Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives

Ken Chen; Wenda Feng; Feida Chen; Sangwhee Lee; Justin Paddock; Thomas M. Jahns; Bulent Sarlioglu

doi:10.1109/ECCE53617.2023.10362513

Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives

Ken Chen, Wenda Feng, Feida Chen, Sangwhee Lee, Justin Paddock, Thomas M. Jahns, Bulent Sarlioglu

Electric Drives Research

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

4 Scopus citations

Abstract

Thermal management is a crucial aspect in the design of motor and drive systems. This paper introduces a coordinated cooling approach utilizing both liquid and air to enhance the integrated motor drive's power density. The proposed solution incorporates a shared water jacket to cool both the machine and power electronics, combined with forced air ventilation for the end windings and rotor. This approach is structurally simpler, less expensive, and more effective than conventional non-interacting cooling schemes. The paper addresses the modeling of key thermal features and nonlinearities including material anisotropy, contact thermal resistance, and uneven winding loss distributions. In addition, this study utilizes a more detailed model of the loss distribution among the winding turns in each slot that delivers a higher level of accuracy. Finite Element Analysis (FEA) results demonstrate the effectiveness of the integrated cooling system for efficiently cooling the designed integrated motor drive system.

Original language	English
Title of host publication	2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023
Publisher	Institute of Electrical and Electronics Engineers Inc.
Pages	4487-4493
Number of pages	7
ISBN (Electronic)	9798350316445
DOIs	https://doi.org/10.1109/ECCE53617.2023.10362513
State	Published - 2023
Event	2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023 - Nashville, United States Duration: Oct 29 2023 → Nov 2 2023

Publication series

Name	2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023

Conference

Conference	2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023
Country/Territory	United States
City	Nashville
Period	10/29/23 → 11/2/23

Funding

ACKNOWLEDGMENT Support for this work has been provided by the US Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Vehicle Technologies Program Office Award Number DE-EE0008704. The authors also gratefully acknowledge the support of the Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC). Special thanks to JMAG and ANSYS for the access to FEA tools. JMAG was used for electromagnetic analysis and ANSYS was used for thermal and fluid analysis.

Keywords

Electric motor
FEA
electric vehicles
integrated motor drive
motor cooling
thermal management

Access to Document

10.1109/ECCE53617.2023.10362513

Cite this

Chen, K., Feng, W., Chen, F., Lee, S., Paddock, J., Jahns, T. M., & Sarlioglu, B. (2023). Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives. In 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023 (pp. 4487-4493). (2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023). Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.1109/ECCE53617.2023.10362513

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title = "Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives",

abstract = "Thermal management is a crucial aspect in the design of motor and drive systems. This paper introduces a coordinated cooling approach utilizing both liquid and air to enhance the integrated motor drive's power density. The proposed solution incorporates a shared water jacket to cool both the machine and power electronics, combined with forced air ventilation for the end windings and rotor. This approach is structurally simpler, less expensive, and more effective than conventional non-interacting cooling schemes. The paper addresses the modeling of key thermal features and nonlinearities including material anisotropy, contact thermal resistance, and uneven winding loss distributions. In addition, this study utilizes a more detailed model of the loss distribution among the winding turns in each slot that delivers a higher level of accuracy. Finite Element Analysis (FEA) results demonstrate the effectiveness of the integrated cooling system for efficiently cooling the designed integrated motor drive system.",

keywords = "Electric motor, FEA, electric vehicles, integrated motor drive, motor cooling, thermal management",

author = "Ken Chen and Wenda Feng and Feida Chen and Sangwhee Lee and Justin Paddock and Jahns, {Thomas M.} and Bulent Sarlioglu",

note = "Publisher Copyright: {\textcopyright} 2023 IEEE.; 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023 ; Conference date: 29-10-2023 Through 02-11-2023",

year = "2023",

doi = "10.1109/ECCE53617.2023.10362513",

language = "English",

series = "2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023",

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Chen, K, Feng, W, Chen, F, Lee, S, Paddock, J, Jahns, TM & Sarlioglu, B 2023, Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives. in 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023. 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023, Institute of Electrical and Electronics Engineers Inc., pp. 4487-4493, 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023, Nashville, United States, 10/29/23. https://doi.org/10.1109/ECCE53617.2023.10362513

Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives. / Chen, Ken; Feng, Wenda; Chen, Feida et al.
2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023. Institute of Electrical and Electronics Engineers Inc., 2023. p. 4487-4493 (2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives

AU - Chen, Ken

AU - Feng, Wenda

AU - Chen, Feida

AU - Lee, Sangwhee

AU - Paddock, Justin

AU - Jahns, Thomas M.

AU - Sarlioglu, Bulent

PY - 2023

Y1 - 2023

N2 - Thermal management is a crucial aspect in the design of motor and drive systems. This paper introduces a coordinated cooling approach utilizing both liquid and air to enhance the integrated motor drive's power density. The proposed solution incorporates a shared water jacket to cool both the machine and power electronics, combined with forced air ventilation for the end windings and rotor. This approach is structurally simpler, less expensive, and more effective than conventional non-interacting cooling schemes. The paper addresses the modeling of key thermal features and nonlinearities including material anisotropy, contact thermal resistance, and uneven winding loss distributions. In addition, this study utilizes a more detailed model of the loss distribution among the winding turns in each slot that delivers a higher level of accuracy. Finite Element Analysis (FEA) results demonstrate the effectiveness of the integrated cooling system for efficiently cooling the designed integrated motor drive system.

AB - Thermal management is a crucial aspect in the design of motor and drive systems. This paper introduces a coordinated cooling approach utilizing both liquid and air to enhance the integrated motor drive's power density. The proposed solution incorporates a shared water jacket to cool both the machine and power electronics, combined with forced air ventilation for the end windings and rotor. This approach is structurally simpler, less expensive, and more effective than conventional non-interacting cooling schemes. The paper addresses the modeling of key thermal features and nonlinearities including material anisotropy, contact thermal resistance, and uneven winding loss distributions. In addition, this study utilizes a more detailed model of the loss distribution among the winding turns in each slot that delivers a higher level of accuracy. Finite Element Analysis (FEA) results demonstrate the effectiveness of the integrated cooling system for efficiently cooling the designed integrated motor drive system.

KW - Electric motor

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KW - electric vehicles

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KW - motor cooling

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BT - 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023

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ER -

Chen K, Feng W, Chen F, Lee S, Paddock J, Jahns TM et al. Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives. In 2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023. Institute of Electrical and Electronics Engineers Inc. 2023. p. 4487-4493. (2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023). doi: 10.1109/ECCE53617.2023.10362513

Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives

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