Research on the Oil Cooling Structure Design Method of Permanent Magnet Synchronous Motors for Electric Vehicles

Shijun Chen (), Cheng Miao, Xinyu Chen, Wei Qian and Songchao Chu
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Shijun Chen: School of Electronic Engineering and Intelligent Manufacturing, Anqing Normal University, Anqing 246133, China
Cheng Miao: School of Electronic Engineering and Intelligent Manufacturing, Anqing Normal University, Anqing 246133, China
Xinyu Chen: School of Electronic Engineering and Intelligent Manufacturing, Anqing Normal University, Anqing 246133, China
Wei Qian: School of Electronic Engineering and Intelligent Manufacturing, Anqing Normal University, Anqing 246133, China
Songchao Chu: Anhui Tongfeng Electronics Co., Ltd., Tongling 244000, China

Energies, 2025, vol. 18, issue 12, 1-17

Abstract: Permanent magnet synchronous motors for electric vehicles (EVs) prioritize high power density and lightweight design, leading to elevated thermal flux density. Consequently, cooling methods and heat conduction in stator windings become critical. This paper proposes a compound cooling structure combining direct oil spray cooling on stator windings and housing oil channel cooling (referred to as the winding–housing composite oil cooling system) for permanent synchronous motors in EVs. A systematic design methodology for oil jet nozzles and housing oil channels is investigated, determining the average convective heat transfer coefficient on end-winding surfaces and the heat dissipation factor of the oil channels. Finite element analysis (FEA) was employed to simulate the thermal field of a 48-slot 8-pole oil-cooled motor, with further analysis on the effects of oil temperature and flow rate on motor temperature. Based on these findings, an optimized oil-cooled structure is proposed, demonstrating enhanced thermal management efficiency. The results provide valuable references for the design of cooling systems in oil-cooled motors for EV applications.

Keywords: permanent magnet synchronous motors for electric vehicles (PMSMs-EVs); oil-cooled motors; oil jet nozzles; housing oil channels; oil temperature and flow rate (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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