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Title: Direct Lamination Cooling of Motors For Electric Vehicles

Abstract

Current designs for electric motors use a housing that acts as both a structural support and as a method of cooling the stator and rotor. This approach to cooling is not as effective as possible because heat must flow from the rotor and stator through the housing to the cooling media. Because the housing must contain the coolant, it is also larger, heavier, and more expensive than necessary. This project develops a motor that uses a direct lamination cooling (DLC) system, passing coolant directly through the stator and eliminating the need for bulky housing, thereby improving heat transfer. Motor size could be reduced by up to 30-40%, mass by up to 20-30%, and cost by up to 30%. Phase I demonstrated that reliable lamination-to-lamination seals and reliable stack-to-manifold seals can be achieved using the methods identified. The addition of the selected sealants adds only slightly to the thermal resistance and pressure drop compared with unsealed counterparts. Phase II builds electric motors and inductors using the DLC method, obtain comparative performance data on the effectiveness of the method, and then obtain operational use data on these components through long term testing in a representative environment. The long-term testing will ensure thatmore » real world aspects of motor and inductor operation (including vibration, temperature cycling, and the presence of electrical and magnetic fields) do not degrade the seals such that leaking occurs or that the thermal performance degrades.« less

Authors:
;
Publication Date:
Research Org.:
AeroViroment, Inc.
Sponsoring Org.:
USDOE
OSTI Identifier:
834533
Report Number(s):
DOE/ER/82940F
TRN: US200815%%596
DOE Contract Number:  
FG03-00ER82940
Resource Type:
Other
Country of Publication:
United States
Language:
English
Subject:
33 ADVANCED PROPULSION SYSTEMS; ELECTRIC-POWERED VEHICLES; ELECTRIC MOTORS; COOLING SYSTEMS; HEAT TRANSFER; PERFORMANCE; ROTORS; STATORS; DESIGN

Citation Formats

Rippel, Wally, and Kobayashi, Drayll. Direct Lamination Cooling of Motors For Electric Vehicles. United States: N. p., 2003. Web.
Rippel, Wally, & Kobayashi, Drayll. Direct Lamination Cooling of Motors For Electric Vehicles. United States.
Rippel, Wally, and Kobayashi, Drayll. 2003. "Direct Lamination Cooling of Motors For Electric Vehicles". United States. https://www.osti.gov/servlets/purl/834533.
@article{osti_834533,
title = {Direct Lamination Cooling of Motors For Electric Vehicles},
author = {Rippel, Wally and Kobayashi, Drayll},
abstractNote = {Current designs for electric motors use a housing that acts as both a structural support and as a method of cooling the stator and rotor. This approach to cooling is not as effective as possible because heat must flow from the rotor and stator through the housing to the cooling media. Because the housing must contain the coolant, it is also larger, heavier, and more expensive than necessary. This project develops a motor that uses a direct lamination cooling (DLC) system, passing coolant directly through the stator and eliminating the need for bulky housing, thereby improving heat transfer. Motor size could be reduced by up to 30-40%, mass by up to 20-30%, and cost by up to 30%. Phase I demonstrated that reliable lamination-to-lamination seals and reliable stack-to-manifold seals can be achieved using the methods identified. The addition of the selected sealants adds only slightly to the thermal resistance and pressure drop compared with unsealed counterparts. Phase II builds electric motors and inductors using the DLC method, obtain comparative performance data on the effectiveness of the method, and then obtain operational use data on these components through long term testing in a representative environment. The long-term testing will ensure that real world aspects of motor and inductor operation (including vibration, temperature cycling, and the presence of electrical and magnetic fields) do not degrade the seals such that leaking occurs or that the thermal performance degrades.},
doi = {},
url = {https://www.osti.gov/biblio/834533}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Jul 30 00:00:00 EDT 2003},
month = {Wed Jul 30 00:00:00 EDT 2003}
}