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Dr.

Yew Chuan Chong (Eddie)


Motor Design Ltd., Ellesmere, Shropshire, UK
www.motor-design.com

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Topics
Background
Thermal analysis methods
CFDvs Thermal Network
Motor-CAD capabilities
Cooling of Electric Machines
Fundamentals of heat transfer for electric
machine application.

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Introduction
 The power output of an electrical machine is
strongly affected by its thermal performance
because machine operating temperature limits the
electric loading, q = f(I)
 Machine life
 “10C half-life rule", every 10 degree Cincrease in
operating temperature cuts insulation life by half.
 permanent magnet, the performance of magnets
decreases with temperature
 the magnets will be demagnetized if theyare
overheated.
 Copper loss, temperature dependent
 Mechanical, elevated temperatures can induce
mechanical stresses due to thermal expansion
 Bearing failure
 Thermal fatigue, variable speed operation.

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Traditional Motor Sizing Methods
 sizing based on single parameter
 thermal resistance Thermal Resistance
 housing heat transfer coefficient
 winding current density RTH [oC/W]
 specific electric loading P [W]
 thermal data from
 simple rules of thumb Twinding Tambient
 5 A/mm2, 12 W/m2/C etc.
 tests on existing motors
 competitor catalogue data Heat Transfer Coefficient
 can be inaccurate h [W/(m2.oC)]
 single parameter fails to describe
complex nature of motorcooling
 poor insight of where to concentrate
design effort
 next slide rules of thumbexamples
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Typical Rules of Thumb  Air Natural Convection
 h = 5-10 W/(m2.C)
 Air Forced Convection
 h =10-300 W/(m2.C)
 Liquid Forced Convection
 h = 50-20000 W/(m2.C)

 Wide range of possible values makes past experience very important


 Otherwise the design will not be correctly sized
 Values may not be valid if change manufacturing process, material, etc.
 Tables taken from: “SPEED Electric Motors”, TJE Miller

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Need for electric motor thermal analysis
 Simple motor sizing based on traditional methods such as
limiting winding current density or specific electric loading are
not good for optimisation
 Depend on experience from the manufacturing process and material
used, so tend to become very inaccurate when trying something new
in a design
 Give designer poor insight into where to concentrate design effort to
reduce temperature rise

 There is a requirement for smaller, low cost and more efficient


motors so more sophisticated thermal analysis is required.

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More Sophisticated ThermalAnalysis
Techniques
Two methods are available:

 Analytical Lumped Circuit Method


 Motor-CAD Therm Module

 Numerical Method
 Finite Element Analysis
 Computational Fluid Dynamics (CFD)
 includes flow

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Analytical Lumped Circuit Analysis
 lumps together the machine parts with
similar temperature into discrete nodes
in anetwork.
 Thermal resistance, heat transfer and
temperature difference are analogous to
electrical resistance, current and voltage.
 The heat flow between the nodes is
modelled using thermal resistances, i.e.
conduction, convection andradiation.
 Proven formulations for difficult heat
transfer mechanisms such as conduction
through bundles of wire in slot, complex
convection (empirical correlations),
interface gaps, etc.
 Power losses are placed at nodes where
heat is generated.

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Analytical Lumped Circuit Analysis
 thermal resistances placed in the circuit to model heat transfer
paths
L

 Conduction, th kA
R

 path area (A) and length (L) from geometry


 thermal conductivity (k) of material
RConvection, 
1
hA
 heat transfer coefficient (h – W/m2/K) is determined empirically from test
th

data or from CFDanalysis (dimensional analysiscorrelations)


 Radiation, 1 T1 T0 
Rth  
 
hA  F T1 4 T04 A

 emissivity () & view factor (F)from surface finish & geometry
 thermal capacitances for transient analysis
 Capacitance = Weight  Specific Heat Capacity

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Thermal Analysis Model Order
Thermal Model Order Elements/nodes Computational Note
time
Computational fluid High Millions hours/days Good to obtain convective
dynamics (CFD) heat transfer coefficient,
predict flowdistribution of a
cooling system, difficult to
perform thermal transients

Finite Element Moderate Thousands mins/hours Good to modelconduction


Analysis (FEA) heat transfer, 2D FEA
thermal solver can solve
specific problem very fast

Lumped Circuit Low 50 to 1000 Nodes seconds Very fast to calculate


Analysis (Full NodeModel) complex thermal transients

 Lumped circuit and numerical solutions have different levelsof


complexity and so model setup and calculation times

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CFD vs Thermal Network
 For thermal network method, the machine is represented by an equivalent thermal
network based upon the machine’s geometry, materials, cooling methods, losses, etc.

 For CFDmethod, the conjugate heat transfer problem is solved numerically based upon
the conservation of mass, momentum andenergy.

 CFD,prepare clean geometry, generate high quality mesh, select turbulence model to
resolve the heat transfer and rotating flow problem.

 Level of details

 Time for solution of CFDis more demanding, duty cycle analysis

 This makes thermal network method useful in the beginning of the machine design
process – to identify the important parameters that affect the thermal performance,

 while CFDis used to fine tuning the thermal design for complex issues, e.g. flow
distribution, pressure drop, heat transfer for hairpin winding, waftereffects, etc.

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CFD, FEA vs Thermal Network
 We need to know ifthe complexities of heat transfer
can be modelled using thermal resistances.
 Forced flow in cooling channels, e.g. developing flow,
noncircular duct, coolant type, etc.
 effects of rotation in rotorcooling channels, airgap.
 Flow resistance model the flow distribution in a cooling
system (fan characteristic and system flow resistance)
 Winding heat transfer

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Design process of electricalmachines
 Prototype – cost to build is
very expensive Design Specification

 Numerical methods – very


time consuming Possible Solutions

 Analytical methods – fast


calculation speed & Analytical Methods
reasonable accuracy Calibration  Electromagnetic model
 Thermal model

 Analytical methods are


critical to reduce the time
Numerical Methods
taken from initial designto
Finite Element Analysis (FEA)
production Computational Fluid Dynamic
(CFD)

Test and Prototype

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Motor-CAD
 Ultra-fast analytical network analysis
software dedicated to thermalanalysis of
electrical machines
 input machine geometry using
dedicated parametric editors
 select cooling type, materials, etc.
 calculate steady state or transient
temperatures
 all difficult heat transfer datais
calculated automatically
 easy to use as motor designers may
not be heat transfer specialists
 18 year of practical experiencebuilt
into the heat transfer and flow
algorithms
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Motor-CAD Motor Types
 Brushless Permanent Magnet (BPM)
 Outer Rotor BPM
 PMDC
 Induction
 Synchronous
 Switched Reluctance
 Claw Pole

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Cooling Types Investigated
Motor-CAD includes proven models for an extensive range of
cooling types:
 TENV: Totally enclosed non-ventilated
 natural convection from housing
 TEFC: Totally enclosed fan cooled
 forced convection from housing
 Through Ventilation
 TE with Internal Circulating Air
 Internal air circulating path
 water jacket as heat exchanger
 Open end-shield cooling
 Water Jackets
 axial or circumferential
 Submersible cooling
 Wet Rotor & Wet Stator cooling
 Spray Cooling
 e.g. oil spray cooing of end windings
 Direct conductor cooling
 e.g. Slot ducts with oil

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Many Geometry Options

 Many geometry options such as housings, rotors, slot types etc.


 Some have more influence on electromagnetic design, others on thermal design

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Flow Network Analysis

 Flow network analysis used to calculate flow


through the ventilation system (through
ventilation, water jackets, etc.)
 Proven empirical correlations to calculate
pressure drop due to duct wall frictionand flow
separation
 Once the flow rate through the cooling system is
calculated we can calculate the fluid velocity and
the corresponding convection heat transfer using
convection correlations.

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Numerical Thermal Analysis
 Subdivide full machine into smaller models (high quality mesh formore
accurate numerical solutions):
 Finite element analysis (FEA)
 Only useful for conduction heat transfer
 Computational fluid dynamics (CFD)
 Can also simulate complex fluid flow

CFD
FEA

Motor-CAD Fluent

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Motor-CAD Integrated Thermal FEA Solver
 Motor-CAD fully integrated FEA thermal solver allows fast
calibration of winding thermal resistance network and
improved understanding of winding hotspot location.

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Computational Fluid Dynamics (CFD)
 Can be time consuming to
construct models and make
calculations
 Useful to filter designsusing
Motor-CAD and just do CFD
on final candidate.
Fluent
 Then use CFDresults to
calibrate Motor-CAD model,
convection and flow
formulations.
 Assistance in CFDmodel setup
using links to Motor-CAD
being developed Fluent

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Winding Temperature Resolution
 The number of nodes in the lumped circuit model for the winding
can be varied depending on the temperature resolution required
and if there is an uneven distribution of losses in the winding
 Improved hotspot prediction

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Live Demo of Motor-CAD

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Sensitivity Analysis
 machine design involves some uncertainty due to the manufacturingprocess,
nature of turbulence, electromagnetic design,etc.
 Sensitivity analysis is recommended to gain an in-depth understanding of the
main restrictions to cooling for a givendesign
 Design effort can then be focused on the main cooling issues

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2
4
Cooling of Electrical Machines
There are three mechanisms by which heat
(energy) is transferred:
 Conduction
 Convection
 Thermal radiation

Fundamentals of heat transfer for electric


machine application.

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Conduction heat transfer
 Heat transfer mode in a solid due to molecule vibration.
 Good electrical conductors are also good thermal conductors.
 Metals have large thermal conductivities due to their well ordered
crystalline structure,
 k is usually in the range of 15 – 400W/m/K.
 Solid insulators have not well ordered crystalline structure and areoften
porous.
 k is typically in the range of 0.1 – 1W/m/K. (better than air with k 
0.026W/m/K)
 In an electrical machine, it would be desirable tohave also materials that
are good electrical insulators and have good thermal conductivity.
 material research to try to achieve this.
 the calculation of conduction is complex forcomposite
components such as winding, bearings, etc.

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Conduction heat transfer
 Heat transfer is transferred from high temperature to lowtemperature.

𝑘𝐴 𝑇ℎ𝑜𝑡 − 𝑇𝑐𝑜𝑙𝑑
𝑄 =
𝐿
𝑇ℎ𝑜𝑡−𝑇𝑐𝑜𝑙𝑑
 Effectiveness of heat flow is determined by R, 𝑄 = .
 Analogous to Ohm's law, 𝐼= 𝑉
𝑅.
 Conduction thermal resistance is calculated using:
𝐿 𝐶
𝑅= [𝑢𝑛𝑖𝑡: ]
𝑘𝐴 𝑊
 L = path length [m]
 A = heat transfer cross section area [m2]
 k = material thermal conductivity [W/m/K]

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Heat extraction through conduction
 high slot fill factor solutions (packing as
much wire as technological possible in the
slots of the electricalmachines).

C. Carstensen, S. Bauer, R. Inderka, R. W. De Doncker,


A. G. Jack, B. C. Mecrow, P. G. Dickinson, D. Stephenson, J. S. Burdess, N. Fawcett, and J. “Efficiency Comparison of Different Winding
T. Evans, “Permanent magnet machines with powdered iron cores and pressedwindings,” Configurations for Switched Reluctance” Vehicle
IEEE Trans. Ind. Appl., vol. 36, no. 4, pp. 1077–1084, Jul./Aug. 2000. Propulsion Drives 20th International Electric Vehicle
Symposium (EVS-20), Long Beach, USA, 2003

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Heat extraction through conduction
 Sometimes slot liner material has significant impact on the
temperature rise between the winding and statorlamination.
 significant research efforts have led to the development of
insulation materials that have a higher thermal conductivity
value.

Slot
liner

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Heat extraction through conduction

 Tesla Model S60 Induction Motor with water cooled statorand


rotor
 End windings are potted
 to dissipate the copper loss in the end windings directly to the
housing water jacket

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Heat extraction through conduction

S. Nategh, A. Krings, O. Wallmark, and M. Leksell, “Evaluation of


impregnation materials for thermal management of liquid-cooled electric
machines,” IEEETrans. Ind. Electron., vol. 61, no. 11, pp.5956–5965, 2014.

 impact of thethermal conductivity of


different potting materials
 high-performance liquid-cooled electric
machines
 k varies from 0.25 to 3.2W/mK

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Radiation Heat transfer
 heat transfer mode from a surface due to energy transferby electromagnetic
waves.
 Radiation thermal resistance is calculated using:
1 𝐶
𝑅𝑟 = [𝑢𝑛𝑖𝑡: ]
ℎ𝑟𝐴
 hr can be calculated using the formula:
𝜎𝜀𝐹1−2 𝑇4 −𝑇4
1 2
ℎ𝑟 =
𝑇1−𝑇2
 hr = radiation heat transfer coefficient [W/m2/K]
 A = area of radiating surface [m2]
 σ = Stefan-Boltzmann constant (5.669x10-8 W/m2/K4)
 T1 = absolute temperature of radiating surface[K]
 T2 = absolute temperature of surface radiated to (ambient)[K]
 ε = emissivity of radiating surface (ε < 1)
 F1-2 = view factor (F1-2 ≤ 1) – calculated from geometry

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Typical Emissivity (ε) Data

 from Stokes Research Institute

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Convection heat transfer
 Heat transfer mode between a surface and a fluid due to fluidmotion.
 Natural Convection – fluid motion due tobuoyancy forces that arise from change
in density of fluid due to the temperature difference.
 Forced Convection – fluid motion due to external forces (fan andpump)
 Two types of flow
 Laminar flow, streamline flow at lower velocities
 Turbulent flow, turbulent eddies created at higher velocities
 Convection heat transfer can be computed as:
 Air Natural Convection
𝑄 = ℎ 𝑐𝐴 𝑇 𝑤𝑎𝑙𝑙 −𝑇 𝑓𝑙𝑢𝑖𝑑  h = 5-10 W/(m2.C)
 Convection thermal resistance is calculated using:  Air Forced Convection
1 𝐶  h =10-300 W/(m2.C)
𝑅𝑐 = [𝑢𝑛𝑖𝑡: ]  Liquid ForcedConvection
ℎ𝑐𝐴
 h = 50-20000 W/(m2.C)
 hc = convection heat transfer coefficient [W/m2/K]
 A = wall surface area [m2]
 Convection depends on the heat transfer coefficient hc that is determined
empirically from test data or from CFDanalysis.

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Convection heat transfer coefficient
 As convective heat transfer is non-dimensionalized with Nusselt number (Nu),
hCcan be calculated using empirical correlations based on dimensionless
numbers (Re, Gr, Pr):
ℎ𝑐 𝐿
𝑁𝑢 = = 𝑓 Re, Gr, Pr
𝑘
 L= characteristic length (m)
 k = fluid thermal conductivity (W/m/K)
 Dimensionless numbers allow the same formulation to be usedwith
different fluids, dimensions and models of dynamic and geometric
similarity to those used in the original experiments.
 A lot of correlations are available inthe literature.
 Motor-CAD automatically selects the most appropriate correlation that
matches the cooling type and geometry shape.
 Cylinder, flat plate, open/enclosed channel,etc.

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Convection Dimensional Analysis – Dimensionless Number
 Reynolds number, 𝑅𝑒 = 𝜌𝑈𝐿
𝜇
𝑔𝛽𝜌 2 𝑇𝑤𝑎𝑙𝑙−𝑇𝑓𝑙𝑢𝑖𝑑 𝐿3
 Grashof number, 𝐺𝑟 = 𝜇2
𝜇𝑐𝑝
 Prandtl number, 𝑃𝑟 =
𝑘
 μ = fluid dynamic viscosity[kg/m/s]
 ρ = fluid density [kg/m3]
 k = thermal conductivity of the fluid[W/m/K]
 cp = specific heat capacity of the fluid[J/kg/K]
 U = fluid velocity [m/s]
 L= characteristic length[m]
 β = coefficient of thermal expansion of fluid[1/K]
 g = acceleration due to gravity[m/s2]

 The dimensionless numbers are functions of fluid


properties, size (characteristic length), fluid velocity
(forced convection), temperature (natural convection)
and gravity (natural convection).

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Natural Convection
General form of natural convectioncorrelation:
𝑁𝑢 = 𝑓 𝐺𝑟,𝑃𝑟 = 𝐶 𝐺𝑟 𝑃𝑟 𝑛
 C& n are curve fitting constants.
 Rayleigh number, Ra = Gr Pr
 Transition from laminar to turbulent flow: 107 < Ra <109
𝑇𝑤𝑎𝑙𝑙+𝑇𝑓𝑙𝑢𝑖𝑑
 All fluid properties are evaluated at the film temperature, 𝑇𝑓 =
2
 The heat transfer coefficient is temperature dependent and it is needed tobe
solved iterative in Motor-CAD.

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Horizontal Cylinder (Natural Convection)

 formulation for average Nusselt number of a horizontal cylinder of diameter D:


𝑁𝑢 = 0.525 𝐺𝑟𝐷 𝑃𝑟 0.25 (104 < GrD Pr < 109) Laminar
𝑁𝑢 = 0.129 𝐺𝑟𝐷 𝑃𝑟 0.33 (109 < GrD Pr < 1012) Turbulent
𝑁𝑢 𝑘
Heat transfer coefficient, ℎ=

 Fluid properties at mean film temperature (average of surface and bulk fluid
temperatures)

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Vertical Cylinder (Natural Convection)
 formulation for average Nusselt number of a vertical
cylinder of height L:
 Laminar flow, 104 < GrLPr < 109,
𝑁𝑢 = 0.59 𝐺𝑟𝐿𝑃𝑟 0.25

 Turbulent flow, 109 < GrLPr < 1012,


𝑁𝑢 = 0.129 𝐺𝑟𝐿𝑃𝑟 0.33

 Heat transfer coefficient, ℎ= 𝑁 𝑢 𝑘


𝐿

 Fluid properties at mean film temperature (averageof


surface and bulk fluid temperatures)

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Vertical Flat Plate (Natural Convection)
 formulation for average Nusselt number ofa
vertical flat plate of heightL:
 Laminar flow, 104 < GrLPr < 109,
𝑁𝑢 = 0.59 𝐺𝑟𝐿𝑃𝑟 0.25

 Turbulent flow, 109 < GrLPr < 1012,


𝑁𝑢 = 0.129 𝐺𝑟𝐿𝑃𝑟 0.33

 Heat transfer coefficient, ℎ= 𝑁 𝑢 𝑘


𝐿

 Fluid properties at mean film temperature


(average of surface and bulk fluid
temperatures)

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Horizontal Flat Plate (Natural Convection)
 Upper face:
 Laminar flow, 105 < GrLPr < 108, upper
𝑁𝑢 = 0.54 𝐺𝑟𝐿 𝑃𝑟 0.25
 Turbulent flow, GrL Pr > 108,
𝑁𝑢 = 0.14 𝐺𝑟𝐿 𝑃𝑟 0.33

 Lower face:
 Laminar flow, 105 < GrLPr < 108,
𝑁𝑢 = 0.25 𝐺𝑟𝐿𝑃𝑟 0.25

 Heat transfer coefficient, ℎ= 𝑁 𝑢 𝑘


𝐿
lower
 Fluid properties at mean film temperature
(average of surface and bulk fluid temperatures)

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Vertical Fin Channel (Natural Convection)
 formulation for Nusselt number of U-shaped vertical channels
(laminar flow):
𝑟×𝐺𝑟 𝑃𝑟 0.75
0.5
𝑁𝑢 = 𝐿
× 1 − exp −𝑍 𝑟
𝑍 𝐿 𝐺𝑟 𝑃𝑟

1−0.483×exp −0.17/𝑎
𝑍 = 24× 3 3
1+𝑎 1+ 1−exp −0.83𝑎 ×9.14 𝑎×exp −465×fin spacing −0.61
2

a = channel aspect ratio, i.e. fin_spacing/fin_depth


r = Characteristic Length (fin hydraulic radius)
= 2 ×fin_depth×fin_spacing/[2×(fin_depth + fin_spacing)]
L= fin height
ℎ= 𝑁𝑢 𝑘/𝑟

 The fluid properties are evaluated at the wall temperature (except


volumetric coefficient of expansion which is evaluated at the mean
fluid temperature).
Ref: Van De Pol, D.W. & Tierney, J.K. : Free Convection Nusselt Number for Vertical U-Shaped Channels, Trans.
ASME, Nov. 1973.

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Horizontal Fin Channel (Natural Convection)
Horizontal Fin Channels

 formulation for Nusselt number ofU-shaped horizontal channels (laminar flow):

0.44 0.17
−7640
𝑁𝑢 = 0.00067 ×𝐺𝑟𝑠 𝑃𝑟 × 1 −exp 𝑃𝑟
𝐺𝑟𝑠
s = fin spacing used as characteristic dimension
ℎ= 𝑁𝑢 𝑘/ 𝑠

Ref: Jones, C.D., Smith, L.F. : Optimum Arrangement of Rectangular Fins on Horizontal Surfaces for Free-Convection Heat Transfer, Trans. ASME, Feb1970.

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Live Demo of Motor-CAD

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Forced Convection
General form of forced convectioncorrelation:
𝑁𝑢 = 𝑓 𝑅𝑒,𝑃𝑟 = 𝐶 𝑅𝑒 𝑚 𝑃𝑟 𝑛
 C, m and n are curve fittingconstants.
 Reis a measure of inertial forces to viscousforces.
 For external flow, laminar/turbulent transition Re 5 x 105
 For internal flow,
 The flow is assumed to be fully laminar when Re< 2300 in Circular/Rectangular
Channels and when Re< 2800 in Concentric Cylinders
 The flow is assumed to be fully turbulent when Re> 5000 (in practice the flow may not
be fully turbulent until Re>10000)
 A transition between laminar and turbulent flow is assumed for Revalues between
those given above.

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Flat Plate Forced Convection (External Flow)
flow

 formulation for average Nusselt number of flat plate (or horizontal cylinder) of length L:
 For laminar flow, Re< 5 x 105,
Nu = 0.664 Re 0.5 Pr 0.33
 For turbulent flow, Re> 5 x 105,
Nu = (0.037 Re0.8 – 871) Pr 0.33
 h = Nu × k / L
 Fluid properties at mean film temperature (average of surface and bulk fluid temperatures)
Ref: Incropera, F.P& DeWitt, D.P.: Introduction to Heat Transfer, Wiley,1990.

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Enclosed Channel Forced Convection (Internal Flow)
 Enclosed channel – Internal flow heat transfer correlations

 For enclosed channel (non-circular duct), Motor-CAD used


the following formulations:
 Dh = Hydraulic diameter (non-circular duct)
𝐷ℎ = 4×𝐶ℎ𝑎𝑛𝑛𝑒𝑙 𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑟𝑒𝑎
𝐶ℎ𝑎𝑛𝑛𝑒𝑙 𝑃𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟
 𝐷ℎ = 2 ×𝑎𝑖𝑟𝑔𝑎𝑝 (concentric cylinders)

 𝑅𝑒 = 𝜌𝑈𝐷 ℎ
𝜇
 h = Nu k / Dh

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Enclosed Channel Forced Convection
Laminar Flow
 Concentric Cylinders (adaptation of formulation for parallel plates which includes entrance length effects):

0.03 ×𝐷ℎ 𝐿 ×𝑅𝑒 𝑃𝑟


𝑁𝑢 = 7.54+ 2
1 + 0.016 ×𝐷ℎ 𝐿 ×𝑅𝑒𝑃𝑟
3

 The 2nd term in the above equation is the entrance length correction which accounts for entrance lengths where the
velocity and temperature profiles are not fully developed.
 Circular Channels (which includes entrance lengtheffects):

0.065 ×𝐷ℎ 𝐿 ×𝑅𝑒 𝑃𝑟


𝑁𝑢 = 3.66+ 2
1 + 0.04 ×𝐷ℎ 𝐿 ×𝑅𝑒𝑃𝑟
3

 Rectangular Channels (adaptation of formulation for round channels):

𝐻 𝐻 2 3 0.065 ×𝐷ℎ 𝐿 ×𝑅𝑒 𝑃𝑟


𝑁𝑢 = 7.46 − 17.02 ++22.43 −9.94 +
𝑊 𝑊 2
1 +0.04× 𝐷ℎ ×𝑅𝑒 𝑃𝑟 3
𝐿

 where H/W = Channel Height/Width Ratio

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Enclosed Channel Forced Convection
Turbulent flow
 Gnielinski's formula for fully developed turbulent flow (3000 < Re< 1×106)

𝑓 8 𝑅𝑒 − 1000 𝑃𝑟
𝑁𝑢 =
1 + 12.7 𝑓 8 1 2 𝑃𝑟2 3 − 1

 Where f is Darcy friction factor and fora smooth wall is:

𝑓 = 0.79ln 𝑅𝑒 − 1.64 −2

 In cooling channels, the fluid boundary layer is


developing at the duct entrance before it becomes
fully developed.

 Correction factor is applied for the developingflow.

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Enclosed Channel Forced Convection
Transition from Laminar to TurbulentFlow

 It is noted that h increases dramatically as the flow regime changes from being laminar to turbulent
flow.
 For transitional flow heat transfer, Nu is calculated for both laminar and turbulent flow using the
above formulations. A weighted average (based on Re) is then used to calculate Nu in the transition
zone.

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Enclosed Channel Forced Convection

Useful hints
 If users cannot model a particular duct using Motor-CAD existing
geometry options, users can model the duct using its hydraulic diameter.
 As the actual duct is not physically modelled, then users need to correct
the convective surface area for thermal resistance, i.e. R=1/hA.

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Enclosed Channel – Slot Water Jacket

 Slot cooling channel


 Specify location, dimensions, duct wall thickness, coolant, flow direction
 Slot cooling will be reflected in the equivalent thermal network.

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Live Demo of Motor-CAD

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Enclosed Channel – Housing Water Jacket

 Housing water jacket


 Specify axial or spiral configuration
 Axial configuration can be used for zig-zag flow water
jacket by setting the number of parallel flowpaths.
 Specify dimensions, coolant, flow direction, etc
 In Motor-CAD, the water jacket cooling can be applied to the housing overhang orat
the active section only.
 As inlet and outlet sections are not modelled, CFDis ideal to calculate heattransfer
with more accuracy, pressure drop.

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Enclosed Channel – Shaft Cooling

 Certain machine types have relatively high rotor loss, e.g.induction


machines.

 Elevated temperature has detrimental effect on machine’s permanent


magnet.

 Shaft cooling channel options:


 Centre hole
 Spiral groove

 Specify dimensions, coolant, flow rate, flow direction,etc.

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Spray / jet impingement Cooling
 Copper loss is the major loss component
 Copper loss (active) can be dissipated by housing
water (liquid) jacket through conduction heat
transfer
 Direct end winding cooling is proposed
 Electric traction drive machine application
 Automatic transmission fluid (ATF) is available in
the vehicle’s transmission
 Impinging automatic transmission fluid (ATF)jets
onto the end winding
 Jet impingement – high heat transfer coefficient
 The ability to use ATFto cool the rotor andend
winding directly has significant advantages in
reducing their temperatures.

[K. Bennion and G. Moreno, “Convective heat transfer coefficients of automatic transmission fluid jetswith
implications for electric machine thermal management,” in ASME 2015 International Technical Conference and
Exhibition on Packaging and Integration of Electronic and Photonic Microsystems (InterPACK2015), 2015, pp.1–9.

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Spray Cooling

 Independent nozzles can be placed on the shaft, endcap and/or


housing
 The Spray Cooling Editor allows user to
 Positions, nozzle number, diameter, flow rate through thenozzles
 Flow source:
 Supplied from external
 Coupled with Housing Water Jacket/Shaft Cooling as the same fluid might beused.

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Spray Cooling

The submerged double jet impingement (SDJI) method for thermal


testing of packages By Evelien Driessens, IMEC and Fulip Chrisiaens,
Alcatel Excerpt from Electronics Cooling Magazine, May 2001.

 Formulation used in Motor-CAD for calculation the heat transfer coefficients of thespray cooling.
 Very complex cooling method due to the fact of the multiphase flow, even difficult to be modelled
using CFD,good customer feedback.
 Rough estimation of the impact of spray cooling on machine thermalperformance
 Sensitivity analysis on spray cooling could be useful.

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Spray / jet impingement Cooling 18AWG

 Experiments to characterise the thermal performance of ATFjet


impingement.
 The effects of ATFtemperature, wire bundles and nozzle jet velocity
on convective HTC.
 Impinging jets were created by an orifice-type-nozzle plate with a
2mm orifice diameter
 Distance between nozzle and test sample is 10mm;
 Jet impingement surface – 12.7 mm diameter surface 22AWG

 4 test samples – smooth (baseline sample), three with surface


features to simulate wire bundles ofAmerican wire gauge (AWG),
e.g. 18 AWG, 22AWG, and 26AWG
[K. Bennion and G. Moreno, “Convective heat transfer coefficients of automatic transmission fluid jetswith
implications for electric machine thermal management,” in ASME 2015 International Technical Conference and
Exhibition on Packaging and Integration of Electronic and Photonic Microsystems (InterPACK2015), 2015, pp.1–9.

26AWG

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5
9
Experimental study of jet impingementcooling
 For baseline sample (smooth)
 The variation of convective htc with jet
impingement velocity
 The experimental results are compared
against the available correlations in the
literature.
 Reasonable agreement
 The jet inlet temperatures haveminimal
influence on convective htc for smooth
surface
 At jet velocity of 10m/s, the htc is about
8000 – 10,000 W/m2K.

o Air Natural Convection


o h = 5-10 W/(m2.C)
o Air ForcedConvection
o h =10-300W/(m2.C)
o Liquid ForcedConvection
o h = 50-20000 W/(m2.C)

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Experimental study of jet impingementcooling
50°C inlet temperature 70°C inlet temperature 90°C inlet temperature

 Impact of jet inlet temperature and wire bundle features on


convective htc.
 The 18 AWG, 22 AWG and 26 AWG samples have minimaleffect
on htc at low jet velocity.
 Some enhancement at high jet velocity for 18 AWG and 22 AWG
sample
 26 AWG has very similar performance to smoothsurface
sample.
 Motor-CAD does not consider the wire bundle features effect.

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Experimental study of jet impingementcooling

 At higher jet velocities, the fluidis being deflected


off the surface.
 This reduce the amount of fluid supplied to the
outer area of the samples, therefore reduce
convective heat transfer performance.
 The effect of fluid deflection is more dominantat
higher temperature.

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Experimental study of jet impingementcooling
 Differential pressure drop across the nozzle versus the jet velocity
 The pressure drop decreases with increasing fluid temperature (lower fluid density)
1
 Pressure loss coefficient, K= ΔP/ (2 𝜌𝑉 )2

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Limitations / Issues / Complexities
 On a larger scale, the heat transfer coefficient varies because not all of the endwinding
is directly impinged upon by the jet.
 The variation in heat transfer (Nu) is due partly to the variation in the local heat transfer
coefficient away from the stagnation point of the jet impinging on the surface.

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Open Fin Channel – Forced Convection
 The empirical correlation used in Motor-CAD for open finchannels
is that of Heiles[1]:

𝜌𝑎𝑖𝑟 ×𝑐𝑝𝑎𝑖𝑟 ×𝐷 ×𝑉𝑎𝑖𝑟


ℎ= ×1 − exp −𝑚
4𝐿

0.214
𝐿0.946 𝑘𝐴𝑖𝑟
𝑚 = 0.1448 × ×
𝐷1.16 𝜌𝐴𝑖𝑟 ×𝑐𝑝𝑎𝑖𝑟 ×𝑉𝐴𝑖𝑟
D = Hydraulic Diameter = 4 x Channel Area / Channel Perimeter (including
open side)
L= Axial length of cooling fin
 Air properties at the film temperature = (Tfree-stream +Twall)/2
 It is assumed that the flow is always turbulent due to the fact that
the radial fans and cowlings used in such machines create
turbulence.
 The h is directly multiplied by a Turbulence Factor in the rangeof
1.7 – 1.9 based on the tests, which seem independent of theflow [1] Heiles, F., "Design and Arrangementof
velocity. Cooling Fins", Elecktrotecknik und
Maschinenbay, Vol. 69, No. 14, July1952.

65
Axial Fin Channel – Air Leakage
 For Blown Over (TEFC)machines, Motor-CAD assumes the air
leaks out of the open channels causing the local Air Velocity
to be lower at the drive end than at the non-drive end.
 Leads to reduction in convection cooling further from the fan

 The air leakage is a complex function of:


 Cowling, fan and fin design
 Fan speed
 Motor size
 Fin roughness
 Restrictions
 etc.

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66
Axial Fin Channel – Air Leakage

 The typical form ofthe reduction in velocity is shown above.


 In Motor-CAD, empirical curves used to estimate air leakage.
 CFDis ideal to calculate leakage with moreaccuracy.

67
67
Axial Fin Channel – Air Leakage

68
68
Calibration of Flow Calculations using CFD
 We are currently developing automated links from Motor-CAD to
CFDto allow automated calibration of such complex flow situation
as blown over semi-open channel leakage, end winding cooling,
water jackets, etc.
 Fan editor been incorporated into Motor-CAD so we can export to CFD

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MOTORDESIGNLIMITED
Thank you for your attention!

Questions are welcomed

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