Thermal analysis of an integrated motor drive with a switching cell array power converter

Abstract

Abstract In modern electric propulsion systems the electric motor is tightly integrated with the power converter and control unit. These so called Integrated Motor Drives can allow for vast improvements in efficiency and volume reduction, due to the elimination of redundant electric components, and the shared case and cooling system between the motor and the power converter. The cooling systems used in these applications must be carefully designed as the motor and power electronics components may feature greatly different temperature limits. This work discusses the development of a thermal model for an integrated motor drive composed by a six phase permanent magnet motor with hairpin windings and a switching-cell-array-based multilevel power converter. The system is modelled by means of a lumped parameter thermal network which includes an accurate model of the motor stator and rotor, as well as the arrangement of the power switches on the converter boards. The conductive resistances are simply obtained from geometric data and material properties. Instead, the convective resistances are evaluated by means of empirical models available in the literature and a CFD model for the cooling jacket. The developed model is employed to assess the feasibility of the presented arrangement of motor and power electronics components from the thermal point of view.