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

Müller, Timo; Blazek, Gustavo; Henning, Frank

Abstract (englisch):
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.

DOI: 10.1504/IJAUTOC.2016.082047
Zugehörige Institution(en) am KIT Institut für Fahrzeugsystemtechnik (FAST)
Publikationstyp Zeitschriftenaufsatz
Publikationsjahr 2016
Sprache Englisch
Identifikator ISSN: 2051-8218, 2051-8226
KITopen-ID: 1000133803
Erschienen in International journal of automotive composites
Verlag Inderscience
Band 2
Heft 2
Seiten 167-186
Schlagwörter 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
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