An advanced lifetime prediction method for permanent magnet synchronous machines

In this paper, a system of coupled and interacting models for dynamic electric and thermal behavior of an electrical machine is presented. The models are specifically designed for maximum execution speed and are suitable for simulating the machine behavior over long time periods and even the entire lifetime of the machine. Nevertheless, the results proved to be remarkably accurate. Arbitrary electrical faults and thermal asymmetries can be simulated. The influence of the winding resistance and magnet temperature on the machine behavior is implemented. The machine models are connected to lifetime models for the winding insulation at different locations and for the bearings. The aging of those machine components over a driving cycle (CADC) was investigated for healthy case and a given machine design. The temperature distribution inside the machine was analyzed for that specific driving cycle.