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

Christian Monissen, Oliver Kusche, Michael Schröder and Jakob Andert ()
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Christian Monissen: Teaching and Research Area Mechatronics in Mobile Propulsion, Faculty of Mechanical Engineering, RWTH Aachen University, Forckenbeckstraße 4, D-52074 Aachen, Germany
Oliver Kusche: Teaching and Research Area Mechatronics in Mobile Propulsion, Faculty of Mechanical Engineering, RWTH Aachen University, Forckenbeckstraße 4, D-52074 Aachen, Germany
Michael Schröder: FEV Europe GmbH, Neuenhofstr. 181, D-52078 Aachen, Germany
Jakob Andert: Teaching and Research Area Mechatronics in Mobile Propulsion, Faculty of Mechanical Engineering, RWTH Aachen University, Forckenbeckstraße 4, D-52074 Aachen, Germany

Energies, 2023, vol. 16, issue 21, 1-27

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.

Keywords: electromagnetic simulation; interior permanent magnet machine; power density; temperature dependent control (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2023
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