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Brown, Ian P.

Publications and source records attributed to Brown, Ian P..

6 records
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DOE OSTI2024

Greybox Thermal Parameter Identification of Electric Machine Stators

The parameters of electric machine thermal equivalent circuit networks are difficult to predict due to material and manufacturing uncertainties. In this paper, a Greybox system identification approach is used to identify parameters of electric machine stator lumped parameter thermal networks (LPTNs). LPTNs provide a low order, computationally efficient, dynamic model of temperatures at specific locations. Second and third order LPTN model structures are defined as state space equations with stator thermal parameters to be identified. To test the Greybox electric machine stator thermal system identification, five stator motorette prototypes were constructed with controlled variations in slot fill and slot liner thickness. The variation in the motorette thermal parameters and thermal time constants are detected using the Greybox identification. Special attention is given to the impact of sampling rate and Greybox data record length on parameter estimation accuracy.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Cast or Additively Manufactured Coils with End Turn Enhanced Heat Transfer Surfaces for Spray or Jet Cooling

Cast or additively manufactured coils present a new opportunity for creativity in thermal management of electric machines. Improvements to the heat transfer of spray or jet cooling of coil end turns through the incorporation of pins or enhanced heat transfer surfaces in the cast end turn surfaces is explored. The thermal response of cast copper half-turns is measured for a range of spray/jet volumetric flow rates and ohmic loss heat fluxes. A significant reduction, ~30%, in the steady state temperature and increased spray cooling heat transfer coefficients was experimentally measured when the pins or enhanced heat transfer surfaces are incorporated.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Implementation of a Metamodel-Based Optimization for the Design of a High Power Density Wound Field Traction Motor

Traction motors onboard electric vehicles (EVs) are faced with ever-increasing power density requirements and cost reduction challenges. Although permanent magnet (PM) traction motors have been favored for their potential of higher power densities, the price and supply volatility of PM materials are the major drawbacks. Instead of a single load point, the performance of a traction motor needs to be optimized over various combinations of torque and speed to represent real-world vehicular driving scenarios, which tends to be a time-consuming task with direct optimizations. In this study, as a PM-free solution, a wound field synchronous motor (WFSM) is designed and optimized using a metamodel-based approach to maximize its efficiency over a custom set of load points, while utilizing a fully per-unitized geometry template. The workflow has proven to be timesaving and the optimal design is prototyped and tested.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Combined Dimensional and Topology Optimization of Synchronous Machine Rotors Using a Material Density Interpolation Method

This article presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) and wound field synchronous machine (WFSM) rotors. Dimensional changes to the permanent magnet (PM) and rotor winding location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh, whereas the presence of copper material for WFSM rotor is interpolated in the same manner. A density based Solid Isotropic Material with Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Four examples are presented to demonstrate the technique: Two flat bar IPMSM, one V-shaped IPMSM, and a WFSM. Here, a comparative study is performed on one of the flat bar IPMSMs using Metamodel of Optimal Prognosis (MOP) based method.

33 ADVANCED PROPULSION SYSTEMS↗