Use of conductive composite sensors for improved condition monitoring of Electric Vehicle motor insulation systems

Electric vehicle (EV) motors are subject to extreme and variable loads, resulting in degradation of winding insulation due to high temperatures. This paper describes research on a new conductive composite sensor, which utilizes insulation resin as the sensor element matrix. The sensor, embedded in the windings of EV motors, will provide remaining design life of the insulation based on actual vehicle operational and environmental conditions. Improved condition monitoring of the insulation systems of high performance EV motors will reduce in-use failures by identifying prematurely degraded insulation systems, and providing data for quality improvement programs.