THERMAL AND LOSS ANALYSIS OF AN E-MOTOR WITH THE IMPLEMENTATION OF SIMULATION MODEL.

This thesis aims to investigate the thermal analysis of an electric motor and the application of simulations to study the thermal behaviour of the system. The main objective is to assess the critical temperatures reached inside the motor and to identify areas of possible overheating or thermal stress. Through this thesis, it is hoped to contribute to the development of increasingly efficient and reliable electric motors. Thermal analysis and simulations are essential tools to ensure the sustainability and efficiency of electric vehicles, thus contributing to the transition towards cleaner and more environmentally friendly mobility. This project consists in the thermal analysis of VI PMSM, through simulation and real measurements, with the goal of better understanding the thermal process inside this motor and to collect data to improve the simulation model. So, to use in future this model and implement it in the test process. The development of the thesis takes place in X phases reported above: 1)??Theory and literature review: a.??Study and evaluate, theoretically and mathematically, which are the losses inside an e-motor. b.??Understand how the heat, produced by the losses, spreads from the heat sources to the outside and to the other components of the motor. c.??From previous theoretical studies, figure out which are the hotspots in this kind of motor that should be investigated with more focus. 2)??Assembling of the prototype motor and simulation model improvement: a.??Discuss with suppliers which known and new technologies can be implemented and used to get the desired measurements, and real possibilities to place additional sensors. b.??Proceed in the assembly and calibration of new sensors. c.??Work on improving the Motor-CAD model, through BOM review and reverse engineering. 3)??Tests and simulations: a.??Set the test bench for testing the prototype motor previously assembled. b.??Discuss which kind of test can and should be performed. c.??Proceed with testing and simulations. 4)??Conclusions: a.??Analyse the real measurements and compare them with the simulations performed in Motor-CAD. b.??Understand the thermal behaviour and performances of the motor and what can be improved. c.??Make and collect suggestions, analysing pro and cons.