Aluminum represents a more sustainable choice than copper in windings of electric machine intended for passenger cars, offering cost and weight advantages at the expenses of higher DC resistance and ensuing losses at low frequency operations, such as in peak condition. However, the overall power loss and efficiency should be evaluated throughout the whole driving cycle of a specific application. This study demonstrates that the overall efficiency of aluminum solutions remains comparable to copper, primarily due to the fact that the most significant contributors to total losses are iron losses at low load and medium speed operations typical of passenger cars. Additionally, this research proves that, despite experiencing higher losses at peak conditions, the maximum winding temperature of the aluminum solution remains within acceptable limits throughout the driving cycle when using the same cooling system as copper. To validate these findings, a comprehensive assessment of the thermal performances of copper and aluminum is conducted using 3D finite element thermal analyses across the entire driving cycle. The analysis adopts a one-way coupled Conjugate Heat Transfer (CHT) approach to accurately evaluate the thermal behavior of both materials under real-world operating conditions.
Assessing Thermal and Efficiency Aspects of Aluminum Hairpin Motors in Passenger Cars / Raimondo, M.; Cutuli, G.; Nuzzo, S.; Barater, D.. - (2024), pp. 1-7. (Intervento presentato al convegno 2024 International Conference on Electrical Machines, ICEM 2024 tenutosi a Torino, ita nel 1-4 September 2024) [10.1109/ICEM60801.2024.10700377].
Assessing Thermal and Efficiency Aspects of Aluminum Hairpin Motors in Passenger Cars
Raimondo M.;Cutuli G.;Nuzzo S.;Barater D.
2024
Abstract
Aluminum represents a more sustainable choice than copper in windings of electric machine intended for passenger cars, offering cost and weight advantages at the expenses of higher DC resistance and ensuing losses at low frequency operations, such as in peak condition. However, the overall power loss and efficiency should be evaluated throughout the whole driving cycle of a specific application. This study demonstrates that the overall efficiency of aluminum solutions remains comparable to copper, primarily due to the fact that the most significant contributors to total losses are iron losses at low load and medium speed operations typical of passenger cars. Additionally, this research proves that, despite experiencing higher losses at peak conditions, the maximum winding temperature of the aluminum solution remains within acceptable limits throughout the driving cycle when using the same cooling system as copper. To validate these findings, a comprehensive assessment of the thermal performances of copper and aluminum is conducted using 3D finite element thermal analyses across the entire driving cycle. The analysis adopts a one-way coupled Conjugate Heat Transfer (CHT) approach to accurately evaluate the thermal behavior of both materials under real-world operating conditions.Pubblicazioni consigliate
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