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

电动机消耗的电力占全球发电量的40%以上。欧盟的目标是通过部署更高效的电动机，到2030年每年减少约4000万吨的二氧化碳排放。电动机也是电动汽车背后的驱动力，目前引领着全球交通运输部门的脱碳努力；它们的效率对于延长电动汽车的行驶里程至关重要。不幸的是，重型、土方机械和飞机的电气化计划（目前约占运输化石燃料消耗的60%）必须克服其他限制，其中包括电机铜绕组在与这些行业相关的电力需求操作中产生的余热的技术障碍。e - cool承诺通过开发整体电机冷却技术来解决这一挑战，通过直接接触，喷雾冷却最大化热量传递。E-COOL的目标是通过整合两项跨学科活动，在与工业创新进入市场所需的时间尺度上实现这一技术突破：(a)开发和制造新型非牛顿性质的油基稀聚合物混合物，当用于喷雾冷却热管理系统时，将改变游戏规则；(b)实施一种通用的喷雾冷却设计方法，并借助新的机器学习（ML）算法进行优化。机器学习工具的训练数据集将通过“基础真相”实验和数值调查获得，这也将在E-COOL中首次进行。设想中的冷却系统旨在为局部温度热点提供前所未有的冷却速率，与当今最先进的技术相比，这可以使电动机的效率平均提高20%。这将允许下一代电动马达在整个运输部门的使用，因此，相对于现有的欧盟计划，促进显著额外的能源和二氧化碳的节省。

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.