Thermal investigation of 12/10 switched reluctance motor adopting different casing fins and materials for e-vehicle application

Maripandi, Karthika; Mahadevan, Balaji; Sehar, Fantin Irudaya Raj Edward; Mangalaraj, Appadurai

doi:10.1590/1517-7076-RMAT-2024-0244

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Articles • Matéria (Rio J.) 29 (3) • 2024 • https://doi.org/10.1590/1517-7076-RMAT-2024-0244 copy

Thermal investigation of 12/10 switched reluctance motor adopting different casing fins and materials for e-vehicle application

Authorship SCIMAGO INSTITUTIONS RANKINGS

ABSTRACT

The current work presents the thermal analysis of a 12/10 switched reluctance motor (SRM) with modified fin arrangements with different materials for e-vehicle applications. Initially, the parameters for the 12/10 SRM were derived using an analytical expression. Electromagnetic analysis was then performed with MagNet software to obtain motor performance metrics such as torque density, ripple, and losses to ensure that the proposed design meets the requirement. Then, a thermal analysis of 12/10 SRM is carried out using Ansys software. Various fin profiles such as conventional rectangular fins, pin fins, thin fins, tapered fins, and tapered slot fins are employed and analyzed to investigate the effectiveness of heat dissipation in motors. The study shows that the tapered slot fin performs better than the other four fin profiles. This is due to its lower mass of 0.53 kg and efficient thermal management (the maximum temperature of the stator outer cover is 31.6 ^°C). In addition, different fin materials like aluminium (Al), aluminium with 1% graphene particles (GP), and aluminium with 2% GP were analysed for tapered slot fins, and it was found that aluminium with 2% GP provides a lower fin temperature of around 30.40 ^°C compared to other fin materials.

Keywords:
Switched reluctance motor; Casing fins; Fin materials; Electromagnetic analysis; Thermal analysis

VARIABLES	EXPRESSION
Stator pole surface area (A_s)	$A_{s} = \frac{D_{BO}}{2} * M_{L} * B_{S}$
Stator pole magnetic flux (φ)	${φ = B}_{s} * A_{s}$
Stator yoke magnetic flux (φ_y)	$φ = \frac{B_{st} * A_{s}}{2}$
Yoke surface area (A_Y)	$A_{Y} = A_{S}$
Stator core thickness (C_T)	$C_{T} = \frac{A_{Y}}{L}$
Stator pole length (S_PL)	$S_{PL} = \frac{D_{SO}}{2} - C_{T} - \frac{D_{BO}}{2}$
Rotor pole surface area (A_r)	$A_{r} = (\frac{D_{BO}}{2} - G_{a}) M_{L} B_{r}$
Rotor core surface area (A_rc)	$A_{rc} = \frac{A_{s}}{1.6}$
Rotor pole length (R_PL)	$R_{PL} = \frac{D_{BO}}{2} - G_{a} - \frac{D_{So}}{2} - \frac{A_{rc}}{L}$

VARIABLES	VALUES
Rated current	108 amps
Stator outer diameter, D_SO	154 mm
Inner diameter of stator, D_BO	84 mm
Machine length, M_L	150 mm
Stator pole length, S_PL	23 mm
Stator pole span, S_PS	12 degrees
Rotor pole length, R_PL	18.5 mm
Rotor pole span, R_PS	18 degrees
Shaft diameter, S_D	19 mm

VARIABLES	OUTPUT
Torque	12.42 Nm
Torque ripple	0.08 p.u.
Efficiency	93.22%
RMS current density	6.5 A/mm²
Torque per unit rotor volume (TRV)	14.95 KNm/m³
Loss - Winding	0.21 KW
Total loss	0.423 KW

FIN GEOMETRY	NO. OF ELEMENTS	NO. OF NODES
1	147799	194820
2	190122	51048
3	564337	918490
4	746851	137837
5	1679057	440504

DIFFERENT FIN PROFILE	FIN TIP TEMPERATURE(°C)	MASS(kg)
12/10 SRM with conventional rectangular fin	39.329	0.8368
12/10 SRM with pin fin	36.199	0.73148
12/10 SRM with thin fin	35.565	0.72293
12/10 SRM with tapered fin	33.507	0.73938
12/10 SRM with tapered slot fin	31.639	0.5379

MATERIALS	THERMAL CONDUCTIVITY (K) w/m k	DENSITY (ρ) kg/m³
Aluminium (Al)	220	2700
Al with 1% GP [³⁵[35] COUSINEAU, J.E., BENNION, K., DEVOTO, D., et al., “Experimental characterization and modeling of thermal resistance of electric machine lamination stacks”, International Journal of Heat and Mass Transfer, v. 129, pp. 152–159, 2019. doi: http://doi.org/10.1016/j.ijheatmasstransfer.2018.09.051. https://doi.org/10.1016/j.ijheatmasstran... ]	280	2695
Al with 2% GP [³⁵[35] COUSINEAU, J.E., BENNION, K., DEVOTO, D., et al., “Experimental characterization and modeling of thermal resistance of electric machine lamination stacks”, International Journal of Heat and Mass Transfer, v. 129, pp. 152–159, 2019. doi: http://doi.org/10.1016/j.ijheatmasstransfer.2018.09.051. https://doi.org/10.1016/j.ijheatmasstran... ]	312.5	2675
M19 [³⁶[36] PRADHAN, S.K., SAHOO, M.R., RATHA, S., et al., “Graphene-incorporated aluminum with enhanced thermal and mechanical properties for solar heat collectors”, AIP Advances, v. 10, n. 6, pp. 065016, 2020. doi: http://doi.org/10.1063/5.0008786. https://doi.org/10.1063/5.0008786... ]	21.9	7450

Laboratório de Hidrogênio, Coppe - Universidade Federal do Rio de Janeiro, em cooperação com a Associação Brasileira do Hidrogênio, ABH2 Av. Moniz Aragão, 207, 21941-594, Rio de Janeiro, RJ, Brasil, Tel: +55 (21) 3938-8791 - Rio de Janeiro - RJ - Brazil
E-mail: revmateria@gmail.com

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[1] Corresponding Author: M. Karthika, e-mail: karthikam@ssn.edu.in, balajim@ssn.edu.in, fantinraj@gmail.com, appadurai86@gmail.com