Lorenzo Pinnisi
Comparative Design and Thermal Performance of Stator Cooling Strategies for a High-Speed Electrically-Excited Synchronous Machine (EESM).
Rel. Andrea Tonoli, Vittorio Ravello. Politecnico di Torino, Master of science program in Automotive Engineering, 2025
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Abstract
The present work investigates and compares three stator cooling configurations for a high-speed, cost-effective Electrically Excited Synchronous Motor (EESM) for automotive application. Starting from a lumped thermal model in MotorCAD to retriever losses and heat distribution, three stator forced liquid cooling solutions were designed: (I) Housing Water-Jacket (WJ), (II) Direct-Slot with in-slot flow (DirectSlotV1), and (III) Direct-Slot with in-slot flow plus stator ducts (DirectSlotV2). The geometries were then defined in SolidWorks and SpaceClaim and solved numerically in Ansys Fluent considering a steadystate non isothermal flow. A 50/50 EGW coolant was used with an inlet temperature of 65°C and four different flow rates (6, 10, 15 and 18 l/min) were tested under the same thermal setup and conditions provided by MotorCAD.
The performance of the solution was evaluated via channel pressure drop Δp, and the maximum reached stator temperature
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