Validation and Parametric Investigations of an Internal Permanent Magnet Motor Using a Lumped Parameter Thermal Model

Journal Article · 06 February 2022 · Journal of Electronic Packaging

DOI: https://doi.org/10.1115/1.4053121 · OSTI ID:1860480

Sequeira, Sebastien ^[1]; Bennion, Kevin  ^[2]; Cousineau, J. Emily  ^[2]; Narumanchi, Sreekant  ^[2]; Moreno, Gilbert  ^[2]; Kumar, Satish ^[1]; Joshi, Yogendra ^[1]

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1. Georgia Institute of Technology, Atlanta, GA (United States)
2. National Renewable Energy Lab. (NREL), Golden, CO (United States)

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multiphysics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a lumped parameter thermal network (LPTN) model of an Internal Permanent Magnet synchronous motor within the commercially available _MOTOR-CAD modeling environment. The validation is based on temperature comparison with experimental data and with more detailed finite element analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations, and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% - for the highest temperature in the slot-winding and the end-winding - was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot-winding and end-winding. As for the LPTN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance.

• Research Organization: National Renewable Energy Laboratory (NREL), Golden, CO (United States)
• Sponsoring Organization: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office
• Grant/Contract Number: AC36-08GO28308; EE0008708
• OSTI ID: 1860480
• Report Number(s): NREL/JA-5400-78672; MainId:32589; UUID:c6a1d929-6c5c-4ff1-a936-e1a0f0baa42a; MainAdminID:64138
• Journal Information: Journal of Electronic Packaging, Journal Name: Journal of Electronic Packaging Journal Issue: 2 Vol. 144; ISSN 1043-7398
• Publisher: ASMECopyright Statement
• Country of Publication: United States
• Language: English