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Dr J Rhett Mayor - Georgia Institute of Technology
- 1. Direct-winding Heat Exchange Cooling Technology (DwHX™) Dr. J.Rhett Mayor President, CEO DHX Electric Machines, Inc. Associate Professor George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology
- 2. “…it will do the work of the world. ” Nikola Tesla 30 hp Induction Motor 230 V, 3φ 90.4% 330 lbs 7110 TWhr (2011) 4.5B barrels of oil
- 3. 30 hp Surface-Mount Permanent Magnet Synchronous Motor 230 V, 3φ 94% 12 lbs Increased Power Density | Increased EMDS Efficiency DwHX Cooling TechnologyTM
- 4. 30 hp Surface-Mount Permanent Magnet Synchronous Motor 230 V, 3φ 94% 12 lbs “More Power. Less Motor. ” DHX Electric Machines, Inc.
- 5. Outline 1. DwHX Cooling Technology™ – by the physics 2. Hawk Series 3. E-Mobility, Sustainable Mobility & The Future of Electric Traction 4. Application Spaces – Opens Possibilities™
- 6. Traditional Water Cooling Technology Water Jacket Direct Lamination Cooling Frame Tooth Slot Stator Windings Conduction Paths Rotor Conduction Paths Flow Channel Flow Channel
- 7. DwHX Cooling TechnologyTM - by the physics R-θ Design plane Power = Torque x Speed Power: Ambient Rejection: Internal Transport: Internal losses: Where:
- 8. No load Load 5,000 rpm 7,500 rpm 10,000 rpm SRM Finite Difference Predictions
- 9. DwHXTM Cooling Technology Rotor Permanent Magnets Windings Stator Direct winding Heat eXchanger Flow Channel
- 10. Active Thermal Capacitance • Ultra high torque density for peaking loads can be achieved through optimal design and existing thermal management techniques • Sustained periods of peaking power significantly increases the thermal management challenge as the thermal capacitance of the frame is insufficient • Active thermal capacitance enables the active control of motor thermal capacitance using micro-feature heat exchanger technology
- 11. Micro feature enhanced convective thermal transport from the winding bundle:
- 12. DHX Design & Analysis Capabilities [1] J. R. Mayor and S. A. Semidey, "Generic electric machine thermal model development using an automated finite difference approach," in 2009 IEEE International Electric Machines and Drives Conference, IEMDC '09, May 3, 2009 - May 6, 2009, Miami, FL, United states, 2009, pp. 137-143. [2] S. A. Semidey, D. Yao, J. R. Mayor, R. G. Harley, and T. G. Habetler, "Optimal Electromagnetic-Thermo-Mechanical Integrated Design Candidate Search and Selection for Surface-Mount Permanent-Magnet Machines Considering Load Profiles," Industry Applications, IEEE Transactions on, vol. 47, pp. 2460-2468, 2011. [3] S. A. Semidey and J. R. Mayor, “Parametric Thermal Estimation of Electric Machines using a Finite Difference Approach,” Submitted for inclusion in PEMD 2014 [4] S. A. Semidey and J. R. Mayor, “Design and Optimization of SMPM Electric Machines Incorporating Direct Windings Heat Exchangers,” Submitted for inclusion in PEMD 2014 Thermo-Mechanical & Electromagnetic FEA Custom thermo- mechanical- electromagnetic design optimization tool [1]-[4] Parametric CAD Solid Modeling Crane 4000
- 13. Hawk Series
- 14. Hawk20 (48V) traction motor 40 Nm max torque 18.4 kW [25 hp] max power 5.4 kg [12 lbs]
- 15. Hawk40 (96 VDC) traction motor 80 Nm max torque 36.8 kW [49 hp] max power 9.2 kg [20.2 lbs]
- 16. Hawk60 (144 VDC) traction motor 120 Nm max torque 55.3 kW [74 hp] max power 11.9 kg [26.2 lbs]
- 18. EV● “The Future of Electric Vehicles is Golf Carts, Not Tesla” – Thomas Bartman, Harvard Business Review, May 14, 2015 ● Bottom of the market with low- speed EVs built of golf-cart platforms is experiencing huge growth. ○ ~100,000 vehicles per year USA ○ ~500,000 vehicles per year China ● Electric Utility Vehicles (EUVs) experiencing similar gains due to incentives and operating advantages in congested city delivery businesses. ● MOTOR OPPORTUNITY SPACE – Compact, high-torque low- voltage traction motors in the 10- 30 hp range
- 19. The Hawk 20 powered golf cart 25mph. With regenerative braking. Demonstrated 55 mile range. More Power, Less Motor.TM
- 20. 100% Green Personal Mobility Capability of DHX motors to provide high kVA on low voltage bus (48Vdc) opens possibility for combined solar & wind-turbine based fast- charging towers.
- 21. OPENS POSSIBILITIESTM Vertical Traction HVACR Marine Green Power Aerospace Factories of the Future DwHXTM Cooling Technology -
- 22. DHX Electric Machines, Inc. 1101 HWY 124, Bldg 5 Hoschton, Georgia 30548 U.S.A @DHXmachines P: +1 (678) 900-1074 e: info@dhxmachines.com www.dhxmachines.com