Thermal Contact Conductivity Prediction with Grey Box Model and Experimental Validation for an Axial Flux Motor

Zhaozong Li, Chengning Zhang, Fengyu Zhang, Zeyuan Xu, David Gerada, Chris Gerada, Xueping Li, Shuo Zhang, Yue Zhao

Research output: Chapter in Book/Conference proceedingConference contributionpeer-review

Abstract

Axial Flux Permanent Magnet Synchronous Motor (AFPMSM) attracts increased attention in recent years due to the inherent high torque density. The yokeless and segment armature is one of the most advanced structures, with reduced axial length and increased efficiency. For the segment armature fixed axial flux motors, encapsulating material is required between the winding and the structure fins. However, it is difficult to calculate the contact thermal conductivity between the fins and windings for the machine thermal performance prediction, due to the multiple material components and different interface pressure. For the complicated materials characteristics analysis, Grey Box theory is proposed to predict the thermal behavior of the non-metallic mixture in the contact region in this paper. Firstly, the axial flux motor topology is presented, as well as a single sector model. Then the Grey Box frame is introduced with the testing rig to train the critical parameters that will be used in thermal model. Through genetic algorism, the thermal conductivity and heat capacity of mixture materials in the area of the segmented armature contact surface are obtained. Finally, the equivalent thermal conductivity in the contact region is updated to a 3D thermal model, which are experimentally validated on a sector model and a prototype motor.

Original languageEnglish
Title of host publication2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022
PublisherInstitute of Electrical and Electronics Engineers Inc.
ISBN (Electronic)9781728193878
DOIs
Publication statusPublished - 2022
Event2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022 - Detroit, United States
Duration: 9 Oct 202213 Oct 2022

Publication series

Name2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022

Conference

Conference2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022
Country/TerritoryUnited States
CityDetroit
Period9/10/2213/10/22

Keywords

  • Axial Flux Motor
  • Encapsulating Material
  • Grey Box Theory
  • Segment Armature

ASJC Scopus subject areas

  • Electrical and Electronic Engineering
  • Mechanical Engineering
  • Safety, Risk, Reliability and Quality
  • Energy Engineering and Power Technology
  • Renewable Energy, Sustainability and the Environment
  • Control and Optimization

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