and structural applications. Their inherently high electrical resistance and low electrical dissipation, coupled with high mechanical strength under wet and high humidity conditions, provide the necessary properties for use in motor windings, wire and cable coatings, filament wound and pultruded structures and laminates. Compared to other impregnating systems (e.g. unsaturated polyesters) their very low volatile contents are remarkable. This paper reports on systems that are cured with classical Lewis acid/amine complexes as well as on new systems that are cured by a radical/cationic mechanism.
{"title":"Single component epoxy systems used for enhanced electrical performance and applications","authors":"T. Kainmuller, R. Moser, R. Kultzow","doi":"10.1109/EEIC.1999.826242","DOIUrl":"https://doi.org/10.1109/EEIC.1999.826242","url":null,"abstract":"Single-component epoxy resin-based systems can be used in a variety of applications including those for high voltage solventless electrical insulating varnishes as well as for casting systems for coils, insulators and bushings. Other important applications include those of reinforced composites and laminates for a wide variety of electrical and structural applications. Their inherently high electrical resistance and low electrical dissipation, coupled with high mechanical strength under wet and high humidity conditions, provide the necessary properties for use in motor windings, wire and cable coatings, filament wound and pultruded structures and laminates. Compared to other impregnating systems (e.g. unsaturated polyesters) their very low volatile contents are remarkable. This paper reports on systems that are cured with classical Lewis acid/amine complexes as well as on new systems that are cured by a radical/cationic mechanism.","PeriodicalId":415071,"journal":{"name":"Proceedings: Electrical Insulation Conference and Electrical Manufacturing and Coil Winding Conference (Cat. No.99CH37035)","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1999-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127140123","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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