Document Type

Article

Publication Date

10-2022

Publisher

Institute of Electrical and Electronics Engineers (IEEE)

Source Publication

IEEE Transactions on Industry Applications

Source ISSN

0093-9994

Original Item ID

DOI: 10.1109/ICEM51905.2022.9910662

Abstract

This paper provides an extensive and comprehensive analysis on characterization of additively manufactured coils and heat pipe based liquid cooling thermal management system, for a 250 kW and 5,000 rpm machine. AC and DC electrical tests at 140 Arms and 70 ADC are conducted on AlSi10Mg additively manufactured coils to extract their thermal and electrical characteristics. Heat pipes and liquid cooling test setups are described and discussed. The thermal discussion is concluded by experimental results showing the effectiveness of the thermal management system proposed in this paper. FEA are performed on the coils using ANSYS Maxwell to accurately predict the losses at frequencies and current levels where the experimental setups face limitations. The FEA calibration process is successfully implemented to match experimental results resulting in a maximum error of 2.4%. Moreover, the FEA results are used to predict experimental losses for the coils at 1250 Hz which is beyond the experimental setup limits.

Comments

Accepted version. IEEE Transactions on Industry Applications, (October 2022). DOI. © IEEE. Used with permission.

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