Design of Low-Pressure Sand Casting Process for Water-Cooled Motor Shell in Electric Vehicle

Jin, Yanzhu; Song, Yulai; Liu, Yaohui; Chen, Wei; Sun, Chi

doi:10.1088/1742-6596/2101/1/012052

Cited by 3 publications

(2 citation statements)

References 3 publications

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“…The housing jacket is made of different alloys, and liquid distribution inside the jacket is provided by axial or tangential cooling ducts with rectangular cross-sections [42,[104][105][106]. The most common technology used to manufacture the housings of such motors is casting using aluminum alloys [137]. The design utilizing an axial arrangement of the ducts decreases the motor's temperature, but the load on the circulation pump is greater due to greater hydraulic losses (pressure drop) in the ducts (Figure 7) [35,102,103].…”

Section: Liquid Cooling Systemsmentioning

confidence: 99%

Recent Developments in Cooling Systems and Cooling Management for Electric Motors

Konovalov,

Tolstorebrov,

Eikevik

et al. 2023

Energies

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This study provides an overview of new trends in the development of cooling systems for electric motors. It includes a summary of academic research and patents for cooling systems implemented by leading motor manufacturers at TRL9. New trends in the cooling management of air and liquid cooling systems are discussed and analyzed with a focus on temperature distribution and its influence on the power-to-dimension ratio of electric motors. The prevailing cooling method for synchronous and asynchronous motors is air cooling using external fins, air circulation ducts, air gaps, and fan impellers to enhance efficiency and reliability. Internal cooling with rotor and stator ducts, along with optimized air duct geometry, shows potential to increase the power-to-dimension ratio and reduce motor size. Liquid cooling systems offer a power-to-dimension ratio of up to 25 kW/kg, achieved through redesigned cooling ducts, stator heat exchangers, and cooling tubes. However, liquid cooling systems are complex, requiring maintenance and high ingress protection ratings. They are advantageous for providing high power-to-dimension ratios in vehicles and aircraft. Discussions on using different refrigerants to improve efficient motor cooling are underway, with ozone-friendly natural refrigerants like CO2 considered to be promising alternatives to low-pressure refrigerants with high global warming potential.

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Section: Liquid Cooling Systemsmentioning

confidence: 99%

Recent Developments in Cooling Systems and Cooling Management for Electric Motors

Konovalov,

Tolstorebrov,

Eikevik

et al. 2023

Energies

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“…This implementation enables a potential increase in the PDR, reaching levels of 2.5-2.7 kW/kg [10,42]. Recent research has suggested that multi-circuit low-temperature cooling systems are a promising solution to provide reliable and safe operation of electric motors together with the high economic efficiency of the cooling method [44][45][46][47]. Such systems have a simple design of cooling circuits, are reliable, small, have flexibility of operation, a high reduction of stator and rotor temperatures, and good motor performance.…”

mentioning

confidence: 99%

Experimental Investigation of a Low-Temperature Three-Circuit Cooling System for an Electric Motor under Varying Loads

Konovalov,

Tolstorebrov,

Kobalava

et al. 2023

Energies

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This study investigates a low-temperature three-circuit cooling system for a 55 kW industrial electric motor. The cooling system provides an increase of the power-to-dimension ratio by 63%, together with an improvement in motor performance. The three-circuit cooling system includes water cooling of the housing and stator and air-cooling of the motor’s interior. The test results show that the motor efficiency was maintained in the range between 92.5 and 94.5%, with respect to the motor’s power. With power increases up to 90 kW, a winding temperature of 67 °C was observed during three hours of operation. This advancement is particularly valuable for vehicles, ships, and aircraft applications, where maximizing power within limited space is crucial. An analysis of the experimental data showed that the cooling system operates at an average efficiency of 79.2%, indicating that roughly 20% of heat was accumulated in the rotor. This leads to a gradual temperature rise, particularly in the rotor, posing a risk of overheating and failure during motor overloads above 90 kW. Enhancing the cooling efficiency within the motor’s interior can be achieved by incorporating extra heat exchangers, implementing evaporative heat transfer, and employing water-cooling circuits at lower temperatures. This, in turn, can boost the electric motor’s power-to-dimension ratio.

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Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part I: Changing Markets, Changing Products

Lehmhus

2022

Metals

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Design of Low-Pressure Sand Casting Process for Water-Cooled Motor Shell in Electric Vehicle

Cited by 3 publications

References 3 publications

Recent Developments in Cooling Systems and Cooling Management for Electric Motors

Recent Developments in Cooling Systems and Cooling Management for Electric Motors

Experimental Investigation of a Low-Temperature Three-Circuit Cooling System for an Electric Motor under Varying Loads

Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part I: Changing Markets, Changing Products

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