An electric traction machine for an electric or a hybrid electric vehicle is usually designed for a specific operating point or cycle. For such an operating point or cycle, the masses and the cooling circuit of the electric machine determine the time dependent temperature distribution within the machine. For a specific load cycle, the thermal simulation of the machine can reveal possible mass and size reductions for a given insulation class of the machine. In addition, such simulations allow the comparison of various cooling concepts. In the machine design process, the first step is a conventional electromagnetic machine design. From the geometric data of this design and the material properties, the parameters of a thermal equivalent circuit can be derived. The differential and algebraic equations of the thermal equivalent circuit are solved by a simulation tool to predict the temperatures of the critical parts in the electric machine. A thermal equivalent circuit is accurate enough to predict the thermal behavior of the critical parts in the electric machine, and yet not too complex, to obtain simulation results with moderate numerical effort. This enables an iterative design process to optimize the drive.
MACHINE DESIGN PROCESSFor the machine to be designed, a certain operating point or cycle has to be specified. The specifications of such an operating point or cycle could be the nominal voltage, frequency and torque, or nominal torque and speed including a voltage/frequency characteristic of the power inverter. In some cases the overload characteristic during acceleration is specified, too. An additional criteria for the electric machine design is to keep the size of the machine, and therefore cost of material as low as possible. The size of the machine is thereby significantly determined by the thermal and electromagnetic utilization with respect to the insulation class.The electromagnetic design is based on the geometric data of the iron core and the windings of the stator and rotor [1,2] of the electric machine. For determining the main geometric data, an initial estimation is performed using some characteristic parameters and experimental knowledge. An electromagnetic calculation software then calculates the magnetic and electromechanical characteristics for the specified operating point or cycle of the induction machine. For this calculation, the non linear iron properties and the estimation of the stray fluxes have to be taken into account. As a result of the calculated magnetic circuit, the magnetic characteristic of the machine is obtained. Some geometric parameters can then be tuned to performed and optimize the electromagnetic utilization considering the actual operating point or cycle. From the geometric data and the material properties, the ohmic resis- * Arsenal Research, Giefinggasse 2, 1210 Vienna, Austria, email: christian.kral@arsenal.ac.at; anton.haumer@arsenal.ac.at; hansjoerg.kapeller@arsenal.ac.at; franz.pirker@arsenal.ac.at tances, the masses and the inertia can be determined.The electr...