DHX uses its proprietary in-house developed Multi-Disciplinary Electromagnetic Design Optimization (MDO) thermal estimation analysis software tool to optimize electromagnetic design, efficiency, and power performance of our motors in conjunction with ANSYS Maxwell software. We have developed and licensed motor design software to corporate clients for in-house motor design functionality and analysis.
DHX Design + Assemble + Test electric motors incorporating the patented, proprietary micro-feature enhanced DwHX cooling technology. The “Direct-winding Heat Exchange” technology is the result of +15 years of research and development in portable power systems, micro-combustion-engine-generator systems, micro-power generation, and micro-channel cooling of computer chips, blending electro-mechanical design, mechatronics, and micro-manufacturing.
Existing cooling strategies in totally-enclosed water-cooled "TEWC" machines have focused on water-jacket based systems, with the cooling occurring in the motor casing, or, more recently, direct-lamination where the flow channel is moved into the stator. The DwHX cooling system targets the main source of heat – the slot heat caused by the windings – by placing the cooling flow channel adjacent to the windings in the center of the slot. This placement substantially reduces the heat conduction paths in the stator, decreasing temperature gradients and enabling more compact cooling. The micro-feature enhancement effect increases the surface area and local fluid velocities in the cooling channel leading to a 25x improvement in cooling capability over standard flow channels. Slot heat is proportional to current squared (I^2) and torque is proportional to current (I), so 25x more cooling capability enables 4 times increase in torque per volume, allowing the motor to produce the same torque in 75% of the space of a conventional motor.
Since 2014, from stator to rotor, each DHX motor is developed to accommodate a modular assembly technique using modular, scalable components. Over molded coils are assembled in a scalable stator lam stack that is encapsulated with polymer, post making electrical connections, to become a monolithic, over molded stator. The teeth and coils are distributed circumferentially with gaps between coils, housing the DHX heat exchangers, incorporating our patented, proprietary DwHX fluid (air is a fluid) cooled technology. The optimized (using our proprietary DHX MDO Code) internal rotor consisting of scalable rotor segments of rectangular or wedge shaped permanent magnets, aligned radially or axially on or inside electric (silicon and exotic) steel lam stacks, (extending outwardly from a central hub), while incorporating the DHX Flux Focusing Wedge (F2W) and Enhanced Convective Rotor Cooling technologies, with skewed or non-skewed segments, on a keyed shaft, to be the perfect electromagnetic companion to the DHX stator. DHX operates in a 20,000 sq.ft R&D facility in metro Atlanta, Georgia, equipped with lean manufacturing assembly cells, CNC machine tools, custom production equipment and testing cells for motors sized up to 3000 kW.