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Study of parameters affecting heat dissipation in an impregnated random wound stator

Heat dissipation from stator windings is one of the most important topics regarding the design of an electric motor, driving the definition of the rated power and thermal class of the machine. As the demand for higher efficiency motors has increased, the request for insulating materials that can improve thermal exchanges has become more frequent. Thus, a study of the impact of impregnating resins with different thermal conductivities and slot filling factors was carried out. A standard production stator was chosen as the specimen for this investigation. Using a Finite Element Model (FEM) simulation, temperatures inside a powered stator were evaluated, initially considering a stator without any insulating resin and a stator with a typical impregnating resin applied to it. Finally, a parametric study on the impact of the thermal conductivity and the slot filling factor of the applied resin was carried out. The FEM stator model was validated by data measured on real objects with a good correlation between the two. The parametric study highlighted the main variables that have an impact on the temperature distribution within the impregnated stator whilst considering different boundary conditions. From this study it was determined that a void-free impregnation of an electric motor stator has a measurable impact on the temperature distribution inside the motor and thus on its thermal management.