Abstract
Designing an effective cooling system for high-power-density in-wheel motors of electric vehicles is required to avoid the irreversible demagnetization of the permanent magnet due to a rise in its temperature. In this study, a water-cooling channel was used between the stator and housing to evaluate the cooling performance of a 25 kW in-wheel motor utilizing the commercially available software Ansys Fluent 19.2. Initially, cooling channels with a single or pair of vortex generators have been used with varying heights for pressure drop evaluation considering the allowable pressure drop of 0.7 bar for a water pump. The results indicates that both a single and a pair of vortex generators satisfy the limit of a pressure drop at the height of 4 and 3 mm, respectively, and the cooling performances of two vortex generators were evaluated at these heights. It has been found that the cooling performance of a permanent magnet is enhanced by 4.1% and 6.5% using a single and a pair of vortex generators, respectively, compared to the cooling channel without a vortex generator. Furthermore, considering the ram air effect on water-cooling channels of in-wheel motors under high-speed conditions, the temperature of the permanent magnet is decreased by about 2.1 °C and was found to be 148.8 °C under the temperature limit of demagnetization of the permanent magnet.
Highlights
In recent years, following the increase in worldwide awareness towards environmental issues such as climate change, stringent regulations have been established for greenhouse gas standards to achieve carbon neutrality
Compared to the batteries used in internal combustion engines, the batteries used in electric vehicles are not sufficiently developed to produce large outputs; one of their limitations concerns battery thermal management for consistent performance [2,3]
High temperatures were observed under the maximum-speed conditions of the inwheel motor with a simple water channel; vortex generators were employed to decrease the temperature of the rotating unit, including the rotor core and permanent magnet
Summary
In recent years, following the increase in worldwide awareness towards environmental issues such as climate change, stringent regulations have been established for greenhouse gas standards to achieve carbon neutrality. It was suggested that the cooling performance of the motor was better at a smaller height and width of the channel but at the cost of a higher pressure drop It is evident from the above literature that numerous designs of the cooling channel have been used at different locations of the electric motor. Following the above reasons for the requirement of the cooling of in-wheel motor and considering the aforementioned limitations in the literature, a water-cooling method was applied to a 25 kW interior permanent-magnet-type in-wheel motor for effective heat dissipation in the present study. The investigation has been made to evaluate the cooling performance of the water channel considering the ram air effect under high-speed operating conditions of an actual in-wheel motor
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