Appropriate Polymer Selection for Insulation of High Voltage Ignition Coils by Combination of Material Index Determination and Novel Heuristical Approach
Tóm tắt
Ignition coils are a device which basically acts as steps-up transformers to provide proper sparks. Ignition coils have been subjected to harsh conditions and can fail due to unnecessary discharges. The insulation material needs to fulfill the specific properties required for insulation. It should provide resistance against unnecessary discharges by having higher breakdown voltage. In addition, insulation material must be able to transfer heat to environment and protect coil from dust particles, greases and lubricating oils. To minimize the probable failures, proper insulation material shall be selected which can withstand high voltages such that to get high quality coils. Initially, three material indices were derived, i.e., Emax × εr, Emax × k and Emax/T to screen adequate materials for this application which were not known in any previous literature study. The main objective is to maximize the breakdown voltage. Hence, Emax × εr, Emax × k and Emax/T were plotted on Cambridge Education System software to screen the appropriate materials for this application. 14 out of 677 materials were shortlisted using aforementioned procedure. Afterward, further selection was made using a new heuristical formula which has been named as critical, objective and subjective factor (COSF) approach. Finally, the selected material, i.e., polyester with chopped glass fiber was used to manufacture the coils which were tested using IS-14380. Experimental results validated theoretical material selection. Bubbles and cracks are the prominent defects that significantly affect the insulation quality. Cracks are generally formed in epoxy-based insulators. In this research, a systematic procedure has been adopted to select high voltage insulating materials for the ignition coil polymeric insulation using CES software and novel heuristic approach which are having better properties in comparison with existing materials.
Tài liệu tham khảo
Kline P C, SAE Trans, 79 (1970) 271
Judge, A.W. Modern electrical equipment for automobile, 2nd Edition. Hall and Chapman, (USA), (1970)
Berk CL, System and Method for Minimizing Cure Induced Residual Stresses in an Epoxy Impregnated Coil, US Patent 0197297A1 (2003)
Ruan G, Kienzle D, Roth D, Becker M, MTZ Worldwide, 74 (2014) 18
GmbH, R.B. Bosch automotive electrics and automotive electronics systems and components, networking and hybrid drive, Ist Edition, Springer Fachmedien Wiesbaden (2014).
Reif K, in Gasoline Engine Management. Springer (2015).
Automotive vehicles - Ignition coils for magneto ignition systems [TED 11: Automotive electrical equipment] IS 14380 (1996)
Sanchez R O, in Proceedings of CARTS (1991) p 42
Nawaz A, MS Thesis, Study of the Problem of Void Formation in Electrical Lamination Parts and its Removal. University of Engineering & Technology, Peshawar (2013)
Ashby, M.F. Material selection in mechanical design, 4th Ed, Butterworth-Heinemann, Burlington, USA. (2011).
Rajan, K.M., Narasimhan, K. An approach to selection of material and manufacturing processes for rocket motor cases using weighted performance index, Journal of Materials Engineering and Performance, 11, 444-449, (2002).
Kuffel, E., Zaengl, W.S., Kuffel, J. High voltage engineering, 2nd Ed. Butterworth-Heinemann, UK, (2000).
Naidu, M.S., Kamaraju, V. High voltage engineering, 2nd Ed. McGraw-Hill, USA, (1996).
Silaghi, M.A. Dielectric Material, In Tech Publisher, Croatia, (2012).
Lienhard IV, J.H., Lienhard V, J.H., A heat transfer textbook, 3rd Ed. Cambridge, USA (2000)
Gammel W A, Ignition Coil, US patent 3041562 (1962)
Yahaya, E.A., Jacob, T., Nwohu, M., Abubakar, A. Power loss due to Corona on high voltage transmission lines. IOSR Journal of Electrical & Electronics Engineering 8(3), 14–19 (2013).
Miyazaki, M., Ando, S., Hinoura, K., Onose, H., Moore, B.K., Influence of filler addition to bonding agents on shear bond strength to bovine dentin. Dental Materials, 11, 234–238 (1995).