UNIVERSIT DE TECHNOLOGIE

COMPIGNE
LABORATOIRE ELECTROMECANIQUE DE COMPIEGNE

LEC (EA 1006)

Thermal Model of Stator Slot for

Small
Synchronous Reluctance
Photo couleur ou NB votre choix plein cadre
M. A. H. Rasid,
A.Ospina,
K. El(72
Kadri
Benkara,
V. Lanfranchi
Machine
RVB, basse
rsolution
dpi),
format JPG,
GIF
3 September 2014

Contents

1. Introduction & context

2. Choosing a modeling method for machine slot
3. Slot homogenization method
4. First model evaluation
5. Modification on slot model and results
6. Conclusion & perspectives

Modlisation thermique des machines lectriques

Introduction: Thermal issue in automotive

application

Positioning of
electrical motor
in dense
compartment
Modlisation thermique des machines lectriques

Severe
temperature
raise
Difficult heat
evacuation

Introduction: Syncrel as a solution

Massive rotor

Segmented rotor

Boldea & al.

2014
Moghaddam &
al. 2010
Boglietti & al.
2006

Rotor with flux

barrier

Axially laminated
rotor

Robust machine
for automotive
application

Passive rotor
structure

Reduced
generated heat

Different rotor
architecture

High
torque/volume
ratio

Modlisation thermique des machines lectriques

Introduction: The most fragile part of the

Syncrel machine

Insulator critical
temperature Tmax

150< Tmax <

240
Depending on
thermal class

High temperature under

the hood / confined
compartment

Precise and reliable

thermal model is crucial

Modlisation thermique des machines lectriques

Introduction: The importance of reliable thermal

6
model

Precise and reliable

thermal model

Design
optimization

Modlisation thermique des machines lectriques

Control &
command
optimization

The Syncrel prototype machine

Segmented rotor
structure

Wounded stator

Thermocouple
Modlisation thermique des machines lectriques

Complete assembled
machine

Choosing a modeling method for machine slot

Most time
consuming

8
Less time
consuming

R equivalent

Full Finite Element Analysis (FEA)

Modlisation thermique des machines lectriques

Choosing a modeling method for machine slot

Most time
consuming

Less time
consuming

R equivalent

Multi-layered equivalent slot deduced from FEA

(to be integrated into LP model)
[Nategh & al., 2012],[Wrobel & al., 2011]
Modlisation thermique des machines lectriques

Choosing a modeling method for machine slot

10

Most time
consuming

Less time
consuming

R equivalent

Adaptation of analytical winding homogenization

(to be integrated into LP model)
[Simpson & al., 2013],[Idoughi & al., 2011]
Modlisation thermique des machines lectriques

Choosing a modeling method for machine slot

11

Most time
consuming

Less time
consuming

R equivalent

Find the best compromise between the three

method:
Validation using an experimental setup in a
Light model
real slot
of a machine stator
Adequate precision
& reliability
Short time of development

Modlisation thermique des machines lectriques

First model tested

Application of winding homogenization

Composite with 3 winding materials

Winding distribution: Random

[Mori & Tanaka, 1988]

Air
and/or
resin

Parameters:
Thermal resistance
Filling factor

Modlisation thermique des machines lectriques

12

Homogenized slot integration into the LP

thermal model

13

Slot geometry is considered of square shape

Equivalent homogenized slot: divided into 2 radial branches

and 2 ortho-radial branches

Slot
homogenization

0.0367 W/m/K

Modlisation thermique des machines lectriques

First model evaluation

14

Digital signal
processor
Power electronic

Syncrel

Experiment in static mode

Current
step (IDC)

Iron losses
calculation

Mechanical
losses

No air turbulent
Only natural exterior convection
Modlisation thermique des machines lectriques

Joule losses

First model evaluation

15
44

First experimental data-model simulation comparison

42

temperature (C)

40

experimental

38
36
34
32

30

0.0367 W/m/K

28

Current step (IDC)

26
24
0

Experimental data
Model simulation
500

1000

1500

Observation:
Important offset on steady-state
temperature
Discrepancy on time constant

Sensitivity studies
Homogenized slot

Modlisation thermique des machines lectriques

2000

time (s)

2500

3000

3500

4000

Modification on slot model

16

The winding homogenization analytical model :

Empirical analytical equation
Done for resin filled winding => irregular
contact not taken into account

Model
New model
proposition

Extra thermal
resistance around the
homogenized winding
representing irregular
contact
Full contact of
Resistance
values
homogenized
slot with
stator stackusing
surface
determined

experimental
fitting

Real case

Homogenized
composites

Modlisation thermique des machines lectriques

Irregular contact of slot

with stator stack surface

Modification on slot model

17

Comparison: experimental data -model simulation

65
60
experimental data
experimental data
experimental data
model simulation
model simulation
model simulation

temperature (C)

55

Robustness of
the fitted
model

50
45

40

35
30
25
20
0

500

1000

1500

2000

time (s)

2500

3000

3500

4000

TABLE I
Error Between Experimental Data and LP Model
Simulation

Current (A)

1.7

3.4

4.8

Steady state
temperature

28C

42.C

62C

Worst case error

(C) / (%)

0C
0%

-1 C
4.9 %

-4 C
9.9%

Steady state error

(C) / (%)

0 C
0%

0 C
0%

1 C
1.8%

Modlisation thermique des machines lectriques

Conclusion & perspective

18

Compromise in modeling slot was researched.

An additional layer (representing contact resistance) needs to

be added to the homogenized winding.

A better model to reduce the transient prediction error to be

researched (addition of capacitive component).

Tool: evaluating the need of filling the slot with resin

Modlisation thermique des machines lectriques

19

Thank you for your attention

Questions?

Modlisation thermique des machines lectriques