Application Analysis of Novel Forced Air-Cooled in Outer Rotor Surface-mounted PMSM with High Power Density
Yu Zhanyang1, Hu Xuyang2, Li Yan2, Jing Yongteng2, Wang Jin2
1. School of Electrical Engineering Shenyang University of Technology Shenyang 110870 China; 2. National Engineering Research Center for REPM Electrical Machines Shenyang University of Technology Shenyang 110870 China
Abstract：Implementing ten key areas of Made in China 2025 has provided a broad platform has been provided to develop all-electric aircraft (AEA). At present, some countries and research institutions have developed AEA. However, only a few successful AEAs are published at home and abroad, and studies about driving motors for AEA are rarely published. Therefore, the research on driving motors with high power density and torque density is important for developing AEA. For this topic, an outer rotor surface-mounted permanent magnet synchronous motor (SPMSM) for two-seat AEA is taken as the research object, and its loss distribution, cooling system design, and temperature rise characteristics are discussed. A driving motor for AEA requires high power density and high torque density, resulting in an extreme state of magnetic load and electrical load. Therefore, it is important to analyze the accurate calculation of loss and the technology of loss suppression. Firstly, to reduce core loss, B35A230 self-bonded silicon steel sheet is used as stator and rotor core, the magnetic property of B35A230 is tested by the method of Epstein frame and ring specimen, and the ratio-loss curves at different frequencies and different flux densities are measured. According to the experimental results of the ring specimen method, a loss model is adopted to improve accuracy. The processing factor is considered, and magnetization modes and harmonic magnetic field are alternated and rotated. Secondly, the influences of slot opening width and axial segment of PM on eddy current loss are analyzed to reduce loss. Finally, to shorten the length of the winding end and reduce copper loss and weight, the processing method of a single-tooth core is adopted to manufacture the prototype, and the analytical model of DC copper loss is built. The loss of outer rotor SPMSM for AEA with high power density is mainly distributed on stator core and winding coils. Thus, traditional forced air-cooled cannot effectively transfer heat to the outside world through the casing and end cover. Due to the limitations of the working place, AEA has higher weight and heat dissipation requirements for the driving motor and its cooling system. The thermal problem of the driving motor is prominent, but water cooling and oil cooling will increase aircraft weight. In addition, because the loss of outer rotor SPMSM is mainly concentrated on the stator core and winding coils, the traditional forced air-cooling method cannot effectively transfer heat outside through the motor housing and end cover. Therefore, a high-performance cooling system based on heat pipe technology is used to solve the problems of excessive temperature rise and weight limitation. One end of the heat pipe is inserted into the stator core yoke, and the other is connected to the cooling structure. Three kinds of cooling structures are designed. Compared with the weight and heat dissipation of three cooling structures, the sunflower radiator was selected finally. On this basis, an experimental test system is built to test the cooling capacity of the proposed cooling system, and the cooling power and average convection coefficient of the radiator are obtained under different cooling conditions. Secondly, the distribution of temperature field under different working conditions, including continuous power, peak power, complete operating, and shock overload, is analyzed. Finally, a 22-pole, 24-slot SPMSM for AEA is designed and manufactured. The temperature rise distribution under different flight conditions is tested, which verified the effectiveness of the forced air-cooled system proposed in this paper.
于占洋, 胡旭阳, 李岩, 井永腾, 王瑾. 新型强迫风冷散热结构在高功率密度外转子表贴式PMSM上应用分析[J]. 电工技术学报, 2023, 38(24): 6668-6678.
Yu Zhanyang, Hu Xuyang, Li Yan, Jing Yongteng, Wang Jin. Application Analysis of Novel Forced Air-Cooled in Outer Rotor Surface-mounted PMSM with High Power Density. Transactions of China Electrotechnical Society, 2023, 38(24): 6668-6678.
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2023, Vol. 38 
