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Review on cooling techniques and analysis methods of an electric vehicle motor

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Abstract

Electric motor is a critical component of an electric vehicle, and proper thermal management is essential for its efficient and reliable operation. As the electric vehicle industry continues to evolve, there is a growing demand for electric motors that can deliver superior performance and high efficiency. These motors are expected to be more powerful and provide higher torque, speed, and power density to meet the performance requirements of electric vehicles; therefore, effective cooling is essential to maintain optimal motor temperature. Improper thermal management causes several issues in electric motors, including demagnetization of magnets, insulation materials aging, reduced efficiency, shorter lifespan, and motor burnout. This article presents a brief review of cooling techniques for electric motors through both numerical and experimental investigations. The researchers have evaluated various cooling techniques for electric motors, which can be broadly categorized as active cooling, passive cooling, and hybrid cooling techniques. This review highlights the temperature variations in different motor components when these cooling techniques are employed, along with the methods used to analyze the motor under different operating conditions and parameters. In conclusion, the paper recommends the most effective cooling techniques for electric motor components based on the analysis performed, providing reasons for their selection. Liquid cooling and passive cooling techniques are found to be efficient thermal management techniques for which the findings are elaborated in detail.

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Abbreviations

AEA:

All electric aircraft

AFPMSM:

Axial flux permanent magnet synchronous motor

AIN:

Aluminum nitride

ANN:

Artificial neural network

BLDC:

Brushless DC motor

CAD:

Computer-aided design

CFD:

Computational fluid dynamics

CHC:

Channel cooling

DSC:

Direct slot cooling

DWHX:

Direct winding heat exchanger

EC:

Evaporative cooling

ETC:

End tip cooling

EV:

Electric vehicle

FEA:

Finite element analysis

FEPM:

Fully enclosed permanent magnet motor

HP:

Heat pipe

HTC:

Heat transfer coefficient in W m-2 K-2

HWDS:

Highway driving schedule

IM:

Induction motor

IPM:

Interior permanent magnet

IPMSM:

Interior permanent magnet synchronous motor

JC:

Jacket cooling

LPTN:

Lumped parameter thermal network

PCM:

Phase change material

PM:

Permanent magnet

PMSM:

Permanent magnet synchronous motor

RAVH:

Rotor axial vent hole

RCPI:

Rotor cooling performance index

RM:

Rounding module

SAVH:

Stator axial vent hole

SEME:

Straight embedded module enclosure

SRM:

Synchronous reluctance motor

UDDS:

Urban dynamometer driving schedule

WJC:

Water jacket cooling

°C:

Temperature in degree Celsius

2D:

2-Dimensional

3D:

3-Dimensional

dT:

Temperature difference

hp:

Horse power

I :

Current in amp

K :

Temperature in kelvin

k :

Loss coefficient

kW:

Power in kilowatts

min:

Time in minutes

s :

Time in seconds

R :

Resistance in ohms

σ :

Stefan-Boltzmann constant (W m-2 K-4).

ε :

Emissivity of the surface

ω :

Angular frequency (rad/s)

β :

Steinmetz constant

Cu:

Copper

Iron:

Iron

Ph:

Phase

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Authors and Affiliations

  1. Department of Mechanical Engineering, Visvesvaraya National Institute of Technology, Nagpur, Maharashtra, 440010, India

    Akshay G. Shewalkar, Ashwinkumar S. Dhoble & Vivek P. Thawkar

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  1. Akshay G. Shewalkar
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  2. Ashwinkumar S. Dhoble
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  3. Vivek P. Thawkar
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A.G.S. helped in idea for the article, literature search, and data analysis, V.P.T. was involved in literature search and draft review, A.S.D helped in critical revision of the work.

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Correspondence to Akshay G. Shewalkar.

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Shewalkar, A.G., Dhoble, A.S. & Thawkar, V.P. Review on cooling techniques and analysis methods of an electric vehicle motor. J Therm Anal Calorim (2024). https://doi.org/10.1007/s10973-024-13091-x

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