高速油冷扁线电机定子油路结构设计及散热特性分析

Structure Design of Stator Oil Circuit and Thermal Characteristics Analysis for High-Speed Oil-Cooled Flat Wire Motor

  • 摘要: 高速、高集成度、高效是车用驱动电机的发展方向,高速永磁扁线电机越来越多用于新能源汽车. 然而,随着电机转速和集成度的提升,扁线绕组的交流损耗和铁芯涡流损耗增大,电机温升增加、效率下降. 水冷式和油水混合冷却方式很难满足高速电机散热要求. 文中提出一种高效散热的电机定子油冷结构,定子铁芯油道直接冷却铁芯、两端喷油环直接喷淋冷却端部绕组. 首先通过采用场-路耦合法,建立最高转速20000 r/min、峰值功率94 kW的永磁扁线驱动电机模型,计算多变工况下电机扁线绕组、铁芯和永磁体损耗. 然后,基于损耗计算结果,采用热网络法和有限元法,分析喷油环结构和油道布置对电机温升的影响. 仿真结果表明优化后的15个锥形沉孔喷淋环结构可以使扁线绕组平均温度降低8.76%,定子铁芯平均温度降低14.77%;采用定子铁芯交错结构时,扁线绕组平均温度降低16.89%,定子铁芯平均温度降低16.42%. 最后,通过电机温升试验验证定子油冷散热结构的有效性.

     

    Abstract: Due to the requirement of automotive motors on high speed, high integration, and high efficiency, high-speed permanent magnet flat-wire motors are being utilized increasingly in electric vehicles. However, with the increase in speed and integration, the alternating current losses and the core eddy current losses also increase, leading to an increase in motor temperature rise and a decrease in efficiency. To solve the problem, an efficient heat dissipation structure was proposed for motor stator oil cooling, cooling the stator core directly with oil channels, and cooling the end windings directly with two end oil spray rings. Based on a field-circuit coupling method, a model of permanent magnet flat-wire motor was established with a maximum featuring speed 20000 r/min and a peak power 94 kW to analyze the losses in the winding, core, and magnets under levity operation condition. And, the impact of the spray ring structure and the oil channel arrangement on the temperature rise of the motor was studied based on the thermal network and finite element method. Simulation results show that the average temperature of the winding can decrease by 8.76% and the average temperature of the stator core can decrease by 14.77% with an optimized spray ring arranged 15 conical sunk holes. Using a stator core with interleaved structure, the average temperature of the winding can decrease by 16.89% and the stator core can decrease by 16.42%. Finally, a motor temperature rise test was arranged for effectiveness validating of the stator oil-cooled heat dissipation structure of the stator oil-cooled heat dissipation structure.

     

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