SUMMARY

The overarching goal of the proposed research is to enhance the design of next-generation, high-power density electrical machines through the optimization using an integrated thermal-electromagnetic design tool that accounts for direct winding heat exchangers (DWXHs). Power density in electric machines is limited by the thermal degradation of the wire insulation. A DWXH inside the stator would increase power density but would have adverse effects on the electromagnetics of the machine. Therefore, the design of next-generation high-power density electrical machines requires an integrated thermal-electromagnetic design tool capable of predicting the machine temperatures and electromagnetics accounting for DWXHs. This design tool will be used in an optimization routine to rapidly locate optimal design solutions within the design space. The final design process will consider the optimal design solutions in more detail with analysis tools such as FEA and CFD. An experimental optimization of the geometries for the DWXHs will be preformed to locate a design with low pressure drop and high heat transfer.