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Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

Conference ·
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This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.
Research Organization:
National Renewable Energy Laboratory (NREL), Golden, CO (United States)
Sponsoring Organization:
USDOE Advanced Research Projects Agency - Energy (ARPA-E)
DOE Contract Number:
AC36-08GO28308
OSTI ID:
1902310
Report Number(s):
NREL/CP-5400-84719; MainId:85492; UUID:a110711d-a78d-4373-a550-5c26f8987ab8; MainAdminID:68183
Country of Publication:
United States
Language:
English

References (12)

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Direct oil cooling of traction motors in hybrid drives conference March 2012
Additively Manufactured Hollow Conductors Integrated With Heat Pipes: Design Tradeoffs and Hardware Demonstration journal July 2021
Thermal Design and Simulation of winding cooling for permanent magnet synchronous motor of electric vehicle conference December 2021
Cooling System of Outer Rotor SPMSM for a Two-Seater All-Electric Aircraft Based on Heat Pipe Technology journal June 2022
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Heat transfer characteristics of spray evaporative cooling system for large electrical machines conference October 2015
Optimal design of cooling system for water cooling motor used for mini electric vehicle conference August 2017

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Related Subjects

DIRECT ENERGY CONVERSION
additive manufacturing
electric machines
heat pipes
specific power
thermal management system