Abstract
An electric traction machine for an electric or a hybrid electric vehicle is usually designed for a specific operating point or cycle. For such an operating point or cycle, the masses and the cooling circuit of the electric machine determine the time dependent temperature distribution within the machine. For a specific load cycle, the thermal simulation of the machine can reveal possible mass and size reductions for a given insulation class of the machine. In addition, such simulations allow the comparison of various cooling concepts. In the machine design process, the first step is a conventional electromagnetic machine design. From the geometric data of this design and the material properties, the parameters of a thermal equivalent circuit can be derived. The differential and algebraic equations of the thermal equivalent circuit are solved by a simulation tool to predict the temperatures of the critical parts in the electric machine. A thermal equivalent circuit is accurate enough to predict the thermal behavior of the critical parts in the electric machine, and yet not too complex, to obtain simulation results with moderate numerical effort. This enables an iterative design process to optimize the drive.
Highlights
MACHINE DESIGN PROCESSFor the machine to be designed, a certain operating point or cycle has to be specified
The common use of XML data files enables a seamless communication between the electromagnetic design software, the electromechanical simulation and the thermal simulation tools
The thermal behavior of an electric machine is modeled by a thermal network model including cooling circuit (Fig. 2)
Summary
For the machine to be designed, a certain operating point or cycle has to be specified. This data format enables a object oriented description of models and clear structuring of data For this purpose, an XML library was developed which can be linked either to standard C and Fortran code for the design software or to Modelica code for the electromechanical and thermal simulation tool. The common use of XML data files enables a seamless communication between the electromagnetic design software, the electromechanical simulation and the thermal simulation tools. This way, batch processes can be performed to compare and – in a future version – to automatically optimize certain machine and cooling designs. The used models and tools represent an innovative step towards the automation of the design process of electric machines
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