Abstract: As power densities exceed 10 kW/L in modern motors, effective thermal management becomes paramount. This article contrasts passive cooling (heat sinks, phase-change materials) with active systems (liquid cooling, forced convection). Computational fluid dynamics (CFD) simulations are used to optimize coolant flow paths in hairpin-wound motors, while experimental data highlights the benefits of nano-fluids and microchannel heat exchangers. Tradeoffs between weight, cost, and thermal resistance are quantified for aerospace and electric vehicle (EV) applications.
Content Highlights:
3D-Printed Heat Exchangers: Additive manufacturing for complex geometries improving heat transfer efficiency.
Phase-Change Material (PCM) Integration: Thermal buffering in inverter-motor units for transient load handling.
Two-Phase Cooling Systems: Dielectric fluid selection for high-voltage motor insulation compatibility.
Condition Monitoring via Thermal Sensors: Prognostic algorithms for winding insulation degradation detection.
