A HOLISTIC APPROACH OF ELECTRIC MOTOR COOLING (E-COOL)

电动马达消耗了全球40%以上的电力。欧盟的目标是通过部署更高效的电动马达，在2030年之前每年节省约4000万吨二氧化碳排放。电动汽车也是电动汽车背后的驱动力，目前引领着全球交通行业的脱碳努力；电动汽车的效率对于延长电动汽车的里程至关重要。不幸的是，重型推土机和飞机的电气化计划(目前约占运输中化石燃料消耗量的60%)必须克服技术障碍，即在与这些行业相关的电力要求很高的作业中，电动马达铜绕组产生过多热量。E-Cool承诺通过开发整体电动马达冷却技术来应对这一挑战，通过直接接触喷雾冷却实现最大限度的热量传递。E-COOL的目标是在与工业创新推向市场所需的时间尺度相适应的时间尺度上实现这一技术突破，方法是整合两个跨学科活动：(A)开发和制造新型油基、非牛顿性质的稀释聚合物混合物，当用于喷雾冷却热管理系统时，将改变游戏规则；(B)实施喷雾冷却的通用设计方法，并借助新的机器学习(ML)算法进行优化。ML工具的训练数据集将通过“地面实况”实验和数值调查获得，这也将是E-Cool首次进行的。设想的冷却系统旨在在局部温度热点提供前所未有的冷却速度，与当今最先进的电机相比，这可以使电动马达的效率平均提高20%。这将允许下一代电动马达在整个交通部门的使用，从而促进相对于现有欧盟计划的显著额外能源和二氧化碳节省。

Electric motors (e-motors) consume more than 40% of electricity produced globally. The EU aims to save ~40Mt of CO2 emissions per year until 2030 by deploying more efficiency e-motors. E-motors are also the driving force behind EVs, currently leading the global efforts for decarbonisation of the transportation sector; their efficiency is crucial in extending EV mileage. Unfortunately, electrification plans for heavy-duty, earth-moving machines and aircrafts (accounting currently ~60% of fossil fuel consumption in transportation) have to overcome, among other limitations, the technological barrier of excess heat generated in the e-motor copper windings during power demanding operations associated with these sectors. E-COOL promises to address this challenge via the development of a holistic e motor cooling technology, maximising heat transfer through direct-contact, spray cooling. E-COOL aims to achieve this technological breakthrough at time-scales compatible to those required for industrial innovation to reach the market, by integrating two interdisciplinary activities: (a) development and manufacturing of novel oil-based, dilute polymer mixtures of non-Newtonian nature, which, when employed in spray-cooling thermal management systems, will be a game-changer; (b) implementation of a universal design methodology for spray cooling, optimised with the aid of new Machine Learning (ML) algorithms. Training datasets for the ML tool will be obtained by ‘ground-truth’ experimental and numerical investigations also to be conducted for the first time in E-COOL. The envisioned cooling system aims to provide unprecedented cooling rates at local temperature hot spots, which can contribute to an average 20% increase in e-motor’s efficiency compared to today’s state-of-the-art. This will allow next-generation e-motor utilisation over the whole range of transportation sectors, thus, facilitating significant additional energy and CO2 savings relative to the existing EU plans.