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As the power density of electric motors increases, oil will be used not only to lubricate the gearbox, but also to cool the motor. The combination of direct oil cooling of the motor and lubrication of the drive train poses new challenges for the lubricant. Since the fluid will be in direct contact with the electrical components, it must have excellent insulation to avoid any current leakage. We have studied the dielectric properties of the fluid under different aging conditions. The fluid also needs to maximize the heat transfer capability to cool the motor. We combined numerical simulations of the motor with stator cooling experiments to identify overheating points in the motor and to evaluate the cooling capacity of our oil. The direct oil cooling system also requires the oil to have good compatibility with motor insulation materials and copper. We evaluated the oil's compatibility with the polymer coating of the wire and copper using a specially designed bench test. Another critical aspect of electric vehicle fluids is high-speed lubrication performance. When the motor is running at high speeds, ball bearings can suffer from insufficient lubricant. Special high-speed bearing bench tests were used to evaluate the ability of the fluid to lubricate high-speed bearings. Transmission components running at high speeds can increase dissolved gas and agitation losses from the oil. We conducted dissolved gas experiments at high speed conditions to study the degassing performance of the fluid.

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