Numerical Study on the Heat Transfer Characteristics of a Hybrid Direct-Indirect Oil Cooling System for Electric Motors

Direct liquid cooling technology has the potential to enhance the thermal management performance of electric motors with continuously increasing energy density. However, direct liquid cooling technology has practical limitations for full-scale commercialization. In addition, the conventionally used indirect liquid cooling imposes higher thermal resistance to cope with the increased thermal management performance of high power density electric motors. Therefore, this study proposes a hybrid direct-indirect oil cooling system as a next-generation cooling strategy for the enhanced thermal management of high power density electric motors. The heat transfer characteristics, including maximum winding, stator and motor housing temperatures, heat transfer coefficient, friction factor, pressure drop, and performance evaluation criteria (PEC), are investigated for different spray hole diameters, coolant oil volume flow rates, and motor heat loss levels. The computational model was validated with experimental results within a 5% error developed to evaluate heat transfer characteristics. The results show that spray hole diameter significantly influences cooling performance, with a larger diameter (1.7 mm) reducing hydraulic resistance while causing a slight increase in motor temperatures. The coolant oil volume flow rate has a major impact on heat dissipation, with an increase from 10 to 20 L/minute (LPM) reducing winding, stator, and housing temperatures by 22.05%, 22.70% and 24.02%, respectively. However, higher flow rates also resulted in an increased pressure drop, emphasizing the importance of the selection of a suitable volume flow rate based on the trade-off between cooling performance and energy consumption. Despite the increase in motor heat loss level from 2.6 kW to 8 kW, the hybrid direct-indirect oil cooling system effectively maintained all motor component temperatures below the critical threshold of 180 degrees C, confirming its suitability for high-performance electric motors. These findings contribute to the development and commercialization of the proposed next-generation cooling strategy for high power density electric motors for ensuring thermal stability and operational efficiency.