SBIR Phase I: Novel Form Winding Insulation System for Motor and Generator Size Reduction and Associated Method of Manufacture

该项目更广泛的影响/商业潜力将使人们能够制造出更小、更高效、更便宜的新型电机。由于电机使用了世界上43%-46%的S电力，由于这一应用使用的剪切量，这可能会对整体电力能源效率产生最大的影响。这些独特的绕组将被出售给电机制造商，或在内部用于制造电机和发电机。通过直接销售给现有的汽车制造商，它将加快对市场的渗透。绕组的市场价值为20亿美元，这种方法有可能占据相当大的市场份额。这项技术可能会影响风力发电、石油天然气钻探、工业制造、航空航天、采矿、运输，以及任何使用20马力以上电机的市场。这个小型企业创新研究(SBIR)第一阶段项目将开发一种工艺，可以用来使电机和发电机更小、更高效、更便宜。该项目将专门解决电机绕组的电气绝缘能力，使其具有高电压能力和高导热能力。这种组合将允许更好的电机冷却，进而提高槽电流密度。这些较高的电流密度将允许电机更小，这将导致更高的效率和更低的电机成本。在本项目中完成的研究将准确地展示如何通过弯曲的复杂机械模拟以及对这种独特绕组的电气绝缘能力的概念的实验证明来完成必要的弯曲。此外，完成这种绕组设计的机器设计将显示一条通向低成本的途径，这将是在行业中广泛采用所必需的。这种组合应该以较低的生产成本表现出在高导热系数下的高电压耐受性。

The broader impact/commercial potential of this project will enable a new class of smaller, more efficient, and cheaper motors to be built. Since the motors use 43% - 46% of the world?s electricity, this has the potential to have one of the greatest impacts on overall electrical energy efficiency due to the shear amount of power this application uses. These unique windings will be sold to motor manufactures or be used in house to build motors and generators. By selling directly to existing motor manufacturers it will accelerate the penetration into the market. The market for windings is $2B and this approach has the potential for significant market share. This technology could impact wind generation, oil&gas drilling, industrial manufacturing, aerospace, mining, transportation, and any market using motors more than 20hp in size.This Small Business Innovation Research (SBIR) Phase I project will develop a process that can be used to make electric motors and generators smaller, more efficient, and cheaper. This project will specifically address the ability of electric insulation of the motor windings to have high voltage capability and high thermal conductivity. This combination will allow better motor cooling and in turn higher slot current densities. These higher current densities will allow motors to be smaller which will result in more efficient and lower cost motors. The research completed in this program will show exactly how the necessary bending can be accomplished with a complex mechanical simulation of the bend as well as experimental proof of concept of the electrical insulating capability of this unique winding. Additionally, a machine design for accomplishing this winding design will be designed to show a path to the low cost that will be necessary for widespread adoption in the industry. This combination should demonstrate a high voltage withstand at a high thermal conductivity all at a low production cost.