Lumped Parameter Thermal Model for the Optimization of an Eddy Current Brake

Abstract

This work presents a thermal modeling approach for evaluating the maximum allowable excitation current in an electrically excited eddy current brake (ECB) integrated into electric vehicle drivetrains. Designed to meet UNECE Regulation No. 13 requirements, the model enables safe operation by predicting temperature development within the excitation windings and rotor. A lumped parameter thermal model (LPTM) is formulated using Biot number analysis to guide geometric simplification and ensure computational efficiency. The model accounts for anisotropic thermal properties, insulation effects, and worst-case boundary conditions. Validation is performed through thermal measurements on a physical rotor and comparison with a high-fidelity FEM simulation. Results confirm the model's accuracy and suitability for design optimization under thermal constraints.