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

Towhid Chowdhury, Salar Koushan, Ali Al-Qarni, Sina Vahid, Ayman El-Refaie, Kevin Bennion, Emily Cousineau, Xuhui Feng, Bidzina Kekelia

Research output: Contribution to journalArticlepeer-review

1 Scopus Citations

Abstract

This paper discusses steps taken to develop a novel 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 finite element analysis is used to determine optimum heat transfer coefficient of the convective boundaries. For some of the convective boundaries, fin-based surface area enhancement is required to reach a target combined overall heat transfer coefficient and surface area performance (UA). This enhancement is worked out using a combination of the Engineering Equation Solver tool and 3D thermal FEA. The thermal management system's UA, and by extension its specific power, sensitivity to coolant temperature is explored. Temperature distribution plots of optimized machine components are also presented and discussed. Lastly, additional heat pipe testing is carried out to study its maximum heat transfer capability's sensitivity to condenser coolant temperature and configuration.
Original languageAmerican English
Pages (from-to)3763-3772
Number of pages10
JournalIEEE Transactions on Industry Applications
Volume60
Issue number3
DOIs
StatePublished - 2024

NREL Publication Number

  • NREL/JA-5400-86676

Keywords

  • additive manufacturing
  • electric aircraft
  • electric machines
  • heat pipes
  • specific power
  • thermal management system

Fingerprint

Dive into the research topics of 'Thermal Management System for an Electric Machine With Additively Manufactured Hollow Conductors With Integrated Heat Pipes'. Together they form a unique fingerprint.

Cite this