Abstract
The operational reliability and high efficiency of modern electrical machines depend on the ability to transfer heat in the construction parts of the machine. Therefore, many authors study various thermal models and work on the development of effective heat dissipation. New insights and methods lead to improved techniques for the thermal design of electrical machines. This paper presents an experimentally validated thermal model of a permanent magnet synchronous motor (PMSM) with an improved slot winding model. It also deals with various approaches to homogenization and equivalent material properties of a tooth-coil winding sub-model. First, an algorithm for building a lumped-parameter thermal network (LPTN) of PMSM is described and its properties and problems are discussed. Subsequently, a sub-model of a slot with a winding based on the finite element method (FEM) is introduced. This sub-model is able to generate different conductor distributions based on probabilistic methods for a specified fill factor. This allows the verification of various homogenization approaches and at the same time it is a tool that automatically calculates thermal resistances for the LPTN.
Highlights
Today, especially with regard to climate challenges, higher energy efficiency and power density of electrical machines are required
It is necessary to be able to implement new machine topologies and new research results into the model as as possible. This is achieved through the concept of sub-models, which divide the electrical motor into individual layers from shaft to housing
This paper presents a new approach for determining the thermal resistances or equivalent thermal conductivities of stator slot winding
Summary
Especially with regard to climate challenges, higher energy efficiency and power density of electrical machines are required. This fact brings new challenges in the design of an electrical motor especially for traction applications and electric vehicles (EV). One of the commonly used construction typologies of PMSM in the automotive industry is a machine with tooth-coil winding or a machine with concentrated winding. This brings the advantage of low-cost production, high torque density and high efficiency [5,6,7]. Wound windings mean great uncertainties and the manufactured winding can differ significantly from the winding modeled by conventional methods
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