A New Concept of Direct Oil Cooling System for AFPM Machines, Numerical Analysis and Optimization

Given the strong growth of the electric drive industry, the automotive sector needs to increase the power density of its motors, leading to a size decrease and, consequently, to economic savings. The increase in power density brings with itself the consequence of increasing the Joule effect losses in the active conductors of the machine. For this reason, the problem of cooling turns out to be of utmost importance precisely because of its direct coupling with mechanical and electromagnetic design. This paper has the aim to perform a CFD analysis concerning the cooling system of a permanent magnet axial flux electric machine. The innovative cooling system studied is a direct one which takes advantage of oil to cool down the DC powered coils. The innovation brought by the present research lays in both the direct axial ejection and the use of oil as coolant. At the current state of art, the coolant flows tangentially and, moreover, water is usually employed instead of oil. The main aim of this analysis will be, after a validation of the numerical code by comparison of the literature data, to minimize the maximum temperature of the coil by means of the proper positioning of the nozzle. © 2024 Institute of Physics Publishing. All rights reserved.