Research On Heat Dissipation And Optimization Of Motor In Extended Range System

With the development and progress of chinese society,the problem of energy saving and environmental protection are increasingly valued by the state.Under this background,new energy vehicles have gradually stepped into people’s lives,among which the extended range electric vehicle has become the leader because of its high range of traditional vehicles and the environmental protection of pure electric vehicles.As the core part of extended range electric vehicle,range extender is mainly composed of generator and engine.Due to the limitations of electric vehicle space and the complex and changeable working environment,the range extender motor must have smaller volume,higher power density and stronger stability,which puts forward higher requirements for motor heat dissipation.This paper will take the 45 KW range extender motor produced by the school cooperative enterprise as the research object,to reduce the temperature of the motor as the research objective,through CAE software to simulate and optimize the heat dissipation of the motor.The work of this paper is divided into simulation and optimization.Firstly,the electromagnetic simulation model is established in MAXWELL to calculate the loss of each part of the original motor,and the total loss is verified by bench test.Then,taking the loss as the heat source,the simplified 3D model of the motor is simulated in the CFD software STAR CCM+,and the temperature rise experiment is set up to prove the effectiveness of the above CAE research method.According to the optimization target and prototype parameters,four kinds of cooling water jacket structures were designed.Through the simulation calculation of each structure,the results are analyzed from the aspects of motor temperature drop and pressure drop,and the optimization scheme meeting the design requirements is selected.Finally,the optimal solution of the cooling system is obtained by matching the best cooling water flow for the qualified scheme.The innovation of this paper lies in the combination of MAXWELL and STAR CCM +,which provides an accurate and feasible simulation method for solving the thermal fluid solid coupling problem of motor.In the design of the water channel of the motor,the innovative structures such as the interlayer connecting column and the water jacket increasing layer by layer are proposed,and their heat dissipation effect is tested through simulation analysis.Through the research of this paper,the heat dissipation scheme meeting the optimization requirements is obtained,and the final temperature drop can reach8.86%.It provides valuable reference for CAE simulation and cooling structure optimization design of extended range water-cooled motor.