Experimental Investigation of a Low-Temperature Three-Circuit Cooling System for an Electric Motor under Varying Loads

This study investigates a low-temperature three-circuit cooling system for a 55 kW industrial electric motor. The cooling system provides an increase of the power-to-dimension ratio by 63%, together with an improvement in motor performance. The three-circuit cooling system includes water cooling of the housing and stator and air-cooling of the motor’s interior. The test results show that the motor efficiency was maintained in the range between 92.5 and 94.5%, with respect to the motor’s power. With power increases up to 90 kW, a winding temperature of 67 °C was observed during three hours of operation. This advancement is particularly valuable for vehicles, ships, and aircraft applications, where maximizing power within limited space is crucial. An analysis of the experimental data showed that the cooling system operates at an average efficiency of 79.2%, indicating that roughly 20% of heat was accumulated in the rotor. This leads to a gradual temperature rise, particularly in the rotor, posing a risk of overheating and failure during motor overloads above 90 kW. Enhancing the cooling efficiency within the motor’s interior can be achieved by incorporating extra heat exchangers, implementing evaporative heat transfer, and employing water-cooling circuits at lower temperatures. This, in turn, can boost the electric motor’s power-to-dimension ratio.