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An external rotor permanent magnet synchronous generator (ERPMSG) model for Range-Extended Electric Vehicles is developed. The temperature field simulation model of the ERPMSG is established. Experimental test of the winding temperature shows that the simulation model is believable and then it is used to optimize the structural parameters of the cooling water channel. It is found that the pressure loss increases with the number of layers of the cooling water channel increasing and the width of the water channel decreasing. In order to obtain a large turbulent effect and a minimum pressure loss simultaneously, the number of layers of the cooling water channel is set to be 3 and the width of the waterway 8 mm. The corner of the water channel is designed round with an optimum radius of 20 mm. After optimization, the cooling performance of the ERPMSG is obviously improved. Compared with the ERPMSG before optimization, the temperature of the ERPMSG with optimum structure parameters of the cooling water channel is lower. The maximum temperatures of the winding, the stator core and the rotor of the ERPMSG with optimum structure parameters of the cooling water channel decrease 8.19 °C, 5 °C and 7.42 °C respectively. Temperature distribution is more uniform in the permanent magnet of the ERPMSM with waterway structure optimization.

A novel permanent magnet synchronous motor with heat pipe for electric vehicle is designed with the aim to reduce the end winding temperature. Software FLUENT is used to simulate the temperature fields. The temperature distribution profile of the winding of the permanent magnet synchronous motor with heat pipe is similar to that of the traditional permanent magnet synchronous motor. But the temperature values of the winding of the permanent magnet synchronous motor with heat pipe are lower than those of the traditional permanent magnet synchronous motor. The area of the region with relative low temperature at permanent magnet synchronous motor with heat pipe is also larger than at traditional permanent magnet synchronous motor. The highest temperature of the winding of the permanent magnet synchronous motor with heat pipe is 16.4°C lower than that of the traditional permanent magnet synchronous motor. The highest temperature and the lowest temperature of the lamination of the permanent magnet synchronous motor with heat pipe are all lower than those of the traditional permanent magnet synchronous motor. The temperatures of the two end caps of the permanent magnet synchronous motor with heat pipe are apparently higher than those of the traditional permanent magnet synchronous motor since some heat generated at the end winding is transferred to the end cap by the heat pipe. The low temperature area at the middle housing of the permanent magnet synchronous motor with heat pipe is larger than that of the traditional permanent magnet synchronous motor. The temperature discrepancy between the evaporator of the heat pipe and the end winding is about 60°C.

Three kinds of novel permanent magnet synchronous motors (PMSM) integrated with heat pipe whose evaporator is treated in different ways for electric vehicle are designed in order to decrease the end winding temperature. The influence of the geometric parameter of the cooling water channel on the thermal–hydraulic performance is analyzed. The temperature difference between the cooling water and the housing decreases, while the pressure loss increases with the spiral number increasing. Channel width and channel height have little influence on the temperature difference but have an apparent effect on the pressure loss. FLUENT, CFD software, is used to simulate the heat dissipation performance of the PMSMs. The highest temperatures of the end winding are 149.9 °C, 140.1 °C, 133.5 °C, and 139.6 °C for the traditional PMSM and the three new PMSMs, respectively. The lowest temperatures of the lamination of the four PMSMs are close. So are the highest temperatures of the lamination. The lowest temperature distribution profiles of the housing of the three new PMSMs do not change apparently compared with that of the traditional PMSM. It shows that after the optimization of the cooling water channel, the cooling water system of the new PMSMs works efficiently although more heat is transferred to the housing. Among the traditional PMSM and the three new PMSMs, new PMSM b shows the best heat transfer capacity.

In this work, we investigate the material growth of the electrodeposited Cu/In/Ga stacked layers selenized by a plasma-assisted Se vapor selenization (PASVS) process at various substrate heating temperatures. For comparison, a merely thermal-assisted Se vapor selenization (TASVS) process is also tested. The PASVS process can help enhance the decomposition of Cu-In-Ga mixed phase and also the formation of Cu-Se and In-Se binary phases when the sample is selenized at 150 °C. However, the use of PASVS process aggravates the element indium loss at the same temperature. Results also indicate that the PASVS process helps to activate the early formation of Ga-Se phase during selenization at 250 °C. The PASVS process generates a porous surface structure with certain CuGaSe2 phase near the surface region at 350 °C. With the increase of selenization temperature, the film selenized by the PASVS process is prone to a grain structure, while it is a polygonal structure in the case of TASVS. The PASVS process is more able to yield a pure CIGS phase with moderate Ga incorporation at a temperature of 550 °C.

Here, a conduction micropump with symmetric planar electrode pairs prepared on flame-retardant glass-reinforced epoxy (FR-4) copper-clad laminate (CCL) is fabricated. It is used to investigate the influence of chamber dimensions on the performance of a conduction micropump and to determine the reliability of the conduction pump when acetone is used as the working fluid. A testing platform is set up to evaluate conduction micropump performance under different conditions. When the chamber height is 0.2 mm, the pump pressure reaches its peak value.

An electrohydrodynamic (EHD) conduction micropump with symmetric planar electrodes is developed to investigate the effect of micropump chamber dimensions on static pressure and flow rate. The interdigitated electrodes are created on an FR-4 CCL (copper clad laminate) using photolithography. The micropump consists of an electrode plate, chamber plate, top and bottom end cover. A 2D numerical simulation study is conducted to provide details about the ion distribution and fluid flow behaviors within a local domain of micropumps with different chamber height. Experimental results show that, by increasing chamber height, the static pressure and flow rate rise with a big slope under a chamber height of 0.2 mm, and henceforth decrease dramatically. The variation trends of static pressure and flow rate with an increase in chamber height are determined by the combination of ion concentration distribution and fluidic circulation formed between the two electrodes. Additionally, the effect of the chamber width and length is experimentally analyzed for optimum pressure and output flow rate.