Thermal Models and Electrical Machine Performance Improvement Using Encapsulation Material

This paper presents thermal finite-element analysis and experiments to demonstrate improvement of electrical machine performance using end-turn encapsulation materials with high thermal conductivity. The thermal performance of electric machines is an extremely important factor for power density and operating life. Forced air and liquid cooling are used to achieve required thermal management and high power density in many modern applications, but addition of high thermal conductivity materials can be adopted and used to reduce temperature rise and increase the machine's output capabilities as well. Thermal finite-element models are developed and evaluated to compare different encapsulation materials under various operating points in this paper. Finally, experimental validation is performed for each case to prove the thermal analysis and to demonstrate the improved machine output capabilities when thermally conductive encapsulants are used.