中国电气工程学报（英文） ›› 2024, Vol. 10 ›› Issue (2): 80-92.doi: 10.23919/CJEE.2024.000059

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  • 收稿日期:2023-10-09 修回日期:2023-11-30 接受日期:2024-01-15 出版日期:2024-06-25 发布日期:2024-07-01

Accurate 3D Thermal Network Development for Direct-drive Outer-rotor Hybrid-PM Flux-switching Generator

Ali Zarghani1, Mohammad Farahzadi2, Aghil Ghaheri1,*, Karim Abbaszadeh3   

  1. 1. Faculty of Electrical Engineering, Shahid Beheshti University, Tehran 1983969411, Iran;
    2. Faculty of Electrical Engineering, University of Science and Culture, Tehran 1461968151, Iran;
    3. Department of Electrical Engineering, K. N. Toosi University of Technology, Tehran 1631714191, Iran
  • Received:2023-10-09 Revised:2023-11-30 Accepted:2024-01-15 Online:2024-06-25 Published:2024-07-01
  • Contact: * E-mail: a_ghaheri@sbu.ac.ir
  • About author:Ali Zarghani was born in Mashhad, Iran, in 1997. He received a B.S. degree from the University of Birjand, Birjand, Iran, in 2018 and a M.S. degree from Shahid Beheshti University, Tehran, Iran, in 2021, both in Power Electrical Engineering. Since 2021, he has been a Research Assistant in the Faculty of Electrical Engineering at Shahid Beheshti University, Tehran, Iran. His research interests include analytical and finite element method development for multi-physics (electromagnetic, thermal, and mechanical) design, modeling, analysis, optimization, and manufacturing of various electromagnetic devices, with a focus on radial and axial flux PM machines for transportation and renewable energy applications.
    Mohammad Farahzadi was born in Tehran, Iran. He received his M.S. degree in Power Electronics and Electric Machines in 2021. He is an Electrical Machine Designer at the Niroo Research Institute and a Researcher in the Laboratory of the K. N. Toosi University of Technology in Tehran, Iran. His research interests include mechanical and electromagnetic analyses by FEM (2D/3D), assessment of demagnetization of permanent magnets, thermal modeling by FEM, LPM, and CFD, as well as design, optimization, and prototyping of electric machines, especially machines of the flux switching permanent magnet, permanent magnet assisted synchronous reluctance, radial flux permanent magnet, axial flux permanent magnet, and doubly salient permanent magnet.
    Aghil Ghaheri received the B.Sc. degree in Electrical Engineering from Shahrood University of Technology, Shahrood, Iran, in 2014, and the M.Sc. and Ph.D. degrees in Electrical Engineering from Shahid Beheshti University, Tehran, Iran, in 2016 and 2022, respectively, where he is currently working as a Postdoctoral Researcher at the Power Electronics and Motor Drives Laboratory. His research interests include permanent magnet and switched-reluctance machines, magnetic gears, and wireless power transfer systems. He has a strong focus on BLDC, flux switching, transverse flux, axial field PM synchronous, flux modulated machines, coaxial magnetic gears, and PCB motors for renewable energy, automotive and household applications. His expertise is finite element analysis, analytical modelling, optimization, manufacturing, and test of electrical machines.
    Karim Abbaszadeh (Senior Member, IEEE) received the B.S. degree in Communication Engineering from the Khajeh Nasir Toosi University of Technology, Tehran, Iran, in 1991, and the M.S. and Ph.D. degrees in Electrical Engineering from the Amir Kabir University of Technology, Tehran, Iran, in 1997 and 2000, respectively. From 2001 to 2003, he was a Research Assistant with the Department of Electrical Engineering, Texas A&M University, College Station, TX, USA. He is currently a Professor with the Department of Electrical Engineering, Khajeh Nasir Toosi University of Technology, Tehran, Iran. He is actively involved in presenting short courses and consulting in his area of expertise to various industries. He is the author of more than 50 published journal articles. His research interests include power electronic and DC-DC and DC-AC converters, electric machinery, variable-speed drives, and propulsion applications.

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Abstract: Heat and thermal problems are major obstacles to achieving high power density in compact permanent magnet (PM) topologies. Consequently, a comprehensive, accurate, and rapid temperature rise estimation method is required for novel electric machines to ensure safe and reliable operations. A unique three-dimensional (3D) lumped parameter thermal network (LPTN) is presented for accurate thermal modeling of a newly developed outer-rotor hybrid-PM flux switching generator (OR-HPMFSG) for direct-drive applications. First, the losses of the OR-HPMFSG are calculated using 3D finite element analysis (FEA). Subsequently, all machine components considering the thermal contact resistance, anisotropic thermal conductivity of materials, and various heat flow paths are comprehensively modeled based on the thermal resistances. In the proposed 3-D LPTN, internal nodes are considered to predict the average temperature as well as the hot spots of all active and passive components. Experimental measurements are performed on a prototype OR-HPMFSG to validate the efficiency of the 3-D LPTN. A comparison of the results at various operating points between the developed 3-D LPTN, experimental test, and FEA indicates that the 3-D LPTN quickly approximates the hotspot and mean temperature of all components under both transient and steady states with high accuracy.

Key words: Direct-drive wind turbine, hybrid-PM flux switching generator, lumped parameter thermal network, temperature estimation, 3D thermal modeling