Thermal Analysis of a 90 kW Induction Motor During Charging and Operation in an Integrated Battery Charger System for Electric Vehicles Using FEM-Based Simulation

This paper presents a simulation-based thermal analysis of a 90 kW, three-phase induction motor integrated into a single-phase Integrated Battery Charger (IBC) system for Electric Vehicles (EVs). The IBC system is designed to charge a 48 kWh Li-ion battery by using five distinct charging levels, ranging from 120 V 12 A, 120 V 16 A, 230 V 16 A, 230 V 32 A, and 230 V 80 A. A Finite Element Method (FEM)-based simulation implemented in MATLAB has been employed to investigate the thermal behavior of the motor during both charging and operation-charging periods. The simulation results provide a detailed temperature distribution across various motor components, enabling a precise estimation of the motor's operational temperature within the charging system. By gaining a comprehensive understanding of the thermal profile, it is possible to optimize the motor's design and cooling strategy to ensure reliable and efficient operation under diverse charging conditions.