Thesis Work for 'Modelling of resin flow in mica paper/resin composite for HV-machine insulation'

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This position reports to

R&D Team Lead

Your role and responsibilities

This is a collaboration between ABB Corporate Research/Västerås, ABB Large Motors and Generators/Västerås, and KTH, Department of Engineering Mechanics/Stockholm. KTH is a strategic research partner to ABB in Sweden. ABB Corporate Research in Västerås, Sweden, drives R&D for all business areas within ABB to find solutions to ABB's next generation products and services. Our facility is equipped with state-of-the art laboratories and simulation environment. A large part of the premises is dedicated for developing new technologies for rotating electrical machines. ABB Corporate Research wants to create an interest in ABB's industrial challenges and ensures relevant competence through our collaboration with universities and research institutes. ABB Large Motors and Generators' unit in Västerås, Sweden, has an installed base of more than 3000 delivered large rotating machines globally. Main applications of ABB's large machines are for compressors, gas- and steam turbine generators, pump- and fan motors and refiners. Our customers operate within the industries of renewable energy, power generation, chemicals, paper, pulp, metal, and mining. The Department of Engineering Mechanics is a part of the Schools of Engineering Science (SCI) at KTH. The Department's research span from fundamental mechanics, fluid mechanics, solid mechanics, engineering acoustics and lightweight structures to the application areas aerospace engineering, naval engineering, vehicle dynamics, railway vehicles and biomechanics. Introduction of the thesis work The electrical insulation system of form-wound large electrical machines is composed of a mica paper/glass fiber/resin composite. The stator of large HV-machines is impregnated in a batch-wise process called global vacuum-pressure impregnation (VPI). During the impregnation the resin penetrates the macroscopic winding structure as well as the microscopic structure of the mica paper. The impregnation time depends on parameters such as resin viscosity, temperature, pressure, and mica paper characteristics. The impregnation time should be optimized, but still be sufficiently long to achieve a satisfactory impregnation quality. After impregnation, the stator is cured in an oven. The electrical lifetime performance of the machine will depend on the composite's quality after impregnation and curing. The Master Thesis work will focus on modelling the mica paper structure and simulating the impregnation process to understand the resin flow and potentially guide in optimization of impregnation parameters as well as include experimental verifications. Details • Start in 2024/2025 • 30 ECTS/högskolepoäng (hp) equivalent to one semester • One student • Most of the work at ABB Corporate Research, Västerås, some parts at KTH, Stockholm • Visit to ABB Machines factory in Västerås Your responsibilities • Literature study on the resin impregnation process of the mica paper/resin composite insulation system for form-wound windings of rotating machines; impregnation on both a macroscopic as well as a microscopic level. • Compile and describe existing software for modeling of resin flow in a porous media. • Make models of parts of or the whole coil structure and simulate the resin flow dependent on resin viscosity, temperature, pressure and time. • Conduct experimental verification of the model using samples based on mica paper/resin components, measuring e.g., paper porosity and resin wetting. • Thesis writing and presentation of work in English.

Qualifications for the role

• Pursuing an MSc degree in the domains of engineering mechanics, composite materials or fluid dynamics.
• Studies in composite materials, resin technology, machine technology, modelling and flow simulation are advantageous.
• Language skills: English - oral as well as written.

More about us

For more information please contact: • Recruiting Manager ABB; David Lindell, +46 (0)72 4613503, david.lindell@se.abb.com • Supervisor at ABB; Göran Paulsson, +46 (0)73 0930096, goran.paulsson@se.abb.com • Co-supervisor at ABB; Binaya Baidar, +46 (0)72 4644063, binaya.baidar@se.abb.com • Supervisor at KTH, Malin Åkermo, +46 (0)70 3206445, akermo@kth.se Positions are filled continuously. Apply with your CV, academic transcripts and a cover letter in English. Please note that we can only accept applications submitted through our online career portal. Applications via e-mail will have to be deleted and not processed due to data privacy requirements. We value people from different backgrounds. Could this be your story? Apply today or visit www.abb.com to read more about us and learn about the impact of our solutions across the globe. #MyABBStory #Li-onsite