Evaluation of the Effect of Operating Parameters on Thermal Performance of an Integrated Starter Generator in Hybrid Electric Vehicles
Abstract
:1. Introduction
2. Numerical Analysis and Experimental Setup
2.1. Motor Design and Performance Characteristics
Components | Value |
---|---|
Maximum output (kW) | 5.7 |
Maximum speed (rpm) | 15,000 |
Rated current (A) | 150 |
Elec. time constant (ms) | 22.06 |
Mech. time constant (ms) | 31.62 |
Maximum current (A) | 330 |
Back-EMF constant per phase (V) | 16.59 |
Efficiency (%) | 92 |
Phase resistance (Ω) | 0.0071 |
Phase inductance | 0.3569 |
2.2. Analysis Model and Boundary Condition
Part name | Material | Density (kg/m3) | Specific heat (J/kg·°C) | Thermal conductivity (W/m·K) |
---|---|---|---|---|
Flange | A6061 | 2698 | 896 | 180 |
Bracket | A6061 | 2698 | 896 | 180 |
Stator core | S18 | 7650 | 486 | 50.8 |
Rotor core | S18 | 7650 | 486 | 50.8 |
Shaft | SM54C | 7650 | 486 | 50.8 |
Coil | Cu | 8660 | 385 | 128 |
Magnet | NdFeB | 7500 | 460 | 9 |
Bearing | STS420J2 | 7900 | 460 | 24.9 |
Fan | SM45C | 7650 | 486 | 50.8 |
Resolver | S18 | 7650 | 486 | 50.8 |
Magnet support | STS304 | 8000 | 500 | 16.2 |
Components | Conditions |
---|---|
Ambient temp. (°C) | 25 *, 45, 65, 85, 105 |
Ambient pressure (Pa) | Atmospheric pressure |
Motor speed (rpm) | 800, 3,000, 4,500 *, 6,000, 7,500, 9,000, 10,500, 12,000, 13,500, 15,000 |
Operating Condition | Part Loss (W) | Total Loss (W) | ||||
---|---|---|---|---|---|---|
Speed (rpm) | Torque (N·m) | Temp. (°C) | Coil | Stator | Bearing | |
800 | 59.64 | 105 | 2360.8 | 14.5 | 1.79 | 2377.1 |
3,000 | 18.56 | 25 | 459.5 | 20.4 | 13.0 | 492.9 |
4,500 | 13.33 | 25 | 459.5 | 17.9 | 23.9 | 501.3 |
45 | 494.9 | 17.8 | 23.9 | 536.6 | ||
65 | 530.3 | 17.7 | 23.9 | 571.9 | ||
85 | 565.8 | 17.7 | 23.9 | 607.4 | ||
105 | 601.2 | 17.6 | 23.9 | 642.7 | ||
6,000 | 10.27 | 25 | 459.5 | 18.4 | 36.9 | 514.8 |
7,500 | 8.47 | 459.5 | 20.2 | 51.5 | 531.2 | |
9,000 | 7.03 | 459.5 | 22.4 | 67.7 | 549.6 | |
10,500 | 6.13 | 459.5 | 25.5 | 85.3 | 570.3 | |
12,000 | 5.77 | 459.5 | 29.5 | 104.3 | 593.3 | |
13,500 | 4.86 | 459.5 | 33.0 | 124.4 | 616.9 | |
15,000 | 4.32 | 459.5 | 37.9 | 145.7 | 643.1 |
2.3. Experimental Setup and Method
Items | Specifications |
---|---|
Thermocouples (T-type) | −200 to 400 °C (±0.1 °C) |
Data logger (Gantner) | E. Gate IP (V3) (2.93 W @ 12.06 V) |
Motor dynamometer (Siemens) | 7.5 kW/18,000 rpm/18 Nm |
Torque transducer (HBM) | 20 Nm (±0.1%) |
RPM sensor (HBM) | 32,000 rpm (±0.01%) |
Power analyzer (Yokogawa) | 15 to 1000 V (±0.02%) |
3. Results and Discussion
3.1. Effects of Operating Parameters in Generating Mode
Heat Transfer Rate (W) | Rotating Speed (rpm) | ||||||||
---|---|---|---|---|---|---|---|---|---|
3,000 | 4,500 | 6,000 | 7,500 | 9,000 | 10,500 | 12,000 | 13,500 | 15,000 | |
Coil → Stator | 365.5 | 347.9 | 345.8 | 337.1 | 329.6 | 322.4 | 315.8 | 309.7 | 303.8 |
Coil → Air | 89.6 | 102.8 | 115.8 | 123.3 | 130.7 | 136.3 | 142.5 | 149.5 | 155.8 |
Stator → Flange | 132.8 | 126.4 | 124.1 | 119.8 | 117.1 | 114.2 | 112.1 | 109.5 | 107.1 |
Stator → Bracket | 114.4 | 107.3 | 106.6 | 101.5 | 97.7 | 93.2 | 90.8 | 90.4 | 88.7 |
Stator → Air | 133.8 | 132.2 | 135.8 | 136.9 | 138.1 | 139.5 | 141.0 | 142.6 | 146.0 |
Bearing → Flange | −5.8 | −0.6 | 7.1 | 13.3 | 20.1 | 27.0 | 34.7 | 42.6 | 50.9 |
Bearing → Bracket | 1.5 | 6.29 | 12.6 | 17.9 | 23.9 | 30.0 | 36.7 | 44.3 | 52.0 |
Flange → Air | 116.3 | 119.0 | 123.6 | 126.2 | 130.8 | 135.2 | 141.1 | 146.7 | 152.7 |
Bracket → Air | 101.3 | 102.9 | 109.2 | 109.9 | 112.4 | 114.2 | 118.8 | 125.8 | 132.3 |
3.2. Effects of Operating Parameters in Starting Mode
3.3. Experimental Result and Analysis Validation
4. Conclusions
Acknowledgments
Author Contributions
Conflicts of Interest
Nomenclature
B | peak magnetic flux density (T) |
ƒ | frequency (Hz) |
Ieff | effective phase current (Arms) |
imax | maximum current (A) |
ka | anomalous eddy current loss coefficient |
ke | eddy current coefficient |
kh | hysteresis coefficient |
Lsp | average turn length (m) |
mrot | rotor part mass (kg) |
N | rotational speed (rpm) |
nr | number of bearing |
nsp | number of turns in series per phase |
Pa | anomalous eddy current loss (W) |
Pcopper | copper loss at coil (W) |
Pe | eddy current loss (W) |
Pfric | friction loss at bearing (W) |
Ph | hysteresis loss (W) |
Piron | iron loss at core (W) |
Pmech | mechanical loss at bearing (W) |
Pwind | windage at fan (W) |
Rcu | copper resistance (Ω·m) |
Rph | coil resistance (Ω) |
Sc | coil section (m2) |
Tcu | copper temperature (K) |
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Lee, M.-Y.; Lim, D.H.; Kim, S.C. Evaluation of the Effect of Operating Parameters on Thermal Performance of an Integrated Starter Generator in Hybrid Electric Vehicles. Energies 2015, 8, 8990-9008. https://doi.org/10.3390/en8088990
Lee M-Y, Lim DH, Kim SC. Evaluation of the Effect of Operating Parameters on Thermal Performance of an Integrated Starter Generator in Hybrid Electric Vehicles. Energies. 2015; 8(8):8990-9008. https://doi.org/10.3390/en8088990
Chicago/Turabian StyleLee, Moo-Yeon, Dong Hyun Lim, and Sung Chul Kim. 2015. "Evaluation of the Effect of Operating Parameters on Thermal Performance of an Integrated Starter Generator in Hybrid Electric Vehicles" Energies 8, no. 8: 8990-9008. https://doi.org/10.3390/en8088990