Finite-element modeling of thermal contact resistances and insulation layers in electrical machines

Small transition layers with a significant temperature drop, such as thermal contact resistances and thin insulation layers, are difficult to consider in coupled finite-element thermal/magnetic models of electrical machines. A novel approach using mesh cuts and duplicated nodes at the thin-layer position is derived and discussed here. Results are compared to classical methods involving the use of nonscaled and scaled finite elements. Practical examples demonstrate the features and implementation aspects of the methods used.