Digital Twin-Enabled Predictive Thermal Modeling for Stator Temperature Monitoring in Induction Motors

Traditional motor temperature rise testing generally uses temperature sensors. To solve problems such as sensor detachment, aging, and space occupation, this study takes a three-phase asynchronous motor as an example to propose a method for building a temperature rise monitoring model driven by a multi-physics field model based on the digital twin framework of power equipment. A twin monitoring model with defined input–output parameters is constructed to solve the problems of measurement inconvenience in traditional methods. Firstly, the losses of the iron core and the winding copper in the motor were obtained through electromagnetic field simulation. Secondly, the temperature distribution of the motor stator was obtained based on the bidirectional coupling characteristics of the magnetic and thermal fields. Subsequently, a temperature field reduced-order model based on the proper orthogonal decomposition method was built in Twin Builder, achieving fast calculation of the motor stator temperature. Finally, using the YE3-80M1-4 motor as the experimental subject, the model’s output results were compared with and validated against the experimental results. The results indicate that the simulation time of the reduced-order model is 2.1 s, and the relative error compared with the test values is within 5%, which confirms the practical applicability of the proposed method.