A critical review on thermal management technologies for motors in electric cars

Wang, Xuehui; Bai, Li; Gerada, David; Huang, Kai‐Fa; Stone, Ian; Worrall, Sean; Yan, Yuying

doi:10.1016/j.applthermaleng.2021.117758

Cited by 124 publications

(41 citation statements)

References 191 publications

(207 reference statements)

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“…3. Mean absolute deviation of 10.6 % is noticed in calculation of Nu with respect to the Eq (8), which proves the accuracy of current numerical results.…”

Section: Grid Independence Analysis and Model Validationsupporting

confidence: 78%

“…Clean vehicles, including pure electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles and fuel cell electric vehicles, compared to conventional internal combustion vehicles, are effective to reduce GHSs and pollutants emission [3][4][5][6][7]. It is estimated that using renewable electric power resources and EVs could reduce the GHS emissions up to 40% [8]. Furthermore, with the rising interest and focus on the EVs, it is expected the 35% of the new cars will be electrified by 2040 [9].…”

Section: Introductionmentioning

confidence: 99%

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Effect of Different Inlet/Outlet Port Configurations on the Thermal Management of Prismatic Li-Ion Batteries

Singh

2022

Journal of Heat Transfer

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Lithium-ion (Li-ion) based batteries are the first choice to supply uninterrupted long power backup to the electric vehicles due to their high energy density, low self-discharge rate and good stability. However, the performance of Li-ion batteries is governed by the maximum temperature and uniformity of temperature distribution in the battery pack. Therefore, an efficient thermal management system is highly desired to keep the operating temperature and temperature distribution of battery pack within safe operating limits. Current work is carried out for that purpose. In the current work, different configurations of inlet and outlet ports have been studied numerically. It is observed that the way fluid leaves the cooling module significantly influences the flow and temperature distribution uniformity of battery pack. Significant improvement in the fluid flow distribution and consequently, lower temperature fluctuation is maintained by the front outlet configurations as compared to the side outlet configurations. Among all SS designs, only SS-Ib at Vin ≥ 5.6 m/s and SS-IV at Vin ≥ 4.8 m/s are found suitable for the thermal management of Li-ion battery pack at the studied range of flow rate. Whereas all SF designs maintained desired Tmax and ΔTmax conditions at Vin ≥ 4.8 m/s. Furthermore, a new design SF-V with open outlet is studied which results in reduction of Tmax by 5 °C and ΔTmax by 64.5% as compared to base design (SS-Ia) at same pressure drop penalty.

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“…3. Mean absolute deviation of 10.6 % is noticed in calculation of Nu with respect to the Eq (8), which proves the accuracy of current numerical results.…”

Section: Grid Independence Analysis and Model Validationsupporting

confidence: 78%

Section: Introductionmentioning

confidence: 99%

Effect of Different Inlet/Outlet Port Configurations on the Thermal Management of Prismatic Li-Ion Batteries

Singh

2022

Journal of Heat Transfer

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“…Thermal management is a key component in achieving the motor‘s efficiency, longevity, and safety. Demagnetization of magnets, ageing of insulation materials, decreased efficiency, shorter lifetimes, and even motor burnout are all results of thermal management failure [261] . The experiments involving polymeric materials in various thermal management techniques of air cooling, impingement cooling, spray cooling, immersion cooling, convection cooling for the stator, winding, and rotor will create the required knowledge pool [256,262] …”

Section: Research Avenues For Polymers In Automobilesmentioning

confidence: 99%

Recent Developments and Research Avenues for Polymers in Electric Vehicles

Gupta¹,

Toksha

Patel³

et al. 2022

The Chemical Record

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Plastics have been an indispensable material of choice in automobiles with wide range of applications such as interior, exterior, under the hood, and lighting/wiring applications. The prime motive of inclusion of these materials is increase in fuel efficiency and reduction in carbon footprint by replacing the energy intensive metallic counterparts. The current decade i. e., the 2020s has seen a recent surge in the sales of electronic vehicles. Although these numbers are promising, the growth in the rest of the parts of the world is not encouraging. It is primarily due to the skepticism involving battery life and efficiency, profitability, and environmental footprint when compared to conventional and hybrid vehicles. Also, a more concerted effort is needed in the lagging areas in order to install the required infrastructure. The emergence of plastics in the development and acceptance of e-vehicles is going to be pivotal especially when the efficiency and profitability are considered as they give the required freedom to the engineers for the design and development of various parts and sizes by replacing the bulkier and more dense materials. Also, the research on bionanocomposites has received great interest from the research community due to their versatility in application along with their eco-friendly nature throughout the lifecycle starting from feedstock up to end-of-life treatment. This review paper will be one of its kind to present a critical review of the recent developments of polymers suitable for use in e-vehicles. Also, a comprehensive discussion comprising of newer research areas for polymers in their use for e-vehicles will be presented.

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“…Further, a technique to cool end-windings by conduction to a liquid cooled annulus was proposed in [14], [15]. These cooling schemes typically occupy valuable stator slot crosssectional area, [9], [12]- [14], [16]- [19], which could otherwise be used for conductor material to reduce DC loss, or they rely on thermal conduction across material interfaces which tend to be poor, [16], [17], [20].…”

Section: Introductionmentioning

confidence: 99%

Direct Thermal Management of Windings Enabled by Additive Manufacturing

Simpson

Yiannakou

Felton

et al. 2023

IEEE Trans. on Ind. Applicat.

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The electrification and hybridization of groundand air-transport, in pursuit of Carbon Net Zero targets, is driving demand for high power-density electrical machines. The power-density and reliability of electrical machines is ultimately limited by their ability to dissipate internally generated losses within the temperature constraints of the electrical insulation system. As the electrical windings are typically the dominant source of loss, their enhanced design is in the critical path to improvements in power-density. Application of metal additive manufacturing has the potential to disrupt conventional winding design by removing restrictions on conductor profiles, topologies and embedded thermal management. In this paper, a modular end-winding heat exchanger concept is presented, which enables effective direct cooling without occupying valuable stator slot cross-section. In addition, this arrangement eliminates the need for a good stator-winding thermal interface, thereby allowing mechanical or other less permanent winding retention methods to be used, facilitating non-destructive disassembly and repair. A prototype winding is fabricated and experimentally tested to demonstrate the feasibility of the concept, yielding promising results.This work has been funded by EPSRC Grant Number EP/f02125X/1 and EP/S018034/1 as part of a Future Electrical Machines Manufacturing (FEMM) Hub feasibility study.

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A critical review on thermal management technologies for motors in electric cars

Cited by 124 publications

References 191 publications

Effect of Different Inlet/Outlet Port Configurations on the Thermal Management of Prismatic Li-Ion Batteries

Effect of Different Inlet/Outlet Port Configurations on the Thermal Management of Prismatic Li-Ion Batteries

Recent Developments and Research Avenues for Polymers in Electric Vehicles

Direct Thermal Management of Windings Enabled by Additive Manufacturing

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