HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

SCHOOL OF ELECTRICAL AND

TECHNICAL REPORT
Name of paper: HEAT DISSIPATION OF PERMANENT MAGNETS FOR
ELECTRIC VEHICLES

Lecturer: Doctor Pham Van Tuynh

Student name: Lê Văn Hưng

Student ID: 20210417

Class ID:
Abstract

Permanent magnet synchronous motors (PMSM) are applied in electric vehicles due to their effectiveness such as
low loss, large torque, and high power density. The improvement of PMSM requires more attention to related
systems, therefore, this paper focuses on optimizing the cooling system for the motor, by creating a model design
and experimental simulation for heat dissipation. First of all, we will show an overview of the PMSM and the
thermal management system. Next, we design the cooling systems based on the analysis of heat transfer model and
water cooling system, which includes water-oil cooling and the spoilers, and electromagnetic-thermal coupling of
cooling channels in the deepened stator slots. Finally, we optimize the model by study thirteen surrogate models,
then we use six multi-objective optimization algorithms (MOOAs) to select the optimal solution. The results show
that the effectiveness of the new cooling channels design is proved, and better cooling system can be achieved.

Nomenclatur
e
BBD Box-behnken design sampling
BP Back propagation neutral network
CCD Central composite design sampling
CFD Computation fluid dynamics
DT Decision trees
ELM Extreme learning machine
EVs Electric vehicles
GEK Gradient enhanced Kriging
GP Gaussian process
GR General regression neutral network
HSPMM High speed permanent magnet motor
KRG Kriging model
LHS Latin hypercube sampling
MOOAs Multi-objective optimization algorithms
MOOM Multi-objective optimization model
MSM Modified Shepard method
PRS Polynomial response surface method
RBF Radial basis function neutral network
RF Random forest
STPMSM Surface type permanent magnet synchronous motor
SVM Support vector machine
SVR Support vector regression
WAS Weighted average surrogate
OSF Optimal space filling design sampling
D Width of water channel
Q Connection angle of water channel
L Length of spoilers
B Width of spoilers
H Height of spoilers

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1. Introduction

Electrical vehicles (EVs) generate a great amount of heat when running at high speed, which may cause danger for
drivers, such as causing permanent demagnetization, which will reduce the motor’s power output and its used time.
The heat of the motor is primarily transferred from the copper loss and iron loss in the motor. Therefore, for the
safety and stability of the motor and the entire electrical vehicle, it is important to have proper cooling systems for
each part of the vehicle that can overheat, this paper focuses on building and optimizing heat dissipation for the
permanent magnet of the motor.

There are two main directions of motor heat dissipation. One is to design a lower loss motor to decrease the
temperature generated at its source, however, this method is difficult since the inherent losses and technical barriers.
The second method is to arrange corresponding thermal management systems on the motor, such as the water jacket,
oil slinger, and oil channel. This method can achieve better heat dissipation effectiveness, so it has been widely
used.

Common methods of thermal management include air cooling, liquid cooling, mixed cooling, etc. Air cooling is
mostly used at present due to its simple structure, convenient installation, and low price. Dong et al investigated the
properties of an open circuit air cooling high-speed permanent magnet motor (HSPMM) and studied the effects of
switching frequency and air gap length on power losses (1). Kim et al studied the effects of the auxiliary cooling fan
(air gap fan) on the high-speed induction motor winding cooling based on the electromagnetic thermal coupling
analysis method. By considering the thermal fluid characteristics and changes in heat flow caused by the air gap fan,
the cooling performance of the motor windings was analyzed and calculated (2). Focusing on liquid cooling, which
is an effective cooling method for motors, there are water cooling, oil cooling, glycol cooling, and others. Based on
different cooling locations, we divided it into motor internal cooling, motor external cooling, and others. Ponomarev
et al. investigated the cooling potential of oil-cooling permanent magnet synchronous motors and proposed a basis
for the selection of coolant flow parameters (3). Mixed cooling refers to cooling methods using multiple cooling
methods, such as water-oil mixed cooling and water-air mixed cooling. Chen et al. provided a dual circulation
cooling method for a totally enclosed permanent magnet motor. The outside was cooled by water circulation, and the
inside was cooled by air circulation. They design a 3D model of a fully enclosed permanent magnet motor with a
water jacket. And they proved the possibility of the scheme via thermal fluid analysis and experiments. The research
on cooling methods is not insightful enough, since the motor thermal management system only stays in designing
scheme, and fails to integrate with the popular engineering optimization model and algorithms.

This paper designs a water-oil mixed cooling system for a surface type permanent magnet synchronous motor
(STPMSM). The result of heat dissipation of the motor proves that a better cooling effect can be achieved. This
paper develops the application of the alternative model method into motor heat dissipation research. It implements
parametric modeling of the cooling system, designs experiments to collect sample points, and builds the motor
surrogate models. This paper takes design variables of spoilers width, length, and height, the motor water channel
width, water channel connection angle, water velocity, and oil velocity, and the design objectives are maximum
temperature (T max), water pressure ( Pw ), and oil pressure ( P0 ).

2. Methodology

The research object of the paper is a type of STPMSM. The motor model is shown in (Fig.1). We ignore the parts
that do not have much effect on heat dissipation and simplify some irregular components. The structural parameters
are presented in (Table 1), and the thermal conductivity is presented in (Table 2). To simplify the calculation, we
consider the loss of each part as the heat source of the motor because the heat is mainly generated by loss.

This section analyses the heat dissipation framework, as shown in (Fig.2), divided into five steps: Parametric
modeling, Initial simulation settings, Design experiments, Surrogate model building, and Model optimization and
solution. Via those steps. The heat dissipation analysis of the motor is completed. The detail of the analysis is shown
in the following sections.

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Fig.2

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2.1 Motor model

Fig.1

The structure of the motor is shown in (Fig.1). Motor mainly includes stator, rotor, permanent magnet, winding,
central shaft, and water jacket, these parts have certain effects on heat dissipation. The 3D assembly model of motor
is shown in Fig.2, which were designed by the three-dimensional modeling software CATIA.

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The common temperature grades of the motor includes seven levels. The motor is mainly in the temperature grade of
H (455K). Therefore, under the peak working condition of “rated speed and maximum output torque”, the
temperature can not pass over 455K to meet the design conditions. Figs. 4 and 5 are the stator temperature
distribution and mixed cooling temperature distribution respectively.

According to the motor flow line table in Fig. 8, the total flow of the motor coolant can be achieved, and the
maximum flow rate of the coolant at the water outlet can also be obtained to be 3.6 m/s. if the flow rate at the water
inlet is increased and the flow resistance of the shell water channel is decreased, the better heat dissipation effect of
the motor can be obtained[16,17].

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2.2 Analyse thermal management system:

The heat dissipation cycle is completed through the cooling water and cooling oil in the water jacket and the hollow
shaft, the hollow is connected to the oil tank.

3. Design analysis

3.1 Heat transfer model analysis:

Table 1
The strutural parameters of the STPMSM
Parameter value Unit
Outer diameter of rotor 72.4 mm

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 Inside diameter of rotor 30 mm
Outer diameter of stator 120 mm
Inside diameter of stator 74 mm
Air gap size 0.8 mm
Number of permanent magnets 4 EA
Effective length of motor 70 mm

Table 2
The thermal conductivity of the STPMSM
Part Material Thermal conductivity
(W/(m K))
Water jacket Aluminum 202.4
Shaft Steel 16.27
Stator Silicon steel 48
Rotor Silicon steel 48
Permanent magnet Magnet 9
Winding Copper 387.6
Air gap Air 0.4291
Water Water 0.6
Oil Oil 0.12

Using CFD (computational fluid dynamics) to analyze the liquid cooling heat transfer. The heat exchange between
the coolant and heat source is realized by the liquid cooling heat dissipation of the motor.

3.2 Cooling system design:

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- Water cooling and oil cooling analysis

The effectiveness of the given cooling scheme is proved by comparing the water oil mixed cooling with the
traditional water jacket cooling.

- Spoilers Analysis:

The spoilers can reduce the temperature of the motor from 325.043K to 320.018K, therefore, it is evident that the
application of the spoilers can improve the heat dissipation of the motor.

- Electromagnetic-thermal coupling of cooling channels in the deepened stator slots:

4. Optimize the model

4.1 Constructing surrogate model:

Using traditional predictive analysis methods and novel machine learning methods, including KRG, GEK, SVR,
PRS, MSM, DT, RF, GP, RBF, BP, and GR.

4.2. Model optimization

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5. Experimental result

Comparison between optimal value and actual value

Comparison between previous research and optimal solution:

6. Conclusion

This paper focuses on analyzing the water oil mixed cooling system of the STPMSM and shows a motor heat
dissipation optimization framework that can be promoted and applied. Through the optimization framework, the
heat dissipation optimization analysis of the cooling system is completed and the optimization heat dissipation
scheme of the motor is proposed. The main conclusions of this paper are as follows:

- A water oil mixed cooling system for STPMSM is studied, which effectively improves the heat dissipation of the
motor by means of internal oil circulation cooling and external water circulation cooling (with spoilers). And
compared with the pure water cooling scheme and the no spoilers scheme, the Tmax is reduced by about 5K.

- An optimization framework for motor heat dissipation optimization analysis is proposed. Through the steps of
parametric modeling, initial simulation settings, design experiments, surrogate model establishment, and model
optimization, the optimized heat dissipation scheme of the motor is obtained. Compared with the initial scheme, the
Tmax is reduced by 2K, however, the coolant pressure is higher.

In this way, in the actual industrial application process, the production of useless prototypes is greatly reduced, and
it can help designers accurately find the most suitable heat dissipation method and heat dissipation parameters,
which has important practical significance and economic value.

7. References

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