Title: Design concept of a lightweight electric motor casing with support from thermomechanical simulations

Authors: Timo Müller; Gustavo Blazek; Frank Henning

Addresses: Institute for Vehicle Systems Technology (FAST), Karlsruhe Institute of Technology (KIT), Rintheimer Querallee 2, Building 70.04, 76131 Karlsruhe, Germany ' Institute for Vehicle Systems Technology (FAST), Karlsruhe Institute of Technology (KIT), Rintheimer Querallee 2, Building 70.04, 76131 Karlsruhe, Germany ' Institute for Vehicle Systems Technology (FAST), Karlsruhe Institute of Technology (KIT), Rintheimer Querallee 2, Building 70.04, 76131 Karlsruhe, Germany

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.

Keywords: 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.

DOI: 10.1504/IJAUTOC.2016.082047

International Journal of Automotive Composites, 2016 Vol.2 No.2, pp.167 - 186

Received: 23 Mar 2015
Accepted: 08 Dec 2015

Published online: 06 Feb 2017 *

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