Comparison of Commonly Used Cooling Concepts for Electrical Machines in Automotive Applications

Lehmann, Robert; Künzler, Moritz; Moullion, Matthias; Gauterin, Frank

doi:10.3390/machines10060442

Cited by 16 publications

(15 citation statements)

References 29 publications

(39 reference statements)

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“…The thermal network method is short in calculation time, but its calculation accuracy depends on the rationality of the thermal network model. He, Chen and Lehmann et al [12], [13] used the fluid-solid coupled simulation to analyze the influence of different cooling methods, flow rate and coolant on the thermal design of the motor. Most motors use the finite element method to calculate the overall temperature [14][15][16].…”

Section: Introductionmentioning

confidence: 99%

Research on Cooling Problem of a Modular Permanent Magnet Synchronous Machine Based on a 3D Equivalent Thermal Network Method

Xu,

Liang,

et al. 2024

IEEE Access

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Due to the huge volume of gearless ball mill direct drive permanent magnet synchronous machine (PMSM), the unwinding modular technology is convenient for its redundant power control, manufacture and maintenance. Several module units are wrapped around the ball mill roller for direct drive. The motor frame adopts a modular structure to achieve complete decoupling between modules. And the cooling problem of the motor is very important for its stable operation. The traditional waterway structure design and cooling analysis methods are difficult to meet the engineering requirements of large modular permanent magnet synchronous machine (MPMSM). A 3D equivalent thermal network method is proposed to study the cooling problem of MPMSM. The design program of modular frame cooling structure is written based on a 3D equivalent thermal network method. According to the temperature distribution of each node, the cyclic check is carried out to quickly design the modular waterway. The cooling effect of the designed waterway structure is analyzed by fluid-solid coupled temperature field simulation. An 80kW prototype is developed and the temperature rise experiment is carried out. The simulation and experiment results prove the rationality of the 3D equivalent thermal network method for MPMSM cooling structure design.INDEX TERMS MPMSM, module decoupling, modular frame cooling structure, 3D equivalent thermal network, fluid-solid coupled temperature field

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Section: Introductionmentioning

confidence: 99%

Research on Cooling Problem of a Modular Permanent Magnet Synchronous Machine Based on a 3D Equivalent Thermal Network Method

Xu,

Liang,

et al. 2024

IEEE Access

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“…[9], The effects of coolant inlet temperature, altitude and inlet flow rate on the motor temperature rise were studied for a PMSM under peak operating conditions. Lehmann et al [10] analyzed numerous influencing factors for thermal design of electrical machines including different cooling methods, different volume flow rates and coolants. In Ref.…”

Section: Introductionmentioning

confidence: 99%

Impact of the Motor Length‐to‐Diameter Ratio on the Selection of Cooling Water Channels for the Permanent Magnet Synchronous Motor

Xiaoyuan,

Shuangshuang,

Lixin

et al. 2023

IEEJ Transactions Elec Engng

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Aiming at the problem of difficulties in heat dissipation for a permanent magnet synchronous motor (PMSM) with high power/torque density, the effect of motor length‐to‐diameter ratio (r0) on the selection of cooling water channels is investigated from the perspective of the geometric parameters of the PMSM in this paper. First, the 3‐D fluid–solid coupled heat transfer models of three actual motors with the length‐to‐diameter ratios of 0.27, 0.81 and 2.04 are established. Every model is calculated under spiral, axial and circumferential cooling water channels, respectively. The cooling effect, cooling energy loss and motor thermal balance are compared and analyzed. Then the optimal cooling water channel for each of three motors is confirmed. Further, the motor temperature rise and fluid differential pressure are plotted. The threshold of motor length‐to‐diameter ratios is determined at which the overall performance of the axial and circumferential cooling water channel is highly similar. The general conclusions of selection of cooling water channels for PMSMs with different geometry shape are summarized. Finally, a prototype with r0 = 0.27 is fabricated and tested, verifying the validity of the fluid–solid coupling simulation analysis. © 2023 Institute of Electrical Engineer of Japan and Wiley Periodicals LLC.

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“…The never-ending demand for power density increase and, thus, reducing the size of the electrical machines have made the thermal examination of their individual regions even more significant and essential [1][2][3][4]. A meticulous analysis of thermal effects has been a pivotal task for an optimum design and efficient operation for different types of electrical machines.…”

Section: Introductionmentioning

confidence: 99%

Thermal Effects in the End-Winding Region of Electrical Machines

et al. 2023

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The main heat transfer mechanism in the end-winding region of electrical machines is convection. In order to increase the air motion, the rotor is equipped with a series of blades. Their geometry is reflected in the fanning factor, i.e., the ratio between the rotor peripheral speed and air velocity. An accurate calculation procedure for the fanning factor has not yet been given. Knowing its value is crucial for the determination of air velocity and heat transfer coefficient (HTC), as the latter describes the end-winding heat removal capability. In this study, the convective heat transfer phenomena between the end winding and air inside the end-winding region were analyzed, with the heat generated only in the end winding, mimicked with a custom designed coil, and air moved by the blades. The analysis was performed by experimental testing and computational fluid dynamics (CFD) modeling. Measurements data were used to build a reliable CFD model. Further on, CFD results were used to derive a generalized analytical equation for calculation of the end-winding HTC, related to blade geometry and rotor rotational speed. The developed analytical model significantly improves the quality of real-time lumped circuit thermal modeling of electrical machines and, thus, enriches this field of science.

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Comparison of Commonly Used Cooling Concepts for Electrical Machines in Automotive Applications

Cited by 16 publications

References 29 publications

Research on Cooling Problem of a Modular Permanent Magnet Synchronous Machine Based on a 3D Equivalent Thermal Network Method

Research on Cooling Problem of a Modular Permanent Magnet Synchronous Machine Based on a 3D Equivalent Thermal Network Method

Impact of the Motor Length‐to‐Diameter Ratio on the Selection of Cooling Water Channels for the Permanent Magnet Synchronous Motor

Thermal Effects in the End-Winding Region of Electrical Machines

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