高速动车组大功率牵引电机温度场分布研究
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摘要
高速铁路是当代高新技术的集成,以其快速、高效、环保等优点在世界各国得到了迅猛的发展。高速动车组普遍采用变频调速交流传动系统,变频调速牵引电机是高速动车组的关键设备之一,其性能对动车组的安全、可靠性具有重要影响。随着动车组牵引功率不断提升,单台牵引电机容量需要大幅度提高。目前由于变流器开关器件的耐压水平无法提高,所以增大输入电流以提高单台电机的输出功率是实现牵引电机大容量化的有效方式之一。但是,大工作电流将使电机的损耗增加,同时由于动车组转向架的轴重和空间体积有限,电机运行和散热状况恶劣,造成牵引电机各部件工作温度升高(有时甚至达到200℃以上),电机内热点温度频繁超限,可能导致电机绝缘失效。因此,准确解析牵引电机电热场分布,发现电机温升热点,对电机冷却系统进行优化改进从而提高电机的服役性能成为大功率牵引电机设计制造的重要问题。
根据电磁场理论构建了高速动车组大功率牵引电机场路耦合分析模型,研究了不同拓扑结构(两电平、三电平)牵引逆变器在正弦脉宽调制、方波控制以及电流跟踪控制方式下的输出特性,解析了牵引电机运行特性及启动过程中的电磁暂态过程,探明了电机瞬态电磁场分布规律。
根据传热学理论构建了高速动车组大功率牵引电机全域三维温度场分析模型,研究了电机的主要传热方式及电机内绝缘层和表面层对传热的影响,确定了电机各部分损耗及等效散热系数的计算方法,解析了电机在额定负载下的稳态三维温度场、热流密度及热应力分布,找到了电机温升热点,并对影响温度场分布的因素进行了敏感度分析。
研究了牵引电机温度场分布对定子绕组电磁线绝缘材料寿命的影响,以纳米复合聚酰亚胺(PI)薄膜为对象,测试分析了绝缘材料在连续方波脉冲下的失效时间,研究了连续高压方波脉冲下绝缘材料电热联合老化机理,得到了方波脉冲的幅值、频率和老化温度对绝缘寿命的影响规律,提出了聚酰亚胺薄膜电应力—热应力联合作用下的寿命模型。
High-speed railway, as the integration of multiple cutting edged techniques in contemporary era, has been developing at an alarming rate from all over the world for its characteristics of speediness, high efficiency and environment protection. High-speed Electric Motor train Unit (EMU) plays a core role in the rail transportation system which has great influence on the safety of passengers as well as the electrical equipment. With the rapid development of China's high-speed railway, the output power of traction motor increases significantly. Due to the limited space of the bogie as well as the maximum output voltage of converter switching device, the input voltage of traction motor cannot be further boosted. Moreover, the operating experience indicates that when the electrical insulation system is strengthened by one level, the output power of motor will correspondingly increase by10%to15%. So it's advisable to boost the output power of every single traction motor by increasing the winding current. However, the large current will inevitably cause huge loss in the motor which results in high temperature rise of each mechanical part (sometimes even reach up to200℃and above). In addition, in order to make full use of magnetic materials, the motor often designed at the point with heavy electromagnetic load. So the loss of the motor increases dramatically which leads to extra heat generated in the motor. Therefore, it has become a hot issue to limit the temperature rise by improving motor cooling system.
The field-circuit coupled model of inverter-fed traction motor was established based on electromagnetic field theory. The output characteristics of the traction inverter using the two level, three-level and current tracking control were analysed. The two-dimensional transient electromagnetic field of the motor was calculation.lt was demonstrated that output voltage did not contain low harmonic spectrum using two-level control, while under three-level control model, the high harmonics was significantly reduced. Current tracking control provided motor current a good dynamic response. Electromagnetic field was mainly concentrated in a thin layer near the surface of the rotor when the motor started. The flux density was relatively high in the stator and rotor tooth. When the motor operated stably, the magnetic field lines were evenly distributed within the stator and rotor core. Due to big starting current, the rotor winding current density along the radial direction became larger.
The global temperature field model of inverter-fed traction motor was set up based on the heat transfer theory. Static three-dimensional temperature field and thermal stress distribution of the motor were calculated at rated load. The influence factors of temperature field were analysed. It was demonstrated that the highest temperature was located at the rotor bars when the motor temperature was stable. There was less different of temperature between rotor core and bars. The overall temperature of the stator region was below that of the rotor region. Stator slot temperature was higher than that of stator core. The temperature of stator surface was the lowest. The maximum heat flux was located in the stator core yoke while the flux density of stator teeth was relatively low. The maximum thermal stress was located in the contact surface between the end of the winding and the stator slot. Thermal coefficient has a negative correlation relationship with the maximum temperature of the stator.The convection coefficient of the stator core surface was the most important factor which impacted the maximum temperature of the stator. Convection coefficient of the ventilation vents played the key role in the maximum heat flux of the stator.
The influence of traction motor temperature distribution on the motor insulation was studied. Insulation material of inverter-fed taction motor winding-polyimide film was set as specimen frequency traction motor. The failure time of the insulating material was tested under the continuous square pulse. The influence of combined thermal and electrical stresses on the failure time was studied. It demonstrated exponential relationship between the aging temperature and insulation life. Also there was inverse power relationship between frequency and life. At last, multifactor life models under combined thermal and electrical stresses were proposed using the multi-stress approach. All the determination coefficients were above0.98which verified its accuracy.
根据电磁场理论构建了高速动车组大功率牵引电机场路耦合分析模型,研究了不同拓扑结构(两电平、三电平)牵引逆变器在正弦脉宽调制、方波控制以及电流跟踪控制方式下的输出特性,解析了牵引电机运行特性及启动过程中的电磁暂态过程,探明了电机瞬态电磁场分布规律。
根据传热学理论构建了高速动车组大功率牵引电机全域三维温度场分析模型,研究了电机的主要传热方式及电机内绝缘层和表面层对传热的影响,确定了电机各部分损耗及等效散热系数的计算方法,解析了电机在额定负载下的稳态三维温度场、热流密度及热应力分布,找到了电机温升热点,并对影响温度场分布的因素进行了敏感度分析。
研究了牵引电机温度场分布对定子绕组电磁线绝缘材料寿命的影响,以纳米复合聚酰亚胺(PI)薄膜为对象,测试分析了绝缘材料在连续方波脉冲下的失效时间,研究了连续高压方波脉冲下绝缘材料电热联合老化机理,得到了方波脉冲的幅值、频率和老化温度对绝缘寿命的影响规律,提出了聚酰亚胺薄膜电应力—热应力联合作用下的寿命模型。
High-speed railway, as the integration of multiple cutting edged techniques in contemporary era, has been developing at an alarming rate from all over the world for its characteristics of speediness, high efficiency and environment protection. High-speed Electric Motor train Unit (EMU) plays a core role in the rail transportation system which has great influence on the safety of passengers as well as the electrical equipment. With the rapid development of China's high-speed railway, the output power of traction motor increases significantly. Due to the limited space of the bogie as well as the maximum output voltage of converter switching device, the input voltage of traction motor cannot be further boosted. Moreover, the operating experience indicates that when the electrical insulation system is strengthened by one level, the output power of motor will correspondingly increase by10%to15%. So it's advisable to boost the output power of every single traction motor by increasing the winding current. However, the large current will inevitably cause huge loss in the motor which results in high temperature rise of each mechanical part (sometimes even reach up to200℃and above). In addition, in order to make full use of magnetic materials, the motor often designed at the point with heavy electromagnetic load. So the loss of the motor increases dramatically which leads to extra heat generated in the motor. Therefore, it has become a hot issue to limit the temperature rise by improving motor cooling system.
The field-circuit coupled model of inverter-fed traction motor was established based on electromagnetic field theory. The output characteristics of the traction inverter using the two level, three-level and current tracking control were analysed. The two-dimensional transient electromagnetic field of the motor was calculation.lt was demonstrated that output voltage did not contain low harmonic spectrum using two-level control, while under three-level control model, the high harmonics was significantly reduced. Current tracking control provided motor current a good dynamic response. Electromagnetic field was mainly concentrated in a thin layer near the surface of the rotor when the motor started. The flux density was relatively high in the stator and rotor tooth. When the motor operated stably, the magnetic field lines were evenly distributed within the stator and rotor core. Due to big starting current, the rotor winding current density along the radial direction became larger.
The global temperature field model of inverter-fed traction motor was set up based on the heat transfer theory. Static three-dimensional temperature field and thermal stress distribution of the motor were calculated at rated load. The influence factors of temperature field were analysed. It was demonstrated that the highest temperature was located at the rotor bars when the motor temperature was stable. There was less different of temperature between rotor core and bars. The overall temperature of the stator region was below that of the rotor region. Stator slot temperature was higher than that of stator core. The temperature of stator surface was the lowest. The maximum heat flux was located in the stator core yoke while the flux density of stator teeth was relatively low. The maximum thermal stress was located in the contact surface between the end of the winding and the stator slot. Thermal coefficient has a negative correlation relationship with the maximum temperature of the stator.The convection coefficient of the stator core surface was the most important factor which impacted the maximum temperature of the stator. Convection coefficient of the ventilation vents played the key role in the maximum heat flux of the stator.
The influence of traction motor temperature distribution on the motor insulation was studied. Insulation material of inverter-fed taction motor winding-polyimide film was set as specimen frequency traction motor. The failure time of the insulating material was tested under the continuous square pulse. The influence of combined thermal and electrical stresses on the failure time was studied. It demonstrated exponential relationship between the aging temperature and insulation life. Also there was inverse power relationship between frequency and life. At last, multifactor life models under combined thermal and electrical stresses were proposed using the multi-stress approach. All the determination coefficients were above0.98which verified its accuracy.
引文
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