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Volume 16
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor

by
Henrry Gabriel Usca-Gomez
1,
David Sebastian Puma-Benavides
2,*,
Victor Danilo Zambrano-Leon
3,
Ramón Castillo-Díaz
4,
Milton Israel Quinga-Morales
5,
Javier Milton Solís-Santamaria
5 and
Edilberto Antonio Llanes-Cedeño
6,*
1
Unit Eloy Alfaro, Alausi 060202, Ecuador
2
School of Engineering and Sciences, Tecnologico de Monterrey, Puebla 72453, Mexico
3
Department of Energy Sciences and Mechanics, Universidad de las Fuerzas Armadas ESPE, Belisario Quevedo, Latacunga 050101, Ecuador
4
Department of Technological and Industrial Processes (PTI), Instituto Tecnológico y de Estudios Superiores de Occidente (ITESO), San Pedro Tlaquepaque 45604, Mexico
5
Faculty of Mechanics, Escuela Superior Politécnica de Chimborazo (ESPOCH), Riobamba 060106, Ecuador
6
Faculty of Architecture and Engineering, Department of Mechanics, Universidad Internacional SEK, Carcelen Campus, Quito 170120, Ecuador
*
Authors to whom correspondence should be addressed.
World Electr. Veh. J. 2025, 16(8), 437; https://doi.org/10.3390/wevj16080437
Submission received: 10 June 2025 / Revised: 31 July 2025 / Accepted: 31 July 2025 / Published: 4 August 2025
Versions Notes

Abstract

The efficiency of electric motors is highly dependent on their operating temperature, with lower temperatures contributing to enhanced performance, reliability, and extended service life. This study presents a comprehensive review of state-of-the-art cooling technologies and evaluates their impact on the thermal behavior of a commercial motor–generator system in high-demand applications. A baseline model of a permanent magnet synchronous motor (PMSM) was developed using MotorCAD 2023® software, which was supported by reverse engineering techniques to accurately replicate the motor’s physical and thermal characteristics. Subsequently, multiple cooling strategies were simulated under consistent operating conditions to assess their effectiveness. These strategies include conventional axial water jackets as well as advanced oil-based methods such as shaft cooling and direct oil spray to the windings. The integration of these systems in hybrid configurations was also explored to maximize thermal efficiency. Simulation results reveal that hybrid cooling significantly reduces the temperature of critical components such as stator windings and permanent magnets. This reduction in thermal stress improves current efficiency, power output, and torque capacity, enabling reliable motor operation across a broader range of speeds and under sustained high-load conditions. The findings highlight the effectiveness of hybrid cooling systems in optimizing both thermal management and operational performance of electric machines.
Keywords: energy efficiency; electric vehicles; permanent magnet motor; electric motor optimization; cooling systems energy efficiency; electric vehicles; permanent magnet motor; electric motor optimization; cooling systems

Share and Cite

MDPI and ACS Style

Usca-Gomez, H.G.; Puma-Benavides, D.S.; Zambrano-Leon, V.D.; Castillo-Díaz, R.; Quinga-Morales, M.I.; Solís-Santamaria, J.M.; Llanes-Cedeño, E.A. A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor. World Electr. Veh. J. 2025, 16, 437. https://doi.org/10.3390/wevj16080437

AMA Style

Usca-Gomez HG, Puma-Benavides DS, Zambrano-Leon VD, Castillo-Díaz R, Quinga-Morales MI, Solís-Santamaria JM, Llanes-Cedeño EA. A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor. World Electric Vehicle Journal. 2025; 16(8):437. https://doi.org/10.3390/wevj16080437

Chicago/Turabian Style

Usca-Gomez, Henrry Gabriel, David Sebastian Puma-Benavides, Victor Danilo Zambrano-Leon, Ramón Castillo-Díaz, Milton Israel Quinga-Morales, Javier Milton Solís-Santamaria, and Edilberto Antonio Llanes-Cedeño. 2025. "A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor" World Electric Vehicle Journal 16, no. 8: 437. https://doi.org/10.3390/wevj16080437

APA Style

Usca-Gomez, H. G., Puma-Benavides, D. S., Zambrano-Leon, V. D., Castillo-Díaz, R., Quinga-Morales, M. I., Solís-Santamaria, J. M., & Llanes-Cedeño, E. A. (2025). A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor. World Electric Vehicle Journal, 16(8), 437. https://doi.org/10.3390/wevj16080437

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