Motorette Thermal Performance Testing and Modeling for an Electric Motor with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

Towhid Chowdhury, Salar Koushan, Sina Vahid, Ayman El-Refaie, Xuhui Feng, Emily Cousineau, Bidzina Kekelia

Research output: Contribution to conferencePaper

Abstract

This paper discusses the design, build and test of a motorette to characterize the thermal performance of an additively manufactured coil integrated with heat pipes. The motorette is powered using a variable frequency AC power supply and cooled through two independent cooling systems. The first cooling system cools the stator core using forced convection of air flowing over a finned heat sink mounted on the stator outer diameter. The second cooling system cools the heat pipes using forced convection of 50-50 water ethylene glycol (WEG) mixture flowing through condenser chambers. A 3D thermal FEA model of the setup is built and heat transfer coefficients (HTC) of convective boundaries are computed using coolant flow rates from test data and empirical equations. Temperature at locations on the coil and heat sink are recorded and compared to thermal model predicted values. A maximum temperature error of 22.7% occurs at 180ARMS and 800 Hz operating point for the AM dual coil. The thermal model provides higher temperatures compared to test results and hence it is on the conservative side but in general, there is good correlation between test and model results. Lastly, opportunities for improvement to both test data measurement and 3D thermal FEA modeling are discussed.
Original languageAmerican English
Pages4509-4515
Number of pages7
DOIs
StatePublished - 2023
EventEnergy Conversion Congress & Expo - Nashville, TN
Duration: 29 Oct 20232 Nov 2023

Conference

ConferenceEnergy Conversion Congress & Expo
CityNashville, TN
Period29/10/232/11/23

NREL Publication Number

  • NREL/CP-5400-87119

Keywords

  • additive manufacturing
  • electric machine
  • heat pipes
  • motorette
  • testing
  • thermal modeling

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