Electric motor drives are the universal work horses of industry driving fans, pumps, power tools, compressors and materials handling/conveyor systems. More energy efficient motor designs are needed to meet increasingly stringent EU efficiency standards. Better thermal management of electric motors could make this achievable. Current technologies rely on expensive copper casings or inefficient air-cooling. Removal of heat from small totally enclosed motors is a recurring problem in the food processing, surgical instruments and materials handling where the motors operate at their limits and run very hot. Adding more copper for heat transfer is not feasible as it makes motors bigger, heavier and more expensive and liquid cooling requires more energy for circulation and maintenance. Moreover, extra mass or volume cannot be easily integrated in compact motor layouts.
We have developed and engineered an improved method of cooling using advanced materials. Nanomaterials, such as carbon nanotubes (CNTs), are at least 6x more thermally conductive than conventional thermal interface materials. We have identified a commercial application and developed engineering solution using specially tailored nanomaterials for the generation of energy-saving, highly efficient motors in partnership with a EU SME drum motor manufacturer.
The findings of CONDUCT has enabled us to up-scale and take specially designed nanomaterials developed under the Starting Grant DEDIGRWOTH to the next level. We have successfully embedded them in drum motor applications and by doing so the thermal resistance of the motors could be reduced up 50%. Further tests are now being developed for the pathway to impact. In parallel, additional interaction with other industrial partners form the F1 motor-sport industries also requiring new solutions to thermal management were established and as a result of these interactions the links were formalised through a Royal Society Industry Fellowship allowing the direct exchange between Academia and Industry. As part of this Fellowship further exploitation of the CONDUCT findings are being sought. Subject to further tests a series of different applications are being looked for the materials developed alone, the processing routes established during the course of this project, as well as their applications.
