To meet the demands of an increasingly environmentally aware consumer, the automotive manufacturers have been actively pursuing hybrid electric vehicle power train systems. These power train systems typically combine a high output electric motor with a high efficiency internal combustion engine to achieve significant improvements in fuel economy and emissions. It is desirable to make the electric motor small so that it fits in the same under hood space as the standard power train. At the same time it is necessary for the electric motor to produce high torque in order to achieve the desired system performance. These conflicting requirements combined with the severe environmental conditions under the hood of the vehicle create an extremely challenging thermal design problem. A twenty-five kilowatt (peak power for one minute), permanent magnet electric machine for a hybrid electric vehicle application was designed and tested. The electric machine is located in the clutch housing of an automatically shifted manual transmission and is subjected to 120 deg C continuous ambient temperatures. The package constraints and duty cycle requirements resulted in an extremely challenging thermal design for an electric machine. The losses in the machine were predicted using models based on first principles and the heat transfer in the machine was modeled using computational fluid dynamics. The simulations were compared to test results over a variety of operating conditions and the results were used to validate the models. Parametric studies were conducted to evaluate the performance of potting materials and cooling topologies. Rotor losses and cooling methods were studied and methods for preventing demagnetization under extreme operating conditions were implemented and validated.
Thermal analysis of an electric machine for a hybrid vehicle
Thermische Analyse einer elektrischen Maschine für ein Hybridfahrzeug
2004
7 Seiten, 5 Bilder, 6 Tabellen, 4 Quellen
Conference paper
English
Thermal Analysis of an Electric Machine for a Hybrid Vehicle
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