Highly Efficient Drive-Integrated Embedded Cooling Enabled ... · Current State-of-the-Art Air...
12
Go Process Intensification Highly Efficient Drive-Integrated Embedded Cool ing Enabled Electric Motors (Highly Cool EMotors) Michael Ohadi, PhD Program Director
Transcript of Highly Efficient Drive-Integrated Embedded Cooling Enabled ... · Current State-of-the-Art Air...
Go Process
Intensification
Highly Efficient Drive-Integrated Embedded Cooling
Enabled Electric Motors (Highly Cool EMotors)
Michael Ohadi, PhD
Program Director
Transformative Impact
1 quad = 1015 BTU = 1.055 x 1018 J
Motor Driven Source Energy
Total (estimated): ~24 quads/year
5% savings with co-design yields 1.2 quads
Motor systems account for ~50% of U.S. electricity
consumption and ~47% of global electricity consumption
Motors are well represented in each of the four major US
energy consumption sectors
Energy Savings Potential and Opportunities for High-Efficiency Electric Motors in Residential and
Commercial Equipment, December 2013, U.S. Department of Energy, Building Technologies Office
29% Transportation21% Residential
32% Industrial 18% Commercial
U.S. TOTAL ENERGY CONSUMPTION 2016
U.S. Total: 97.6 quadsSource: U.S. EIA Monthly Energy Review February 2018
1Highly Cool EMotors
Opportunities in Transportation: electrification of ground,
marine, and air transportation (e.g. more electric aircraft) critically
relies on high efficiency and more compact/less weight motors
Many opportunities in Industrial, Commercial, and Defense
Sectors: Huge energy efficiency impact and low payback periods
The Need
2Highly Cool EMotors
Cooling fins at motor surface Stacked stator laminations with fins
Exploded view of electric motor
Cooling of Electric Motors
Electric motors generate a large amount of heat
Exceeding temperature limits are detrimental!
10°C above the limit reduces the lifetime by 50%
Challenges
• irregular geometry
• non-uniform heat generation
Cooling methods
• natural convection cooling
• forced convection cooling
• liquid cooling (single / two phase)
3Highly Cool EMotors
Current State-of-the-Art Air Cooling of Motors
Chuck Young, Cool Facts About Cooling Electric Motors,
IEEE Industry Applications Magazine, Nov-Dec 2015, pp. 47-56
Totally enclosed fan cooled enclosure,
up to ~ 300 kW
Air flow through open drip-proof enclosure
Open drip-proof enclosure
Bulky, with limitations for variable speed motors:
Inefficient cooling at low RPM
4Highly Cool EMotors
K. Bennion, NREL, 2016
Direct Winding Heat
Exchanger (DWHX) &
thermally conductive
potting compound
S.A. Semidey, Ph.D. thesis, Georgia Tech, 2012
End Winding Jet Impingement
Axial Channels and
Conductive Potting
Compound
C. Rhebergen, M.S. Thesis, McMaster University, 2015
Recent Motor Thermal Management Advances
Allows more Uniform Cooling
Reduces Windage Losses
Eliminates Local Weak Points
5Highly Cool EMotors
0
15
30
Vo
lum
e S
pecif
ic
Po
we
r [k
W/L
]The Jing-Jin 120 kW traction motor, representing Best In Class typical automotive traction system, is used as the benchmark
for transformative advantage of enhanced cooling
c. JING-JIN Electric Technologies Co., LTD
c. DHX Internally Cooled Motor
0
4
8
SOA With ImprovedCooling
Po
we
r D
en
sit
y[k
W/k
g]
0
10
20
SOA With ImprovedCooling
To
rqu
e D
en
sit
y[N
m/k
g]
0
15
30
We
igh
t[k
g]
40% Lighter!
96% Efficiency, 330 V DC
120 kW peak, ~3000 RPM
Glycol/Water Cooled
Enhanced Cooling For Smaller, Lighter, and Higher Specific Power!
6Highly Cool EMotors
Integration of motor and drive in one single enclosure eliminates the drive enclosure and cables, introducing substantial
compaction and additional energy efficiency
Integration of Motor, Drive, and Power Electronics!
TM Jahns, UW-Madison
WBG-Enabled Current Source Inverters for Integrated PM Machine Drives
ARPAE-Sponsored Research, CIRCUITS, Program Manager Dr. Isik Kizilyalli, 2017
COOLING?Also, additional power electronics
advances necessary (substrate embedded
passives capacitors, inductors, et al.)
7Highly Cool EMotors
Leveraging - Embedded Chip Cooling
Moore’s Law + High Flux Electronics: ≥ 1 𝑘𝑊/𝑐𝑚2
Embedded Two-Phase Cooling
Eliminates all but die and convective thermal
resistances
𝑄 = 𝑈 𝐴 Δ𝑇Star Level
Heat Fluxes
Conventional Air Cooling Embedded Two-Phase Cooling𝑇∞
𝑇𝑗
Embedded
Cooling
0 00 0
How to
increase h?
0
Two-Phase
Cooling
8Highly Cool EMotors
Integration of Motor, Drive, and Power Electronics!
Motor, Drive & Power Elec. Integration
From Bulky motors with Inefficient Cooling to …
… More Compact, More Efficient motors with
Embedded Cooling - Highly Cool EMotors!
Embedded Cooling
Increased Power Density
Highly Cool EMotors 10
What is Next? – ARPA-E Hard Goals!
Payback Period < 5 Years
0
4
8
12
SOA With ImprovedCooling
What's Next?
Po
we
r D
en
sit
y
[kW
/kg]
0
10
20
30
SOA With ImprovedCooling
What's Next?
Vo
lum
e S
pe
cif
ic P
ow
er
[kW
/L]
0
10
20
SOA With ImprovedCooling
What's Next?
To
rqu
e D
en
sit
y[N
m/k
g]
94%
96%
98%
100%
SOA What's Next?
Eff
icie
nc
y
DOE VTO: 1.4 kW/kg by 2022
DOE VTO: 4 kW/L by 2022
DOE VTO: 94 % by 2022
Highly Cool EMotors 9
