Insulation reliability issues in high frequency/transient environments of next generation high power electronics

As the auto industry develops zero-emission vehicles, a potential EV (electric vehicles) safety and reliability engineering issue exists. High-voltage, high-frequency transients and related waveforms that are part of powering EV traction motors may damage the insulating materials in wiring harnesses, interfaces, and connectors. Specifically, under voltages above the Paschen minimum, these fast transients result in creating an intense-corona environment, causing premature electrochemical aging of the insulation, followed by premature insulation failure. Understanding the aging rates within such system will permit adequate engineering safety margins to be incorporated therein to achieve full life-cycle reliable operation. In this paper, studies regarding aging rates insulation system under intense corona activity are presented along with recommended engineering practices to obviate the observed very high aging rates of such systems.