Fracture failure analysis of insulation with initial crack defect for stator end-winding in induction motor by using magnetic-structural coupling model

Abstract

The insulation mechanic failure in stator end-winding of induction motor is usually an early and serious cause to weaken the residual breakdown electrical field strength and produce the short-circuit fault, especially subjecting to the combination of dynamical electromagnetic forces, mechanical stress and vibration. In this paper, the fracturebehavior of insulation layer with considering the initial crack defects and end-hoop support failures in end-windings were analyzed by using magnetic-structural coupling model and finite element method (FEM). Firstly, the distributions of magnetic flux density and electromagnetic force around the stator end region were determined by injecting three-phase alternating current. Secondly, the dynamic characteristics of deformation, stress and strain in winding insulation were respectively calculated by coupling the transient electromagnetic and structural analysis. Furthermore, the weak points of the concentrated stress and strain were located. Thirdly, the crack model mounted in winding insulation is defined and simulated by employing three-dimensional (3-D) semi-elliptical crack element. To evaluate the fracture mechanism and the degree of crack expansion quantitatively, the stress intensity factor (SIF) was introduced. Finally, the influence of crack location, direction, depth and end-hoop support failure on SIF and crack propagation were investigated. Results show that the concentrated stress at knuckle part of the coil insulation is lager quite larger than that of other parts. The SIF of transverse crack is larger than that of longitudinal cracks. The larger the initial crack depth in the stator end-winding insulation, the more serious the tendency and degree of crack fracture. Local end-hoop support failure also has an important influence on the crack propagation. Results in this study may contribute to the understanding of fracturefailure behaviors in insulation under dynamical electromagnetic vibration and provide necessary theoretical reference for fault diagnosis and prediction of stator winding in induction motors.