Thermal Dissipation of High-Speed Permanent Magnet Synchronous Motor Considering Multi-Field Coupling: Simulation Application and Experiment Realization

High-speed direct-drive Permanent Magnet Synchronous Motors (PMSMs), supported by elastic foil gas bearings, are integral to hydrogen fuel cells. However, some problems still need to be solved for the multi-field coupling analysis of PMSMs. For example, no detailed thermal dissipation analysis methods can be used for this type of PMSM. This study aimed to conduct calculation methods for the electromagnetic, loss and temperature fields. The process involved both calculation and experimental research. The parameters of a 10 kW and 90 kr/min PMSM were given, and the electromagnetic field and electrical performance were analyzed. Then, loss calculations were conducted to provide the basis for solving the thermal problem. Stator iron loss mainly contributed to the total electromagnetic loss, which accounted for 71.4%. Temperature field simulation was carried out using the water and air cooling methods, yielding the highest temperature value (375 K) at the stator pole shoes, and the temperature of the winding reached 363 K. Furthermore, operational experiments were carried out using electrical performance and temperature output data to verify the calculation results. The results obtained strongly indicated that the proposed models and method provided a reliable multi-field coupling analysis of PMSM thermal dissipation in engineering and industrial applications.