Multifactor Coupling Analysis in Ex e Motor Certification: Standardized Validation of Corona Discharge, Thermal Performance, and Purging Effectiveness

This study introduces an advanced testing framework for enhanced safety in explosion-proof motors (Ex e), targeting key challenges in high-voltage and intelligent applications. The system combines multi-physics coupling analysis with three innovative technologies: ultra-high-frequency sensing (300 MHz-3 GHz) for corona detection, digital twin thermal simulation(< 1s resolution) for temperature monitoring, and CFD-optimized purging systems ^[1], Experimental validation reveals outstanding performance metrics, including ±2 cm discharge localization accuracy, ±0.5 K thermal prediction precision, and a 30% improvement in gas exchange efficiency. The passage highlights three pivotal technological advancements: 1) A novel altitude-environment corona model that integrates Monte Carlo stochastic elements ($\boldsymbol{\sigma=0.15}$) to quantify an 8.7 μΩ.m decrease in resistivity per 10% increase in humidity; 2) An innovative hybrid thermal monitoring technique that merges embedded sensors with traditional resistance methods; 3) An intelligent purging system compliant with ATEX/IECEx Zone 1 standards, offering ±3% pressure control and a response time of under 2 seconds. Applied to 10kV motor certification, this framework achieves a 98.7% fault detection accuracy, effectively linking theoretical progress with practical industrial safety needs.