Analytical thermal model for fast stator winding temperature prediction

This paper introduces an innovative thermal modelling technique which accurately predicts the winding temperature of electrical machines, both at transient and steady state conditions, for applications where the stator Joule losses are the dominant heat source. The model is an advanced variation of the classical Lumped Parameter Thermal Network approach, with the expected degree of accuracy but at a much lower computational cost. A 7-node Thermal Network is first implemented and an empirical procedure to fine-tuning the critical parameters is proposed. The derivation of the low computational cost model from the Thermal Network is thoroughly explained. A simplification of the 7-node Thermal Network with an equivalent 3-node Thermal Network is then implemented, and the same procedure is applied to the new network for deriving an even faster low computational cost model. The proposed model is then validated against experimental results carried on a Permanent Magnet Synchronous Machine which is part of an electro-mechanical actuator designed for an aerospace application. A comparison between the performance of the classical Lumped Parameter Thermal Network and the proposed model is carried out, both in terms of accuracy of the stator temperature prediction and of the computational time required

Evolution and Modern Approaches for Thermal Analysis of Electrical Machines

In this paper, the authors present an extended survey on the evolution and the modern approaches in the thermal analysis of electrical machines. The improvements and the new techniques proposed in the last decade are analyzed in depth and compared in order to highlight the qualities and defects of each. In particular, thermal analysis based on lumped-parameter thermal network, finite-element analysis, and computational fluid dynamics are considered in this paper. In addition, an overview of the problems linked to the thermal parameter determination and computation is proposed and discussed. Taking into account the aims of this paper, a detailed list of books and papers is reported in the references to help researchers interested in these topics

Computationally Efficient Strand Eddy Current Loss Calculation in Electric Machines

A fast finite element (FE) based method for the calculation of eddy current losses in the stator windings of randomly wound electric machines is presented in this paper. The method is particularly suitable for implementation in large-scale design optimization algorithms where a qualitative characterization of such losses at higher speeds is most beneficial for identification of the design solutions that exhibit the lowest overall losses including the ac losses in the stator windings. Unlike the common practice of assuming a constant slot fill factor s f for all the design variations, the maximum s f in the developed method is determined based on the individual slot structure/dimensions and strand wire specifications. Furthermore, in lieu of detailed modeling of the conductor strands in the initial FE model, which significantly adds to the complexity of the problem, an alternative rectangular coil modeling subject to a subsequent flux mapping technique for determination of the impinging flux on each individual strand is pursued. Rather than pursuing the precise estimation of ac conductor losses, the research focus of this paper is placed on the development of a computationally efficient technique for the derivation of strand eddy current losses applicable in design optimization, especially where both the electromagnetic and thermal machine behavior are accounted for. A fractional-slot concentrated winding permanent magnet synchronous machine is used for the purpose of this study due to the higher slot leakage flux and slot opening fringing flux of such machines, which are the major contributors to strand eddy current losses in the windings. The analysis is supplemented with an investigation on the influence of the electrical loading on ac winding loss effects for this machine design, a subject that has received less attention in the literature. Experimental ac loss measurements on a 12-slot 10-pole stator assembly will be discussed to verify the existing trends in the simulation result

Solving the More Difficult Aspects of Electric Motor Thermal Analysis in Small and Medium Size Industrial Induction Motors

With the ever-increasing pressure on electric motor manufacturers to develop smaller and more efficient electric motors, there is a need for more thermal analysis in parallel with the traditional electromagnetic design. Attention to the thermal design can be rewarded by major improvements in the overall performance. Technical papers published to date highlight a number of thermal design issues that are difficult to analyze. This paper reviews some of these issues and gives advice on how to deal with them when developing algorithms for inclusion in design software

A Computationally Efficient Method for Calculation of Strand Eddy Current Losses in Electric Machines

In this paper, a fast finite element (FE)-based method for the calculation of eddy current losses in the stator windings of randomly wound electric machines with a focus on fractional slot concentrated winding (FSCW) permanent magnet (PM) machines will be presented. The method is particularly suitable for implementation in large-scale design optimization algorithms where a qualitative characterization of such losses at higher speeds is most beneficial for identification of the design solutions which exhibit the lowest overall losses including the ac losses in the stator windings. Unlike the common practice of assuming a constant slot fill factor, sf, for all the design variations, the maximum sf in the developed method is determined based on the individual slot structure/dimensions and strand wire specifications. Furthermore, in lieu of detailed modeling of the conductor strands in the initial FE model, which significantly adds to the complexity of the problem, an alternative rectangular coil modeling subject to a subsequent flux mapping technique for determination of the impinging flux on each individual strand is pursued. The research focus of the paper is placed on development of a computationally efficient technique for the ac winding loss derivation applicable in design-optimization, where both the electromagnetic and thermal machine behavior are accounted for. The analysis is supplemented with an investigation on the influence of the electrical loading on ac winging loss effects for a particular machine design, a subject which has received less attention in the literature. Experimental ac loss measurements on a 12-slot 10-pole stator assembly will be discussed to verify the existing trends in the simulation results

Electro-thermal design and optimization of high-specific-power slotless PM machine for aircraft applications

A 1 MW high-frequency air-core permanent-magnet (PM) motor, with power density over 13 kW/kg (8 hp/lb) and efficiency over 96\%, is proposed for NASA hybrid-electric aircraft application. In order to maximize power density of the proposed motor topology, a large-scale multi-physics optimization, which is not favorable for current electrical machine software, is needed to obtain the best design candidates, which is not favorable for current electrical machine software. Therefore, developing electromagnetic (EM) and thermal analytical methods with computational efficiency and satisfactory accuracy is a key enabling factor for future multi-physics optimization of motor power density. This dissertation summarizes the efforts of developing an electro-thermal analysis and optimization scheme of the proposed motor for aircraft applications. Component hardware tests including windage loss, fan performance, full-scale stator temperature and litz-wire were conducted to validate the proposed prediction methods and provide calibrations in the motor design analysis. Furthermore, slotless litz wire winding geometry and strand size are optimized with the developed electro-thermal modeling including transposition effects. After gaining confidence in the developed electro-thermal models, an optimization design toolbox is built for the hybrid-electric engine systems study. The first application study is in partnership with Rolls Royce's Electrically Variable Engine Project to study thermal management system integration effects on motor sizing. The second study is in collaboration with Raytheon Technologies to study motor transient performance with phase change materials integration, which can be tailored to a hybrid-electric engine mission profile

Design optimization of a short-term duty electrical machine for extreme environment

This paper presents design optimisation of a short term duty electrical machine for extreme environments of high temperature and high altitudes. For such extreme environmental conditions of above 80⁰C and altitudes of 30km, thermal loading limits are a critical consideration in machines, especially if high power density and high efficiency are to be achieved. The influence of different material on the performance of such machines is investigated. Also the effect of different slot and pole combinations are studied for machines used for such extreme operating conditions but with short duty. In the research, A Non-dominated Sorting Genetic Algorithm (NSGAII) considering an analytical electromagnetic model, structural and thermal model together with Finite Element (FE) methods are used to optimise the design of the machine for such environments achieving high efficiencies and high power density with relatively minimal computational time. The adopted thermal model is then validated through experiments and then implemented within the Genetic Algorithm (GA). It is shown that, generally, the designs are thermally limited where the pole numbers are limited by volt-amps drawn from the converter. The design consisting of a high slot number allows for improving the current loading and thus, significant weight reduction can be achieved