Thermal security is a key concern for the design of components in electric powertrains. For electric motors this often means to define and test suitable cooling concepts that guarantee a maximum end winding temperature under time varying peak and continuous electrical loads. As a result, it is desired to have digital twins for real-time prediction of component dynamics. In this paper a 1D–3D synergetic modeling approach is presented for early design discovery and faster design iteration of electric motors in a virtual development cycle, where flow through the cooling channels is based on 1D Navier–Stokes equation and thermal conduction through the motor structure is based on 3D heat transport. Moreover, for real-time drive cycle prognoses, a simplified physics based reduced order modeling approach is presented. The permanent magnet synchronous motor investigated in this paper is based on a hybrid cooling concept to include direct winding spray cooling and indirect housing channel cooling. Four different designs of cooling channels are investigated in terms of design criteria such as maximum temperature and heat rejection. The final model with chosen design is implemented to test the entire operational range of electric motor in case of transient drive cycles. In conclusion, this paper successfully demonstrates how to overcome the limitations of computationally expensive 3D CFD simulation for e-motor design and integrated system transient analysis.
Synergetic 1D–3D Reduced Order Modeling Techniques for Electric Motor Design Analysis
Proceedings
2022-03-15
16 pages
Aufsatz/Kapitel (Buch)
Elektronische Ressource
Deutsch
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