VP6-07 A High-power Density Permanent Magnet Machine Featuring a Novel Lightweight Rotor with A Fin Reuse Structure
Creators: Jianzong Yu
Jiangtao Yang
Shoudao Huang
Publisher: name: IEEE
Year: 2025

High-power density permanent magnet machine (HDPMM) has been widely concerned in aerospace propulsion, vehicle drive, industrial automation and so on, because of its excellent performance [1]. Due to the high temperature rise of permanent magnet (PM) of HDPMM, PM is extremely sensitive to temperature rise, it shows that it is extremely important to carry out thermal management on the PM [2]. Currently, enhancing the heat dissipation capacity of PMs is an effective method to suppress the temperature rise[3]. For surface HDPMM, materials with poor thermal conductivity are usually used to bind the PMs, making heat dissipation more difficult [4]. And the wind cooling of the rotor requires additional fans or blades, which increases the complexity of the system. In this paper, a novel lightweight rotor of HDPMM with fin reuse structure (FRS) is proposed. It can improve the thermal management of the PMs without external devices. As shown in Fig. 1, FRS includes the fin on the inside of lightweight rotor frame, which are inclined at a certain angle to realize fluid self-driving. The flow field and temperature distribution are shown in Fig. 2. It can be seen that FRS can provide enough driving force for flow field, and form an axial flow velocity greater than 10m/s on the fin surface. From Figs. 2(b) and (c), it can be seen that FRS can reduce the temperature of PMs from 256.97 °C to 148.5 °C, a decrease of 42.25%. To show the excellent heat dissipation performance of FRS, the heat dissipation effects of FRS are further compared with those of traditional fin heat dissipation structure, ventilation heat dissipation structure, fin and ventilation heat dissipation mixed structure. To explore the influence mechanism of key parameters of FRS on its cooling effect, this paper also investigates different designs of heat dissipation fins, investigating the impact of the number, length, width, and inclination angle of the fins on the fluid flow characteristics, machine power characteristics, and temperature rise of the PMs. Finally, the heat dissipation performance of the structure is tested by experiments. More research contents will be shown in the full text.References: [1] Wang X. et al., “A critical review on thermal management technologies for motors in electric cars,” Appl. Therm. Eng., vol. 201, p. 117758, Jan. 2022. [2] A. S. Fawzal, R. M. Cirstea, K. N. Gyftakis, T. J. Woolmer, M. Dickison, and M. Blundell, “Fan Performance Analysis for Rotor Cooling of Axial Flux Permanent Magnet Machines,” IEEE Trans. Ind. Appl., vol. 53, no. 4, pp. 3295–3304, Jul. 2017. [3] B. B. St-Jacques, R. Shi, and P. Pillay, “An Enhanced PMSM Cooling Design for Traction of an Electric Vehicle,” IEEE Trans. Transport. Electrific., pp. 1–1, 2023. [4] H. Fang, R. Qu, J. Li, P. Zheng, and X. Fan, “Rotor Design for High-Speed High-Power Permanent-Magnet Synchronous Machines,” IEEE Trans. Ind. Appl., vol. 53, no. 4, pp. 3411–3419, Jul. 2017.
High-power density permanent magnet machine (HDPMM) has been widely concerned in aerospace propulsion, vehicle drive, industrial automation and so on, because of its excellent performance [1]. Due to the high temperature rise of permanent magnet (PM) of HDPMM, PM is extremely sensitive to temperature rise, it shows that it is extremely important to carry out thermal management on the PM [2]. Currently, enhancing the heat dissipation capacity of PMs is an effective method to suppress the temperature rise[3]. For surface HDPMM, materials with poor thermal conductivity are usually used to bind the PMs, making heat dissipation more difficult [4]. And the wind cooling of the rotor requires additional fans or blades, which increases the complexity of the system. In this paper, a novel lightweight rotor of HDPMM with fin reuse structure (FRS) is proposed. It can improve the thermal management of the PMs without external devices. As shown in Fig. 1, FRS includes the fin on the inside of lightweight rotor frame, which are inclined at a certain angle to realize fluid self-driving. The flow field and temperature distribution are shown in Fig. 2. It can be seen that FRS can provide enough driving force for flow field, and form an axial flow velocity greater than 10m/s on the fin surface. From Figs. 2(b) and (c), it can be seen that FRS can reduce the temperature of PMs from 256.97 °C to 148.5 °C, a decrease of 42.25%. To show the excellent heat dissipation performance of FRS, the heat dissipation effects of FRS are further compared with those of traditional fin heat dissipation structure, ventilation heat dissipation structure, fin and ventilation heat dissipation mixed structure. To explore the influence mechanism of key parameters of FRS on its cooling effect, this paper also investigates different designs of heat dissipation fins, investigating the impact of the number, length, width, and inclination angle of the fins on the fluid flow characteristics, machine power characteristics, and temperature rise of the PMs. Finally, the heat dissipation performance of the structure is tested by experiments. More research contents will be shown in the full text.References: [1] Wang X. et al., “A critical review on thermal management technologies for motors in electric cars,” Appl. Therm. Eng., vol. 201, p. 117758, Jan. 2022. [2] A. S. Fawzal, R. M. Cirstea, K. N. Gyftakis, T. J. Woolmer, M. Dickison, and M. Blundell, “Fan Performance Analysis for Rotor Cooling of Axial Flux Permanent Magnet Machines,” IEEE Trans. Ind. Appl., vol. 53, no. 4, pp. 3295–3304, Jul. 2017. [3] B. B. St-Jacques, R. Shi, and P. Pillay, “An Enhanced PMSM Cooling Design for Traction of an Electric Vehicle,” IEEE Trans. Transport. Electrific., pp. 1–1, 2023. [4] H. Fang, R. Qu, J. Li, P. Zheng, and X. Fan, “Rotor Design for High-Speed High-Power Permanent-Magnet Synchronous Machines,” IEEE Trans. Ind. Appl., vol. 53, no. 4, pp. 3411–3419, Jul. 2017.