Thermal Real-Time Monitoring of a Gearbox Integrated IPM Machine for Hybrid-Electric Traction

Aiming to monitor the temperatures of critical components of gearbox integrated interior permanent magnet synchronous machines for hybrid-electric vehicles, we present the development of a real-time lumped parameter thermal network model. To this aim, sensitivity and heat flow path analyses are first carried out to identify the most relevant thermal paths. Next, the influence of the gearbox integration on the temperatures within the electric machine and its consideration in the modeling are investigated. The models are then verified experimentally, showing an accuracy of ±5 K. Finally, challenges and uncertainties of the real-time on-board modeling context are ultimately discussed.