Design concept of a lightweight electric motor casing with support from thermomechanical simulations. (2016)

• Record Type: Journal Article
• Authors: Müller, Timo; Blazek, Gustavo; Henning, Frank
• Is Part Of: International journal of automotive composites. Volume 2:Number 2(2016)
• Page Start: 167
• Page End: 186
• Publication Date: 2016
• Subjects: computer-assisted engineering -- CAE -- electric motors -- fibre-reinforced polymers -- FRPs -- finite element analysis -- FEA -- heat transfer -- automotive composites -- component design -- motor cooling -- polyamide-6 -- thermal stress analysis -- hybrid electric vehicles -- HEVs -- hybrid vehicles -- lightweight components -- electric motor casing -- motor casing design -- thermomechanical simulation; Composite materials in automobiles -- Periodicals; 629.232
• Languages: English
• ISSNs: 2051-8218

Abstract

Electric and hybrid electric vehicles and lightweight components are important issues for the automotive industry in the pursuit for the reduction of carbon emissions. In this study, a fibre-reinforced polymer (FRP) casing for a high-power electric motor was designed, with focus on the cooling system effectiveness. Heat transfer simulations were performed to prove the effectiveness of different proposed cooling systems. A design concept using the selected cooling system and 30 wt% glass fibre-reinforced polyamide-6 as the material for the casing was submitted to a thermomechanical analysis. Results show a maximum temperature of 105°C in the casing and stresses well within the limits of the material. For this material, the design concept shows a potential for ~65% weight reduction. The possibility of using other FRPs is also briefly discussed.