THERMAL SCIENCE

International Scientific Journal

THE IMPROVED HEAT DISSIPATION EFFICIENCY AND ENERGY CONSUMPTION IMPACT OF NEW ENERGY VEHICLE MOTORS BASED ON HEAT PIPE TECHNOLOGY

ABSTRACT
This paper constructs a heat dissipation model that couples the motor structure with the characteristics of heat pipes. Combining experiments and simulations, this paper analyzes the impact of heat pipe lay-out on heat dissipation efficiency and quantitatively evaluates the energy efficiency optimization effect. A 150 kW permanent magnet synchronous motor and a 120 kW asynchronous induction motor were tested under different loads. After installing the heat pipes, the maximum temperature at 100% rated load dropped from 142.3-108.5°C for the permanent magnet synchronous motor, and from 138.7-105.2°C for the asynchronous motor, both reductions exceeded 30°C. Regarding energy consumption, the hourly power consumption at rated load dropped from 14.8-13.4 kWh for the permanent magnet synchronous motor, a 9.4% reduction, and from 15.2-13.9 kWh for the asynchronous motor, an 8.5% reduction. The simulation was conducted using ANSYS Workbench 2023 R2. The temperature field distribution shows that the high temperature zone has been reduced by over 60%, and the temperature gradient has dropped from 25°C per cm to 12°C per cm, with a deviation of less than 5% from experimental data. This research provides theoretical support for improving motor reliability and reducing vehicle energy consumption.
KEYWORDS
PAPER SUBMITTED: 2025-04-23
PAPER REVISED: 2025-06-28
PAPER ACCEPTED: 2025-08-13
PUBLISHED ONLINE: 2025-11-29
DOI REFERENCE: https://doi.org/10.2298/TSCI2506277D
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2025, VOLUME 29, ISSUE No. 6, PAGES [4277 - 4285]
REFERENCES
[1] Zhao, H., et al., A comprehensive Review and Experimental Investigation on Heat Pipes Application in Electrical Machines, IEEE Transactions on Transportation Electrification, 9 (2022), 2, pp. 2267-2281, 10.1109/tte.2022.3207504
[2] Hadi, M. W., et al., Innovative Thermal Management System for Electric Vehicle Batteries: Phase Change Material, Heat Pipe and Heat Sink Box Integration, Heat Transfer Engineering, 46 (2025), 6, pp. 503-513, 10.1080/01457632.2024.2325275
[3] Zhao, H., et al., Effectiveness of Thermal Interface Materials on Electrical Machines Thermal Performance with Heat Pipes, IEEE Transactions on Transportation Electrification, 10 (2023), 1, pp. 1274-1285, 10.1109/tte.2023.3274554
[4] Xu, Z., et al., Thermal Management of Drive Motor for Transportation: Analysis Methods, Key Factors in Thermal Analysis, and Cooling Methods - A Review, IEEE Transactions on Transportation Electrification, 9 (2023), 3, pp. 4751-4774, 10.1109/tte.2023.3244907
[5] Yu, Z., et al., Cooling System of Outer Rotor SPMSM for a Two-Seater All-Electric Aircraft Based on Heat Pipe Technology, IEEE Transactions on Transportation Electrification, 8 (2021), 2, pp. 1656-1664, 10.1109/tte.2021.3127555
[6] Chowdhury, T., et al., Thermal Management System of an Electric Machine With Additively Manufactured Hollow Conductors with Integrated Heat Pipes, Proceedings of the Institution of Mechanical Engineers - Part E: Journal of Process Mechanical Engineering, 238 (2024), 3, pp. 3763-3772, 10.1109/tia.2024.3353720
[7] Afzal, A., et al., A Critical Review on Renewable Battery Thermal Management System Using Heat Pipes, Journal of Thermal Analysis and Calorimetry, 148 (2023), 16, pp. 8403-8442, 10.1007/s10973-023-12100-9
[8] Zhao, H., et al., Heat Pipe Bending Effect on Cooling Effectiveness in Electrical Machines, IEEE Transactions on Energy Conversion, 38 (2023), 3, pp. 2011-2021, 10.1109/tec.2023.3249971
[9] He, L., et al., Review on Thermal Management of Lithium-Ion Batteries for Electric Vehicles: Advances, Challenges, and Outlook, Energy & Fuels, 37 (2023), 7, pp. 4835-4857, 10.1021/acs.energyfuels.2c04243
[10] WafirulHadi, M., et al., Thermal Management System Based on Phase Change Material (PCM) and Heat Pipe in Lithium-Ion Electric Vehicle Batteries, Journal of Advanced Research in Experimental Fluid Mechanics and Heat Transfer, 3 (2021), 1, pp. 26-35
[11] Zhang, Z., et al., Optimal Design of Multi-Channel Water Cooled Radiator for Motor Controller of New Energy Vehicle, CES Transactions on Electrical Machines and Systems, 6 (2022), 1, pp. 87-94, 10.30941/cestems.2022.00012
[12] Geng, W., et al., Windings Indirect Liquid Cooling Method for a Compact Outer-Rotor PM Starter/Generator with Concentrated Windings, IEEE Transactions on Energy Conversion, 36 (2021), 4, pp. 3282-3293, 10.1109/tec.2021.3084507

© 2026 Society of Thermal Engineers of Serbia. Published by the Vinča Institute of Nuclear Sciences, National Institute of the Republic of Serbia, Belgrade, Serbia. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International licence