Study of the Cooling Performance of Electric Vehicle Motors Using a Centripetal-Inclined Oil Spray Cooling System

Efficient cooling systems are crucial for achieving high efficiency and power density in electric vehicle motors. To enhance motor cooling performance, a novel oil spray cooling system was developed, referred to as the centripetal-inclined oil spray (CIOS) cooling system. The CIOS cooling system features axial oil channels evenly distributed on the surface of the stator core, with each channel connected at both ends to stepped oil channels. This configuration allows for direct oil spraying towards the center at specific inclined angles without the need for additional components such as nozzles, oil spray rings, and oil spray tubes, which reduces costs, minimizes the risk of oil leakage, and enhances motor reliability. Electromagnetic and computational fluid dynamic simulations were conducted on the motor with the CIOS cooling system. The results indicated that the CIOS cooling system adversely impacted core losses and torque, while these effects were minimized after optimization, with losses increasing by up to 0.29% and torque decreasing by up to 0.45%. The CIOS cooling system achieved stable oil spraying, forming oil films on the end-winding with a maximum formation rate of 49.4% and an average thickness of 1.56 mm. Compared to the motor with oil spray rings, the motor with the CIOS cooling system exhibited lower temperatures across all components and more uniform cooling. Finally, the cooling performance of the CIOS cooling system was verified through experiments, and the results showed that the measured temperature closely matched the simulated results, with a maximum error of 5.9%. The findings in this study are expected to provide new insights for optimizing oil cooling systems in electric vehicle motors.