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<p>To address the critical challenge of precise thermal management in oil-cooled permanent magnet synchronous motors (PMSMs) for electric vehicles, this study develops an active flow control strategy that simultaneously ensures thermal safety and energy efficiency. We propose a lumped parameter thermal network (LPTN) model integrating electromagnetic loss computation and adaptive thermal resistance correction, enabling high-fidelity 3D temperature prediction validated by test. Based on this model, a PID co-control algorithm dynamically regulates oil flow rates via real-time temperature feedback. The results show that under the NEDC and WLTC cycles, this strategy: (1) Ensure that the temperature of the stator-slot winding remains below the insulation threshold of 155&#xa0;°C for its surface insulation material, and that temperature fluctuations are controlled within ± 0.5&#xa0;°C; (2) compared to constant-current cooling, the oil pump energy consumption is reduced by 0.00937 kWh under NEDC cycle conditions and by 0.00865 kWh under WLTC cycle conditions. This study provides an intelligent thermal control solution for high-power density permanent magnet synchronous motors, achieving a balance between operational reliability and energy efficiency.</p>

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Active flow control for oil cooling in electric motors using lumped parameter thermal networks

  • 期刊论文

  • 发表日期：

    2026年1月9日

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  • Yan Zhang,
  • Zijun Ma,
  • Jiadong Fu,
  • Liange He,
  • Boru Jia,
  • Limin Wu,
  • Song He

摘要

To address the critical challenge of precise thermal management in oil-cooled permanent magnet synchronous motors (PMSMs) for electric vehicles, this study develops an active flow control strategy that simultaneously ensures thermal safety and energy efficiency. We propose a lumped parameter thermal network (LPTN) model integrating electromagnetic loss computation and adaptive thermal resistance correction, enabling high-fidelity 3D temperature prediction validated by test. Based on this model, a PID co-control algorithm dynamically regulates oil flow rates via real-time temperature feedback. The results show that under the NEDC and WLTC cycles, this strategy: (1) Ensure that the temperature of the stator-slot winding remains below the insulation threshold of 155 °C for its surface insulation material, and that temperature fluctuations are controlled within ± 0.5 °C; (2) compared to constant-current cooling, the oil pump energy consumption is reduced by 0.00937 kWh under NEDC cycle conditions and by 0.00865 kWh under WLTC cycle conditions. This study provides an intelligent thermal control solution for high-power density permanent magnet synchronous motors, achieving a balance between operational reliability and energy efficiency.