Intelligent optimization of double-helix oil cooling system for outer rotor in-wheel motors based on multi-physics coupling simulation

Outer rotor in-wheel motors face critical thermal management challenges due to constrained heat dissipation within wheel hubs, limiting their application in electric vehicles. This study addresses the research gap of inadequate cooling solutions for high-power-density motors by developing an innovative double-helix oil cooling system through multi-physics coupling optimization. The proposed framework integrates MotorCAD-Maxwell-Ansys platforms to simultaneously analyze electromagnetic losses, thermal conduction, and fluid dynamics. Key findings demonstrate that the optimized double-helix configuration achieves 28% heat dissipation efficiency enhancement, 17% temperature uniformity improvement, and 5°C peak temperature reduction compared to conventional single-channel systems, while maintaining an acceptable 15% pressure drop penalty. Experimental validation confirms 96.9% correlation with simulation results. This research provides practical thermal management solutions crucial for advancing electric vehicle motor technology.