Thermal calculation and experimental study of a double-disk magnetic coupler

Aiming to tackle the difficulties and inaccuracies in calculating the temperature field of double-disk magnetic coupler, a novel thermal calculation method is proposed, integrating the equivalent thermal network method and CFD method. This approach deviates from traditional methods that substitute empirical formulas with rotational speed. An equivalent thermal network model is established to ascertain the temperature rise at each network node. Additionally, a fluid-solid coupling model is constructed, and the impact of uneven air temperature distribution on air density, specific heat capacity, dynamic viscosity, and thermal conductivity is analyzed using the least squares method. The results reveal that after incorporating variable temperature air physical properties, the high-temperature area of the copper conductor decreases, the calculated temperature rise aligns closer to actual values, and air friction loss on the copper surface is reduced by 6.5 %. Experimental verification, conducted on a 55 kW double-disk magnetic coupler, demonstrates maximum errors of 8.86 % and 6.53 % when comparing experimental values to those calculated by the equivalent thermal network method and CFD method, respectively, thereby validating the proposed method. This research provides a theoretical reference for thermal calculations in double-disk magnetic coupler.