Thermal-fluid-machine Co-design and Performance Optimisation of Highly Integrated Electric Drive Systems

Yichen Zhou

doi:10.47297/taposatWSP2633-456937.20250610

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Thermal-fluid-machine Co-design and Performance Optimisation of Highly Integrated Electric Drive Systems

Volume 6, Issue 10

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Thermal-fluid-machine Co-design and Performance Optimisation of Highly Integrated Electric Drive Systems
Thermal-fluid-machine Co-design and Performance Optimisation of Highly Integrated Electric Drive Systems
Jinqiu Centre, Xinhangdao, Hangzhou, Zhejiang, 311400, China
Vol. 6, Issue 10, Pages: 184-192(2025)
Published：30 October 2025
DOI：10.47297/taposatWSP2633-456937.20250610
Accepted：

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Zhou Yichen.Thermal-fluid-machine Co-design and Performance Optimisation of Highly Integrated Electric Drive Systems[J].Theory and Practice of Science and Technology,2025,06(10):184-192.
DOI：

Zhou Yichen.Thermal-fluid-machine Co-design and Performance Optimisation of Highly Integrated Electric Drive Systems[J].Theory and Practice of Science and Technology,2025,06(10):184-192. DOI： 10.47297/taposatWSP2633-456937.20250610.

摘要

Abstract

Aiming at the challenges of heat dissipation and reliability brought about by the high integration of electric drive systems in new energy vehicles

this paper proposes an innovative integrated cooling scheme based on the core concept of "heat-flow-machine" co-design. By designing a shared substrate for the cooling runners and a direct contact cooling structure with insulating oil

the scheme achieves a deep integration and optimisation of the thermal management system of the motor and inverter. In the study

a high-precision thermal-fluid coupling simulation model is established

and the thermal performance and pumping power consumption of the system are analysed under different cooling oil flow rates under the guidance of active thermal management strategy. The core results show that the maximum junction temperature (T

of the SiC chip is stabilized below 140 ℃ under the high ambient temperature of 40 ℃ and the rated load condition

which provides sufficient heat dissipation redundancy; by comparing with the traditional indirect cooling scheme

the present scheme reduces the total thermal resistance of the system by about 37.5%

which significantly enhances the system's heat dissipation performance; moreover

through the trade-off analysis of the pressure loss and the power consumption of pumping

the Q In addition

through the trade-off analysis of pressure loss and pumping power consumption

Q=1.5 L/min is determined as the optimal thermal equilibrium operating point of the system

which achieves the optimal balance between heat dissipation performance and net efficiency of the system. This paper strongly demonstrates the great potential of the integrated thermal-fluid-machine co-design in improving the volumetric power density and operational reliability of the electric drive system.

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references

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