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<p>Effective thermal management is essential for enhancing the efficiency and lifespan of series-wound DC motors in electric vehicle (EV) applications. This study aims to evaluate the thermal performance of a DC series motor under different cooling strategies, using experimental and numerical methods. A real-time test setup was developed to measure torque, current, and temperature, integrating multiple thermocouples for accurate thermal monitoring. Labview software was utilised for data acquisition and analysis, ensuring precise heat flux measurements. The results reveal that implementing an oil-based direct cooling system reduces peak winding temperatures by approximately 18% compared to air cooling, leading to a 7% improvement in motor efficiency. Additionally, the thermal gradient across the motor was reduced, minimising hotspots that contribute to long-term performance degradation. The study demonstrates that optimised cooling methods significantly enhance thermal stability, ensuring reliable motor operation in demanding EV conditions. These results offer important information for enhancing motor design and refining cooling techniques for increased robustness and effectiveness.</p>

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Evaluation and Simulation of Oil-based Direct Cooling System in Series DC Motors for Electric Vehicle Applications

  • 期刊论文

  • 发表日期：

    2025年9月26日

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  • R. Dheivanai,
  • B. Prasanth,
  • G. Karthikeyan

摘要

Effective thermal management is essential for enhancing the efficiency and lifespan of series-wound DC motors in electric vehicle (EV) applications. This study aims to evaluate the thermal performance of a DC series motor under different cooling strategies, using experimental and numerical methods. A real-time test setup was developed to measure torque, current, and temperature, integrating multiple thermocouples for accurate thermal monitoring. Labview software was utilised for data acquisition and analysis, ensuring precise heat flux measurements. The results reveal that implementing an oil-based direct cooling system reduces peak winding temperatures by approximately 18% compared to air cooling, leading to a 7% improvement in motor efficiency. Additionally, the thermal gradient across the motor was reduced, minimising hotspots that contribute to long-term performance degradation. The study demonstrates that optimised cooling methods significantly enhance thermal stability, ensuring reliable motor operation in demanding EV conditions. These results offer important information for enhancing motor design and refining cooling techniques for increased robustness and effectiveness.