增程器风冷电机散热方案仿真分析及测试验证

Simulation Analysis and Test Verification of an Air Cooled E-Motor Heat Dissipation Design for Range Extender

风冷电机在小功率增程器市场有广泛的应用,特别是工程机械方面,但由于风冷方式的冷却能力相对较弱,需进行充分的散热验证。本文以一台额定功率25kW增程器用风冷电机为研究对象,首先采用流-热-固耦合模拟方法对电机壳外流场及电机各部件的温度分布和温升进行稳态仿真分析、对绕组温升进行动态仿真分析,再通过台架温升测试验证了风冷电机散热结构设计的合理性。分析结果表明该电机风冷散热方案满足散热需求,电机温升约为75℃,环境温度45℃的线圈最高温度为120℃,满足电机绝缘耐热等级为F级的要求。电机的仿真温升和实测温升基本一致,验证该风冷散热设计方案设计的可行性和仿真方法的可靠性。

Air cooled e-motor is widely applied in low-power range extender,especially in engineer machinery.However,heat dissipation verification is required due to the weak air cooling capacity.In this paper,an air cooled e-motor for range extender with a rated power of 25 kW is studied.First,the steady-state simulation of the flow field outside the e-motor shell,the temperature distribution and temperature rise of the the e-motor parts are performed using the fluid-thermal-solid coupling simulation method.Second,the winding temperature rise is evaluated via dynamic simulation method.Last,the design verification of cooling structure of the air cooled e-motor is carried out through the bench temperature rise test.The results showed that e-motor dissipation performance meets the requirements.The temperature rise of the e-motor was 75℃.The maximum temperature of the coil was 120℃with an ambient temperature of 45℃.This meets the requirements of e-motor heat-proof class of F.The simulated temperature rise was consistent with measured temperature rise,which validates the heat dissipation design and the simulation method.