Parametric Thermal Sensitivity Analysis of 225kW High Speed PMSM for Blower Application

When a high-speed permanent magnet synchronous machine (HSPMSM) operates at full load condition, maximum temperature rises. The most temperature-sensitive part is the winding insulation that can affect the machine's lifespan and reliability. Thus, winding thermal optimization is essential. In this paper, the 225kW 34500 rpm PMSM with totally enclosed fan cooled axial ventilation system (TEFCAVS) has been taken as an example to be used in blower applications. Firstly, the fast estimation for the distribution of airflow and temperature by LPTN is predicted for the machine under full load conditions; then machine's hotspot temperature was identified. Secondly, parametric thermal sensitivity is conducted by design optimization Simulink's toolbox considering critical-parameters of TEFCAVS. The parameters with a remarkable influence on winding maximum temperatures, such as slot's linear thermal conductivity, lamination to housing interface contact, and airgap heat transfer, are chosen as a thermal design variable. The best variable can be obtained regarding the magnitude of influence and trend on mitigating maximum winding temperature. An investigation shows that the maximum winding temperature is mitigated significantly by the determined optimal thermal parameters. Finally, the 225kW HSPMSM is prototyped and tested with optimal thermal parameters; the winding temperature test results are then correlated with estimated results to validate the optimized thermal design.