Design Optimization of Immersion Cooled Electric Motor by CFD Simulations

The increasing electrification of vehicles demands electric machines with higher torque and power density, necessitating advanced thermal management solutions. Stator immersion cooling is a promising approach to meet these requirements. This study investigates the thermal performance of an immersion cooling system and optimizes its design using computational fluid dynamics (CFD) simulations. The results demonstrate that incorporating baffles and deflectors significantly enhances convective heat transfer, leading to lower and more uniform hairpin end-winding temperatures. The optimized design improves motor torque density by nearly 50%.