A thermal modeling approach and experimental validation for an oil spray-cooled hairpin winding machine

Zhang, Fengyu; Gerada, David; Xu, Zeyuan; Liu, Chuan; Zhang, He; Zou, Tianjie; Chong, Yew Chuan; Gerada, Chris

Abstract

While the electromagnetic aspects of hairpin windings are actively being investigated and discussed in recent literature, including the design rules together with the loss calculation and reduction techniques, the thermal performance and modeling aspects have received less attention to date. In hairpin windings, the conductors (pins) are comparatively larger and arranged as separate components in parallel within the slot. In contrast, conductors randomly overlap and contact each other for traditional random windings. The differences in the aforementioned winding physical characteristics result in a different methodology to develop the thermal network. This article presents a 3-D lumped parameter thermal network (LPTN) approach for an oil-spray cooled hairpin winding, which includes the slot thermal model configuration, the end-winding connections, together with different methodologies of analyzing the end-winding sprayed oil characteristics. The aforesaid thermal model captures unique features related to the winding technology and cooling mechanism, such as the nonuniform end-winding temperature caused by the uneven oil-spray cooling effects. Finally, taking an existing propulsion drive hairpin stator and a bespoke-designed test setup, the presented steady-state thermal modeling approach is experimentally validated covering various experimental tests, including different spray conditions.

Citation

Zhang, F., Gerada, D., Xu, Z., Liu, C., Zhang, H., Zou, T., Chong, Y. C., & Gerada, C. (2021). A thermal modeling approach and experimental validation for an oil spray-cooled hairpin winding machine. IEEE Transactions on Transportation Electrification, 7(4), 2914--2926. https://doi.org/10.1109/tte.2021.3067601

• Journal Article Type: Article
• Acceptance Date: Mar 4, 2021
• Online Publication Date: Mar 19, 2021
• Publication Date: Dec 1, 2021
• Deposit Date: Nov 19, 2024
• Journal: IEEE Transactions on Transportation Electrification
• Electronic ISSN: 2332-7782
• Publisher: Institute of Electrical and Electronics Engineers
• Peer Reviewed: Peer Reviewed
• Volume: 7
• Issue: 4
• Pages: 2914--2926
• DOI: https://doi.org/10.1109/tte.2021.3067601
• Public URL: https://nottingham-repository.worktribe.com/output/35430971
• Publisher URL: https://ieeexplore.ieee.org/document/9381873