Travail de fin d'études et stage[BR]- Travail de fin d'études : Validation and calibration of the thermal models used in the motor optimisation tools developed in the ZONDA project[BR]- Stage d'insertion professionnelle

Abstract

Over the past few years, Punch Powertrain NV. developed a Multi-disciplinary Design Optimisation (MDO) platform for the design of their lie of electric machines for EV-Powertrains. Apart from the electromagnetic performance, the platform considers various fields of study such as structural, thermal and NVH behaviour when optimising a design. The studies in this master thesis revolve around the use of the thermal model within the MDO platform. First, the model was validated against mea surement data to calibrate the thermal network. The data was collected from a machine using a water jacket and hollow shaft cooling. It was shown that although some deviation exists between the model and measurements, no additional calibration was required. Following the validation, an MDO study was executed to demonstrate the benefits of adding direct oil cooling through jet nozzles aimed at the end-windings. The results showed an increase the volumetric power density (VPD) by 20 [%] can be achieved compared to water jacket alone. However, this VPD improvement comes with a decrease of the overall efficiency by 4.8 [%]. Finally, several parameters of the two initial cooling techniques was performed. It showed the best parameters for a better heat extraction are the fluid inlet temperature and flow rate. However, this comes at the price of a higher pumping power and a further power consumption.