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Cooling Strategies for an Electric Motor with Additively Manufactured Hollow Conductors and Distributed Power Electronics Integrated with Heat Pipes

Conference ·
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This paper discusses design tradeoffs and thermal modeling explored in cooling strategies for an aircraft propulsion electric motor with additively manufactured coils and distributed power electronics integrated with heat pipes. Design tradeoffs include heat pipe Qmax performance related to inclination, condenser configuration, coolant type, coolant flow path complexity, and ease of access to modular power electronics. Three cooling strategies were selected and realized into CAD models. These models were further evaluated using 3D thermal FEA and optimization tools to explore cooling geometry details that include fin thickness, spacing and count with the objective to minimize fin mass under a set of constraints. Lastly, motorette test data is presented comparing air versus liquid cooling of heat pipes.

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:
2294063
Report Number(s):
NREL/CP-5400-88774; MainId:89553; UUID:e42e3ef7-55b3-4e3d-aa05-184bee8bebfe; MainAdminId:71780
Resource Relation:
Conference: Presented at the IEEE Energy Conversion Congress and Exposition (ECCE), 29 October - 2 November 2023, Nashville, Tennessee
Country of Publication:
United States
Language:
English

References (2)

Designing the Insulation System for Motors in Electrified Aircraft: Optimization, Partial Discharge Issues and Use of Advanced Materials December 2021
Design of High Current, High Power Density GaN Based Motor Drive for All Electric Aircraft Application November 2022

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Related Subjects

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION,ENGINEERING
additive manufacturing
cooling strategy
design tradeoff
electrical machine
heat pipes
motorette testing