Impact of air pressure variations on electrical vehicle motor insulation

Abstract Variation in air pressure severely affects the insulation of electric vehicle (EV) motors, hence weakening the reliability of EVs for safe operation. Nomex‐polyimide‐Nomex, a typical insulation material for EV motors, was used to investigate the motor insulation performance under different air pressures. The results show that the partial discharge inception voltage is significantly reduced for EV motors operated at lower air pressures, and the probability of partial discharge (PD) occurrence is increased. The macroscopic results reveal that the active area of the PD expands at low pressure, while the non‐corroded ring appears in the centre. Additionally, although the number and amplitude of the PD increase significantly with decrease in air pressure, the active area of the PD expands and electrical stress on the insulation per unit area increases slowly. Therefore, when the pressure decreased from 60 to 40 kPa, the endurance life does not show a significant downward trend. Furthermore, the dielectric constant and loss of the low‐pressure samples significantly change during the ageing process, which further indicates critical degradation of the insulation. The aforementioned investigations reveal that the air pressure at different altitudes has a significant impact on the performance of insulation materials.