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A Study on Scaling Laws for Thermal Parameters of Permanent Magnet Synchronous Machines

Right-sizing of electric machines can optimize the efficiency of electric vehicles and improve the driving range. Conventional scaling laws are based on magnetics without considering the thermal impacts. Therefore, the objective of this contribution is to find the scaling laws for the parameters in the low-order lumped parameter thermal model, which enable to evaluate the thermal overload of the permanent magnet synchronous machine in the electric powertrain optimization in an early development stage. By using the scaling laws the average temperature of the components can be well estimated. The average temperature deviation between scaling law and Motor-CAD yields less than 9 °C. In the sensitivity analysis, the thermal behaviors of the stator, the end winding and the rotor are demonstrated. The temperature development of the stator with different scaling factors is operating point dependent due to the different losses distribution. The length and the diameter of the PMSM has almost the same impact on the rotor temperature, while the end winding temperature is more sensitive to the radial scaling.