Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

T. Chowdhury; S. Koushan; A. Al-Qarni; A. El-Refaie; Kevin Bennion; Emily Cousineau; Xuhui Feng; Bidzina Kekelia

doi:10.1109/ICEM51905.2022.9910918

Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

T. Chowdhury, S. Koushan, A. Al-Qarni, A. El-Refaie, Kevin Bennion, Emily Cousineau, Xuhui Feng, Bidzina Kekelia

Center for Integrated Mobility Sciences

Research output: Contribution to conference › Paper › peer-review

8 Scopus Citations

Abstract

This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.

Original language	American English
Pages	1920-1926
Number of pages	7
DOIs	https://doi.org/10.1109/ICEM51905.2022.9910918 https://doi.org/10.1109/ICEM51905.2022.9910918
State	Published - 2022
Event	2022 International Conference on Electrical Machines, ICEM 2022 - Valencia, Spain Duration: 5 Sep 2022 → 8 Sep 2022

Conference

Conference	2022 International Conference on Electrical Machines, ICEM 2022
Country/Territory	Spain
City	Valencia
Period	5/09/22 → 8/09/22

Bibliographical note

See NREL/CP-5400-82597 for preprint

NREL Publication Number

NREL/CP-5400-84719

Keywords

Additive Manufacturing (AM)
Electric Machines
Heat Pipes
Specific Power (SP)
Thermal Management System (TMS)

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Cite this

Chowdhury, T., Koushan, S., Al-Qarni, A., El-Refaie, A., Bennion, K., Cousineau, E., Feng, X., & Kekelia, B. (2022). Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes. 1920-1926. Paper presented at 2022 International Conference on Electrical Machines, ICEM 2022, Valencia, Spain. https://doi.org/10.1109/ICEM51905.2022.9910918, https://doi.org/10.1109/ICEM51905.2022.9910918

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title = "Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes",

abstract = "This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.",

keywords = "Additive Manufacturing (AM), Electric Machines, Heat Pipes, Specific Power (SP), Thermal Management System (TMS)",

author = "T. Chowdhury and S. Koushan and A. Al-Qarni and A. El-Refaie and Kevin Bennion and Emily Cousineau and Xuhui Feng and Bidzina Kekelia",

note = "See NREL/CP-5400-82597 for preprint; 2022 International Conference on Electrical Machines, ICEM 2022 ; Conference date: 05-09-2022 Through 08-09-2022",

year = "2022",

doi = "10.1109/ICEM51905.2022.9910918",

language = "American English",

pages = "1920--1926",

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Chowdhury, T, Koushan, S, Al-Qarni, A, El-Refaie, A, Bennion, K, Cousineau, E , Feng, X & Kekelia, B 2022, 'Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes', Paper presented at 2022 International Conference on Electrical Machines, ICEM 2022, Valencia, Spain, 5/09/22 - 8/09/22 pp. 1920-1926. https://doi.org/10.1109/ICEM51905.2022.9910918, https://doi.org/10.1109/ICEM51905.2022.9910918

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T1 - Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

AU - Chowdhury, T.

AU - Koushan, S.

AU - Al-Qarni, A.

AU - El-Refaie, A.

AU - Bennion, Kevin

AU - Cousineau, Emily

AU - Feng, Xuhui

AU - Kekelia, Bidzina

N1 - See NREL/CP-5400-82597 for preprint

PY - 2022

Y1 - 2022

N2 - This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.

AB - This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.

KW - Additive Manufacturing (AM)

KW - Electric Machines

KW - Heat Pipes

KW - Specific Power (SP)

KW - Thermal Management System (TMS)

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T2 - 2022 International Conference on Electrical Machines, ICEM 2022

Y2 - 5 September 2022 through 8 September 2022

ER -

Chowdhury T, Koushan S, Al-Qarni A, El-Refaie A, Bennion K, Cousineau E et al.. Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes. 2022. Paper presented at 2022 International Conference on Electrical Machines, ICEM 2022, Valencia, Spain. doi: 10.1109/ICEM51905.2022.9910918, 10.1109/ICEM51905.2022.9910918

Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

Abstract

Conference

Bibliographical note

NREL Publication Number

Keywords

Access to Document

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Cite this