This study considers the design of surface-mounted permanent magnet electrical machines for high-speed applications and proposes a methodology to determine the maximum achievable power density. The whole approach can be used further for thermal behavior analysis of the electrical machine for other types of traction application such as road vehicle application. This paper provides also the thermal basics for the transition from natural convection to effective conduction in the air gap of the totally enclosed electrical machine during calculation of the thermal FEA. Additionally, the influence of the Open-Circuit Fault (OCF) on the thermal behavior of the PSM is estimated. The transient thermal behavior calculation of a totally enclosed PSM is implemented. In this work, the approach for the thermal behavior calculation of multiphase PSM using Finite Element Analysis (FEA) is introduced. Since a high temperature is the main reason of failure during operation and, at the same time, there is a trend to decrease of the machine size and increase power density, the calculation of the thermal behavior becomes the important aspect of the whole machine design.
Moreover, the use of a multiphase machine is one of the possibilities to reach the abovementioned high fault tolerance. Due to high power density and efficiency, the most common type of electrical machine that can be used in such applications is the permanent magnet synchronous motor (PSM). Additionally, the limited energy storage makes it necessary to use the electrical drive system with the highest possible efficiency. In case of the flight traction application, the main difficulties are connected with the high-fault tolerant demand and with necessity to have the system with the smallest possible weight. Nowadays internal combustion engines are being replaced with electrical drives in various traction applications in order to reach ecological goals. The 1.12 MW, 18,000 rpm HSPMM is prototyped with experiments conducted on it, while the test data are then compared with the calculated results, which validate the correctness of the solution method of the coupled field. Thus, HSPMM temperature and fluid field can be simulated numerically by the finite volume methods, while the spatial temperature distributions for the machine main components are analysed in this study. With the influences from temperature gradient and water flow rate considered, the heat transfer coefficients of water pipe surfaces are obtained by the application of the inverse iteration method. According to the theory of computational fluid dynamics and heat transfer, the computation model of fluid–solid–heat coupling heat transfer is established, and the coupled field is calculated using finite volume method with fundamental assumptions and corresponding boundary conditions. In order to accurately estimate the temperature rise for high‐power high‐speed permanent magnet machines (HSPMMs), a novel temperature calculation method considering the non‐linear variation of material properties with temperature is proposed based on multi‐physics co‐simulation analysis.
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