Thermal Modelling for Electric Machines Using Thermal Capacitance Calculation Method: External Rotor Switched Reluctance Motor Case Study

Abstract

This thesis characterizes the transient thermal response of a 12/16 External Rotor Switched Reluctance Machine (ERSRM) for an E-bike application. A method for calculating coil capacitance based on machine design parameters was introduced and implemented into a standard commercial Lumped Parameter Thermal Network (LPTN). A sizing criterion was proposed for the cuboid number in a physically accurate LPTN coil model design. This sizing criterion considers the change in model size with motor speed or forced convection. The LPTN with a more accurate calculation of capacitance within the coil and a known number of cuboids in the coil was validated with experimental results. An analytical proof was provided that a small number of capacitances is not sufficient to model a typical power-dense coil design. The validated model was used to study the impact of a more accurate capacitance calculation method on motor temperature. Both overload and rated operation were investigated. During overload conditions, it was found that the standard capacitance calculation from commercial software massively underestimated the heating rate and peak temperature of the coil hot spot, even with the same number of cuboids. The capacitance of the rest of the motor was able to be varied and investigated for its effects on cooldown dynamics. It was found that for short-time transients the coil could be assumed to act adiabatically in this operating range. Operating points across the operating envelope for the motor under study were mapped to determine the region where the adiabatic assumption could be made. It was shown that a transition occurred where the adiabatic assumption ceases to be valid.