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

Chowdhury, Towhid; Koushan, Salar; Al-Qarni, Ali; Vahid, Sina; EL-Refaie, Ayman; Bennion, Kevin; Cousineau, Emily; Feng, Xuhui; Kekelia, Bidzina

doi:10.1109/tia.2024.3353720

Title: Thermal Management System for an Electric Machine With Additively Manufactured Hollow Conductors With Integrated Heat Pipes

Journal Article · 14 January 2024 · IEEE Transactions on Industry Applications

DOI: https://doi.org/10.1109/tia.2024.3353720 · OSTI ID:2298934

^[1]; Koushan, Salar ^[1];

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^[1]; Bennion, Kevin ^[2];

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Marquette Univ., Milwaukee, WI (United States)
National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Here, this paper discusses steps taken to develop a novel 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 finite element analysis is used to determine optimum heat transfer coefficient of the convective boundaries. For some of the convective boundaries, fin-based surface area enhancement is required to reach a target combined overall heat transfer coefficient and surface area performance (UA). This enhancement is worked out using a combination of the Engineering Equation Solver tool and 3D thermal FEA. The thermal management system's UA, and by extension its specific power, sensitivity to coolant temperature is explored. Temperature distribution plots of optimized machine components are also presented and discussed. Lastly, additional heat pipe testing is carried out to study its maximum heat transfer capability's sensitivity to condenser coolant temperature and configuration.

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Research Organization:: National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Organization:: USDOE Advanced Research Projects Agency - Energy (ARPA-E)

Grant/Contract Number:: AC36-08GO28308; AR0001352

OSTI ID:: 2298934

Report Number(s):: NREL/JA-5400-86676; MainId:87450; UUID:42290fb6-5323-4475-86c0-c506ccfd56e6; MainAdminId:71751

Journal Information:: IEEE Transactions on Industry Applications, Journal Name: IEEE Transactions on Industry Applications Journal Issue: 3 Vol. 60; ISSN 0093-9994

Publisher:: IEEECopyright Statement

Country of Publication:: United States

Language:: English

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32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
additive manufacturing
electric aircraft
electric machines
heat pipes
specific power
thermal management system

Title: Thermal Management System for an Electric Machine With Additively Manufactured Hollow Conductors With Integrated Heat Pipes

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