Thermal Mapping of a High-Speed Electric Motor Used for Traction Applications and Analysis of Various Cooling Methods—A Review

Abstract

This paper gives a comprehensive review of advanced cooling schemes and their applications to the permanent magnet synchronous motors (PMSMs), as well as investigating the electrical motor’s topologies its thermal design issues, materials and performances. Particularly, the electromagnetic and electric performances, machine sizing, together with the structural design, are given. In addition, the work addresses the motor’s material design and properties along with its insulation performance, which is the main goal of optimization. Mainly, thermal mapping with analysis is provided according to the different cooling methods, including air-cooling, water-cooling, oil-cooling, heat-pipe-cooling, potting silicon gelatin cooling, and as well as cooling strategies for tubes and microchannels. The most common special features and demands of the PMSMs are described in the appearance of the motor’s failures caused by uncontrolled temperature rise. In addition, heat sources and energy losses, including copper loss, core loss versus motor speed, and output power, are analyzed. The review of the proposed cooling methods that will achieve the required heat transfer of the PMSM is presented with numerical simulations and measurements data. A review of numerical methods and results, including the finite element methods (FEM), such as the Ansys CFD software, to obtain a high-accuracy thermal mapping model of the PMSM system is given. The revived methods and design requirements due to PMSM temperature profile and cooling flow at different rotor speeds and torque loads are investigated. Finally, the motor design recommendations, including the newly developed cooling solutions, which enable it to effectively redistribute the temperature and heat transfer, increasing the efficiency of the PMSM machine, are laid out.

Supporting the Transition Towards Electromobility in the Construction and Mining Sector: Optimization Framework and Demonstration on an Electrical Hauler

“…A gearbox is typically used to scale the output torque or speed, but due to the intrinsic nature of electric motors, i.e., their torque and speed characteristics and high overall efficiency contour, EVs are usually equipped with a single-or dual-speed gearbox (Sorniotti et al, 2011). But for battery EVs, there are many options for motors, such as induction motors, switched reluctance motors, and permanent magnet synchronous motors (PMSM) that all belong to the category of AC motors (Gundabattini et al, 2021).…”

Modeling and Simulation of Electric Motors Using Lightweight Materials

“…It has also been observed that most high-power applications of electric motors, such as high-performance cars (e.g., Tesla and Porsche) employ fluid-cooled electric motors It has also been observed that most high-power applications of electric motors, such as high-performance cars (e.g., Tesla and Porsche) employ fluid-cooled electric motors for better cooling efficiency compared to fan cooling, which also takes up space and can lead to overheating. Electric motors are used for various applications ranging from industrial to domestic applications, and induction motors (rotating or linear) are the most used units [7][8][9][10][11]. Water-cooling systems might suffer from leakage issues if not properly designed and maintained.…”

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

“…Various cooling systems for electric motors have been presented in the literature. Among them, the closedloop forced liquid cooling offers the best thermal performance compared to open-or closedloop forced air cooling [2][3][4]. In general, such topologies can be categorized according to the primarily cooled machine part into stator, shaft or end-winding cooling concepts.…”