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Thermal modeling and experimental validation of mid-conductor winding cooling

Ilya T'Jollyn (UGent) , Jasper Nonneman (UGent) and Michel De Paepe (UGent)
(2024) HEAT TRANSFER ENGINEERING. p.1-16
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Abstract
A direct cooling method for windings of electrical machines, mid-conductor winding cooling, is studied. Spaces between the wires are utilized as coolant channels, with a liquid being pumped through the winding along the length. This results in the elimination of thermal interface resistances, a high heat transfer area and heat transfer coefficient while maintaining the same cross-sectional area for the copper winding. A thermohydraulic model is made and validated to analyze the heat transfer rates and pressure drop. Validation measurements with a water-glycol mixture as coolant show that the modeled and measured pressure drop correspond within 0.07 bar and the modeled and measured winding temperature within 3 °C. When made relative to the temperature difference between winding and coolant, the deviation is equal to 12%. The validated model is used to analyze the performance when utilizing oil as coolant. For a winding temperature of 180 °C and a pressure drop of 1 bar, using the novel cooling method results in a maximal attainable current density equal to 39.4 A/mm2 which is 41% higher than that attainable with spray end winding cooling.
Keywords
electric machine, windings, heat transfer, thermal management, direct oil cooling, mid-conductor winding cooling

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Citation

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MLA
T’Jollyn, Ilya, et al. “Thermal Modeling and Experimental Validation of Mid-Conductor Winding Cooling.” HEAT TRANSFER ENGINEERING, 2024, pp. 1–16, doi:10.1080/01457632.2023.2220470.
APA
T’Jollyn, I., Nonneman, J., & De Paepe, M. (2024). Thermal modeling and experimental validation of mid-conductor winding cooling. HEAT TRANSFER ENGINEERING, 1–16. https://doi.org/10.1080/01457632.2023.2220470
Chicago author-date
T’Jollyn, Ilya, Jasper Nonneman, and Michel De Paepe. 2024. “Thermal Modeling and Experimental Validation of Mid-Conductor Winding Cooling.” HEAT TRANSFER ENGINEERING, 1–16. https://doi.org/10.1080/01457632.2023.2220470.
Chicago author-date (all authors)
T’Jollyn, Ilya, Jasper Nonneman, and Michel De Paepe. 2024. “Thermal Modeling and Experimental Validation of Mid-Conductor Winding Cooling.” HEAT TRANSFER ENGINEERING: 1–16. doi:10.1080/01457632.2023.2220470.
Vancouver
1.
T’Jollyn I, Nonneman J, De Paepe M. Thermal modeling and experimental validation of mid-conductor winding cooling. HEAT TRANSFER ENGINEERING. 2024;1–16.
IEEE
[1]
I. T’Jollyn, J. Nonneman, and M. De Paepe, “Thermal modeling and experimental validation of mid-conductor winding cooling,” HEAT TRANSFER ENGINEERING, pp. 1–16, 2024.
@article{01H2FYRQPYZFCTHBQJ28E2Q9AN,
  abstract     = {{A direct cooling method for windings of electrical machines, mid-conductor winding cooling, is studied. Spaces between the wires are utilized as coolant channels, with a liquid being pumped through the winding along the length. This results in the elimination of thermal interface resistances, a high heat transfer area and heat transfer coefficient while maintaining the same cross-sectional area for the copper winding. A thermohydraulic model is made and validated to analyze the heat transfer rates and pressure drop. Validation measurements with a water-glycol mixture as coolant show that the modeled and measured pressure drop correspond within 0.07 bar and the modeled and measured winding temperature within 3 °C. When made relative to the temperature difference between winding and coolant, the deviation is equal to 12%. The validated model is used to analyze the performance when utilizing oil as coolant. For a winding temperature of 180 °C and a pressure drop of 1 bar, using the novel cooling method results in a maximal attainable current density equal to 39.4 A/mm2 which is 41% higher than that attainable with spray end winding cooling.}},
  author       = {{T'Jollyn, Ilya and Nonneman, Jasper and De Paepe, Michel}},
  issn         = {{0145-7632}},
  journal      = {{HEAT TRANSFER ENGINEERING}},
  keywords     = {{electric machine,windings,heat transfer,thermal management,direct oil cooling,mid-conductor winding cooling}},
  language     = {{eng}},
  pages        = {{1--16}},
  title        = {{Thermal modeling and experimental validation of mid-conductor winding cooling}},
  url          = {{http://doi.org/10.1080/01457632.2023.2220470}},
  year         = {{2024}},
}
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