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Experimental Study on Behavior of Coolants, Particularly the Oil-Cooling Method, in Electric Vehicle Motors Using Hairpin Winding

Author

Listed:
  • Taewook Ha

    (School of Mechanical Engineering, Chung-Ang University, Seoul 06974, Korea)

  • Nyeon Gu Han

    (School of Mechanical Engineering, Chung-Ang University, Seoul 06974, Korea)

  • Min Soo Kim

    (School of Mechanical Engineering, Chung-Ang University, Seoul 06974, Korea)

  • Kyu Heon Rho

    (School of Mechanical Engineering, Chung-Ang University, Seoul 06974, Korea
    School of Computer Science and Engineering, Chung-Ang University, Seoul 06974, Korea)

  • Dong Kyu Kim

    (School of Mechanical Engineering, Chung-Ang University, Seoul 06974, Korea
    School of Computer Science and Engineering, Chung-Ang University, Seoul 06974, Korea)

Abstract

This paper analyzes the characteristics of oil behavior in the oil-cooling of motors with hairpin winding to understand how to maximize cooling performance. The oil cooling is performed by directly spraying oil onto the motor components. The results show that as the temperature of the oil increases, the viscosity decreases, and the oil film is formed more evenly; however, oil splashing also increases. Similarly, as the flow rate increases, oil splashing also increases, but the amount of oil forming the oil film increases. However, the oil film is not affected by the rotor’s rotation. In contrast, the immersed oil is found to be closely related to the rotor’s rotation. As the rotational speed increases, the immersion oil is mixed with the air, and oil churning occurs. The mixing phenomenon increases as the temperature and flow rate of the oil increases. The higher the oil level, the greater the oil churning. As the oil is mixed with air, the heat transfer coefficient decreases, which adversely affects the thermal management of the motor. As a result, when considering the oil film and the immersion oil, the optimal oil temperature, flow rate, and oil level are at 60 °C, 0.140 kg/s, and 85 mm, respectively. The results of this paper give important information about EV motor cooling and can contribute to the development of high-performance motors.

Suggested Citation

  • Taewook Ha & Nyeon Gu Han & Min Soo Kim & Kyu Heon Rho & Dong Kyu Kim, 2021. "Experimental Study on Behavior of Coolants, Particularly the Oil-Cooling Method, in Electric Vehicle Motors Using Hairpin Winding," Energies, MDPI, vol. 14(4), pages 1-15, February.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:4:p:956-:d:497834
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    References listed on IDEAS

    as
    1. Chengming Zhang & Qingbo Guo & Liyi Li & Mingyi Wang & Tiecheng Wang, 2017. "System Efficiency Improvement for Electric Vehicles Adopting a Permanent Magnet Synchronous Motor Direct Drive System," Energies, MDPI, vol. 10(12), pages 1-27, December.
    2. Zabdur Rehman & Kwanjae Seong, 2018. "Three-D Numerical Thermal Analysis of Electric Motor with Cooling Jacket," Energies, MDPI, vol. 11(1), pages 1-15, January.
    3. Dong Hyun Lim & Moo-Yeon Lee & Ho-Seong Lee & Sung Chul Kim, 2014. "Performance Evaluation of an In-Wheel Motor Cooling System in an Electric Vehicle/Hybrid Electric Vehicle," Energies, MDPI, vol. 7(2), pages 1-11, February.
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    Cited by:

    1. Mingyu Choi & Gilsu Choi, 2021. "Modeling, Investigation, and Mitigation of AC Losses in IPM Machines with Hairpin Windings for EV Applications," Energies, MDPI, vol. 14(23), pages 1-18, December.
    2. Junjie Zhao & Bin Zhang & Xiaoli Fu & Shenglin Yan, 2021. "Numerical Study on the Influence of Vortex Generator Arrangement on Heat Transfer Enhancement of Oil-Cooled Motor," Energies, MDPI, vol. 14(21), pages 1-17, October.
    3. Dimitrios Rimpas & Stavrοs D. Kaminaris & Dimitrios D. Piromalis & George Vokas & Konstantinos G. Arvanitis & Christos-Spyridon Karavas, 2023. "Comparative Review of Motor Technologies for Electric Vehicles Powered by a Hybrid Energy Storage System Based on Multi-Criteria Analysis," Energies, MDPI, vol. 16(6), pages 1-24, March.
    4. Lino Di Leonardo & Giuseppe Fabri & Andrea Credo & Marco Tursini & Marco Villani, 2022. "Impact of Wire Selection on the Performance of an Induction Motor for Automotive Applications," Energies, MDPI, vol. 15(11), pages 1-19, May.

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