Research on cooling performance of natural air-cooled drive motor with internal oil-cooled chassis

doi:10.3785/j.issn.1006-754X.2024.03.411

2024, Vol. 31

Issue (6): 733-740 DOI: 10.3785/j.issn.1006-754X.2024.03.411

【Special Column】Key Technologies of Design, manufacture, operation and maintenance for New Energy Equipment and Their Applications under the Carbon Peaking and Carbon Neutrality Goals

Research on cooling performance of natural air-cooled drive motor with internal oil-cooled chassis

Zehao HUANG^1,²(

),Yanjing XIE²(

),Xiaoting ZHANG³,Yongpeng CAO³,Dong LI³

^1.Key Laboratory of Advanced Manufacturing Technology for Automobile Parts, Ministry of Education, Chongqing University of Technology, Chongqing 400054, China
^2.School of Vehicle Engineering, Chongqing University of Technology, Chongqing 400054, China
^3.Chongqing Tsingshan Industrial Co. , Ltd. , Chongqing 402761, China

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Abstract

Aiming at the problems of permanent magnet synchronous motors with high power density, large torque and small volume for vehicle driving, such as small effective heat dissipation area of traditional air-cooled structure and high temperature of internal components caused by electromagnetic loss during operation, an oil-air hybrid cooling method with natural air cooling of internal cavity oil-cooled chassis was proposed, to meet the temperature performance requirements of each component in the drive motor. The equivalent thermal network method was used to calculate the temperature of the stator winding, stator, permanent magnet and rotor in the drive motor under different working conditions, and the highest temperature of the drive motor appeared at the stator winding. Then, the temperature at the stator winding end of the drive motor was measured by experiment and compared with the simulation results. The relative error between the simulation results and the measured results was less than 5%. The results showed that the temperature of the stator winding and other components of the oil-air hybrid cooling drive motor under different working conditions dropped obviously and met the temperature performance requirements, which indicated that the oil-air hybrid cooling method had good heat dissipation performance and high cooling efficiency. The research results can provide reference for the development of heat dissipation systems for vehicle drive motors.

Key words： drive motor loss temperature oil-air hybrid cooling cooling performance

Received: 27 December 2023 Published: 31 December 2024

CLC:

U 469.72

Corresponding Authors: Yanjing XIE E-mail: zehaohuang@cqut.edu.cn;xie17853569663@163.com

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Cite this article:

Zehao HUANG,Yanjing XIE,Xiaoting ZHANG,Yongpeng CAO,Dong LI. Research on cooling performance of natural air-cooled drive motor with internal oil-cooled chassis. Chinese Journal of Engineering Design, 2024, 31(6): 733-740.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2024.03.411 OR https://www.zjujournals.com/gcsjxb/Y2024/V31/I6/733

内腔油冷机壳自然风冷驱动电机冷却性能研究

针对车辆驱动用高功率密度、大扭矩、小体积永磁同步电机的传统风冷结构有效散热面积小，以及运行时因存在电磁损耗而导致内部各部件温度过高的问题，提出了一种内腔油冷、机壳自然风冷的油风混合冷却方式，以满足驱动电机内部各部件的温度性能要求。采用等效热网络法计算了不同工况下驱动电机定子绕组、定子、永磁体和转子的温度，得到驱动电机的最高温度出现在定子绕组处。随后，通过实验对驱动电机定子绕组端部的温度进行了测量并与仿真结果进行对比，仿真结果与实测结果的相对误差均在5%以内。结果表明，不同工况下油风混合冷却驱动电机定子绕组及其余各部件的温度下降明显且均满足温度性能要求，说明油风混合冷却方式的散热性能良好，冷却效率高。研究结果可为车用驱动电机散热系统的研制提供参考。

关键词： 驱动电机, 损耗, 温度, 油风混合冷却, 冷却性能

Table 1 Basic parameters of drive motor

Fig.1 External characteristic curves of drive motor

Table 2 Operating parameters of drive motor under different working conditions

Fig.2 1/8 two-dimensional model of drive motor

Table 3 Simulation results of drive motor loss under different working conditions

Table 4 Equivalent thermal conductivity of each component and medium of drive motor

Fig.3 Equivalent thermal network node distribution of cooling system for drive motor

Table 5 Corresponding nodes of each component of drive motor

Fig.4 Simulation results of winding temperature with air-cooling under peak working condition

Fig.5 Simplified three-dimensional model of drive motor with oil-air hybrid cooling

Table 6 Factor level table for orthogonal design experiment of internal oil-cooling structure

Table 7 Simulation results of winding temperature under different parameter combinations (rated working condition)

Fig.6 Temperature simulation results of each component of drive motor with oil-air hybrid cooling

Table 8 Maximum steady-state temperature of winding with oil-air hybrid cooling

Table 9 Maximum transient temperature of winding with oil-air hybrid cooling

Fig.7 Burial position of PT100 thermistor at the end of winding

Fig.8 Experimental bench for drive motor temperature measurement

Fig.9 Comparison between simulation and measured values of winding end temperature under different working conditions

Table 10 Comparison of maximum temperature of winding end under different working conditions


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