A New Analytical Thermal Model of Distributed Winding Wheel Machine for Electric Vehicles

Abstract

Due to the complex boundary conditions of the thermal analysis method (AM), the error of the calculation results is large, and the lumped-parameter thermal network (LPTN) mostly focuses on the solution of the average temperature. This paper proposes a thermal analytical model for wheel-motor windings, which includes LPTN and AM to solve the problems of boundary condition extraction and maximum temperature solution in AM. The heat transfers between the end caps of electric vehicle wheels and the outside air are considered by the model. The node temperature of LPTN can be adopted as the boundary condition of the proposed analytical method to predict and calculate the maximum temperature and average temperature of the wheel motor and improve the accuracy of temperature rise calculation. To further analyze the winding temperature, the armature winding is divided into active winding and end winding for calculation respectively. In the calculation of active winding, based on the equivalent area method, the active winding and other materials are layered into a series of equal-width rectangular rings through a novel layered strategy. The compensated thermal resistance (TR) is introduced into the analytical model of end winding, and the accuracy of the end temperature solution is improved by the iteration of compensated TR. Finally, the effectiveness and correctness of the proposed analytical thermal model for motor temperature rise prediction are verified on a 2kW distributed double-layer winding wheel motor.