Ma Mingze, Gan Hongyi, Shang Xiao, Song Linsen, Zhang Yiwen, Liu Jingru, Liu Chunbai, Hao Yanzhong, Zhang Xinming
School of Mechanical and Electrical Engineering, Changchun University of Science and Technology, Changchun 130022, China.
FAW Tooling Die Manufacturing Co., Ltd., Changchun 130000, China.
Polymers (Basel). 2024 Dec 17;16(24):3514. doi: 10.3390/polym16243514.
The curing process of hair-pin motor stator insulation is critical, as residual stress increases the risk of partial discharge and shortens a motor's lifespan. However, studies on the stress-induced defects during insulation varnish curing remain limited. This research integrates three-dimensional numerical simulations and experimental analysis to develop a curing model based on unsaturated polyester imide resin, aiming to explore the mechanisms of residual stress formation and optimization strategies. A dual fiber Bragg grating (FBG) sensor system is employed for simultaneous temperature and strain monitoring, while curing kinetics tests confirm the self-catalytic nature of the process and yield the corresponding kinetic equations. The multi-physics simulation model demonstrates strong agreement with the experimental data. The results show that optimizing the curing process reduces the maximum stress from 45.1 MPa to 38.6 MPa, effectively alleviating the stress concentration. These findings highlight the significant influence of the post-curing temperature phase on residual stress. The proposed model offers a reliable tool for stress prediction and process optimization in various insulating materials, providing valuable insights for motor insulation system design.
发卡式电机定子绝缘的固化过程至关重要，因为残余应力会增加局部放电的风险并缩短电机的使用寿命。然而，关于绝缘漆固化过程中应力诱导缺陷的研究仍然有限。本研究结合三维数值模拟和实验分析，开发了一种基于不饱和聚酯亚胺树脂的固化模型，旨在探索残余应力形成的机制和优化策略。采用双光纤布拉格光栅（FBG）传感器系统同时监测温度和应变，而固化动力学测试证实了该过程的自催化性质并得出相应的动力学方程。多物理场模拟模型与实验数据显示出高度一致性。结果表明，优化固化过程可将最大应力从45.1MPa降至38.6MPa，有效缓解应力集中。这些发现突出了后固化温度阶段对残余应力的重大影响。所提出的模型为各种绝缘材料的应力预测和工艺优化提供了可靠的工具，为电机绝缘系统设计提供了有价值的见解。
