Testing and validating the electrical insulation performance of full-size compact high-voltage direct current (HVDC) gas-insulated systems, gas-insulated transmission lines (GIL) and gas-insulated switchgears (GIS) is very costly and take long time. Therefore, a reduced scale system was designed and constructed to study thoroughly the spacer’s performance when subjected to higher electric fields under HVDC with different shapes, made of new advanced materials, and housed in new SF₆-free gas environment. Since the stationary DC electric field distribution along the spacer is controlled by spacer material conductivity and strongly depends upon its shape, this, the first part of two articles, proposes in a first step based on electric field calculations with COMSOL Multiphysics software, an optimized shape of a spacer model using a standard high-voltage alternating current (HVAC) alumina-filled epoxy material. Then, two novel types of materials were introduced and investigated: (i) modified filled epoxy material with a lower temperature-dependent conductivity than that of the standard HVAC material, which is interpreted by a lower thermal activation energy; and (ii) nonlinear resistive field grading material with a low nonlinearity coefficient, with and without the presence of a temperature gradient which occurs under operating service load. The numerical results show that, despite that the DC optimized profile of the spacer made of standard HVAC, alumina-filled epoxy is very effective in relaxing the electric field magnitudes along the spacer under uniform temperature—its distribution is significantly affected by the presence of a high temperature gradient causing the maximum electric field shifts along the spacer surface towards the earthed flange. Under this condition, the modified filled epoxy material with a weaker temperature-dependent conductivity results in a significant reduction of the electric field enhancement, representing thus a relevant key solution for HVDC GIL/GIS applications. Nonlinear resistive field grading material is also effective but seems unnecessary. The optimized DC spacer models are being fabricated for tests verification with C4-Perfluoronitrile (C4-PFN, 3M^TM Novec^TM 4710)/CO₂ and Trifluoroiodomethane (CF₃I)/CO₂ gas mixtures in the reduced scale gas-insulated test prototype.

Spacers for the HVDC GIS/GIL play an important role in mechanically supporting conductors and separating compartments. At the same time, their insulation performance affects the stability and safety of system operation. Design rules and knowledge specific to AC spacers do not apply to those of DC spacers. Considering the shape influence on the surface electric field intensity of the spacer under HVDC applied voltage, as determined in our previous work, an optimized shape of a spacer model based on finite element electric field calculations and using standard HVAC alumina filled epoxy material and two novel types of materials were studied. The simulation’s results show that the DC shape optimization of the spacers can effectively reduce the electric field magnitudes along the spacer under different temperature gradients. To verify practically these findings, this paper presents the reduced scale gas insulated prototype that was constructed, the optimized DC spacers that were fabricated and the DC testing results using SF₆-free surrounding gas: C4-Perfluoronitrile (C4-PFN, 3M^TM Novec^TM 4710)/CO₂ and Trifluoroiodomethane (CF₃I)/CO₂. The results show that the shape-optimized spacer models made of conventional HVAC filled epoxy material have successfully passed the tests up to the maximum applicable ±123 kV DC exceeding thus ±119 kV DC that corresponds to the nominal voltage ±500 kV DC of the full scale.

In order to improve the performance and reduce the manufacturing cost of Magnetic Suspension Linear Synchronous Motor (MSLSM). This article presents a robustness optimization design for the motor by using 6 sigma( 6σ) method. First, In order to obtain optimized structural parameters, the method takes the maximum acting force per unit volume as optimization target and selects main structural parameters as optimization parameter. Meanwhile, the basic performance index of the motor was taken as constraint condition. Thereafter, the robust optimization scheme are compared with deterministic optimization scheme and initial design scheme. From the comparison, we can see that the performance and reliability of the motor are improved significantly by 6 σ robustness optimization method. Furthermore, inefficiency of the optimization design of the MSLSM can be greatly reduced. Finally, the experimental results of MSLSM prototype show that the optimization method is effective.