CFD Analysis of an Electric Motor's Cooling System: Model Validation and Solutions for Optimization

Gammaidoni, Tamara; Zembi, Jacopo; Battistoni, Michele; Biscontini, Giulia; Mariani, Alessandro

doi:10.1016/j.csite.2023.103349

Cited by 12 publications

(3 citation statements)

References 21 publications

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“…Research Subject Coolant Software Major Conclusions [15] Analysis of a cooling system for an internal permanent magnet synchronous motor (250 kW)…”

Section: Researchmentioning

confidence: 99%

Innovative Design of Cooling System for a High-Torque Electric Machine Integrated with Power Electronics

Sadeghianjahromi,

Bradley,

McMahon

2024

Machines

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The growth of electrical machine applications in high-torque environments such as marine propulsion and wind energy is encouraging the development of higher-power-density machines at ever higher efficiencies and under competitive pressure to meet higher demands. In this study, numerical simulations are performed to investigate the characteristics of air cooling applied to a 3 MW high-torque internal permanent magnet electric machine with integrated power electronics. The whole system of the main machine and two converters at either end are modelled with all details. Effects of different parameters on the total pressure drop and air flow rate to the machine and converters are examined. Results show that by changing the converter outlet hole size, the air flow rate to the machine and converter can be adjusted. Air guides and pin vents reveal excellent performance in the distribution of air to laminations and windings with a penalty of some increase in pressure drop, which is more pronounced when using smaller outlet holes. Furthermore, the air return manifold increases the pressure drop and causes a reduction in air flow rate to the converter. Insulation between compression plate and laminations is an unavoidable component used in electric machines and acts as a thermal insulator. However, it can also significantly augment pressure drop, especially in combination with smaller outlet holes. Thermal studies of the integrated power electronics illustrate that components’ temperatures are less than the temperature limit, confirming enough air through the converter. Analysis of power electronics in the case of fan failure provides the operational time window for the operators to respond.

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“…Research Subject Coolant Software Major Conclusions [15] Analysis of a cooling system for an internal permanent magnet synchronous motor (250 kW)…”

Section: Researchmentioning

confidence: 99%

Innovative Design of Cooling System for a High-Torque Electric Machine Integrated with Power Electronics

Sadeghianjahromi,

Bradley,

McMahon

2024

Machines

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“…For obtaining optimal designs for the structure of motor cooling systems, scholars attempted to establish more accurate temperature models or use optimization algorithms to seek solutions. Gammaidoni et al 23 constructed a model for investigating rotor’s overheating in complex motor geometries and provided two optimization solutions to reduce temperatures in a range from 25 K to 120 K. Wang et al 24 proposed a novel direct cooling structure for the primary core and windings and the proposed cooling structures can significantly reduce the thermal resistances between the heat source and the coolant and thus improves the cooling performance. Lin et al 25 used the NSGA-II optimization algorithm for conducting the multi-objective optimized driving strategy of dual-motor EVs.…”

Section: Introductionmentioning

confidence: 99%

Collaborative optimization on cooling channel flow resistance and winding temperature for integrated cooling of motor and controller

Tan,

Yuan,

Tang

2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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The efficiency and working performance of the motor and controller system in micro-electric vehicles depends mainly on its thermal performance, which is contingent upon effective and active cooling. The working temperature of the motor and controller may be too high during operation, which properly causes motor power reduction or motor breakdowns. Therefore, it is crucial to design a good cooling channel for better cooling the integrated motor and controller system. This work proposes an integrated cooling channel of motor and controller, and the fluid-solid coupling analysis is applied for analyzing the velocity, pressure distributions of the cooling channel, and temperature distributions of motor solid components. Meanwhile, the collaborative optimization method based on the multi-island genetic algorithm (MIGA) is used to attain optimal design parameters of the integrated cooling channel of the motor and controller for obtaining a better cooling channel design with lower flow resistance and lower winding temperatures. Results show that the original cooling channel’s flow resistance and maximum winding temperature are 31.87 kPa and 120.04°C, respectively. The flow resistance and winding temperature are pretty significant. After optimization, the local vortex flow and zero velocity area in optimal cooling channel design are improved, the coolant flow velocity becomes more uniform, and the flow resistance is significantly reduced. The flow resistance and maximum winding temperature of the optimal cooling channel design are 12.5 kPa and 116.76°C, respectively, which are decreased compared with the original cooling channel structure, with a decrease of 39.4% and 2.7%, respectively. The research findings in this work can provide theoretical reference for solid components temperature evaluation of motor and give valuable data to cooling performance evaluation and optimization of integrated cooling channel for motor and controller system.

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“…In addition, the motor rotor does not have a fan, as it is a ferromagnetic tube that rotates at a speed of 60…120 rpm. When the unit operates with a layer of loose material, the latter performs the function of a cooler when heated [5][6][7]. At the same time, the temperature of the rotor is kept within 100…135℃.…”

Section: Introductionmentioning

confidence: 99%

Simulation Model of Double Motors Screw Unit with a Solid Rotor in ANSYS Twin Builder

Pliuhin,

Tsegelnyk,

Trubai

2023

LEPE

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This article is devoted to solving the problem of simulation modeling of the electric drive system of two induction machines with an external solid rotor, rigidly connected to each other. This design is due to research aimed at optimizing mechanical characteristics and increasing the stability of the mixing regime of mixtures of loose materials of different dispersions using a multifunctional screw-type energy converter (MFEC). The task presents difficulties from the point of view of ensuring the productivity of drying wet loose material. On the one hand, in order to ensure a given percentage of moisture reduction during its advancement along the surface of the screw, it is necessary to have a low speed of rotation of the rotor to increase the contact time of the material with the hot surface of the rotor. On the other hand, reducing the rotation speed of the rotor reduces the intensity of its heating, which negatively affects the performance of the unit as a whole. A third challenge is to provide high torque at low rotational speed to prevent high-density material from buckling. In the previous publications of the authors, a study was conducted to solve such problems due to a specific combination of motor and brake modules of the auger, but such an approach did not give positive results. Solving the specified problems is possible due to the reproduction of such a complex electromechanical system and electric drive system in the ANSYS Twin Builder software. The article shows a detailed vector field-oriented control (FOC) system applied to two modules of the screw unit. Each of the modules represents a reduced-order model (ROM) that works in coupling simulation with the electromechanical processes in ANSYS Twin Builder. This paper will be useful both for specialists in the field of electric drive and for researchers who are engaged in the development of digital twins of complex systems.

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CFD Analysis of an Electric Motor's Cooling System: Model Validation and Solutions for Optimization

Cited by 12 publications

References 21 publications

Innovative Design of Cooling System for a High-Torque Electric Machine Integrated with Power Electronics

Innovative Design of Cooling System for a High-Torque Electric Machine Integrated with Power Electronics

Collaborative optimization on cooling channel flow resistance and winding temperature for integrated cooling of motor and controller

Simulation Model of Double Motors Screw Unit with a Solid Rotor in ANSYS Twin Builder

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