Measurement-Based Identification of Lumped Parameter Thermal Networks for sub-Kw Outer Rotor PM Machines

This work is on deriving precise lumped parameter thermal networks for modeling the transient thermal characteristics of electric machines under variable load conditions. The goal is to facilitate an accurate estimation of the temperatures of critical machines' components and to allow for running the derived model in real time to adapt the motor control based on the load history and maximum permissible temperatures. Consequently, the machine's capabilities can be exhausted at best considering a highly-utilized drive. The model shall be as simple as possible without sacrificing the exactness of the predicted temperatures. Accordingly, a specific lumped parameter thermal network topology was selected and its characteristics are explained in detail. The measurement data based optimization of its critical parameters through an evolutionary optimization strategy, and the therefore utilized experimental setup will be described in detail here. Measurement cycles were recorded for modeling and verification purposes including both static and dynamic test cycles with changing load torque and speed requirements. Applying the proposed hybrid approach for determining the model's parameters through involving physics-based equations as well as numerical optimization followed a significant improvement of the preciseness of the predicted motor temperatures compared to solely determining the networks's coefficients based on expert knowledge. Thereby, the validation included both the original measurement data as well as extra measurement runs. The proposed and applied strategy provides an excellent basis for future thermal modeling of electric machines.