This project presents a study conducted on a brushless permanent magnet motor, a performance variant and a passenger variant of Aurobay, focusing on thermal management strategies using MotorCAD simulation. The investigation includes the implementation of a cooling jacket and spraycooling concepts to enhance motor continuous performance. An optimization tool is employed to analyze the sensitivity of each cooling method parameters.

The study evaluates the impact of coolant and oil flow rates on temperature distribution across the magnet and windings. Results indicate that a higher flow rate improves motor cooling efficiency, yet a lower flow rate achieving comparable cooling effectiveness is designed and validated through simulations. Additionally, end winding cooling with nozzles, positioned both front and rear, proves to be effective. These findings provide a framework for designing coolant jackets and spray cooling systems necessary for optimal motor operation under higher continuous operation conditions including the top speed operation for Aurobay.