The small power PM BLDC motors play a more and more important role in the industry and domestic applications as it was presented in Introduction. Therefore, further thermal and coupled studies of the other machines of this type could fill the literature gap. The fur-ther analyses may be extended to the coupling procedure with the mechanical field. It would allow for the estimation of the thermal and mechanical stress for the specific motor compo-nents.
In the dissertation, thermal numerical models based on the steady state calculations were introduced. Therefore, further research could incorporate the transient models to be investigated. The validation of the future models can be conducted on the basis of the pre-sented experimental part of the dissertation. The transient analysis would also allow for the investigation of the other heat dissipation intensification concepts such as application of the PCM during the short overload periods.
In the further work, the additional active methods could be also investigated. In accor-dance with the methods presented in the Introduction Section, the approaches such as the water jackets, heat pipes, oil spraying on the basis of biodegradable ingredients could be the object of these studies. The multiphase modelling approach of the heat pipes application in the small power electric motors could also be worth studying.
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[56] Z. Rehman, K. Seong, Three-D numerical thermal analysis of electric motor with cool-ing jacket, Energies 11 (1) (2018). ❞♦✐✿✶✵✳✸✸✾✵✴❡♥✶✶✵✶✵✵✾✷.
[57] R. Wrobel, P. H. Mellor, D. Holliday, Thermal modeling of a segmented stator wind-ing design, IEEE Trans. Ind. Appl. 47 (5) (2011) 2023–2030. ❞♦✐✿✶✵✳✶✶✵✾✴❚■❆✳✷✵✶✶✳
✷✶✻✶✼✹✶.
[58] K. H. Lee, H. R. Cha, Y. B. Kim, Development of an interior permanent magnet motor through rotor cooling for electric vehicles, Appl. Therm. Eng. 95 (2016) 348–356. ❞♦✐✿
✶✵✳✶✵✶✻✴❥✳❛♣♣❧t❤❡r♠❛❧❡♥❣✳✷✵✶✺✳✶✶✳✵✷✷.
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✷✾✶✾✺✵✻.
URL❤tt♣s✿✴✴✐❡❡❡①♣❧♦r❡✳✐❡❡❡✳♦r❣✴❞♦❝✉♠❡♥t✴✽✼✷✸✹✼✵✴
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J. Heat Mass Transf. 53 (4) (2010) 797–810. ❞♦✐✿✶✵✳✶✵✶✻✴❥✳✐❥❤❡❛t♠❛sstr❛♥s❢❡r✳
✷✵✵✾✳✵✾✳✵✷✷.
[61] W. M. Yan, H. Y. Teng, C. H. Li, M. Ghalambaz, Electromagnetic field analysis and cool-ing system design for high power switched reluctance motor, Int. J. Numer. Methods Heat Fluid Flow (2019).❞♦✐✿✶✵✳✶✶✵✽✴❍❋❋✲✵✽✲✷✵✶✽✲✵✹✺✵.
[62] M. H. Park, S. C. Kim, Thermal characteristics and effects of oil spray cooling on in-wheel motors in electric vehicles, Appl. Therm. Eng. 152 (2019) 582–593. ❞♦✐✿✶✵✳
✶✵✶✻✴❥✳❛♣♣❧t❤❡r♠❛❧❡♥❣✳✷✵✶✸✳✶✶✳✵✺✼.
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[64] M. R. Guechi, P. Desevaux, P. Baucour, C. Espanet, R. Brunel, M. Poirot, Spray cooling of electric motor coil windings, J. Comput. Multiph. Flows 8 (2) (2016) 95–100. ❞♦✐✿
✶✵✳✶✶✼✼✴✶✼✺✼✹✽✷❳✶✻✻✺✸✽✾✺.
[65] G. Zhu, X. Liu, L. Li, H. Chen, W. Tong, J. Zhu, Cooling System Design of a High-Speed PMSM Based on a Coupled Fluidic-Thermal Model, IEEE Trans. Appl. Super-cond. 29 (2) (2019) 1–5. ❞♦✐✿✶✵✳✶✶✵✾✴❚❆❙❈✳✷✵✶✾✳✷✽✾✷✸✵✺.
[66] F. Zhang, D. Gerada, Z. Xu, X. Zhang, C. Tighe, H. Zhang, C. Gerada, Back-iron Ex-tension Thermal Benefits for Electrical Machines with Concentrated Windings, IEEE Trans. Ind. Electron. PP (c) (2019) 1–1. ❞♦✐✿✶✵✳✶✶✵✾✴t✐❡✳✷✵✶✾✳✷✾✵✸✼✺✽.
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❛♣♣❧t❤❡r♠❛❧❡♥❣✳✷✵✶✽✳✶✷✳✶✹✶.
[68] M. Polikarpova, P. M. Lindh, J. A. Tapia, J. J. Pyrhönen, Application of Potting Material for a 100 kW Radial Flux PMSM, 2014 Int. Conf. Electr. Mach. (2014) 1–6.
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Electr. Syst. Aircraft, Railw. Sh. Propuls. Road Veh. Int. Transp. Electrif. Conf. ESARS-ITEC 2018 (2019) 1–6❞♦✐✿✶✵✳✶✶✵✾✴❊❙❆❘❙✲■❚❊❈✳✷✵✶✽✳✽✻✵✼✻✵✵.
[71] Y. Querel, L. Garbuio, A. Kedous-Lebouc, L. Gerbaud, Y. Querel, T. Boussey, J. C. Mipo, S. Personnaz, Axial flux machine design taking into account cooling and convection heat transfer, 2019 10th Int. Power Electron. Drive Syst. Technol. Conf. PEDSTC 2019 (2019) 718–722❞♦✐✿✶✵✳✶✶✵✾✴P❊❉❙❚❈✳✷✵✶✾✳✽✻✾✼✷✽✶.
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Echenique Subiabre, Improving the thermal performance of rotary and linear air-cored permanent magnet machines for direct drive wind and wave energy applica-tions, IEEE Trans. Energy Convers. 34 (2) (2019) 773–781. ❞♦✐✿✶✵✳✶✶✵✾✴❚❊❈✳✷✵✶✽✳
✷✽✽✶✸✹✵.
[73] E. Armando, A. Boglietti, E. Carpaneto, A. Castagnini, M. Seita, Thermal Performances of Induction Motors for Applications in Washdown Environment, IEEE Trans. Ind.
Appl. PP (c) (2019) 1–1. ❞♦✐✿✶✵✳✶✶✵✾✴t✐❛✳✷✵✶✾✳✷✾✶✼✹✶✾.
[74] J. Samek, C. Ondrusek, J. Kurfurst, A review of thermal conductivity of epoxy com-posites filled with Al2O3 or SiO2, 2017 19th Eur. Conf. Power Electron. Appl. EPE 2017 ECCE Eur. 2017-January (2017) 1–6. ❞♦✐✿✶✵✳✷✸✾✶✾✴❊P❊✶✼❊❈❈❊❊✉r♦♣❡✳✷✵✶✼✳
✽✵✾✾✸✾✻.
[75] S. Wang, Y. Li, Y.-Z. Li, J. Wang, X. Xiao, W. Guo, Transient cooling effect analyses for a permanent-magnet synchronous motor with phase-change-material packaging (2016). ❞♦✐✿✶✵✳✶✵✶✻✴❥✳❛♣♣❧t❤❡r♠❛❧❡♥❣✳✷✵✶✻✳✵✽✳✵✸✻.
[76] G. Fang, W. Yuan, Z. Yan, Y. Sun, Y. Tang, Thermal management integrated with three-dimensional heat pipes for air-cooled permanent magnet synchronous motor, Appl. Therm. Eng. 152 (February) (2019) 594–604.❞♦✐✿✶✵✳✶✵✶✻✴❥✳❛♣♣❧t❤❡r♠❛❧❡♥❣✳
✷✵✶✾✳✵✷✳✶✷✵.
[77] A. Lindner, I. Hahn, Practical evaluation of a passive stator cooling concept with-out thermal stacking, Proc. - 2017 IEEE Work. Electr. Mach. Des. Control Diagnosis, WEMDCD 2017 (2017) 132–139❞♦✐✿✶✵✳✶✶✵✾✴❲❊▼❉❈❉✳✷✵✶✼✳✼✾✹✼✼✸✻.
[78] L. Cheng, X. Yi, B. H. Min, K. Haran, Ring Motor Front Wheel for Electric Motorcy-cle, 2019 IEEE Power Energy Conf. Illinois, PECI 2019 (2019) 1–8❞♦✐✿✶✵✳✶✶✵✾✴P❊❈■✳
✷✵✶✾✳✽✻✾✽✾✶✶.
[79] J. Huang, S. Shoai Naini, R. Miller, D. Rizzo, K. Sebeck, S. Shurin, J. Wagner, A Hybrid Electric Vehicle Motor Cooling System- Design, Model, and Control, IEEE Trans. Veh.
Technol. 68 (5) (2019) 1–1. ❞♦✐✿✶✵✳✶✶✵✾✴t✈t✳✷✵✶✾✳✷✾✵✷✶✸✺.
[80] X. Zhang, J. Yu, G. Su, Z. Yao, P. Hao, F. He, PIV measurement and simulation of turbu-lent thermal free convection over a small heat source in a large enclosed cavity, Build.
Environ. 90 (2015) 105–113. ❞♦✐✿❤tt♣✿✴✴❞①✳❞♦✐✳♦r❣✴✶✵✳✶✵✶✻✴❥✳❜✉✐❧❞❡♥✈✳✷✵✶✺✳
✵✸✳✵✶✺.
[81] A. Aubert, S. Poncet, P. Le Gal, S. Viazzo, M. Le Bars, Velocity and temperature measure-ments in a turbulent water-filled Taylor-Couette-Poiseuille system, International Jour-nal of Thermal Sciences 90 (2015) 238–247. ❞♦✐✿✶✵✳✶✵✶✻✴❥✳✐❥t❤❡r♠❛❧s❝✐✳✷✵✶✹✳
✶✷✳✵✶✽.
[82] B. Melka, J. Smolka, Z. Bulinski, J. Hetmanczyk, D. Makiela, A validated numerical model of heat and mass transfer in a PM BLDC electric motor(2016) 1409–1413❞♦✐✿
✶✵✳✶✶✵✾✴❙P❊❊❉❆▼✳✷✵✶✻✳✼✺✷✺✽✽✺.
URL❤tt♣✿✴✴✐❡❡❡①♣❧♦r❡✳✐❡❡❡✳♦r❣✴st❛♠♣✴st❛♠♣✳❥s♣❄❛r♥✉♠❜❡r❂✼✺✷✺✽✽✺
[83] B. Melka, J. Smolka, J. Hetmanczyk, Z. Bulinski, D. Makiela, A. Ryfa, Experimen-tally validated numerical model of thermal and flow processes within the perma-nent magnet brushless direct current motor, Int. J. Therm. Sci. 130 (2018) 406–415.
❞♦✐✿✶✵✳✶✵✶✻✴❥✳✐❥t❤❡r♠❛❧s❝✐✳✷✵✶✽✳✵✹✳✵✷✾.
[84] B. Melka, J. Smolka, J. Hetmanczyk, P. Lasek, Numerical and experimental analysis of heat dissipation intensification from electric motor, Energy (jun 2019).❞♦✐✿✶✵✳✶✵✶✻✴
❏✳❊◆❊❘●❨✳✷✵✶✾✳✵✻✳✵✷✸.
[85] Constant Termperature Anemometers equipment.
URL❤tt♣✿✴✴✐♠❣♣❛♥✳♣❧✴♦❢❡rt❛✴❝③✉❥♥✐❦✐✲t❡r♠♦❛♥❡♠♦♠❡tr②❝③♥❡✲❤♦t✲✇✐r❡✴
[86] Constant Termperature Anemometers principle of operation.
URL ❤tt♣s✿✴✴✇✇✇✳s❝✐❡♥❝❡❞✐r❡❝t✳❝♦♠✴t♦♣✐❝s✴❡♥❣✐♥❡❡r✐♥❣✴
❝♦♥st❛♥t✲t❡♠♣❡r❛t✉r❡✲❛♥❡♠♦♠❡t❡r
[87] Documentation describing the bearing losses estimation.
URL❤tt♣✿✴✴t✐♥②✉r❧✳❝♦♠✴②①❡r③✻✺✸✴
[88] ANSYS®Academic Research Fluent, Release 17.0, Help System, ANSYS, Inc.
[89] J. Smolka, User-Defined Functions programming in Ansys Fluent. Fundamentals of numerical modelling of thermal processes in electric devices and machines, Silesian University of Technology, Institute of Thermal Technology, Gliwice, Poland, 2019, (in Polish).
[90] R. Wrobel, P. H. Mellor, A general cuboidal element for three-dimensional thermal modelling, IEEE Transactions on Magnetics 46 (8) (2010) 3197–3200. ❞♦✐✿✶✵✳✶✶✵✾✴
❚▼❆●✳✷✵✶✵✳✷✵✹✸✾✷✽.
[91] Material: Aluminum 6061-O.
URL ❤tt♣✿✴✴✇✇✇✳♠❛t✇❡❜✳❝♦♠✴s❡❛r❝❤✴❉❛t❛❙❤❡❡t✳❛s♣①❄▼❛t●❯■❉❂
✻✷✻❡❝✽❝❞❝❛✻✵✹❢✶✾✾✹❜❡✹❢❝✷❜❝✻❢✼❢✻✸
[92] Material: Alliance N-33 Neodymium Iron Boron Magnetic Material.
URL ❤tt♣✿✴✴✇✇✇✳♠❛t✇❡❜✳❝♦♠✴s❡❛r❝❤✴❉❛t❛❙❤❡❡t✳❛s♣①❄▼❛t●❯■❉❂
✼❢✽❜✼✽❝✽✾❜✵✺✹❜✶✻❛❝❝❡❡✽✵❢✾❛✸✻✸✻✷✻
[93] K. Azar, J. Graebner, Experimental determination of thermal conductivity of printed wiring boards, in: Twelfth Annual IEEE Semiconductor Thermal Mea-surement and Management Symposium. Proceedings, IEEE, 1994, pp. 169–182.
❞♦✐✿✶✵✳✶✶✵✾✴❙❚❍❊❘▼✳✶✾✾✻✳✺✹✺✶✵✼.
URL ❤tt♣✿✴✴✐❡❡❡①♣❧♦r❡✳✐❡❡❡✳♦r❣✴❧♣❞♦❝s✴❡♣✐❝✵✸✴✇r❛♣♣❡r✳❤t♠❄❛r♥✉♠❜❡r❂
✺✹✺✶✵✼
[94] S. W. Churchill, H. H. Chu,Correlating equations for laminar and turbulent free con-vection from a vertical plate, International Journal of Heat and Mass Transfer 18 (11) (1975) 1323 – 1329. ❞♦✐✿❤tt♣s✿✴✴❞♦✐✳♦r❣✴✶✵✳✶✵✶✻✴✵✵✶✼✲✾✸✶✵✭✼✺✮✾✵✷✹✸✲✹. URL ❤tt♣✿✴✴✇✇✇✳s❝✐❡♥❝❡❞✐r❡❝t✳❝♦♠✴s❝✐❡♥❝❡✴❛rt✐❝❧❡✴♣✐✐✴
✵✵✶✼✾✸✶✵✼✺✾✵✷✹✸✹
[95] Material: Aluminum, Al.
URL ❤tt♣✿✴✴✇✇✇✳♠❛t✇❡❜✳❝♦♠✴s❡❛r❝❤✴❉❛t❛❙❤❡❡t✳❛s♣①❄▼❛t●❯■❉❂
✵❝❞✶❡❞❢✸✸❛❝✶✹✺❡❡✾✸❛✵❛❛✻❢❝✻✻✻❝✵❡✵✫❝❦❝❦❂✶
[96] Material: High Density Polyethylene (HDPE), Injection Molded.
URL ❤tt♣✿✴✴✇✇✇✳♠❛t✇❡❜✳❝♦♠✴s❡❛r❝❤✴❉❛t❛❙❤❡❡t✳❛s♣①❄▼❛t●❯■❉❂
❢❝❡✷✸❢✾✵✵✵✺❞✹❢❜❡✽❡✶✷❛✶❜❝❡✺✸❡❜❞❝✽
[97] Shaft material.
URL❤tt♣s✿✴✴❜r❡✳✐s✴♠❖❨❱❉❈❲❱❩
[98] Material: AISI 1045 Steel, hot rolled.
URL ❤tt♣✿✴✴✇✇✇✳♠❛t✇❡❜✳❝♦♠✴s❡❛r❝❤✴❉❛t❛❙❤❡❡t✳❛s♣①❄▼❛t●❯■❉❂
✹❜✵✺✺✸❞❛❢✾❝✷✹✺❡✻✽✹❢✷✶✾✾❛✹✽✶✼✾❞✽✾
[99] A. Boglietti, E. Carpaneto, M. Cossale, S. Vaschetto, M. Popescu, D. A. Staton, Stator winding thermal conductivity evaluation: An industrial production assessment, IEEE Trans. Ind. Appl. 52 (5) (2016) 3893–3900. ❞♦✐✿✶✵✳✶✶✵✾✴❚■❆✳✷✵✶✻✳✷✺✽✷✼✸✵.
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Abstract Ph.D. Thesis, Bartłomiej Melka
Coupled thermal electromagnetic numerical modelling of an effective heat dissipation process from an electric motor
Bartłomiej Melka
Institute of Thermal Technology, Silesian University of Technology, Gliwice, Poland, Bartlomiej.Melka@polsl.pl
Environmental and political tendencies prompt the industry to reduce the usage of non-renewable energy sources to mitigate anthropogenic degradation of the environment. It leads to, e.g. increase of the meaning of electrical power drives in transport and other branches of industry, at the same time replacing internal combustion engines that are characterised by a lower efficiency of energy conversion. In this case, the electric motor construction process ought to be based on the best engineering achievements grounded on the multi-physical analyses. Therefore, in the electric motor design process, the thermal analysis should play an important role. It allows to estimate the maximum temperature in the machine and to find the location of the potential overheating. The motor construction should also be protected from reaching a temperature higher than allowable that may lead to the machine failure. It is especially important for motor elements such as winding insulation. Moreover, thermal analysis allows for reduction of the machine size with maintaining the safety margin and thus also allows for the material cost reduction. On the other hand, the heat dissipation in-tensifications implemented on the basis of thermal analysis allows to overload the machine and reduce the temperature of the specific motor elements, e.g. windings. The amount of the copper losses is connected with windings resistance that is temperature-dependent. There-fore, the thermal motor behaviour optimisation could also lead to the reduction of the cop-per losses in the machine. As a result, the lower temcop-perature of the internal motor compo-nents could also ensure maintaining the operational point beyond demagnetization of the permanent magnets in motors such as Permanent Magnet Brushless DC (PM BLDC) mo-tor. This all mean that the thermal analysis should always be included in the electric motor design process.
Therefore, the main aim of the dissertation is the thermal analysis of the selected PM BLDC low power motor. Moreover, the heat dissipation intensifications, based on passive techniques, were proposed and then verified experimentally and numerically.
Firstly, the dissertation describes experimental activities carried out during the research.
The measurement procedures are described as two independent experimental campaigns performed on the dedicated test rig. The first one focused on the measurements of the air velocity within and around the analysed motor and simultaneously on the temperature mea-surements. In the first experimental campaign, constant temperature anemometers were positioned in 28 positions to collect the values of the vertical velocity component of the hot air above the motor installed in the test rig. Moreover, two velocity components were recorded using Laser Doppler Anemometry technique within the rear part of the investigated motor. During the first experimental campaign, thermal measurements were also conducted using a set of 22 calibrated thermocouples. The temperature and velocity measurements al-lowed to investigate the natural convection phenomena occurring in the motor losses dis-sipation. First experimental campaign allowed to measure 11 operating points of the motor work. The second experimental campaign was focused only on the thermal measurements using a set of calibrated thermocouples and infrared thermography. In this campaign, differ-ent passive heat dissipation intensification concepts were investigated. During the second experimental campaign, 6 operating points were recorded for each variant of heat dissipa-tion enhancement.
Abstract Ph.D. Thesis, Bartłomiej Melka
The experimental part of the research was used to validate the created computational fluid dynamics (CFD) models. These models were built on the basis of the motor complex geometry. During the numerical research, two thermal models were introduced to investi-gate thermal motor behaviour. The first one was formulated and validated in the conditions occurring in the first experimental campaign. The second thermal model was created and next validated on the base of the second experimental campaign. Moreover, it covered the proposed heat dissipation intensifications. The models were based on the standard govern-ing equations used in CFD, while many of the model properties were implemented as the user defined functions. The motor losses were implemented in thermal models as the
The experimental part of the research was used to validate the created computational fluid dynamics (CFD) models. These models were built on the basis of the motor complex geometry. During the numerical research, two thermal models were introduced to investi-gate thermal motor behaviour. The first one was formulated and validated in the conditions occurring in the first experimental campaign. The second thermal model was created and next validated on the base of the second experimental campaign. Moreover, it covered the proposed heat dissipation intensifications. The models were based on the standard govern-ing equations used in CFD, while many of the model properties were implemented as the user defined functions. The motor losses were implemented in thermal models as the