Development of New Motor for Compact-Class Hybrid Vehicles

Sano, Shinya; Yashiro, Takahisa; Takizawa, Keiji; Mizutani, Tsukasa

doi:10.3390/wevj8020443

Cited by 33 publications

(14 citation statements)

References 1 publication

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“…The orange block , which is defined as (10), associates with heat exchange between the shaft and the flow. In addition, an equivalent thermal conductivity _ , -see (11), is used to simulate the natural convection heat transfer across the air-gap to the housing, where the housing is set at room temperature. The thermal conductive resistance of the coolant is _ , visualized as a light blue blockdefined in (12).…”

Section: A the Lumped Parameter Thermal Network (Lptn) For Static Statementioning

confidence: 99%

“…In order to overcome this drawback, an extra rotor cooling system is then used in such later-developed vehicles as the Tesla S60 [9], where the coolant is introduced into the system via a coupling connected to a stationary inner tube and is driven back to the gap between the injection tube and the hollow shaft. In addition, hollow-shaft cooling scheme has been combined with housing cooling [10] and the end winding spray cooling [11,12]. The much more detailed cooling approaches for automotive traction motors can be found in [13].…”

Section: Introductionmentioning

confidence: 99%

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Thermal Analysis of an Oil-Cooled Shaft for a 30 000 r/min Automotive Traction Motor

Gai

Chong

Adam

et al. 2020

IEEE Trans. on Ind. Applicat.

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This paper investigates an oil-based shaft cooling system as applied to a 30,000 rpm automotive traction motor. Firstly, iron and air friction losses are identified over a range of operating speeds. Analytical and numerical approaches are then proposed to estimate thermal performance of steady and dynamic states, respectively. Finally, experiments are conducted to evaluate the impact characteristics of this cooling system, such as the rotational speed, the inlet coolant velocity and the amount of heat loss. Based on simulation and testing of prototype, the shaft rotational velocity can significantly enhance the heat exchange between coolant and internal surface of the hollow-shaft, across whole length of the shaft. However, when the rotational velocity reaches 30,000 rpm, the effect of high rotational velocities on heat exchange weakens due to the flow becoming saturated.

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Section: A the Lumped Parameter Thermal Network (Lptn) For Static Statementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Thermal Analysis of an Oil-Cooled Shaft for a 30 000 r/min Automotive Traction Motor

Gai

Chong

Adam

et al. 2020

IEEE Trans. on Ind. Applicat.

View full text Add to dashboard Cite

show abstract

“…However, the main drawback with the housing water jacket cooling system is the occurrence of high thermal resistance between the coolant and end winding and rotor, where normally the hot spot appears. In order to overcome this drawback, the Chevrolet Bolt [2] and the Toyota Prius MY17 IV [3] introduce a direct oil spray cooling on the end winding and this can avoid the unnecessary thermal contact resistances. In addition, the Tesla S60 [4] has demonstrated a rotor cooling, which provides a practical method on the rotor overheating by shortening the heat flow path.…”

Section: Introductionmentioning

confidence: 99%

Numerical prediction and measurement of pressure drop and heat transfer in a water‐cooled hollow‐shaft rotor for a traction motor application

Gai

et al. 2021

IET Electric Power Appl

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This article addresses the rotating effect on the pressure loss and heat transfer coefficient (HTC) of a hollow‐shaft rotor cooling system for an automotive traction motor. Firstly, a numerical model based on computational fluid dynamics (CFD) was established to fully understand the mechanism of rotational flow patterns. Experiments were then performed to measure and compare heat exchange and pressure loss between rotating and stationary conditions with the assistance of an analytical thermal model. Finally, trends of pressure drop and HTC at various rotational rates were explained in detail. Based on CFD simulations and experimental prototype testing, two opposite effects: boosting or diminishing on pressure drop and heat transfer due to rotation have been identified. Moreover, the rotation can significantly improve the overall HTC and pressure loss of an axial turbulent flow. As a result, a significant drop in terms of rotor temperature is identified for an automotive traction motor when such a rotor cooling system is implemented.

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“…To overcome the above problem, one solution is to implement the novel oil spray cooling on EV motors as the latest cooling method. For instance, Toyota Company unveiled the combination of the hairpin winding and direct oil spray cooling method in its latest Toyota Prius [10]. This cooling enables to cool the end winding and rotor directly.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Prototype Axial Flux Switched Reluctance Electrical Machine

Tiismus

Kallaste

Vaimann

et al. 2021

2021 28th International Workshop on Electric Drives: Improving Reliability of Electric Drives (IWED)

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This paper presents a survey about implementing hairpin winding with an oil spray cooling system on the new generation of electrical vehicle (EV) motors as an option to produce high power density, high efficiency, costeffectiveness, lightweight, reliable EV motors. It provides the advantages and drawbacks of this rectangular winding compared to random winding and considers the hairpin winding production aspects. According to the high AC losses of this configuration, the paper considers two conventional approaches for calculating these losses with their advantages and drawback. Then it proposes the novel hybrid FEA method for calculating the AC copper losses to overcome the weaknesses of analytical and numerical methods. Finally, it provides a holistic view related to the oil spray cooling of the electrical machine and points the future work associated with this cooling method

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Development of New Motor for Compact-Class Hybrid Vehicles

Cited by 33 publications

References 1 publication

Thermal Analysis of an Oil-Cooled Shaft for a 30 000 r/min Automotive Traction Motor

Thermal Analysis of an Oil-Cooled Shaft for a 30 000 r/min Automotive Traction Motor

Numerical prediction and measurement of pressure drop and heat transfer in a water‐cooled hollow‐shaft rotor for a traction motor application

Additive Manufacturing of Prototype Axial Flux Switched Reluctance Electrical Machine

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