Numerical Modeling of Direct-Oil-Cooled Electric Motor for Effective Thermal Management 2020-01-1387
Electric motor performance is critically limited by amount of heat that can be effectively dissipated. Recent developments in electric motor cooling have been employing direct oil spray/splash based cooling for improved performance. Simulation of distinct two phase (air and oil) flow and associated heat transfer for such applications has been computationally very challenging, hence limited in modeling details. This paper describes a two phase numerical study in which oil flow and heat transfer within a direct-oil-cooled electric motor are analyzed using CFD software. This analysis determines the oil flow field around the electric motor and identifies potential hot spots. The temperature of motor components is predicted using a conjugate heat transfer approach. This method is used to generate a detailed temperature field of all the components of motor at different operating conditions. Numerical results are compared with the temperature measurements at discrete locations in motor.