Optimizing coolant loop design across the stator core: A research study.

Area of Science:

• Engineering
• Thermal Management
• Electric Motors

Background:

• High-power electric motors generate substantial heat, necessitating effective cooling solutions.
• Current liquid cooling designs often limit motor power density.
• Optimizing coolant loop design is crucial for advanced motor performance.

Purpose of the Study:

• To investigate the impact of coolant channel placement on heat dissipation in high-power motor stators.
• To compare the thermal performance of novel coolant channel designs against conventional jacket cooling.
• To validate simulation findings with experimental data.

Main Methods:

• Computational fluid dynamics (CFD) simulations were employed to analyze various coolant channel configurations.
• Experimental testing was conducted to verify simulation accuracy and assess cooling feasibility.
• Air-proof tests were performed to evaluate the structural integrity of the coolant channels.

Main Results:

• Optimal coolant loop placement was identified as being tightly integrated with stator slots for maximum heat transfer.
• The optimized coolant channel design demonstrated superior heat dissipation efficiency over jacket cooling.
• The coolant channels maintained seal integrity up to 0.5 MPa pressure.
• Methods for reducing internal coolant pressure, such as increasing parallel loops or adjusting channel proximity to slots, were identified.

Conclusions:

• Integrated coolant channels across the stator core offer an efficient alternative to jacket cooling for high-power motors.
• Strategic placement of coolant channels is key to maximizing thermal performance and power density.
• The proposed cooling method is robust and feasible for practical applications.