We Design + Assemble + Test electric motors incorporating the patented, proprietary micro-feature enhanced DwHX cooling technology developed in Professor J. Rhett Mayor’s research lab at the School of Mechanical Engineering at Georgia Tech. 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.
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 for corporate clients for in-house motor design functionality and analysis.