Determination of Aerodynamic Losses of Electric Motors

Abstract

The energy efficiency of machines is nowadays an intensively studied problem. The efficiency of the induction motor is dominantly influenced by the rotor’s and stator winding’s temperature. The main goal of the research presented in this paper is to develop a methodology based on Computational Fluid Dynamics (CFD) analysis of internal and external aerodynamics, which is necessary for the optimisation of cooling of the induction motors. In this paper, the theoretical, as well as the numerical study of the internal and external aerodynamics of the induction motor, is described and verified by the experimental measurements. In the CFD-based numerical study, the Reynolds-averaged Navier–Stokes (RANS) turbulence modelling approach was applied to the flow field simulations inside and outside the induction motor. The complexity of the solved problem is increased not only by the geometric asymmetry but also by the flow’s asymmetric character caused by the fan’s rotation to cool the motor casing. This increases demand, especially on computational resources, as it is impossible to create a simplified numerical model incorporating symmetry. The volume flow of the cooling air and velocity between ribs was measured for the experimental study. Comparing the results of the Computational Fluid Dynamics (CFD) simulations and data obtained from the experimental measurement, we concluded that the results of CFD simulations are in good relationship with the results of experimental measurement and analytical approximations. An experimentally validated CFD model of the induction motor, the so-called digital twin, will be in the future used for virtual optimisation of the new designs concerning minimising losses and maximising efficiency, respectively.