Electrical Performance Analysis of Enameled-Extruded Wires Based on Partial Discharges and Voltage Endurance

This study aims to explore an economically feasible enameled wire technology based on sol-gel, offering enhanced performance compared to traditional enameled wire. The evaluation involves assessing insulation configurations for copper wires designed for high-temperature applications, with a proposed configuration combining sol-gel solution on enamel and polyphenylene sulfide (PPS) extrusion resins. Electrical performance is compared across these insulation configurations, building upon their demonstrated higher thermal performance in prior research. Experimental data, including partial discharge (PD) parameters, dielectric strength, and electrical aging endurance, are collected from twisted pair samples for each insulation type. Promising results emerge from PD studies, favoring hybrid technology (enameled-extruded wires) over the classical approach polyesterimide (PEI) + polyamide (PAI) enameled wires. Measurements reveal a higher intensity of PDs for classical enameled wires under 3 kV–50 Hz. Moreover, lifespan models under voltage stress indicate that enameled-extruded wires with PPS extruded resin have advantages, withstanding 1525 min compared to 530 min for classical wires under 3 kV–50 Hz. A correlation between lifespan under voltage stress and PD intensity is observed. Furthermore, microfillers on PPS show lower results compared to nonfilled enameled -extruded wire configurations.