Power Density Increase in Permanent-Magnet Synchronous Machines Considering Active Thermal Control

Energies, vol. 16, pp. 7369

Abstract

The power density of electric machines for future battery electric vehicles must be further increased to improve customer benefits. To this end, this paper compares two state-of-the art electrical traction machines and evaluates the potential for increasing the power density using a third, novel high-speed machine design. The analysis is performed using an electromagnetic finite element analysis, a thermal network with lumped parameters, and a coupled electromagnetic–thermal simulation. The simulations of the three machines evaluate the potential for increasing the power density and overload margins, as well as reducing material consumption. With regard to the active thermal control, the new design aims for reduced thermal capacities and increased loss density to optimize the thermal controllablity and overall performance. The thermal active control is analyzed in thermal transient simulations and electromagnetic simulations with different magnet temperatures. The results show that higher magnet temperatures benefit efficiency and reduce losses for low torque at high speeds. However, a colder magnet is needed for maximum torque at base speed. A maximum loss reduction of 24% is achieved with a 100 °C magnet-temperature difference at maximum speed and low torque.

Authors 3

1. Christian Monissen Aachen Faculty of Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Teaching and Research Area Mechatronics in Mobile Propulsion, Faculty of Mechanical Engineering, RWTH Aachen University, Forckenbeckstraße 4, D-52074 Aachen, Germany

2. Michael Schröder Aachen FEV Europe GmbH

   FEV (Germany)

   Affiliation as printed

   FEV Europe GmbH, Neuenhofstr. 181, D-52078 Aachen, Germany

3. Jakob Andert corresponding Aachen Faculty of Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Teaching and Research Area Mechatronics in Mobile Propulsion, Faculty of Mechanical Engineering, RWTH Aachen University, Forckenbeckstraße 4, D-52074 Aachen, Germany