Heat-pipes in electric machines : Heat management in electric traction motors

Abstract: The world is continually changing towards more energy efficient alternatives and less pollution. For the traction market, electric powertrains have become the go-to method, superior to both steam and diesel-electric hybrid systems. For subways and trams the natural development now is towards smaller motors with high power output, the goal is to use as much space as possible for the passengers and keep the performance of a larger motor setup. One problem with increasing the power density of the motors is that the accumulated heat from losses also increases per volume. All motors have different efficiency and different limits on temperatures in different parts. For this project a closed, self-ventilated traction motor with axis height 250mm (CSV250) was evaluated. The motor has an input power just above 140kW and the identified limiting factor is the temperature of the bearings, specifically the front bearing located at the fan side of the motor.   An already existing and partly validated ANSYS MotorCAD model was used for full system overview and as a guide to build a COMSOL Multiphysics model of the motor rotor. The COMSOL model could be effectively changed to represent different configurations of the solution. The COMSOL solver is based on the finite element method, FEM, whereas the MotorCAD model is built as a thermal network with lumped parameter method, LPM.    The proposed solution to the high temperature is implementation of heat-pipes in strategic positions. This project only contains evaluation of heat-pipes positioned in the center of the shaft deployed in three different configurations: a short heat-pipe transferring heat from the bearing to the fan, a long heat-pipe transferring heat from the active rotor parts to the fan and a long heat-pipe similar to previous case but with the heat-pipe insulted at the bearing section. The simulations yield performance specifications for the solution design that will give the expected result, complemented with theory this can then give the full appliable solution to the specified problem.   For the short heat-pipe case a decrease in temperature form 116.5 to 96.5°C was achieved in the front bearing by increasing the heat-transfer from the bearing towards the fan with 84.4W. This is well under the preferred temperature of maximum 110°C. In the long heat-pipe case a total of 360W was dispersed through the fan and this lowered the highest temperature point in the rotor from 172.2 to 160.8°C but with the negative effect of increasing the temperature of the front bearing. In the third case the insulation of the long heat-pipe in the bearing section managed to lower this increased temperature from 130.4 to 122.4°C while 360W were still transferred through to the fan. This is under the absolute maximum at 130°C but over 110°C. The results point towards the possibility to increase power density and keeping temperatures manageable using heat-pipes but further work and experiments is needed to prov the concept.