Abstract
This paper proposes a new construction with a heat sink integrated into the concentrated wound coils of an axial flux, direct liquid cooled electrical machine. A preliminary assessment of the effectiveness of the heat sink and its position is made using computational fluid dynamics. Lumped-parameter thermal models are also developed, thus allowing accurate comparison of the thermal profile of the two constructions. Following experimental calibration of the model and thermal validation, the temperature profile of the new construction is compared to that from a traditional concentrated wound coil. The model is then used to estimate the effect of the new construction on the current density of the stator windings. The paper demonstrates that for an axial flux motor run at a typical operating point of 300 Nm and 1500 rpm, the maximum temperature is reduced by 87 K. The current density can be increased by 140% before the limiting maximum coil temperature is achieved.
Highlights
IntroductionConcentrated windings offer a high slot-fill factor, low cogging torque and greater fault tolerance [2]
This paper aims to improve the current density by developing a new construction of a concentrated winding in which a heat sink is integrated into the coil
This paper presents a means for improving current density by addressing the heat transfer from electrical machine windings, and is organized in the following manner
Summary
Concentrated windings offer a high slot-fill factor, low cogging torque and greater fault tolerance [2] Their simple manufacturing process lowers manufacturing costs [3]. The maximum winding temperature was shown to provide a major limitation for increasing the current and torque densities of the machines. This paper aims to improve the current density by developing a new construction of a concentrated winding in which a heat sink is integrated into the coil. This allows for a more effective cooling of the inner coils by reducing the thermal resistance.
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