Research and optimization of additive electric machine liquid cooling jacket

Abstract

To evaluate the efficiency of cooling jackets, a set of CFD-calculations of traditional and prospective configuration in the program complex Ansys CFX was carried out. At the same time, optimization was carried out on the basis of a two-pass spiral cooling jacket by introducing various ribs and turbulizer pins. As a result of the conducted research it was determined that the traditional helical cooling jacket does not allow to provide the required quality of thermal regulation under the given boundary conditions and constraints, and the use of a two-pass spiral cooling jacket allows to significantly improve the thermal state of the structure, but to achieve the given requirements should adapt the design by introducing additional ribs and pins-turbulizers. The proposed final topology of the spiral double-entry cooling jacket with increased ribs, additional ribs in the channels around the inlet and outlet regions and turbulizer pins around the outlet region allows to provide high-quality thermal regulation of the structure with satisfaction of the requirement for the maximum temperature of the EM stator not more than 200°C. Double-entry spiral cooling jacket optimization was carried out by introducing different fins and turbulizing pins. The study demonstrated the advantages of liquid cooling jackets with complex configuration and local heat exchange intensification by introducing fins and turbulizing pins, which can be produced using additive manufacturing.