Electromagnetic coils are indispensable components for energy conversion and transformation in various systems across industries. However, electromagnetic coil insulation failure occurs frequently, which can lead to serious consequences. To facilitate predictive maintenance for industrial systems, it is essential to monitor insulation degradation prior to the formation of turn-to-turn shorts. This paper experimentally investigates coil insulation degradation from both macro and micro perspectives. At the macro level, an evaluation index based on a weighted linear combination of trend, monotonicity and robustness is proposed to construct a degradation-sensitive health indicator (DSHI) based on high-frequency electrical response parameters for precise insulation degradation monitoring. While at the micro level, a coil finite element analysis and twisted pair accelerated degradation test are conducted to obtain the actual turn-to-turn insulation status. The correlation analysis between macroscopic and microscopic effects of insulation degradation is used to verify the proposed DSHI-based method. Further, it helps to determine the threshold of DSHI. This breakthrough opens new possibilities for predictive maintenance for industrial equipment that incorporates coils.
Keywords: electromagnetic coils; health indicator; high-frequency electrical response parameters; insulation degradation monitoring; threshold setting.