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Thermal analysis of electric motors
for automotive applications
SPIN Applicazioni Magnetiche www.spinmag.it
Thermal analysis
2
Motors for automotive applications operate in a wide range of the torque-speed plane
Lumped-parameter models are needed for fast analysis
• Special motors and other devices  sT Activate (by Altair)
• Classical motors  Motor-CAD (by Motor-Design)
SPIN Applicazioni Magnetiche www.spinmag.it
Lumped-parameters thermal models
of classical motors
using Activate by Altair and Motor-CAD by Mdl
3
SPIN Applicazioni Magnetiche www.spinmag.it 4
• Squirrel-cage induction motors
• Permanent magnet brushless motors (inner and outer rotor)
• Switched reluctance motors
• Permanent magnet DC collector motors
• Wound rotor synchronous motors
• Claw-pole motors
• Single-phase squirrel-cage induction motors
• Wound-field collector motors
• Synchronous reluctance (SynchRel) motors
Available motor types
SPIN Applicazioni Magnetiche www.spinmag.it
Example: brushless motor
5
Radial view Axial view
SPIN Applicazioni Magnetiche www.spinmag.it
Steady-state thermal analysis
6
SPIN Applicazioni Magnetiche www.spinmag.it
Drive cycle calculation with vehicle model
7
SPIN Applicazioni Magnetiche www.spinmag.it
Duty-cycle transient analysis power graph
8
SPIN Applicazioni Magnetiche www.spinmag.it
Duty-cycle transient analysis temperature graph
9
SPIN Applicazioni Magnetiche www.spinmag.it
Thermal envelope (max 160 °C on windings and 140 °C on magnets)
10
SPIN Applicazioni Magnetiche www.spinmag.it
Lumped-parameters thermal models
of special motors and other devices
using Modelica blocks in sT Activate
11
SPIN Applicazioni Magnetiche www.spinmag.it
INPUT DATA: POWERS
Thermal models generally require power injections or withdrawals as
inputs.
Powers Temperatures
Thermal
model
Power values can be obtained in several ways:
• Directly inserted by user as input data
• Evaluated by an electric circuit in Activate
(e.g. equivalent circuit of an IM)
• Read from a text file (e.g. “filename.csv”)
12
SPIN Applicazioni Magnetiche www.spinmag.it
Thanks to the txt/csv input file it is possible to take in account variable loss
profiles vs time
13
SPIN Applicazioni Magnetiche www.spinmag.it
PARAMETRIZATION
In order to have a powerful tool for thermal modelling, the Activate model is
fully parametrized: user has to insert geometric and physical data as inputs.
14
SPIN Applicazioni Magnetiche www.spinmag.it
Example: squirrel cage induction motor
The basic idea is to radially and axially divide the motor, forming annular
sectors each one with its own physical properties:
15
SPIN Applicazioni Magnetiche www.spinmag.it
Output transient temperatures: Motor-CAD validation
Motor-CAD radial view
Activate Motor-CAD
Temperature[°C]
16
SPIN Applicazioni Magnetiche www.spinmag.it
Example: axisymmetric electromagnet
The basic idea is to radially and axially divide the motor, forming annular
sectors each one with its own physical properties:
List of colors employed in the image:
Blue  moving core
Red  fixed core
Yellow  winding
White  airgap
Green  plastic sprocket
Turquoise  top disc
Brown  brass bushing
Purple  armatureR axis
Z axis
17
SPIN Applicazioni Magnetiche www.spinmag.it
Square-wave = 1
Electromagnet is turned ON
Moving core is pulled down
Square-wave = 0
Electromagnet is turned OFF
Wide airgap between cores
Activation
blocks
18
SPIN Applicazioni Magnetiche www.spinmag.it
The thermal behavior of the electromagnet is influenced by ON-OFF state,
as visible below.Temperature[°C]
19
Spin Seminario L'Aquila - Analisi Termica

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Spin Seminario L'Aquila - Analisi Termica

  • 1. Thermal analysis of electric motors for automotive applications
  • 2. SPIN Applicazioni Magnetiche www.spinmag.it Thermal analysis 2 Motors for automotive applications operate in a wide range of the torque-speed plane Lumped-parameter models are needed for fast analysis • Special motors and other devices  sT Activate (by Altair) • Classical motors  Motor-CAD (by Motor-Design)
  • 3. SPIN Applicazioni Magnetiche www.spinmag.it Lumped-parameters thermal models of classical motors using Activate by Altair and Motor-CAD by Mdl 3
  • 4. SPIN Applicazioni Magnetiche www.spinmag.it 4 • Squirrel-cage induction motors • Permanent magnet brushless motors (inner and outer rotor) • Switched reluctance motors • Permanent magnet DC collector motors • Wound rotor synchronous motors • Claw-pole motors • Single-phase squirrel-cage induction motors • Wound-field collector motors • Synchronous reluctance (SynchRel) motors Available motor types
  • 5. SPIN Applicazioni Magnetiche www.spinmag.it Example: brushless motor 5 Radial view Axial view
  • 6. SPIN Applicazioni Magnetiche www.spinmag.it Steady-state thermal analysis 6
  • 7. SPIN Applicazioni Magnetiche www.spinmag.it Drive cycle calculation with vehicle model 7
  • 8. SPIN Applicazioni Magnetiche www.spinmag.it Duty-cycle transient analysis power graph 8
  • 9. SPIN Applicazioni Magnetiche www.spinmag.it Duty-cycle transient analysis temperature graph 9
  • 10. SPIN Applicazioni Magnetiche www.spinmag.it Thermal envelope (max 160 °C on windings and 140 °C on magnets) 10
  • 11. SPIN Applicazioni Magnetiche www.spinmag.it Lumped-parameters thermal models of special motors and other devices using Modelica blocks in sT Activate 11
  • 12. SPIN Applicazioni Magnetiche www.spinmag.it INPUT DATA: POWERS Thermal models generally require power injections or withdrawals as inputs. Powers Temperatures Thermal model Power values can be obtained in several ways: • Directly inserted by user as input data • Evaluated by an electric circuit in Activate (e.g. equivalent circuit of an IM) • Read from a text file (e.g. “filename.csv”) 12
  • 13. SPIN Applicazioni Magnetiche www.spinmag.it Thanks to the txt/csv input file it is possible to take in account variable loss profiles vs time 13
  • 14. SPIN Applicazioni Magnetiche www.spinmag.it PARAMETRIZATION In order to have a powerful tool for thermal modelling, the Activate model is fully parametrized: user has to insert geometric and physical data as inputs. 14
  • 15. SPIN Applicazioni Magnetiche www.spinmag.it Example: squirrel cage induction motor The basic idea is to radially and axially divide the motor, forming annular sectors each one with its own physical properties: 15
  • 16. SPIN Applicazioni Magnetiche www.spinmag.it Output transient temperatures: Motor-CAD validation Motor-CAD radial view Activate Motor-CAD Temperature[°C] 16
  • 17. SPIN Applicazioni Magnetiche www.spinmag.it Example: axisymmetric electromagnet The basic idea is to radially and axially divide the motor, forming annular sectors each one with its own physical properties: List of colors employed in the image: Blue  moving core Red  fixed core Yellow  winding White  airgap Green  plastic sprocket Turquoise  top disc Brown  brass bushing Purple  armatureR axis Z axis 17
  • 18. SPIN Applicazioni Magnetiche www.spinmag.it Square-wave = 1 Electromagnet is turned ON Moving core is pulled down Square-wave = 0 Electromagnet is turned OFF Wide airgap between cores Activation blocks 18
  • 19. SPIN Applicazioni Magnetiche www.spinmag.it The thermal behavior of the electromagnet is influenced by ON-OFF state, as visible below.Temperature[°C] 19