This paper studies the fluid flow and heat transfer characteristics of nanofluids as advance coolants for the cooling system of electric motors. Investigations are carried out using numerical analysis for a cooling system with spiral channels. To solve the governing equations, computational fluid dynamics and 3D fluid motion analysis are used. The base fluid is water with a laminar flow. The fluid Reynolds number and turn-number of spiral channels are evaluation parameters. The effect of nanoparticles volume fraction in the base fluid on the heat transfer performance of the cooling system is studied. Increasing the volume fraction of nanoparticles leads to improving the heat transfer performance of the cooling system. On the other hand, a high-volume fraction of the nanofluid increases the pressure drop of the coolant fluid and increases the required pumping power. This paper aims at finding a trade-off between effective parameters by studying both fluid flow and heat transfer characteristics of the nanofluid.

In this paper, the overall performance of an electric machine cooling system was examined in terms of heat transfer and fluid flow. The structure of the cooling system was based on the cooling jacket method. The cooling jacket contains spiral channels surrounding the stator and end-windings of the electric machine. Al₂O₃-water nanofluid is used inside the channels as the cooling fluid. The concentration of nanoparticles and the geometric structure of the cooling system have special effects on both aspects of heat transfer and fluid flow. Therefore, in this paper, the overall performance of the cooling system was evaluated by considering these effects. This study compared the importance of heat transfer and fluid flow performances on the overall performance of the cooling system. Numerical analyses were performed by 3D computational fluid dynamics and 3D fluid motion analysis. The analyses were carried out based on the 3D finite element method using the pressure-based solver of the Ansys Fluent software in steady mode.

Electrified powertrains in the transportation sector have increased significantly in recent years, thanks to the need for decarbonization of the on-the-road transport means. However, management of powertrains still deserves particular attention to assess necessary improvements for reducing electric consumption and increasing the mileage of the vehicles. In this regard, electric motor cooling is essential for maintaining optimal performance and longevity. In fact, as electric motors operate, they generate heat due to electric and magnetic phenomena as well as mechanical friction. If not properly managed, this heat can lead to decreased efficiency, accelerated wear, or even failure of critical components. Effective cooling systems ensure that the motor runs within its ideal temperature range, reducing the occurrence of the mentioned concerns. This improves operational reliability and, at the same time, contributes to energy savings and reduced maintenance costs over the components’ life. In this study, the cooling of the rotor of a 130-kW electric motor via refrigerating fluid circulating inside the shaft has been investigated. Two configurations of fluid passages have been considered: a direct-through flow crossing the shaft along its axis and a hollow shaft with recirculating flow, with three types of rotating helical configurations at different pitches. The benefits when using nanofluids as a cooling medium have also been evaluated to enhance the heat transfer coefficient and decrease temperature values. Compared with the baseline configuration using standard fluids (water), the proposed solution employing nanofluids demonstrates effectiveness in terms of heat transfer coefficients (up to 28% higher than pure water), with limited impact on pressure losses, thus reducing rotor temperature by up to 30 K with respect to the baseline. This study opens the possibility of integrating the cooling of the rotor with whole electric motor cooling for electric and hybrid powertrains.

This study investigates the cooling performance of a passive cooling system for electric motor cooling applications. The metal-based phase change materials are used for cooling the motor and preventing its temperature rise. As compared to oil-based phase change materials, these materials have a higher melting point and thermal conductivity. The flow field and transient heat conduction are simulated using the finite volume method. The accuracy of numerical values obtained from the simulation of the phase change materials is validated. The sensitivity of the numerical results to the number of computational elements and time step value is assessed. The main goal of adopting the phase change material based passive cooling system is to maintain the operational motor temperature in the allowed range for applications with high and repetitive peak power demands such as electric vehicles by using phase change materials in cooling channels twisted around the motor. Moreover, this study investigates the effect of the phase change material container arrangement on the cooling performance of the under study cooling system.