Thermal modeling of hollow conductors for direct cooling of electrical machines

A direct cooling design using hollow conductors with the coolant flowing inside can significantly improve the heat dissipation in an electrical machine. To predict the thermal performances of an electrical machine with such cooling configuration, this paper proposes a computationally efficient thermal model of hollow conductors with direct cooling features. The hollow conductor is modeled using four equivalent solid cuboidal elements with a three-dimensional thermal network and internal heat generation. The heat transfer coefficient between the coolant and conductors is determined by an empirical model considering fluid dynamics behaviors. Axial discretization is performed to take into account the nonuniform temperature distribution along the axial direction. Experimental validation is performed with a U-shaped hollow conductor test rig. Compared to computational fluid dynamics analysis, the proposed thermal model is much more computationally efficient, and thus can be incorporated into design optimization process and electrothermal simulations of the electrical machine over a driving cycle.