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Three stator cooling jacket concepts, including a new cooling jacket concept with parallel straight spiral channels, are evaluated for electric machine of mild hybrid electric car. Steady-state cooling jacket thermal flow analysis and transient-state full motor simulations with circumferential, axial, and spiral jacket concepts are carried out to predict their heat transfer performance and temperature distribution. A prototype motor has been made with the new jacket concept. Infrared thermography is performed to detect the transient temperature distribution of the motor stator windings and laminations for validation of the thermal flow analysis. [ABSTRACT FROM AUTHOR]

Through analytical equations followed by a systematic optimization study using high-fidelity finite-element (FE) models, the torque capability of three common synchronous machine technologies—namely, a permanent magnet (PM) synchronous machine (PMSM) with V-shaped rare-earth rotor magnets, a PMSM with deep V-shaped ferrite rotor magnets, and a synchronous reluctance machine (SynRM) with four layers of conforming flux barriers are compared for an application in a 48-V mild hybrid electric car. The optimization of the deep V-shaped ferrite PMSM automatically resulted in a spoke-type PM layout for maximum torque production. Yet, an optimized SynRM with conforming flux barriers was achieved that could produce a higher torque than ferrite PMSM. One machine technology is selected and six variants of it, with two rotor PM layouts each with three alternative pole-slot combinations, are subsequently subjected to a large-scale FE model-based drive-cycle design optimization. Various pole-slot combinations are methodically compared in terms of drive-cycle losses, active material cost, torque ripple, and PM demagnetization level. More than 20 000 designs were analyzed over ten energy-centric torque-speed points to identify an optimal design solution. The results of multiphysics analysis incorporating electromagnetics, computational fluid dynamics, and structural analyses are provided, including a study on three different water jacket concepts. A final design is prototyped and primary experimental results are provided. [ABSTRACT FROM AUTHOR]

Large-scale design optimization of electric machines is oftentimes practiced to achieve a set of objectives, such as the minimization of cost and power loss, under a set of constraints, such as maximum permissible torque ripple. Accordingly, the design optimization of electric machines can be regarded as a constrained optimization problem (COP). Evolutionary algorithms (EAs) used in the design optimization of electric machines including differential evolution (DE), which has received considerable attention during recent years, are unconstrained optimization methods that need additional mechanisms to handle COPs. In this paper, a new optimization algorithm that features combined multi-objective optimization with differential evolution (CMODE) has been developed and implemented in the design optimization of electric machines. A thorough comparison is conducted between the two counterpart optimization algorithms, CMODE and DE, to demonstrate CMODE’s superiority in terms of convergence rate, diversity and high definition of the resulting Pareto fronts, and its more effective constraint handling. More importantly, CMODE requires a lesser number of simultaneous processing units which makes its implementation best suited for state-of-the-art desktop computers reducing the need for high-performance computing systems and associated software licenses. [ABSTRACT FROM PUBLISHER]