Multiobjectively optimized PMSynRM cooling for increased vehicle efficiency

Paper in proceeding, 2021

In this paper, a preliminary design of a representative light duty battery electric vehicle (BEV) traction electric motor with minimum rare-earth material content is presented. A quasi-3D approach for electromagnetic loss distribution is chosen to handle the higher end-winding temperatures. The losses from the electromagnetic solver are then fed into the full 3D conjugate heat transfer computations (CHT) to investigate electric motor cooling jacket concepts, which were designed using a novel full 3D fluid mechanic topology optimization approach. In the presented topology optimization technique, the design space is not limited to the parametrized geometric entity as done in the conventional parametric optimization technique, but instead the whole packaging space is taken as the parameter set. Dimensioned in a multidisciplinary fashion to meet thermal, fluid mechanic and electromagnetic requirements, the reported electric motor is expected to be cooled at a higher rate. Finally, a system study to quantify the impact of increased cooling on the traction motor is also included.