Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors

Payam Shams Ghahfarokhi; Andrejs Podgornovs; Ants Kallaste; Toomas Vaimann; Anouar Belahcen; Antonio J.Marques Cardoso

doi:10.1109/IWED52055.2021.9376390

Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors

Payam Shams Ghahfarokhi^*, Andrejs Podgornovs, Ants Kallaste, Toomas Vaimann, Anouar Belahcen, Antonio J.Marques Cardoso

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

17 Citations (Scopus)

368 Downloads (Pure)

Abstract

This paper presents a survey about implementing hairpin winding with an oil spray cooling system on the new generation of electrical vehicle (EV) motors as an option to produce high power density, high efficiency, cost-effectiveness, lightweight, reliable EV motors. It provides the advantages and drawbacks of this rectangular winding compared to random winding and considers the hairpin winding production aspects. According to the high AC losses of this configuration, the paper considers two conventional approaches for calculating these losses with their advantages and drawback. Then it proposes the novel hybrid FEA method for calculating the AC copper losses to overcome the weaknesses of analytical and numerical methods. Finally, it provides a holistic view related to the oil spray cooling of the electrical machine and points the future work associated with this cooling method

Original language	English
Title of host publication	Proceedings of 2021 28th International Workshop on Electric Drives
Subtitle of host publication	Improving Reliability of Electric Drives, IWED 2021
Publisher	IEEE
Number of pages	5
ISBN (Electronic)	978-0-7381-4443-6, 978-1-6654-1456-2
DOIs	https://doi.org/10.1109/IWED52055.2021.9376390
Publication status	Published - 22 Mar 2021
MoE publication type	A4 Conference publication
Event	International Workshop on Electric Drives - Virtual, Online Duration: 27 Jan 2021 → 29 Jan 2021 Conference number: 28

Workshop

Workshop	International Workshop on Electric Drives
City	Virtual, Online
Period	27/01/2021 → 29/01/2021

Keywords

electric vehicle
electrical motors
hairpin winding
spray cooling
thermal management

Access to Document

10.1109/IWED52055.2021.9376390

ELEC_Ghahfarohki_et_al_Oil_Spray_Cooling_IWED_2021_acceptedauthormanuscriptAccepted author manuscript, 390 KB

Cite this

Ghahfarokhi, P. S., Podgornovs, A., Kallaste, A., Vaimann, T., Belahcen, A., & Cardoso, A. J. M. (2021). Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors. In Proceedings of 2021 28th International Workshop on Electric Drives: Improving Reliability of Electric Drives, IWED 2021 Article 9376390 IEEE. https://doi.org/10.1109/IWED52055.2021.9376390

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title = "Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors",

abstract = "This paper presents a survey about implementing hairpin winding with an oil spray cooling system on the new generation of electrical vehicle (EV) motors as an option to produce high power density, high efficiency, cost-effectiveness, lightweight, reliable EV motors. It provides the advantages and drawbacks of this rectangular winding compared to random winding and considers the hairpin winding production aspects. According to the high AC losses of this configuration, the paper considers two conventional approaches for calculating these losses with their advantages and drawback. Then it proposes the novel hybrid FEA method for calculating the AC copper losses to overcome the weaknesses of analytical and numerical methods. Finally, it provides a holistic view related to the oil spray cooling of the electrical machine and points the future work associated with this cooling method ",

keywords = "electric vehicle, electrical motors, hairpin winding, spray cooling, thermal management",

author = "Ghahfarokhi, {Payam Shams} and Andrejs Podgornovs and Ants Kallaste and Toomas Vaimann and Anouar Belahcen and Cardoso, {Antonio J.Marques}",

note = "Funding Information: This work has been supported by the European Regional Development Fund within the Activity 1.1.1.2 “Post-doctoral Research Aid” of the Specific Aid Objective 1.1.1 “To increase the research and innovative capacity of scientific institutions of Latvia and the ability to attract external financing, investing in human resources and infrastructure” of the Operational Programme “Growth and Employment” (No.1.1.1.2/VIAA/3/19/501). Publisher Copyright: {\textcopyright} 2021 IEEE. Copyright: Copyright 2021 Elsevier B.V., All rights reserved.; International Workshop on Electric Drives ; Conference date: 27-01-2021 Through 29-01-2021",

year = "2021",

month = mar,

day = "22",

doi = "10.1109/IWED52055.2021.9376390",

language = "English",

booktitle = "Proceedings of 2021 28th International Workshop on Electric Drives",

publisher = "IEEE",

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}

Ghahfarokhi, PS, Podgornovs, A, Kallaste, A, Vaimann, T, Belahcen, A & Cardoso, AJM 2021, Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors. in Proceedings of 2021 28th International Workshop on Electric Drives: Improving Reliability of Electric Drives, IWED 2021., 9376390, IEEE, International Workshop on Electric Drives, Virtual, Online, 27/01/2021. https://doi.org/10.1109/IWED52055.2021.9376390

Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors. / Ghahfarokhi, Payam Shams; Podgornovs, Andrejs; Kallaste, Ants et al.
Proceedings of 2021 28th International Workshop on Electric Drives: Improving Reliability of Electric Drives, IWED 2021. IEEE, 2021. 9376390.

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

TY - GEN

T1 - Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors

AU - Ghahfarokhi, Payam Shams

AU - Podgornovs, Andrejs

AU - Kallaste, Ants

AU - Vaimann, Toomas

AU - Belahcen, Anouar

AU - Cardoso, Antonio J.Marques

N1 - Conference code: 28

PY - 2021/3/22

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N2 - This paper presents a survey about implementing hairpin winding with an oil spray cooling system on the new generation of electrical vehicle (EV) motors as an option to produce high power density, high efficiency, cost-effectiveness, lightweight, reliable EV motors. It provides the advantages and drawbacks of this rectangular winding compared to random winding and considers the hairpin winding production aspects. According to the high AC losses of this configuration, the paper considers two conventional approaches for calculating these losses with their advantages and drawback. Then it proposes the novel hybrid FEA method for calculating the AC copper losses to overcome the weaknesses of analytical and numerical methods. Finally, it provides a holistic view related to the oil spray cooling of the electrical machine and points the future work associated with this cooling method

AB - This paper presents a survey about implementing hairpin winding with an oil spray cooling system on the new generation of electrical vehicle (EV) motors as an option to produce high power density, high efficiency, cost-effectiveness, lightweight, reliable EV motors. It provides the advantages and drawbacks of this rectangular winding compared to random winding and considers the hairpin winding production aspects. According to the high AC losses of this configuration, the paper considers two conventional approaches for calculating these losses with their advantages and drawback. Then it proposes the novel hybrid FEA method for calculating the AC copper losses to overcome the weaknesses of analytical and numerical methods. Finally, it provides a holistic view related to the oil spray cooling of the electrical machine and points the future work associated with this cooling method

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KW - electrical motors

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KW - thermal management

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BT - Proceedings of 2021 28th International Workshop on Electric Drives

PB - IEEE

T2 - International Workshop on Electric Drives

Y2 - 27 January 2021 through 29 January 2021

ER -

Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors

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Keywords

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