Cooling of 1 MW Electric Motors through Submerged Oil Impinging Jets for Aeronautical Applications

Electrification of aircraft is a very challenging task as the demand for energy and power is high. While the storage and generation of electrical energy are widely studied due to the limited specific energy and specific power of batteries and fuel cells, electric machines (power electronics and motors) which have years of experience in many industrial fields must be improved when applied to aviation: they generally have a high efficiency but the increase in power levels determines significant thermal loads which, unlike internal combustion engines (ICE), cannot be rejected with the exhaust. There is therefore a need for thermal management systems (TMSs) with the main objective of maintaining operating temperatures below the maximum level required by electric machines. Turboprop aircraft, such as the ATR 72 or the Dash 8-Q400, are commonly used for regional transport and are equipped with two gas turbine engines whose combined power is in the order of 4 MW. Electric and hybrid propulsion systems for these aircraft are being studied by several leading commercial aviation industries and start-ups, and the 1MW motor size seems to be the main option as it could be used in different aircraft configurations, particularly those that exploit distributed electric propulsion. With reference to the topics mentioned above, the present work presents the design of a TMS for a high-power motor/generator whose electrical architecture is known. Once integrated with the electrical part, the TMS must allow a weight/power ratio of 14 kW/kg (or 20 kW/kg at peak power) while maintaining the temperature below the limit temperature with reasonable safety margins. Submerged jet oil is the cooling technique here applied with a focus on diathermic oil. Parameters affecting cooling, like rotor speed and filling factor, are analysed with advanced CFD.