Reduced-order modeling of a cooling system for a variable pole induction motor

Miller, Holton C.

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https://hdl.handle.net/2142/129314 Copy

Description

Title

Reduced-order modeling of a cooling system for a variable pole induction motor

Author(s)

Miller, Holton C.

Issue Date

2025-05-08

Director of Research (if dissertation) or Advisor (if thesis)

• Miljkovic, Nenad
• Banerjee, Arijit

Department of Study

Mechanical Sci & Engineering

Discipline

Mechanical Engineering

Degree Granting Institution

University of Illinois Urbana-Champaign

Degree Name

M.S.

Degree Level

Thesis

Keyword(s)

Variable Pole Induction Motor, Electrothermal Codesign, Reduced Order Model, Drive Cycles

Abstract

Electrothermal co-design is an approach that has enabled e-machine designers to improve the capabilities of power electronics to meet high performance demands. The United State Department of Energy has established the goal of achieving an 88% reduction in motor and electronics volume in electronic traction drive systems, while also minimizing or eliminating the use of permanent magnets. Induction motors have been identified as viable alternatives to permanent magnet machines that provide the benefits of low cost, high reliability, and ruggedness. Adding pole count as an additional degree of freedom in induction motor design expands the speed and torque range of the motor while also improving power density and efficiency. In this work, the electrothermal codesign for a toroidally wound variable pole induction machine and cooling system is presented. Toroidal windings offer thermal benefits by increasing the available surface area for heat transfer. COMSOL Multiphysics and a Foster thermal equivalent circuit reduced order model are used in thermal design. The reduced order model is used to rapidly predict the maximum temperature rise in the stator windings when subjected to core and winding losses. Steady state operating conditions and transient drive cycles are simulated to assess the performance of cooling jacket designs. It is found the reduced order model is accurate to within 1 °C for both steady state and transient simulations compared to COMSOL. Using these techniques, the cooling jacket is optimized to minimize pumping losses while enabling the IM to safely operate with a large speed and torque range within temperature limits. The final cooling jacket design enables the IM to deliver 110 kW of continuous power and 200 kW of power for 30 seconds. Peak temperatures are also found to be below 115 °C during representative drive cycles. Simulation results are presented for the final, optimized cooling system design.

Graduation Semester

2025-05

Type of Resource

Thesis

Handle URL

https://hdl.handle.net/2142/129314

Copyright and License Information

Copyright 2025 Holton Miller

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