Republic Islamic of Iran

Ministry of Scientifics and Technology

Islamic Azad University
Qazvin Branch
Faculty of Mechanical Engineering
M.Sc. Thesis on Energy Conversion department

Numerical analysis of various fin configurations and

environmental conditions in order to enhance thermal
performance of induction electric motors

A Thesis
Submitted to Mechanical Engineering
University of Azad Islamic in a partial Fulfillment of the
Requirements for the degree of Master of science in Mechanical
Engineering

By
Raheem Hasan Abbas

Supervisor by

Dr. Ghasem Akbari

June 2023 IRAN Dhu al-Qi ' dah

 ‫ِبْس ِم الَّلـِه الَّر ْح َم ٰـ ِن الَّر ِحيِم‬
‫وُقِل اْع َم ُلوا َفَس َيَر ى ُهَّللا َعَم َلُك ْم َو َر ُس وُلُه َو اْلُم ْؤ ِم ُنوَن‬
‫َو َس ُتَر ُّدوَن ِإَلى َع اِلِم اْلَغ ْي ِب َو الَّش َه اَد ِة َفُيَن ِّب ُئُك ْم ِبَم ا ُكْنُتْم‬
‫َت ْع َم ُلوَن‬

‫صَد َق هللا الَع ِظ يم‬

‫سورة التوبة اية ‪105‬‬

Supervisors' Certification
This is to certify that this thesis entitled " Numerical analysis of various
fin configurations and environmental conditions in order to enhance
thermal performance of induction electric motors " was prepared by
Raheem Hassan Abbas under our supervision at the Department of
Mechanical Engineering Qazvin Islamic Azad University of in a partial
fulfillment of the requirements for the degree of Master of Science in Power
conversation.

I
Linguistic Certification
This is to certify that this Thesis entitled “" Numerical analysis of
various fin configurations and environmental conditions in order to
enhance thermal performance of induction electric motors” presented by
Raheem Hassan Abbas was reviewed linguistically. Its language was
amended to meet the style of English language.

DEDICATION

II
 This thesis is dedicated to my wife, and my sons who stood by me for the
purpose of completing my postgraduate studies and who sacrificed a lot for me.

Acknowledgment

III
 In the period of preparing this thesis, I have been in contact with many
people, researchers, academics and practitioners. They have contributed to
enhancing my understanding and ideas. In particular, I would like to express my
sincere appreciation to my main thesis supervisor, Professor Dr. Ghasem Akbari
for his support, guidance and constructive guidance. I am also indebted to the
Islamic Azad University of Qazvin, Department of Mechanical Engineering for
providing a special atmosphere for study. My friends in the Diwaniyah water
district also deserve special thanks for their help and support. My fellow
graduate students must also be acknowledged for their support. I also express
my sincere appreciation to my colleague, Master's student Hussain Ali Salman,
who has been of assistance to me on various occasions. I am grateful to all of
my family.

IV
ABSTRACT
The induction motor is used in many different daily domestic and
industrial applications, such as hydraulic water pumping in agriculture and the
supply of drinking water for houses and public buildings .Because of continuous
operation, there is an increase in the temperature of the motor, and the
continuation of this leads to damage to the motor, so there was a great need to
cool the motor before Reaching the damage condition of the motor and the
presence of fins on the motor body for the purpose of increasing the surface
area, dissipating heat by convection, and reducing the motor temperature. The
induction motor is examined and analyzed by the total number of fins, their
height, fin shape, and changing weather conditions, using the ANSYS Steady-
state program. The reduction in insulation temperatures will result in increased
motor insulation life or allow the motors to be overloaded (increased output)
without exceeding insulation thermal ratings. when we compared the result that
we obtained in this simulation with the result of the base case we found the
result its very near and the percentage of different in the result its( 1.48,2.84,
6.64, 7.49 ) K for this case . for the purpose of improving heat transfer to the
atmosphere, the shape of the fins was changed to be concave instead of
rectangular , and repeated the simulation by ANSYS 2021 R2 at same
boundary condition for fin 5 with length fin (5,10,15,20 )mm It was found that
the temperature of the fin5 L 5 122.56 °C (395.71 K) ,117.05 C(390.2 K),for Fin
5 L 10 ,99.38 C(372.53 K) for Fin5 L 15 and 91.07 C (364.22K) for Fin5 L 20
by comparing the results, it was found that the temperature of the concave fin 5L
with a length of 5 mm was less than the temperature of the rectangular fin at tip
fin. That’s mean the new shape for (concave fin) is better than the rectangular
fin shape by (1.63)K and the percentage of enhancement (1.3)%. The results
show that the distance between the fins and the shape of the fins is the most
important factor in reducing the temperature of an electrical motor.

Keywords: Heat convection, Concave fin, Rectangular fin, Induction motor,

Temperature dissipation.
V
List of Contents

Title page No.

Supervisors' Certification...................................................................................I
Linguistic Certification.....................................................................................II
DEDICATION................................................................................................III
Acknowledgment............................................................................................IV
ABSTRACT.....................................................................................................V
List of Contents...............................................................................................VI
LIST OF FIGURES........................................................................................IX
LIST OF TABLES...........................................................................................X
List of symbols................................................................................................XI
Chapter 1...........................................................................................................1
Introduction.......................................................................................................1
1.1 Background..............................................................................................1
1.2 Problem statement....................................................................................2
1.3 Literature Review.....................................................................................3
1.4 Objective of study..................................................................................11
1.5 work objective........................................................................................11
Chapter 2:........................................................................................................12
2.1INTRODUCTION...................................................................................12
2.2 Heat transfer in electric motor................................................................13
2.2.1 conduction mode..............................................................................14
2.2.1.1 winding....................................................................................15
2.2.1.2 Metallic material......................................................................16
2.2.2 convection mode..............................................................................18
2.2.2.1 stator –rotor air gap convection...............................................19
2.2.2.2 Rotor End-Disk convection.......................................................19
2.2.2.3 End-Space Regions Convection.................................................20
2.3 Electric Motor Cooling Methods...........................................................20
2.3.1 External Cooling Methods...............................................................22
2.3.1.1 External Cooling through Fins.................................................23

VI
 2.3.1.1.1 Natural Convection with Fins.................................................24
2.3.1.2 Frame Channels and Pipes.........................................................25
2.3.1.2.1 Smooth Channels....................................................................26
2.3.1.2.2 Friction coefficient..................................................................26
2.3.1.2.3 Channels with Perturbations...................................................26
2.3.1.3 External Heat Pipes and Two-Phase Loop................................27
2.3.1.3.1 Heat pipe.................................................................................27
2.3.2 Internal Cooling Methods.............................................................28
2.3.2.1 End-Space Potting......................................................................29
2.3.2.2 Metallic Bars.................................................................................29
2.3.2.3 Phase-Changing Materials (PCM) Cooling...............................30
2.4 Air Cooling.............................................................................................31
2.4.1 Air Jet Impingement.....................................................................32
2.4.2 Air Jet Impingement on Rotating Disk..........................................32
2.4.3 Air Jet Impingement on winding..................................................33
2.5 Liquid Cooling.....................................................................................34
2.5.1 Internal Flow Liquid Cooling..........................................................34
2.5.1.1 Liquid Jets and Sprays...............................................................35
2.5.1.2 Liquid Jets..................................................................................36
2.5.1.3 Liquid Sprays.............................................................................36
2.6 Internal Heat Pipes and Two-Phase Loop..............................................37
2.7 Electric Motor System Definition........................................................37
2.7.1 Electric -Motor Geometry and Materials Properties........................38
2.7.2 Boundary conditions........................................................................40
2.7.3 Electric Motor Losses (Heat Sources).............................................41
2.7.3.1 Iron Losses..............................................................................42
2.7.3.2 Mechanical Losses.....................................................................42
2.7.3.1.1 Copper Losses.........................................................................43
2.8 Modeling Assumptions........................................................................43
2.8.1 Geometry..........................................................................................44
Chapter 3.........................................................................................................45
3.1 Methodology..........................................................................................45

VII
 3.2 Mesh generation.....................................................................................53
3.3 Case 1:....................................................................................................55
3.4 Case 2.....................................................................................................55
Chapter4..........................................................................................................56
Results and Discussions..................................................................................56
1- Validation.................................................................................................56
1.1Case.........................................................................................................56
1.2 CASE 2...................................................................................................58
1.3 CASE 3...................................................................................................60
1.4 CASE 4...................................................................................................62
Chapter5..........................................................................................................68
Conclusion and Suggestions for Future studies..............................................68
Methods........................................................................................................68
Results..........................................................................................................68
Conclusion....................................................................................................69
Recommendations........................................................................................69
Limitations...................................................................................................69
Reference.........................................................................................................71

VIII
LIST OF FIGURES
Fig.1 components of an electric motor................................................................13
Fig. 2 The types of heat transfers in electric motor............................................14
Fig.3 Electric motor cooling methods.................................................................22
Fig.4 Types of electric motor losses....................................................................42
Fig. 5 the search mechanism...............................................................................46
Fig. 6 structure of an Induction motor................................................................50
Fig .7 Axial finned housing used in fan-cooled motors......................................51
Fig. 8 Heat input to fins.......................................................................................52
Fig .9 Heat dissipation to surrounding environment. (rectangular fins).............52
fig. 10 Meshing of induction motor.....................................................................53
Fig.11 relation between GRID and Heat flux......................................................54
Fig. 12 the concave fin anew shape.....................................................................55
Fig. 13 Validation between case base fin 5 (rectangular ) and fin 5
(rectangular ) Simulation....................................................................................57
Fig. 14 temperature distribution ( 20 fins ).......................................................57
Fig .15 comparing between Temperature at tip rectangular fin 5 and concave
fin5 ......................................................................................................................59
Fig.16 Temperature distribution in concave fin 5...............................................59
Fig .17 Result of fin5 concave with changing ,material ,distance, Temperature
ambient................................................................................................................61
Fig.18 Temperature distribution in concave fin 5 (changing ambient
Temperature.........................................................................................................61
Fig .19 Relation between temperatue at tip fin and distance between fins.........63
Fig.20 Temperature distribution in rectangular fin 7 (changing distance between
fins 12mm)..........................................................................................................63
Fig.21 comparison between Temperature at tip fins 5,7,9,11.............................64
Fig. 22 The effectiveness of variable number of fins..........................................65
Fig. 23 The efficiency of variable length of fins.................................................66

IX
LIST OF TABLES
Table 1 Induction motor-design data...................................................................3
Table 2 Natural convection correlation coefficients..........................................49
Table 3 Relation between Grid (element ) and Heat flux for simulation1..........54
Table 4 Validation between base Article and (rectangular fin) Simulation 1.....58
Table 5 Comparing rectangular fin and concave fin.........................................60
Table 6 Result of fin5 concave with changing, material, distance, Temperature
ambient..............................................................................................................62
Table 7 Relation between temperatuer at tip fin and distance between
fins(rectangular).................................................................................................64
Table 8 comparison between Temperature at tip fins 5,7,9,11.........................65
Table 9 The effectiveness of variable number of fins.........................................66
Table 10 The efficiency of variable length of fins...............................................67

X
List of symbols
h heat transfer coefficient , W/m2 k .

q heat flux , W/m2

T Temperature , K

μ dynamic viscosity kg/ms

Nu Nusselt number
Re Reynolds number
Gr Grashof number
Pr Prandtl number
ρ fluid density , Kg/m3
k fluid thermal conductivity , W/ m◦K
cp fluid specific heat capacity , kj /kg K
v fluid velocity , m/s
ΔT difference between surface and fluid temperatures , K
L characteristic length of the surface , m
β coefficient of cubical expansion for the gases β = 1/(273 + T Fluid), K
g gravitational attraction force , m/s2
Ac Cross-sectional area of each fin m2
Ap fin profile area m2
p fin perimeter, m
t fin thickness, m
L fin length m

ᵋ fin effectiveness
N number of fins
Δ total distance
ξ distance between fins

XI
Chapter 1
Introduction
1.1 Background
A three-phase squirrel cage induction motor drive is commonly used for
hydraulic pump driving applications. The main reasons an induction motor
should be used in this situation are their lower cost, simplicity, and durability.
Compared to other DC motors, the induction motor requires no maintenance and
will significantly improve system performance for the same investment. The
essential principle behind induction motor operating is Faraday's
electromagnetic induction. The motor's constant speed is determined by the line
frequency and the number of magnetic pole pairs inside. When this engine is
used for agricultural purposes, it must run for a very long time in order to pump
the water. There may be a little amount of speed slip when the motor is fully
loaded. In a similar vein, The electric drive's performance will decline if the
overheating lasts a long time. To work around this, manufacturers generally
design various fin configurations around the electric motor. This expands the
surface area and allows for effective heat dissipation. Energy efficiency indexes
have been subject to a thorough evaluation methodology developed [1]. The
correlations between electrical and hydraulic properties are determined by a
range of measurements. It is anticipated that the new type will improve the
efficiency of the pump drive. The amount of heat that an object radiates depends
on its conduction, convection, and radiation rates. the temperature difference
between an object and its surroundings, the convective heat transfer rate, used in
heat-exchanging parts like computer CPU heatsinks, automotive radiators, and
heat exchangers in power plants. Additionally, they are used in more current
technology, such as hydrogen fuel cells. Nature has made use of the fin
phenomena as well. Jackrabbits and fennec foxes use their ears as fins to
dissipate heat generated by the circulation of their blood.[2]

1
Automobile radiators: Small fins on a radiator increase the device's surface
area, which improves the ability of the coolants to While the car is moving, the
air traveling through the radiator cools the liquid inside. convey heat [2]

Computer CPU heatsinks: The little fins on a radiator increase the device's
surface area, which improves the coolants' capacity to conduct heat more
effectively.[2]

The power plant's heat exchangers: Radial fins, which are frequently
found in TENV (Totally Enclosed Non-Ventilated) roller table duty motors,
have the purpose of preventing the buildup of molten iron on the motor. [2]

Electric motors and transformers: The motor's longitudinal fins allow

natural cooling. In fully insulated fan-cooled motors, air from the fan passes
through the fins to cool the motor. Radial fins are often seen in entirely
enclosed, non-ventilated roller table duty motors with the purpose of preventing
the buildup of molten iron on the motor's surface. Fins are surfaces that protrude
from an object in hydrogen fuel cells to increase convection and speed up heat
transfer to or from the environment. [2]

The evaporators and condensers in air conditioning and

refrigeration systems use fins: As the coolant runs via the numerous little
wires that are positioned between the pipes, heat is transferred from the pipes
and dissipated to the atmosphere, acting as a simple radiator fin. The motor is
specifically run with one core material and three different winding materials to
ensure optimal material selection. The materials chosen depend on parameters
like price and bulk. [2]

1.2 Problem statement

For the induction motor case with fins, the steady state thermal analysis
will be presented. The simulations will be for an electric motor with nominal
rotational speed 1500 rpm. Through the surface fins of the motor case, the heat

2
from the core is released into the atmosphere. Simulation of dissipative heat
transfer through the motor will be performed using ANSYS Fluent and
numerical results will be validated based on the available literature. The required
physical characteristics and parameters of electric motor will also be obtained
from the literature, as presented in Table 1 for instance. Optimization of thermal
characteristics will be performed based on parametric study, by changing the
shape and arrangement of fins, material and environmental conditions. The best
practices from previous studies will be utilized to accelerate finding the most
influential configurations.

Table 1 Induction motor-design data

Stator parameter Rotor parameter

Number of slots 18 No of rotor bars 21

Housing Diameter 140 mm Rotor Bar Opening 1.5 mm

Stator Lamination Diameter 130 mm Rotor Bar Opening Depth 1.5 mm

Stator Bore 80 mm Rotor Bar width 4 mm

Tooth Width 7 mm Air gap 1 mm

Slot Depth 18 mm Shaft Diameter 25 mm

Slot Opening 3 mm Induction Motor – Hydraulic

Tooth Tip Depth 1 mm Pumping Applications

Tooth Tip Angle 30 ° Power 5 kw

1.3 Literature Review

Ambuj & et al. [2] used ANSYS Workbench® to simulate the heat
transport processes through multiple finned surfaces of different geometries and
materials. In this experiment, ANSYS2016® C was utilized to simulate Pin Fin,
Plate Fin, and Elliptical Pin fin geometries. the efficiency of the pin fin was
computed; According to the connection,

3
 η = cosh [m(L-x)] / cosh (mL) . FD inter face The differences between
simulated and theoretical temperature distribution findings. can be accounted
due to errors in meshing and other computational discrepancies.
In the research conducted by H. Lavric , & et al .[3] The most appropriate
way to determine the efficiency of VFDP systems is by using the direct method
of determining the drive system efficiency. In this method, the electrical
parameters at the drive inlet and the hydraulic parameters at the drive outlet, i.e.
in the pipeline in which the pump is installed, need to be measured. It was
essential in the presented case that the measurements were carried out without
interruption of the industrial production process . Detailed analyses of the
energy efficiency indicators for variable frequency driven pumps in the
industrial system for cooling technological water revealed, that the pumps and
accompanied electrical motors are heavily oversized. The motors are classified
in the worst and out-of-date efficiency class IE1. Also, the pumps have less
favorable efficiency data since they are almost twenty years old.

Bhambere & et al . [4] Studies the heat sensitivity of induction motors

using total enclosed fan cooling (TEFC). Thermal parameters are adjusted in
specific, and their impacts on temperature rise are demonstrated. The findings
help identify the most crucial thermal factors and make it possible to create
reliable designs that are insensitive to manufacturing tolerances. Five TEFC
motors have undergone thermal tests and simulations. By using sensitivity
analysis, we can determine the most crucial thermal design parameters and
assess how sensitive the design is to changes in these parameters. When creating
reliable designs that are insensitive to manufacturing tolerances, it's critical to
identify this information. Additionally, the research has shown a convenient
method for creating thermal models for TEFC induction motors. The diameter of
the perforations varied from 4 mm to 10 mm, increasing in diameter by 2 mm.
The inquiry yields information about the temperature distribution over the
induction motor's surface. The results lead to the conclusion that improving heat

4
transfer from an induction motor's housing requires increasing the size of the
perforations on the fins. When compared to the other possibilities, the 11 holes,
each 10 mm in diameter, produced the greatest temperature drop, according to
the quantitative analysis of the examples discussed.
This study Ya-Chi Chen & et al [5] is focused on enhancing the housing
fin's cooling capacity for Total Enclosed Fan Cooled (TEFC) motors. For the
optimizer to work with different motor frame sizes, the parameter database was
non-dimensionalized. In some instances, the ideal fin configuration reduces
thermal resistance to heat convection from the fin surface by more than 50%
when compared to the original fin design. The study's goals were to determine
the critical design factors for the motor fin system of TEFC motors and to create
a fin optimizer to hasten the design process. The CFD parametric analysis
revealed that: 1) there is an ideal fin pitch to produce the best fin cooling; 2) fin
height has a greater impact on fin cooling performance than fin thickness; and 3)
there is an optimal fin pitch.
Valenzuela &et al, [6] focuses on evaluating the finned frame's capacity
for heat transfer at various cooling fan speeds and with various fin counts and
sizes. Separate analyses are carried out in four axial sectors of four distinct
frames since the heat transmission is greatly dependent on air speed and
turbulence. An internal cylindrical heater with regulated losses heats every
sector for every frame in an even, thermally isolated manner. Based on these
findings, a quick and precise approach for sizing finned frames is suggested. The
temperature rise from the enclosure to the surrounding air is around 30% to 40%
of the overall temperature rise of the winding's hottest location. Finding the
frame's heat transmission coefficient to the environment is therefore very
important. In this study, we present an empirical evaluation of the heat transfer
coefficient of four finned frames with various fin counts and fin sizes, at various
cooling fan speeds between 300 and 1800 r/min, in four axial sectors. The

5
outcomes amply demonstrated the impact of various cooling fan speeds on the
heat transfer coefficient.
Given by Satrstegui et al. [7]The most pertinent theoretical presumptions
and equations are included in an analytical thermal model of an IC71W
Induction Machine (IM), Experimentation using measurements is used to
validate this concept. Two characteristics were found to have essentially little
effect on the system, particularly the distance between cooling ducts and the
distance between the ducts and the stator stack. The analytical thermal model
was used to develop some criteria for the primary parameters that define the
water jacket and the shaft. To analyze the impact of wafters in this cooling
system, CFD techniques were applied. Wafters dramatically reduced
temperatures in some areas of the machine by raising the heat transfer
coefficient on most surfaces in contact with the internal air.
In This research Ai & et al.[8] Employing a flow-thermal coordination
mechanism, this study examines the heat transfer properties of the externally
ventilated path of a small, 4 pole, 6 kV, 2500 kW motor. Experimental test
findings are used to set up and validate a computational model. By improving
the deflection angle a and outlet angle b, external fan efficiency is increased
from 28.80% to 29.96%, and outlet flow is increased by 0.08 m3/s. The cooler's
heat transfer properties and temperature distribution are determined by the fluid
and temperature coupling field in accordance with the results of external fan
optimization. It is discovered that the temperature of the inner ventilated path's
hyper thermal fluid has dropped from 75 C to 53.7 C; The cryogenic fluid's
temperature in the externally ventilated channel rises concurrently from 23 C to
49.4 C. The post-optimized cooler's internal fluid outlet temperature decreases
by 3 C, while the exterior fluid temperature rises by 2.5 C. The cooling effect
and fan performance have both improved. By altering the angle (a = 42) and
outlet angle (b = 53) of the fan blades, the performance of an external fan is

6
increased. The study's findings can serve as a useful tool for creating high power
density induction motors.
In the present study Davin & et al. [9] centers on using lubricating oil to
cool electrical motors. On each side of a 40 kW test machine, oil is injected to
directly cool the stator coil end-windings. The same parameters, including
frequency, voltage, current, number of poles, number of coils, and finite element
method, were used to analyze all models using ANSYS Maxwell software.
While having a lower flow rate than the other two injection types, these nozzles
have cooling efficiency that is comparable to them. When oil is injected at the
top and the end winding surfaces gain from a larger flow rate, the dripping
injector is the most effective. Jet impacts are still small and don't seem to be
working.

In this work, conducted by Mirosław Grabowski, et al. [10] The

comparison of the findings of numerical and experimental analyses of heat
conduction in the finned casing of an electric motor is presented. A 3D
geometrical model of the 7.5 kW motor was imported into the COMSOL
Multiphysics program. A numerical model of heat conduction in the motor
housing was constructed after defining the thermophysical parameters of the
housing material and heat flows produced in the motor, as well as after setting
boundary conditions. The model made it possible to determine the steady-state
temperature distribution in the cross section of the housing. The FLIR SC7600
thermovision camera was used to conduct research into the temperature
distribution in order to validate the model. Thermography was used to record the
steady-state temperature distribution on the motor housing surface while it was
idle. The true values of temperature differences measured across the housing
cross section differed from the calculated ones by no more than 10%, indicating
that the produced thermograms were in satisfactory quantitative agreement with
the simulated temperature distribution. According to the study, a thermovision

7
camera is an effective experimental tool for testing numerical models of the heat
transfer phenomena in an electric motor's finned casing.

Abdullah & et al. [11] Using the finite element method, the natural
convection heat fluxes from a horizontal rectangular fin embedded with
rectangular perforations of a two aspect ratio have been studied. The outcomes
for the perforated fin and its comparable solid fin have been compared. A
parametric analysis of the fin's geometrical dimensions and its thermal
characteristics was done. The study looked at how perforations increased fin
area and heat transfer coefficients. It was discovered that, compared to the
corresponding solid one, there is an increase in heat dissipation and a decrease in
weight for a specific range of rectangular dimensions and spacing between
holes. Also, as fin thickness and thermal conductivity rise, so does the
perforated fin's ability to enhance heat transmission. To better understand the
elements impacting heat transmission along the length of the fin,

In this study by Khaled et al. [12], heat transfer via fins susceptible to two
different convective media is modelled and analytically investigated. This
category of fins is referred to as a "biconvection fin." The following five cases
are examined: Case A is composed of bi-convection thickness-wise bi-metallic
fins; Case B is composed of bi-convection span-wise rectangular fins; Case C is
composed of bi-convection longitudinal fins; Case D is composed of bi-
convection perimeter-wise fins with uniform cross-section; and Case E is
composed of bi-convection perimeter-wise permeable fins. The effective
thermal conductivity, cross-sectional area, fin indices, and the difference
between the base and effective free stream temperatures are all found to boost
the heat transfer using Bi-convection fins. For examples A, D, and E, the fin
heat transfer rate can be reduced at a specific effective free stream temperature
value. For case B, it is possible to reduce the fin heat transfer rate at specified
values of the relative span height and convection coefficient ratio. With specific

8
fin index and convection coefficient ratio values and for case C, the rate of heat
transfer via the fins can be maximized.

Ismail & et al. [13] investigate different kinds of perforations in the shape
of tiny channels, such as square, circular, triangular, and hexagonal cross
sections, and compare their thermal capabilities to enhance heat sink cooling
performance. By using a control volume based finite element approach with an
unstructured non-uniform grid system, the governing equations are solved.
Based on the length of the fin, flow and heat transfer parameters are shown for
Reynolds numbers ranging from 2 x 104 to 4 x 104, with Prandtl number
assumed to be Pr = 0.71. The turbulent flow parameters are predicted using a k-e
turbulence model with a RANS foundation. Findings demonstrate that compared
to other types of fins, those with circular holes perform better in terms of
thermal and hydrodynamic dynamics. thought of her Under turbulent flow
conditions, perforations improve the thermal performance of heat sinks.
Perforation geometry also plays a significant impact in this improvement.
Compared to the other forms of heat sinks examined in this research, circular
perforated fins exhibit a higher fin effectiveness value (PFE) for the same
surface area. Compared to ordinary solid fins, perforated fins use less cooling
(fan) power.

Sharqawy & et al. [14] conducted an investigation to investigate the

effectiveness of straight fins of various designs when subjected to concurrent
heat and mass transfer mechanisms. The driving forces behind heat and mass
transmission are, respectively, the temperature and humidity ratio variations.
When the fin is completely wet, analytical solutions are found for the
temperature distribution over the fin surface. Together with studying the ideal
fin dimensions, the impact of atmospheric pressure on the effectiveness of the
fin was also investigated. It is shown that the solutions offered in this study are a
special case of the closed-form solutions for a dry fin situation presented in

9
numerous textbooks. In this work, a novel linear approximation model for the
relationship between the temperature over the surface of the fins and the
humidity ratio. The wet fin parameter, m, can be easily calculated from the dry
fin parameter, mo, using a correction table.The thermal optimization of a plate-
fin heat sink with the thickness of the fins varied in the direction normal to the
fluid flow was examined by Kim &et al. [15]. The volume averaging theory
served as the foundation for the optimization model (VAT). It was demonstrated
that by allowing the fin thickness to expand in the direction normal to the fluid
flow, the thermal resistance of the plate-fin heat sink can be decreased. The
thermal resistance might drop by up to 15% when using a heat sink that is
cooled by water. As the pumping force or heat sink length changes, the quantity
of the reduction also changes. For this optimization, a model based on the
volume averaging theory (VAT) was employed. In the instance of a water-
cooled heat sink, the thermal resistance was decreased by as much as 15% when
compared to heat sinks with uniform-thickness fins. If either the pumping power
or heat sink length changes, the amount of the reduction also changes. The
variable-thickness-fin heat sink is anticipated to be useful for as a next-
generation cooling solution due to its outstanding thermal performance.

A cylinder fin body is modelled and transient thermal analysis is

performed using Pro/Engineer and ANSYS in the study by Phani et al. [16]. For
two-wheeler air cooling systems, these fins are utilized. Aluminum alloy A204
is compared to magnesium alloy and aluminum alloy 6061 in the current study.
The study takes into account the numerous characteristics, including the shape
(Rectangular and Circular), thickness, and geometry of the fin (3 mm and 2.5
mm) decrease in thickness Also, by changing the fin's shape to a circle, the body
weight is reduced, which boosts the fin's efficiency and rate of heat
transmission. When magnesium alloy is employed, the weight of the fin body is
also decreased. The findings indicate that employing circular fins made of
Aluminum Alloy 6061 is preferable since the fins' heat transfer rate, efficiency,

10
and effectiveness are higher. When compared to current engine cylinder fins, the
weight of the fin body is reduced when circular fins are used.

1.4 Objective of study

This study follows a practical objective. It deals with numerical

examination of different fin geometries, configurations and materials in the
electric motor in order to improve heat dissipation capabilities. A better
understanding of the factors affecting heat transfer along the fin with a
comparison of the proposed fin geometry and its performance with previous
studies will be concerned.

1.5 work objective

1- Optimize the shape of the fins and arrange them to maximize heat dissipation
from the electric motor.

2- Statement of the effects of physical and environmental conditions on the

thermal performance of the engine.

11
Chapter 2
2.1 INTRODUCTION
The big question is how to set up a motor to tolerate over temperature
conditions for a short period that can occur. This leads to the research how to
incorporate a bidirectional selective active control element of heat flow system
for motor thermal control, lowering the electrical insulation temperatures and
controlling the ΔT of the core and windings, providing a more thermally stable
condition to improve motor performance by reducing electrical insulation
temperatures and stresses and achieving longer electrical insulation life .their
operation is dependent on the environmental conditions , In case they are in a
place where the environment cannot extract the specified heat flow (due to the
ambient temperature, in hot spots – inside e.g. foundries – or outside – in full
sun or in poor air circulation conditions, electrical vehicles [38], low density of
air at higher altitude, or low humidity) these motors will not be able to fulfil
their role. They will only be able to be loaded partially or will fail early after a
short operational life or will need to be oversized, with a very significant penalty
in efficiency (efficiency drops sharply at lower loads). [17] cooling of electric
motors is a critical problem in the motor design and manufacturing industry
because of heat generation by the motor. In addition, the temperature rise could
cause the deterioration of insulation in windings. Motor efficiency decreases as
temperature increases with increasing energy loss. It is realized that the design
of motors should not only be focused on electric matters, but also control of all

12
different disciplines of electrodynamics, thermodynamics, metallurgy,
chemistry, static and dynamic strength of structures [8][18]

Fig.1 components of an electric motor

2.2 Heat transfer in electric motor

When the motor is used in deferent purposes, motor needs to run for a
very long duration to pump the water. At that time, sometimes it needs to run in
a full load condition or running in slower speed due to the voltage variations. At
the time of full load condition, the small amount of speed slip may occur.
Similarly, Due to voltage variations or voltage fluctuations, the motor tends to
run at a slower speed. When the motor runs at a slower speed, severe
overheating of the motor occurs. The overheating persists for a long time; it will
degrade the performance of the electric drive. [1]. There are several ways to
improve the electrical machine performance by cooling. For example, effective
machine air cooling can be achieved by increasing the volume of the machine,

13
enlarging the outer surface area of the machine by adding cooling fins, and
blowing air through the internal parts of the machine as effectively as possible
[8]. Another common cooling method, an indirect liquid cooling approach,
employs water jackets placed close to the stator windings to keep them cool [7],
[8][19]. Instead of using water, certain oils can serve as both the coolant fluid
and as a lubricant for the gearbox [4][19] The removal of excessive heat from
system components is essential to avoid damaging effects of burning or
overheating. Therefore, the enhancement of heat transfer is an important subject
of thermal engineering (Sahin and Demir ,2008a)[2] Modern heat exchangers
are required to be designed in such a way that their size is reduced and more
compactness is achieved. For achieving this the heat transfer coefficient must be
increased [2] .

winding
conduction
mode
metalic materail

Heat transfer in electric

motor stator-rotor air gap
convaction

conductive
mode rotor end - disk

end spasmeant

Fig. 2 The types of heat transfers in electric motor

2.2.1 conduction mode

As motors further increase in size, the ability to cool the motor with
conduction cooling systems become less effective. Conduction cooling is
inadequate to deal with the heat generated by losses of large motor. [33] [17]

14
due to the low efficiency of conduction heat transfer, When such problems occur
at these levels, there will be no significant impact of optimizing other heat
transfer modes (such as convection) on the thermal behavior of electric
machines. Changing the materials, their ratios in heterogeneous elements, or
even their dimensions would make a difference. However, any change in these
characteristics will influence the loads of the machine and can affect its
electrical performance. A trade-off decision is required between thermal and
electromagnetic constraints [33][5]

2.2.1.1 winding
the temperature rise suppressed of the asynchronous motor winding by
optimizing the motor fan cover, the casing and the end cover, and filling a kind
of selected material with better thermal conductivity between the winding end
and the casing,[9] for optimizing the wind path of the motor by suppressing the
excessive temperature rise, changing the length of the radial ventilated duct of
the stator and rotor and increasing the vent of stator. [8], Relative dissipation is
more important at higher oil temperature, which is linked to the decreased
viscosity. However, these effects do not counterbalance the temperature
difference between winding and oil as absolute global dissipation is lower at a
higher oil temperature. [9] The thermal management of a motor is important
because the thermal characteristics of a motor are strongly related to its lifespan
and efficiency [1–3]. And for the thermal management of a motor, it is essential
to identify the internal temperature of the motor. Many studies have been
conducted to predict the temperature distribution of a motor with various motor
types and operating conditions. Most studies have focused on the thermal
characteristics of the stator and winding instead of the air-gap flow between the
stator and rotor. Li [5] examined the winding temperature variation with a
combined rotor-impeller structure in a permanent magnet electric motor. Kim et
al. [6] optimized the blade and inlet geometries for a brushless DC motor to
minimize the winding temperature. Xie and Wang [7] studied the effects of a

15
damaged rotor component on the thermal characteristics of the stator and
winding in an induction motor. Wang et al. [8] The heat flow from the windings
embedded in the slots to the end-windings was estimated from the axial
temperature gradients given by thermocouples embedded in the coils near the
slot exits. For the high voltage winding, no consistent trend could be obtained
from the thermocouples in this region, probably because an insulating material
was not used for the core laminations in this case.However, a worst case
estimate indicated that the axial heat flow between the end-winding at the fan
end and the stator core never exceeded 10% of the dissipation within the end-
winding.[20]

2.2.1.2 Metallic material

Materials used in fins depend on heat transfer characteristics of the
material. The materials generally used are Aluminum Alloy A204 which has
thermal conductivity of110150W/m k, and Aluminum alloy 6061 which has
higher thermal conductivity. Cast iron and copper alloy are also used. As heat
exchangers are used in a wide variety of environments, they require a range of
construction materials. Several different fin material options exist, allowing the
heat exchanger to operate in environments ranging from mild office applications
through to more aggressive coastal and manufacturing environments Three key
fin materials are offered: the standard being natural aluminum, a pre-coated
aluminum called “Blue Fin”, and copper. “Blue fin” offers a further level of
resistance to environmental conditions, with copper offering the best possible.
Natural Aluminum is the standard fin material used in all Coils Australia heat
exchangers due to the excellent cost/performance combination it provides. When
coated with Standard Finish corrosion protection this provides a highly cost-
effective solution for general operating conditions. Aluminum alloys have long
been used in the production of heat exchanger fins. The comparative properties
of the different alloys used for this purpose has not been an issue in the past,
because of the significant thickness of the fin stock material. However, in order

16
to make fins lighter in weight, there is a growing demand for thinner fin stock
materials, which has emphasized the need for improved mechanical properties,
thermal conductivity and corrosion resistance. Blue Fin is a high performance
pre-coated aluminum fin material. Blue Fin appears as an anodized finish with a
gloss blue tone that remains flexible. The Blue Fin coating is applied to the raw
aluminum fin stock. For harsh environments that are particularly corrosive to
aluminum, Blue Fin is the solution. Copper is used In applications where the
heat exchanger can’t be easily replaced, it demands that the materials used in the
coil provide the best possible corrosion resistance to maximize service life. With
its superior thermal conductivity, corrosion resistance and strength compared
with aluminum, copper is the ideal choice for demanding environments. Copper
finned heat exchangers are more suited to environments where improved
thermal performance is required. They are also suited to more abrasive
environments because unlike a recoated fin, a copper finned coil will not wear
out and fail. For the manufacture of welded fin tubes are used non-alloy steels
(e.g. P235) and low alloy steels C-Mo, C-Cr-Mo in grades 15Mo3, 13CrMo4.4,
10CrMo9-10 acc. PN-EN 10216- 2+A2: 2007 and P91. As the material on the
fin, is most often used ferrites steels such as DC01, DC03, DC04 (EN 10130)
and 16Mo3 (EN 10028), X2CrTi12 (EN 10088-2). These steels are wieldable
steel group. [2] The aluminum is the material which is used for the cooling
system because it is a widely used one. [2][1]. Each metal has different
properties like weight, cost, conductivity, flexibility, tensile strength, color, heat
resistance, etc. [21]. Al is much cheaper than Cu and Ag, has low conductivity,
flexibility, high tensile strength, less weight, and corrosive nature.

Cu wires are better than Al, which can resist the temperature effect. Also,
Al wires can be corrosive and causes fire. As a result, most industries prefer Cu
instead of Ag material because it is dense and uneconomical. Cu is preferred due
to (i) Higher melting point than Al and Ag while inducing low thermal stress for
casting dies; (ii) Lowest thermal expansion coefficient due to which Cu can be

17
distorted, after cooling from the casting temperature than Al and Ag; (iii) High
thermal conductivities which is useful for designing a uniform rotor bar at the
time of the crystallization process and avoiding overheating when the machine is
running and (iv) A higher bulk modulus than Ag which can provide strongest
mechanical support for the rotor structure.Their features makes Cu user suitable
conductor for winding material. In order to concentrate on machine efficiency,
In order to demonstrate the selection’s adaptability, case studies are given,
which will help readers choose the right material for their particular design and
application. the motor. Fe core and Al winding materials provides better
performance than other winding materials, because the efficiency and torque
other winding materials, are negative when the motor is at a standstill and
loaded condition.[5]

2.2.2 convection mode

Convection is the heat transfer process due to fluid motion. In natural
convection, the fluid motion is due entirely to buoyancy forces arising from
density variations in the fluid. In a forced convection system, the fluid
movement is by an external force, e.g., fan, blower, and pump. If the fluid
velocity is large, then turbulence is induced. In such cases, the mixing of hot and
cold air is more efficient, and there is an increase in heat transfer. The turbulent
flow will, however, result in a larger pressure drop such that with a given
fan/pump, the fluid flow rate will be reduced. Proven empirical heat transfer
correlations based on dimensionless analysis are used to predict the heat transfer
coefficient h [W/(m2 ◦C)] for all convection surfaces in the machine [5]–[8], [15],
[16].[22] The convective heat transfer depends on the convective heat transfer,
surface area of the fins and temperature difference between fin surface and
environment[7][1] It is the determination of these two values which links heat
and fluid flow and makes it possible to consider both at the same time. Seen
from the direction of the airflow, all channels are parallel to each other. It is
assumed that changes in their geometry do not have a significant impact on the

18
operating point of the fan and a constant pressure loss Δp in each separate
channel can be set. The average air temperature in each channel is initially set to
40 °C, defining the properties such as specific density ρ, viscosity μ, and thermal
conductivity ka . The flow resistance R and the volumetric flow rate v˙ are then
calculated iteratively to fulfill the condition set in [26] .

2.2.2.1 stator –rotor air gap convection

considered the internal fluid–solid coupling to study the temperature
distribution of a permanent magnet motor, obtained the temperature distribution
law of each part of the motor under different operating conditions, and
optimized the winding mode of the motor and the gap between the casing and
stator core to reduce the temperature rise [8] If the stator slot is optimized, an
efficiency improvement and reduction of harmonic losses can be obtained [11]
[5]. The stator geometry has major parameters for generating the perfect motor
designs based on the core depth, slot depth, teeth width, slot width, and slot
height.[12][5] In this paper discussed the issues related to convection cooling
from the surface of the electric machine, turbulent cooling along the end
winding and heat transfer across the air gap were discussed in.[4][3] The
induction motor had an open-type air cooling system. The stator was cooled by
cooling fins, which surrounded the exterior of the stator. Air from an external
fan entered the induction motor through six inlets with 0.2 m3/s. This air was
distributed through the stator-rotor air gap and duct, which consisted of its fins,
fin base, and frame. These two flows merged after passing through the air gap
and ducts. Finally, air was discharged through six outlets. An air-gap fan was
used to increase the flow rate through the air gap. The fan was attached onto the
shaft at both side of the entrance and exit of the air gap.[23]

2.2.2.2 Rotor End-Disk convection

Rotor cooling vanes, also called wafters, are attached to the rotor end.
Acting as a fan, these wafters improve the convective heat transfer coefficient in
the stator end windings (αendw). This increase of (αendw) can be crucial

19
depending on the cooling system, which is fundamental for air displacement
inside the machine [7]. The maximum shaft diameter can be determined to
restrict the saturation level of the rotor core[5] the rotating parts in contact with
the air and the oil can be described as a flat rotating disc and a rotating cylinder,
respective to the rotor side and shaft. Considering the wall velocities, the areas
and the vicinity of windings, the rotor disc is assumed to play a key role in heat
transfer within the side chambers. The last key parameter is the rotor speed [9]

2.2.2.3 End-Space Regions Convection

heat convection through the air within the machine is modeled using two
thermal resistances in series between the end-windings and the housing end-
cap . The reason is that their temperature is considerably lower than that of the
end-windings, meaning most of heat dissipation at the end-space will occur at
the end-winding. Convection within the end-space has been modeled as series
connection of thermal resistances between the end-windings and the housing
end-caps.[24] Convection for all surfaces within the internal sections of the
machine must be modeled; this is particularly important for the end-windings
since they are typically the hottest point in the machine. The convection cooling
of internal surfaces can be complex because the fluid flow depends on many
factors, including the end-winding shape and length, added fanning effects due
to wafters (i.e., simple fan features that are included on induction motor squirrel-
cage end-rings), simple internal fans, surface finish of the rotor end sections, and
turbulence [9][22].

2.3 Electric Motor Cooling Methods.

Thermal management of electric motors is a complex challenge because
of the multiple heat transfer paths within the motor and the multiple materials
and thermal interfaces through which the heat must pass to be removed. The
technical challenges to motor thermal management are summarized by
Hendershot and Miller as follows: “Heat transfer is as important as
electromagnetic and mechanical design. The analysis of heat transfer and fluid

20
flow in motors is actually more complex, more nonlinear, and more difficult
than the electromagnetic behavior” [3]. The heat generated by the electric motor
is distributed throughout multiple components within the electric motor. For
example, heat is generated due to losses within the stator slot-windings, stator
end-windings, stator laminations, rotor laminations, and rotor magnets or
conductors. The distribution of the generated heat within the components is
dependent on the motor type and the operating condition (torque/speed) of the
motor. The selected cooling approach for the motor impacts the path of heat
flow through the motor and the temperature distribution of components. For
example, a motor cooled with a stator cooling jacket will require heat generated
within the slot windings to pass through multiple material layers and material
interfaces before the heat is extracted through the cooling jacket. The thermal
properties of the materials and the thermal contact resistances due to the material
interfaces impact the temperature distribution inside the motor as heat flows into
the cooling jacket. Alternatively, direct cooling of the windings with oil or ATF
reduces the heat transfer path from the motor windings to the coolant.[25]In
order to prevent the increase in motor heat, finned motor housing is applied as
its extended area of the outer surface enhances heat dissipation to the
environment, thus facilitating temperature stabilization and keeping of the
acceptable operating conditions.[10] the effective use of an electrical component
is limited by its maximum operational junction temperature. To achieve a
desired component temperature, excess heat dissipated by the device must be
transferred to the environment. The most common method for transferring heat
from the component to the environment is to use a heat sink. To estimate a
component’s junction temperature, a required value is the heat sink’s thermal
resistance [2]

21
Fig.3 Electric motor cooling methods

2.3.1 External Cooling Methods

There are several ways to improve the electrical machine performance by
cooling. For example, effective machine air cooling can be achieved by
increasing the volume of the machine, enlarging the outer surface area of the
machine by adding cooling fins, and blowing air through the internal parts of the
machine as effectively as possible [7]. Another common cooling method, an
indirect liquid cooling approach, employs water jackets placed close to the stator
windings to keep them cool [7], [9 Direct liquid cooling methods have mainly
been applied to very large electrical machines [12–15][ ].This cooling system
includes a water jacket that enhances heat transfer from the stator to the housing,
which makes the system suitable primarily for machines with substantial losses
in the stator. Although substantial research has been conducted on thermal
analysis, there are not many criteria related to the design and optimization of
cooling systems for electric machines. Despite the fact that it is not common in
the literature to find criteria for thermal design, some optimization tools can be
found: [39][6] presents a simple technique in which a higher thermal

22
conductivity path between the center of the slot and the cooling arrangement is
created, thus increasing the heat flow away from the slot center, and [40][6]
designs a water cooled direct drive permanent magnet motor that considers
efficiency and structural strength through thermal and structural analysis.
approaches water jacket design by introducing a design methodology using FEA
methods, [42][6] studies the efficiency of the fluid flow in the water jacket, and
[43][6] supports the optimization of water jacket for motors in an orthogonal
experiment. Because of the lack of research on water jacket design, there is still
a lack of criteria to define the main parameters of the water jacket, such as the
water jacket topology, the cooling ducts area, the distance between ducts, the
distance between the stator stack and the cooling ducts, the quality of the contact
surface between stator and housing, etc. [6]

2.3.1.1 External Cooling through Fins

Fins are most commonly used in heat exchanging devices such as
radiators in cars, computer CPU heatsinks, and heat exchangers in power plants.
They are also used in newer technology such as hydrogen fuel cells[2] The use
of highly effective fins increases the heat transfer surface area, which leads to
substantial increase in the heat transfer rate. Conditions for heat transfer: When
the pin height to pin diameter, ratio is less than four these are called short pin fin
arrays thermal flow patterns around the fins, fin cross-section, fin length and fin
material, determines the final fin performance.[11] there are many situations
where fins may have two different convection coefficients as well as two
different free stream temperatures. These types of fins are named in this work as
"Bi-convection fins”. Bi-convection fins can be found in heat exchangers
involve condensation or evaporation, cooling or heating of storage tanks and
heat transfer through fins separating two immiscible fluid . [12] Extended
surfaces (fins) are frequently used in heat exchanging devices for the purpose of
increasing the heat transfer between a primary surface and the surrounding fluid.
Various types of heat exchanger fins, ranging from relatively simple shapes,

23
such as rectangular, square, cylindrical, annular, tapered or pin fins, to a
combination of different geometries, have been used (Sahin and Demir, 2008b).
[2] in most cases, the area of heat transfer is increased by utilizing extended
surfaces in the form of fins attached to walls and surfaces (Bergles, 1981). Fins
are normally used as heat transfer enhancement devices. As the extended
surfaces (fins) technology continues to grow, new design ideas emerge including
fins made of anisotropic composites, porous media, perforated and interrupted
plates (Kakac et al., 1981; Bergles, 1981; AlEssa and Al-Hussein, 2004;
Mullisen and Loehrke, 1986).Due the high demand for lightweight, compact,
and economical fins, the optimization of fin size is of great importance.
Therefore, fins must be designed to achieve maximum heat removal with
minimum material expenditure and easy manufacturing procedure (Prasad and
Gupta, 1998; Kutscher, 1994; Al-Essa, 2000 ) [2] the solid fins have the lowest
value of heat the circular perforated fins have highest heat transfer performance
and can exchange more heat between primary surface and the ambient air.
removal rate. Perforated fins show better heat removal rate due to the extended
surface area.[13] ting of storage tanks and heat transfer through fins separating
two immiscible fluids[12]

2.3.1.1.1 Natural Convection with Fins

Finned heat transfer surfaces are widely used in many industrial
applications such as, air conditioning, refrigeration and chemical processing
systems [13] The cooling system of most low-voltage motors up to 250 kW is
formed by a finned frame and a fan with a cover attached to the non drive end,
which impels the cooling air along the fin channels [7] The amount of
conduction, convection, or radiation of an object determines the amount of heat
it transfers. Increasing the temperature gradient between the object and the
environment, increasing the convection heat transfer coefficient, or increasing
the surface area of the object increases the heat transfer. Sometimes it is not
feasible or economical to change the first two options. Thus, adding a fin to an

24
object, increases the surface area and can sometimes be an economical solution
to heat transfer problems. Both the performance reliability and life expectancy
of equipment are inversely related to the component temperature of the
equipment [11]. the heat transfer coefficient between finned housing and air was
measured for different numbers and dimensions of the fins. [26]

2.3.1.1.2 Forced Convection with Fins

A totally enclosed fan-cooled (TEFC) electrical machine emits most of

its losses via its finned outer surface that is blown over with air as coolant.
Therefore, it is necessary to consider both the fluid flow over the surface and the
heat flow in the housing simultaneously. This is often referred to as conjugate
heat transfer (CHT) problem [3] Most systems cool the motor case or internal
space by adding axial air flow using blowing blades and sometimes augmented
by rotor channels That can be implemented as a circulating channel inside the
case or by a technique called totally enclosed fan cooling (TEFC): a rotating fan
blowing air over the finned carter. Carter cooling implies a long thermal path
between the high loss points (i.e., the windings) and the coolant. High heat
fluxes must pass through electric insulating components and interfaces formed
between parts of the machine [1 ][9] As the motors increase in size (larger
frames), internal fans can further improve heat management circulating air
internally helping to transport the internal heat to the outer casing [2][17] The
preferred cooling flow design was one in which the cooling fan pushes the air
through the motor instead of pulling the air out of the motor..[3][18]

2.3.1.2 Frame Channels and Pipes

Channels are classified into two groups: smooth channels and channels
with perturbations (ribs). a numerical study was conducted by simulating a three
dimensional, viscous, steady turbulent flow model and examining the heat sink
geometry, and it was discovered that by decreasing rib spacing and increasing
rib height for the same flow rate, the pressure drop and heat transfer increases

25
significantly. Researchers optimized the electric motor frame by studying
convection disturbances at the outer section of the electric motor. The results
reveal that in the improved design of the frame, the convection area increases
and the temperature in the optimized system was significantly lower [14][3]

2.3.1.2.1 Smooth Channels

To limitation the problem, two sources of heat and a number of sinks
according to the number of channels need to be set. An evenly distributed heat
flow of constant total value is applied to the inner side of the housing (Pstator).
This is the major source of heat coming from the stator. Additional heat is
inserted from the warm air of the inner circuit (Piair). The sum of both fractions
is the total amount of heat dissipated (Ptotal). The heat transfer into the channels
is defined by convective boundary conditions. These are set for each channel
individually, according to their geometry. For the evaluation of their geometry,
only the cross section is regarded and any influence on the in- or out-flow
conditions is neglected. [26]

2.3.1.2.2 Friction coefficient

Friction factor for all the fins decreased with the increase of Re, In the
laminar flow regime the triangular shape with minimum fin density showed the
minimum pressure drop while the elliptical shape with highest fin density had
the maximum pressure drop. Whereas in the turbulent flow the elliptical shape
fins had the minimum pressure drop and the triangular shaped fins had the
maximum pressure drop [2].

2.3.1.2.3 Channels with Perturbations

The geometry of the channel, formed by the armature, the permanent
magnets, and the motor shell, is determined by the motor magnetic design.
Modifying the dimensions of the flow channels will result in motor efficiency
reduction. To increase the cooling rate by reducing the flow resistance in the
motor section is not recommended. Reducing the resistance in the diffuser is

26
proposed. Second, choosing an impeller design to fit the total flow resistance is
critical to the cooling design. The channels are formed by the two permanent
magnets, the armature, and the motor steel shell. The flow velocity in the
channels is very high compared to the flow velocity in the commutator region.
When the cooling flow leaves the relatively large space above the armature and
enters the channels, the air is accelerated and large pressure head is consumed.
The high air velocity and the interaction between the channel flow and the film
flow further increase the flow resistance in the motor section. [18]

2.3.1.3 External Heat Pipes and Two-Phase Loop

Heat pipe is a heat transfer element that relies on the phase change of its
own internal mass to achieve heat transfer. It has high thermal conductivity and
also has some characteristics that other heat transfer elements cannot match Heat
pipes have a high thermal conductivity, but there are certain heat transfer limits,
and their thermal conductivity is influenced by many factors heat pipes can be
arranged in the motor stator outward heat conduction, or arranged in the rotor as
a rotating heat pipe, and put forward specific examples of applications.
However, due to the limitation of processing and manufacturing level, the
application of heat pipe in motor cooling system has not been popular. With the
development of science and technology, the requirements of compact structure,
high power density and high reliability are put forward for the permanent
magnet synchronous motor, which poses new challenges to the thermal design
of the motor. The heat pipe cooling technology with simple structure, high
thermal conductivity and high reliability has great advantages for solving the
problems of large heat generation and concentrated heat dissipation area of new
motors [21].

2.3.1.3.1 Heat pipe

Heat pipe for motor cooling is mainly divided into two forms: one is
installed in the heat-generating parts of the stator and rotor of the motor,
exporting heat to the two ends of the motor where it is easy to dissipate, thus

27
reducing the temperature rise of the motor. The other is the rotating heat pipe
motor, which make the rotor itself into a rotating heat pipe, the heat of the motor
rotor is brought to one end of the motor through the rotating heat pipe to
dissipate, and at the same time the temperature rise of the stator winding is also
reduced. The use of both forms of heat pipes can increase the power of the
motor while maintaining the winding insulation and heat resistance requirements
[21] authors investigated the thermal management system for electric motors
employing L shaped heat pipes in an experimental setting. The motor surface
temperature was lowered by 33.8 degrees Celsius, according to the results. The
finite element approximation approach was used to investigate conductive and
convective heat transport through a finned casing of an electric motor. [17][4]

2.3.2 Internal Cooling Methods

direct liquid cooling approach to the stator cooling for a 100 kW electric
machine. A 100 kW permanent-magnet, axial-flux, double-stator, single-rotor
prototype motor was retrofitted with helical tooth coil windings formed from a
hybrid conductor comprising a stainless steel coolant conduit tightly wrapped
with stranded Litz wire. Litz wire, generally used to reduce the winding power
losses of inductors and transformers, may consist of hundreds of thin oxidized
copper strands [17] [19]. This direct liquid cooling approach provides a direct
heat path from the windings to the cooling liquid, which circulates and is cooled
in the primary loop. The direct liquid cooling method could prove beneficial for
hybrid vehicle applications, because the excellent cooling performance enables
optimally compact and lightweight traction drives. [19] The cooling system of a
compact high-efficiency high-voltage motor is mainly composed of internal
ventilated path and external ventilated path. The internal ventilated path
transmits the internal heat of the motor to the cooler of the external ventilated
path and the heat is dissipated to the surrounding air, A cording to the pressure
of the fluid in the fluid network, the internal ventilated path is divided into three

28
parts: the end, stator and rotor and the internal fan, and the three boundary zones
are coupled by selecting appropriate boundary conditions[8].

2.3.2.1 End-Space Potting

Convection for all surfaces within the internal sections of the machine
must be modeled; this is particularly important for the end-windings since they
are typically the hottest point in the machine. The convection cooling of internal
surfaces can be complex because the fluid flow depends on many factors,
including the end-winding shape and length, added fanning effects due to
wafters (i.e., simple fan features that are included on induction motor squirrel-
cage end-rings), simple internal fans, surface finish of the rotor end sections, and
turbulence.[9][22] . End-windings are usually the hottest spots in an electric
machine. High performance electric motors may employ specific cooling
methods for the end-windings [21], [19]. For the case of industrial induction
machines, fins attached to the rotor short-circuit rings (usually known as
wafters) have been traditionally employed in totally enclosed designs to boost
the airflow within the end-space region [13], [14]. [24]

2.3.2.2 Metallic Bars

Special manufacturing procedures were developed to produce both the
hybrid conductor cable and the tooth coil winding pairs. Litz wires with a steel
tube inside pose certain challenges in the winding process because of the
bending of the tubes. The steel tube walls are relatively thin, and therefore, the
winding should be manufactured by a special technique to avoid flattening of the
steel tube while pressing the Litz wires in order to reach the maximum possible
copper space factor. The windings were produced manually for the proof-
ofconcept machine. Common piping tools are utilized e.g. for cutting the pipes
and end connection are done by cutting ring tube couplings. During the
assembling it was notified that sharp bends are not acceptable in the case of Litz

29
wires with tubes because the insulations on the surface area will shift when the
wires are bent. Therefore, this new winding procedure should be automated for
large scale manufacturing. [19]

2.3.2.3 Phase-Changing Materials (PCM) Cooling

A thermal energy storage (TES) system is considered an ideal solution to
reduce energy consumption in heating or cooling buildings. TES systems hold
thermal energy in the form of hot or cold materials for later utilization [3].TES
systems can be classified by how energy is stored: sensible heat, latent heat, and
chemical TES systems [2–4]. Latent heat TES systems can store 5–14 times
more energy than sensible heat TES systems [6].

Phase-change materials (PCMs) are well-known TES materials, utilizing

both sensible and latent heat to store energy. PCMs are classified according to
raw materials: inorganic, organic, and eutectic PCMs. Inorganic PCMs are
formed from salt hydrates and metallic alloys [6,7]. Supercoiling and phase
segregation are common issues in inorganic PCMs. They can cause loss of
energy storage capacity and delay in phase-change temperature. Therefore,
many researchers have studied how to solve these drawbacks. Atul Sharma et al.
[5]suggested adding a nucleating agent, such as nucleion, which can easily
initiate crystal formation. Sutjahja et al. [21] studied the effects of chemical
nucleator additives suchas SrCl2_6H2O, BaCO3, and K2CO3 on the super
cooling behavior of CaCl2_6H2O PCM. Among the additives, SrCL2_6H2O
showed the best performance in preventing super cooling. Palittin [10] adopted
sonocry stallization by using ultrasound radiation to crystallize CaCl2_6H2O. In
order to minimize phase segregation, thickener agents have been used.Absorbent
polymer [29], polyethylene glycol [30], silicon rubber [31], cellulose
derivatives[27,29,32], and polyvinyl alcohol [29] have been added as thickening
agents to inhibit or minimize phase segregation. An inorganic PCM,

30
MnCl2_4H2O, was confirmed to increase latent heat and decrease super cooling
when it was used as an additive in Mn (NO3)2_6H2O PCM [33]. However,there
have been no previous studies regarding the properties of MnCl2_4H2O as a
PCM rather than an additive. The objective of this study was to measure and
investigate the Thermophysical properties of inorganic MnCl2_4H2O PCMs.
The specimens were delivered in liquid, solid, and dual phases. The scope of
investigation comprised (1) superheating and supercoiling analyses of the
Thermophysical properties (melting/solidification temperatures and latent heats)
of single-phase PCMs under endo/exothermic processes using DSC; (2) in
particular, analyzing the supercoiling behavior of PCMs, which were treated to a
homogeneous condition; and (3) determining thermal conductivities and thermal
diffusivities analyses of single-phase PCMs.[27].

2.4 Air Cooling

The cooling of electric motors is a critical issue in the motor design and
manufacturing industry. Engineers have realized that the design of electric
machines should not only sharply focus on electrical design. Instead, the good
command and control of all different disciplines of electrodynamics,
thermodynamics, metallurgy, chemistry, static and dynamic strength of
structures, and kinetics are necessary [1][19]. A better cooling design can
improve not only the motor efficiency but also the motor operational reliability
[2–4][19]. A good cooling design can significantly reduce the motor noise level,
which has become a critical concern in the current home appliance market [5–7]
[19]. In addition, the life of an electric[19]The fluid flow and heat transfer in the
motor is a complex process. The reasonable fluid flow plays an important role in
the ventilation and cooling of the motor. However, in view of the low utilization
of the fluid between the stator core and the casing, the reasonable optimization
will be carried out in the future to improve the cooling and energy saving effect
of the motor.[14] The two common approaches for active cooling include: 1)
directly cooling the motor with ATF, and 2) cooling the motor with a cooling

31
jacket surrounding the stator. The advantages of either cooling approach depend
on the application's coolant availability, the motor geometry, and the motor loss
distribution. The advantage of cooling using ATF is it is possible to directly cool
the motor windings or rotor. [ 25] Cars and trucks using direct air cooling
(without an intermediate liquid) were built over a long period beginning with the
advent of mass produced passenger cars and ending with a small and generally
unrecognized technical change.[16] the thermal resistance of an air-cooled heat
sink can be reduced by about 15% by increasing the fin thickness in the flow
direction [6][15].

2.4.1 Air Jet Impingement

Jet impingement is an attractive cooling mechanism due to the capability
of achieving high heat transfer rates. This cooling method has been used in a
wide range of industrial applications such as annealing of metals, cooling of gas
turbine blades, cooling in grinding processes [1][28] and cooling of photovoltaic
cells [2][28]. Jet impingement has also become a viable candidate for high-
powered electronic and photonic thermal management solutions and numerous
jet impingement studies have been aimed directly at electronics cooling [3-8]
[28]. The key parameters determining the heat transfer characteristics of a single
impinging jet are the Reynolds number, Prandtl number, jet diameter and jet-
totarget spacing. Nozzle geometry can also have a sigficant influence on heat
transfer [13] [28].

2.4.2 Air Jet Impingement on Rotating Disk

Both spray cooling and jet impingement cooling work on the principle of
impingement and give high heat transfer rates. A comparison of their
performance has been made using the correlation for multiple-jet liquid
impingement [27][29], At low liquid mass flux, and for low degrees of superheat
or surface temperatures slightly below the saturation temperature, the film
evaporation regime is characterized by long evaporation time. Heat is

32
transferred from the surface through the liquid film and dissipated by
evaporation at liquid–vapor interface and by sensible heating of the fluid. An
increase in the liquid flow results in an increase in the convective heat transfer to
the liquid and the evaporative heat transfer decreases due to the formation of a
thicker film [19][29]. The spray droplets impinging on the liquid film produce
turbulence that enhances convective

heat transfer, mixing and evaporation. In general, the heat transfer

characteristics of sprays are strong functions of the type of coolant and its sub
cooling, mass flux and spray characteristics. Sprays are characterized by the
droplet diameter, velocity and the spray pattern. [7] [29]

2.4.3 Air Jet Impingement on winding

The overall heat transfer coefficient on the endwinding at the air outlet
end (the fan end) was roughly double that at the air inlet end, the converse of the
situation for lap and concentric wound motors. Large spatial variations in the
end-winding local heat transfer coefficients occured. This is attributed to the
open nature of the winding which results in the individual loops behaving as
separate bodies, each with a flow pattern dependent upon the angle of the
approaching flow. The primary differences between the low and high voltage
configurations lie in the openness and topography of the stator windings, and in
the presence of the protruding rotor bar ends which form crude additional fans in
the high voltage motor. Lap winding yields an almost continuous surface which
is somewhat irregular and rough. Concentric winding results in the wire bundles
retaining their identities giving more openness at the stator face, and a deeply
fluted, irregular surface. High voltage windings have strips completely separated
from each other and wrapped with insulation resulting in a very open structure
over the full length of the end-winding. Changes in winding openness and
surface irregularity are expected to result in different air flows and flow
distributions giving variations in the magnitude, and possibly the behavior, of
the heat transfer coefficients. Marked differences in flow distribution were

33
observed between the lap and concentric wound motors (2), but while the heat
transfer coefficients were higher for the concentric wound motor, the general
behavior was similar. In particular, the end-winding overall heat transfer
coefficient at the inlet end was roughly double that at the fan end for both cases.
[20].

2.5 Liquid Cooling

Liquids have heat transfer coefficients 100 times higher than that of the
gases different oil cooling injections have been investigated [11]. The presence
of oil, even a restricted amount, significantly improves global heat transfer
compared to air only. Indeed, with oil injection, the dissipation power is
multiplied by a factor 2.5 to 5 f or all configurations, the oil flow rate is the main
factor for global efficiency [8] The largest electrical machines (typically 300
MW to 1000 MW) employ water cooled conductor stator windings to remove
the heat caused by internal losses [2, 40, 41]. Even water-cooled rotor windings
have been built to remove internal heat, but this approach has not been widely
employed [2][17]. the design of the water flow system is more complex when
compared to the air-cooling system, and its initial costs are higher. The parts of
water-cooled systems might add complexity, weight, and coPhase change
material cooling is taken place by means of absorbing the thermal energy by the
phase change material at its phase transformation. The PCM changes its phase
by absorbing the thermal energy and it needs an external cooling system in order
to re-gain its earlier state (9). Applications of PCM in electronics industry
already exist. However, utilization of PCM in motor cooling applications is still
at research levelst of the engine. This system is better for higher-power
machines that produce high waste heat but can move more weight. Another
main complexity in water-cooled motors is the requirement of a pump, a pipe to
transport water, and a radiator, when compared to the requirement of only a fan
in the air-cooled motor to expel excess heat out of the motor [12].[31] Liquid

34
cooling is also employed in maritime vehicles. For vessels, the seawater itself is
mostly used for cooling. In some cases, chemical coolants are also employed (in
closed systems) or they are mixed with seawater cooling. [16].

2.5.1 Internal Flow Liquid Cooling

External flow liquid cooling: here are many ways of representing the
water jacket; introduce the water jacket as an additional node in the thermal
network, represents the water jacket with a single node for the whole model,
includes a negative loss generator to represent the heat evacuated by the water
jacket, [21] proposes an equivalent thermal circuit network separating the water
jacket from the model representing the machine and adds another conductance
matrix to the general equation that represents the fluid in the machine Our model
was developed using a new approach in which water was modelled with many
nodes as points of study in axial direction . However, these nodes were not
computed, and they were modelled as constant temperature nodes.
Consequently, these nodes became a boundary condition for the problem .Nodes
from the water jacket were connected to the housing by convective thermal
resistances. The stator stack and its winding dissipate all their losses through the
water jacket, achieving better thermal performance [7].

2.5.1.1 Liquid Jets and Sprays

The injector produces a multi-jet pattern with a moderate velocity,
because of the fragility of the conductors. . For the dripping and multi-jets
injectors, in all configurations, jets are laminar(Red < 460).Injectors differ from
each other by the oil pattern and flow rate range. The means for the generation
of the pattern are also different as mist nozzles require relatively high pressure
level (until 5 bars for these tests) while the dripping injectors generate negligible
pressure loss. Multi-jets represent an intermediate need for the pump pressure.
These injectors, despite their different flow rate ranges, have been chosen to
compare the effect of changing the position and the pattern of the oil injection
on windings dissipation power.[9] Impingement heat transfer has been used

35
extensively in industry because of the high rates of cooling it provides. Several
reviews document the heat and mass transfer characteristics of both liquid [1]
and gas [2±4] jets. The associated high heat transfer rate is due to the stagnating
mass that impacts at high speeds on the impingement surface. Boiling spray
cooling is a logical extension to the concept of impingement cooling, and has
been studied rather extensively [5±8]. In this situation, the impingement surface
temperature is maintained below the saturation temperature of the spray liquid.
Sprays show promises in this cooling convguration because of the large surface
area that is formed when a liquid is atomized into many droplets by the spray
nozzle. Phenomena that depend on hydrodynamic mixing and/or that operate at
the interface of boundaries, such as heat transfer, are often intensive because of
this increased interface area. [30]

2.5.1.2 Liquid Jets

A new technique of cooling by spraying oil with or without the use of
nozzles is described . This technique fills the oil in the motor partially in such a
way that the rotor when rotates splashes oil around the end space and cools the
surfaces where it splashes over. However, cooling oil should be chemically
stable, inert, nontoxic, non-flammable, low dielectric constant, high dielectric
strength, and high electric resistivity . [ 17] Liquid–vapor phase change and
liquid cooling by impinging jets or sprays are attractive cooling options for
removing high heat fluxes because of the higher heat transfer coefficients
associated with them. Spray and jet cooling techniques are considered as
competing options for this application. The reliability of microelectronic devices
demands the near elimination of all spatial temperature variations [2][29].
Unlike jets, sprays provide better temperature uniformity across the heat-
dissipating surface [3][29]. Based on experiments using air-assisted full-cone
water sprays, Oliphant et al. [4][29] noted that spray cooling provides the same
heat transfer rates as a jet at a substantially lower mass flux.[29].

2.5.1.3 Liquid Sprays

36
 In the mist nozzle and dripping cases, the concentration of drops and
droplets is dense, and a substantial part of the flow rate is directed toward the
rotating parts, thus redistributing oil within the domain [9]. the spray cooling
provides the same heat transfer rates as a jet at a substantially lower mass flux.
heat transfer and critical heat flux for full-cone sprays using single nozzle [4–10]
or multiple nozzles [11,12]. The temperatures encountered in these applications
are quite elevated and the cooling occurs with phase change. Since a large
amount of latent heat is associated with the phase change, such sprays are
capable of removing high heat fluxes from a surface [8] [29]

2.6 Internal Heat Pipes and Two-Phase Loop

heat pipes are static heat pumps which are capable of transporting thermal
energy. It is an enclosed structure where working fluid absorbs heat energy and
evaporates. Then the working fluid is transferred to the condenser where it is
condensed. The capillary action moves the working fluid between the condenser
end and the evaporation end. Heat pipes needs an external cooling system such
as a fan in order to remove heat from the working fluid. (8) Two-phase jet
impingement is a promising technology for achieving high heat removal rates at
moderate pressure losses. In two-phase jet impingement, one or more jets
impinge liquid onto a heated surface, where it boils. This cooling approach can
achieve high-heat transfer coefficients in both single- and two-phase operation
—with an enhanced critical heat flux (CHF) compared to pool boiling [30].
Because the liquid/vapor mixture has a relatively large outflow path compared
to channel geometries, vapor generation only causes minimal pressure drop
increases [2]. These characteristics make two-phase jet impingement an
attractive starting point for the development of a low-pressure-drop heat sink for
electronics cooling applications. [30] When investigating the two-phase flow,
the flow, and therefore the heat transfers, will be biased by the entry conditions,
the fluid properties and the rotation, thus enabling key parameters to be
identified. The entry conditions are defined by the oil injection pattern and the

37
flow rate. The liquid properties might be reduced to the oil temperatures at
which viscosity is highly variable [8]

2.7 Electric Motor System Definition

The induction motor is used in pumps, conveyors, winders, wind tunnels,
furnaces and other industrial equipment [2] Industrial electric motors consume
30–40% of the electric energy produced worldwide and up to 70% of the
domestic electricity production in some countries [1][10]. Of the total cost of
purchase and usage of an electric motor, the share of consumed electric energy
is about 90% and therefore, energy efficiency of the motor is of key importance
[2][10]. induction motors are known to maintain favorable operating
characteristics in a wide load range from 75% to 100% of the rated output [7].
The characteristics of a motor can be improved by reducing the losses of
supplied energy due to its conversion to heat that is dissipated to the
environment [6][10]. Heat is generated during motor start-up and speed control,
as well as during normal operation [7][10]. an efficient motor can be designed
with Steel 1008 as core and Cu as a winding material. Ag is also the best choice
for motor winding, but it is expensive compared to other materials. [17] the
motor life was limited by the insulation material. The rate at which the
insulation materials ‘age’ was approximately doubled for each additional 10 C
temperature rise.The cooling air velocity needs to be high enough to provide
adequate heat transfer on the cooling surface[8][18].

2.7.1 Electric -Motor Geometry and Materials Properties

Machine design is the first step for the successful operation of the
motors which impacts manufacturing cost and profit. In the design process,
defining the size of the machine is one of the prominent steps which is highly
challenging. The factors to be considered in the design are stator and rotor
diameters, number of slot, iron core length, insulation material, winding, the size
of the IM, and the type of material. In general, a large-diameter motor generates

38
more torque while producing less speed, and a small-diameter motor generates
more speed while producing less torque. The size of the motor will decrease as
the flux density increases, and the motor size will reduce as well. Moreover, the
increase in flux density beyond the rated value, develops the magnetic core’s
saturation. This saturation will produce overheating, which leads to motor
failure In addition, increase in flux density reduces size of the motor diameter.
Hence, cooling issues need to be addressed while choosing diameter. Hence it is
necessary to lengthen the motor to meet the operating temperature limits. As a
result, the operating temperature, wire size, torque, and speed must be balanced.
Hence a trade-off is made between the length and diameter of the motor. Also,
design of motor mainly depends on the application. Different diameters and
lengths have different material requirements. [23][30] Hence, optimizing the
geometry of the motor can enhance its performance. The utilization of the
material for motor manufacturing is also one of the primary key factors for
improving its efficiency. The most commonly used materials in motor
manufacturing are Iron (Fe), Carbon steel 1008, and Carbon steel 1010 [14][30]
laminated cores; Aluminum (Al), Copper (Cu), and Silver (Ag) for windings Al
is used as a conventional rotor bar material for induction machines to encounter
thermal, metallurgical, and mechanical requirements due to its high
conductivity, low cost, and excellent physical properties. For the past 20 years, a
more expensive material, Cu, has been proposed for rotor bars because it has
more than 60% higher conductivity than Al to achieve higher mechanical
efficiency. The long-term operational benefits of using Cu rotor bar is to readily
cover the additional expense of Cu rotor machines [15][30]. It has been proven
that adopting the Optimized Cu bars improves low-medium starting torques.
Instead, the Al cage is recommended in many applications for attaining strong
starting capability, especially with a limited starting current. This work defines a
new strategy for optimizing the SCIM [16][30]. Even though, Ag is proposed as
a virtual rotor bar material, it has higher conductivity than Cu [17][30].

39
However, Ag is not feasible for commercial purposes due to higher cost and its
low melting point. Therefore, the choice of core laminate is significant to
achieve higher efficiency [18,19][30] in the design are stator and rotor
diameters, number of slot, iron core length, insulation material, winding, the size
of the IM, and the type of material. In general, a large-diameter motor generates
more torque while producing less speed, and a small-diameter motor generates
more speed while producing less torque. The size of the motor will decrease as
the flux density increases, and the motor size will reduce as well. Moreover, the
increase in flux density beyond the rated value, develops the magnetic core’s
saturation. This saturation will produce overheating, which leads to motor
failure. In addition, increase in flux density reduces size of the motor diameter.
Hence, cooling issues need to be addressed while choosing diameter. Hence it is
necessary to lengthen the motor to meet the operating temperature limits. As a
result, the operating temperature, wire size, torque, and speed must be balanced.
Hence a trade-off is made between the length and diameter of the motor. Also,
design of motor mainly depends on the application. Different diameters and
lengths have different material require he motor is specifically operated with one
core material and three different winding materials to ensure optimum material
selection. T The material selection depends on the mass and cost [24].
Generally, soft magnetic materials are used as the core of the motors. Therefore,
efficient SCIM can be attained by analyzing efficiency, power factor, torque,
slip, and speed. The choice and combination of material can be described as
follows: Fe is one of the metals that can carry magnetic field created by the
poles inside the motor. Al is used as windings to reduce motor weight, increase
thermal conductivity, provides cooling effect and prevents the magnetic field
from the external equipment. his combination is typically used for DC motors.
The material preferences for AC motors are steel and Cu used as core and
winding, respectively. Iderite. Carbon steel 1008 has a high percentage of
carbon as an alloying element with a manganese content of 1.2% and a silicon

40
content of 0.4%. In addition, carbon steel 1010 also contain less nickel,
aluminium, chromium, Cu, and molybdenum, along with 0.10% carbon.
Although this steel has a low strength, it can be quenched and tempered to make
it stronger [27] [30].

2.7.2 Boundary conditions

In order to define a convective boundary condition, it is necessary to set a
heat transfer coefficient and an average temperature . It is the determination of
these two values which links heat and fluid flow and makes it possible to
consider both at the same time [22].

2.7.3 Electric Motor Losses (Heat Sources)

The losses can be divided into four categories depending on the motor
component (mainly rotor and stator) involved: load losses in the winding, losses
in the core, mechanical losses due to friction, and additional losses caused by
inaccurate manufacturing and assembly of components [8][10]. In the total
energy loss, the share of load losses is typically about 50%, the core and
mechanical losses contribute by 15% each, and the share of additional losses is
20%. The losses result in a temperature rise that may lead to significant thermal
load on the motor components. [9][10]. Losses can be seen as heat sources that
increase the temperature of the electric machine . When natural convection is
insufficient to ensure safe operating temperatures, great attention should be paid
to the design of a motor cooling system . [1][ 32]. Ventilated motors, require the
use of a fan blowing air over or inside the motor. Often, this fan can be mounted
on the motor shaft thus realizing a self-ventilated machine [4][ 32]. Fans can be
classified into three different categories based on air flow direction and on their
suitability to specific applications: centrifugal, axial and mixed fans [5,6][32]
the inherent drawback of IM is its low efficiency and losses; that includes stator
and rotor copper loss, core loss, friction loss [9,10]. Moreover, IM performance

41
relies on geometric dimensions such as stator, rotor slots, and core length [11 ]
[25]The larger the motor the more complex the heat extraction system and the
higher the associated maintenance costs[19]The various losses in an IM were
described in Bin et al. [11]. However, in this review paper, only the major
losses, that is, iron losses, copper losses and mechanical losses have been
considered in the following section.[33]

stator stray- Air-gap Mechanical power

load and power windge loss
copper loss electromagna
rotor-stray load and
stator core loss tic power
rotor input copper loss
power
W=SI 2 SR.S = Wr 2
I rR .r
P ag=
T agw.syn

Fig.4 Types of electric motor losses

2.7.3.1 Iron Losses

Iron losses are the second most dominant type of loss, which produces
hysteresis and eddy current losses in IMs, primarily instigated by time-varying
magnetic fields [14][33]. The core losses are primarily quantified by the
Steinmetz equation whose coefficients can be treated as constants or variables
depending on the operating conditions [15][33]. To analyze the iron loss in an
inverter-fed induction motor, a piecewise variable pa parameter iron loss
(PVPIL) model could be used [16][33], where the PVPIL model is useful to
determine the effect of diverse extents and frequencies of flux densities on the
hysteresis and eddy current losses. According to the PVPIL model, the iron
losses can also be described by the expression [16][33].

42
2.7.3.2 Mechanical Losses
Windage and friction losses are the two major causes of mechanical loss
produced in an IM. Friction losses that are heat-dependent are significantly
related to bearings. The friction ultimately leads to heat generations, thereby
increasing the local temperature. Minimization of the loss could be done with
the help of lubricants and good quality bearings. The mechanical windage and
friction loss are given as [17][33]

2.7.3.1.1 Copper Losses

All the IMs predominantly suffer this loss majorly due to Joule heating
caused by the resistivity of the conductors. In addition to this, the overall copper
losses are highly impacted by the proximity and frequency-dependent skin
effects [12][33]. The copper losses are also temperature-dependent whose effect
can be determined by substituting the resistivity as a function of temperature
[13].[33]

2.8 Modeling Assumptions

Because the internal cooling mode of the motor is forced air cooling, and
the Reynolds number of the fluid in the motor inlet is 4490 > 2300, so the
calculation region is solved by the turbulence model (Baojun et al., 2019); (2)
The flow velocity of the fluid in the motor is much smaller than the speed of
sound, so the Mach number is very small, so the fluid in the motor is treated as
an incompressible fluid (Xinggang et al., 2017); (3) With air as the cooling
medium, the influence of buoyancy and gravity can be ignored under standard
atmospheric pressure (Gyanendra et al., 2020); (4) Assume that all the cooling
air blown from the external fan enters the cooler, and the air of internal
ventilated path circulates in the internal ventilated path[9] an assumption was
adopted that heat dissipation to the environment does not exceed.5% of the
motor’s power consumption.[10] calculations in this study are based on
assuming steady state one dimension heat conduction, uniform heat transfer
coefficient over the whole fin solid surface (perforated or solid) and uniform

43
heat transfer coefficient within the perforation, niggling radiation effects, no
heat sources/sinks in the fin body with uniform base and ambient temperatures
homogeneous and isotropic fin material with constant thermal conductivity and
the side area of the fin is much smaller than that of its surface area[3].

2.8.1 Geometry
Machine design is the first step for the successful operation of the motors
which impacts manufacturing cost and profit. In the design process, defining the
size of the machine is one of the prominent steps which is highly challenging.
This section describes the process involved in designing 5 HP, 415 V, 50 Hz
(IM) for EV applications. The Maxwell tool helps to design and estimate the
performance of the stator and rotor geometry using RMxprt. The factors to be
considered in the design are stator and rotor diameters, number of slot, iron core
length, insulation material, winding, the size of the IM, and the type of material.
In general, a large-diameter motor generates more torque while producing less
speed, and a small-diameter motor generates more speed while producing less
torque. The size of the motor will decrease as the flux density increases, and the
motor size will reduce as well. Moreover, the increase in flux density beyond the
rated value, develops the magnetic core’s saturation. This saturation will
produce overheating, which leads to motor failure. In addition, increase in flux
density reduces size of the motor diameter. Hence, cooling issues need to be
addressed while choosing diameter. Hence it is necessary to lengthen the motor
to meet the operating temperature limits. As a result, the operating temperature,
wire size, torque, and speed must be balanced. Hence a trade-off is made
between the length and diameter of the motor. Also, design of motor mainly
depends on the application. Different diameters and lengths have different
material requirements [23][4]

44
Chapter 3
3.1 Methodology
High temperatures in electric motors is a major problem suffered by users
of these motors. Manufacturers try to reduce the effects of this rise by paying
attention to determinants to prevent failure of the electric motor when operating
as a result of high temperature. He has studied the effect of the number of fins
on the motor body to get rid of excess heat. The induction motor is used in many
industrial and residential. effective fin arrangement is mandatory for efficient
cooling of an induction motor drive which employed for Hydraulic pumping
applications. The mostly used fin arrangement opted by the motor manufacturers
is Axial type fins with natural convection. The contribution of this study is to
change the shape and arrangement of the fins ,their material, and the
environmental conditions in order to enhance heat transfer characteristics in this
work we can use two type of fins rectangular and concave Here in the present
work, the induction motor is designed by ANSYS drawn Then, the model is
imported into ANSYS program . Through that, we obtained the temperature
distribution in various parts of an induction motor. Then this model is escalated
to the ANSYS the various numbers of fin arrangements are designed, and
thermal analysis is carried out by means of varying the number of fins , shapes
and environment conditions.

45
 * select suatable
* base paper simulation
* Data collection
selaction program ,
ANSIS2021R2

built proposed Vlidation model & bult the base paper

model test model

*Evaluation • Fine-tuning

Fig. 5 the search mechanism

Theoretical foundations of heat conduction problems have now developed

into a branch of applied mathematics where problem solutions are determined
by solving partial differential equations we ith various initial and boundary
conditions. The governing equation can be presented as:
∂T
ρcp
∂t
−∇ ⋅ ( k ∇ T )=Q ………………………. (1)

In steady-state conditions, that is, at constant temperature distribution, the

first left-hand term of this equation equals zero. According to the resulting
equation, Fourier equation, heat flux q is then is directed normal to an
isothermal surface and its value is directly proportional to the temperature
gradient [13]:
q=−k ∇ T ……………………………………….. (2)
From the theoretical point of view, differential equations that describe
heat conduction can have an arbitrary number of solutions as the integration
constants can be arbitrarily selected. In order to find a unique solution that
corresponds to specific heat transfer conditions, it is necessary to specify
problem geometry (in the case under study, the shape and dimensions of the

46
motor housing), properties of the housing material and ambient air (densities,
thermal conductivities and their dependence) and cross- border
conditions including:
 initial conditions that define temperature distribution in the housing at a
selected moment of time (time zero),
 boundary conditions that define heat transfer conditions at the outer surface
of the housing.
 ambient temperature 28 ,35 °C
The motor under study is equipped with a self-ventilation system
employing an axial impeller mounted on the rotor shaft. The rotating impeller
induces an air flow that intensifies heat transfer at the outer surface of the
housing. The thermal interaction between motor housing and the environment
can be reflected by a boundary condition expressing heat convection from the
surface of the housing to the ambient air:

( ∂∂ Tn )=¿ h (T
−2 k inf – Tamb ) ……………………………..(3)
where h denotes convective heat transfer coefficient, T inf is surface
∂T
temperature, Tamb is ambient temperature, ∂ n is temperature derivative along the

direction normal to isothermal surface. The value of the heat transfer coefficient
can be analytically
determined. The radial fan mounted on the motor shaft induces turbulent
air flow along the housing. Due to the positioning of fins on the housing, the air
flows in semi-open channels for which the heat transfer coefficient can be
calculated from the formula given in [17]:
C p Dν
h=ρ ( 1− ⅇ−n ) …….….…………………………………………… (4)
4L
Parameter n can be calculated from the formula:

( )
0.946 0 ⋅214
L ka
n=0 ⋅1448 1 ⋅16 ……………………………………………. (5)
D ρC pv

47
 where ka denotes thermal conductivity of air, v – air velocity, L –
characteristic length of the heat-transfer surface, D – hydraulic diameter (four
times the channel area divided by the channel perimeter, including the open
side)[8]. Convection is the heat transfer process due to fluid motion. In natural
convection, the fluid motion is due entirely to buoyancy forces arising from
density variations in the fluid. Proven empirical heat transfer correlations based
on dimensionless analysis are used to predict the heat transfer coefficient h [W/
(m2 C°)] for all convection surfaces in the machine [5]–[8], [15], [16]. Many
such correlations are built in [3], where the most appropriate formulation for a
given surface and flow condition is automatically chosen. This means that the
user need not be an expert in heat transfer analysis to use the software
effectively. Forced convection heat transfer from a given surface is a function of
the local flow velocity. In order to predict the local velocity, a flow network
analysis can be used to calculate the flow of fluid (air or liquid) inside the
machine. Empirical dimensionless analysis formulations are used to predict
pressure drops for flow restrictions such as vents, bends, contractions, and
expansions .For natural convection, the typical form of the convection
correlation is shown as follows:
Nu = a ・ (Gr ・ Pr )b ……………………………………….……. (6)
where a, and b are constants given in the correlation. The following
correlations also have to be considered:
Gr = β ・ g ・ ΔT ・ ρ2 ・ L3/ μ2 …………………………..,,……… (7)
Pr = cp ・ μ / k ………………………………………………………… (8)
Nu = h ・ L/k ……………………………………………………….… (9)

R = 1/ (h ・ A) ………………………………………………………… (10)
Natural convection heat transfer is a primary function of the fluid
properties and of the temperature difference between the considered solid
component and the fluid. The advantage of using empirical formulations based
on dimensionless analysis is that the same formulation can be used for similarly

48
shaped geometries with a size that is different from that of the original
experiments and/or with a different fluid. In addition, altitude has a significant
effect on convection cooling and is fully accounted for, as the variation in air
pressure ,density, and temperature variation with altitude can easily be modeled.
The calculation of natural convection heat transfer is often a requirement for
axial finned housing used in fan-cooled machines, as shown in Fig.5. This is
because natural convection can dominate the cooling at low fan speeds, as in the
case of motors used in variable-speed drives. Correlations for basic shapes such
as horizontal and vertical cylinders and flat plates can be used to predict the
convection heat transfer for the more simple smooth housing structures found in
electrical machines. Table 1 gives suitable values for a and b coefficients to be
used in (1) for such housing surfaces .Values are given for both laminar and
turbulent flow, together with the Gr ・ Pr product at which the transition to
turbulent flow occurs [5]–[7].[31]
Table 2 Natural convection correlation coefficients
Shape Gr.Pr a
b
Laminar to turbulent laminar
laminar

Horizontal cylinder 109 0.525 0.25

Vertical cylinder 10 9 0.59
0.25
Vertical flat plate 10 9 0.54
0.25
Horizontal plate upper 10 8 0. 54
0.25
Horizontal plate lower 10 5 0.25
0.25

Investigation provides the temperature distribution and heat flux of the

fins due to high temperature inside the stator. From the findings, we can infer

49
which one is the best conformation for successful cooling for the induction
motor drive used in Hydraulic pumping applications Table 1, which shows the
design information of an induction motor used for hydraulic pumping
applications. By using this data, the induction motor was designed by using
ANSYS applications, Figuere ( 6) shows the structure of an Induction motor
which is designed by using ANSYS 2021 R2.

Fig. 6 structure of an Induction motor

we can sense, the temperature near to the core is very high and it will
become reduced nearly to the housing. The temperature near to the core is
around 142 °C (415.15)K , and the temperature near to the housing is 127 °C
(400.15) K . This overheated temperature needs to get dissipated into the
environment employing natural convection. For this purpose, the motor
manufacturers provide fins over the motor. That will increase the surface of heat
dissipation, through this efficient cooling is obtained. Many types of fin
configurations are available. The most used one is an axial type fin arrangement.
Fig. 7 which shows the axial fin mounted induction motor.

50
Fig .7 Axial finned housing used in fan-cooled motors

The steady state thermal analysis is presented for the induction motor case
with fins.. The heat from the core is dissipated to the atmosphere through motor
case surface fins. Induction motor along with radial fin is modeled in ANSYS
21R2 is shown in fig.6. Geometry with various numbers of fin and different
height is modeled. The fin length is dissimilar from 5 mm to 20 mm with
increment of 5 mm length. The number of fins is varied from 5 to 11 with
addition of 2 numbers .[1]

The geometry is discretized in fine size (Fig. 10) for the efficient solving
of elements in the solver. The temperature input in the inner wall surface of
motor case (Fig. 8) and convective heat dissipation loss to atmosphere from fin
surface (Fig. 9) is given as boundary condition. As the number fins increases
the average surface temperature at the fin tip decreases. The convective heat
transfer depends on the convective heat transfer, surface area of the fins and
temperature difference between fin surface and environment. The convective
heat transfer between motor case surface and atmosphere is taken as (h = 15
W/m2 C° ) [7]. The surrounding atmospheric temperature is considered as
28°C.

51
Fig. 8 Heat input to fins

52
Fig .9 Heat dissipation to surrounding environment. (rectangular fins)

3.2 Mesh generation

Structured mesh and unstructured mesh are the two most common mesh
generating methods. For basic geometry, structured mesh is used, whereas for
complicated geometry, unstructured mesh is used. Fig. 10 shows a meshed
model with (325584) mesh element. Several structured networks with different
mesh sizes were implemented in order to ensure network independence of the
results. Fig.11 shows. Results obtained from size over networks are similar.
Therefore, the results from the mesh size can be considered as a network-
independent solution is (0.0012) mm. An adequate fine mesh was created for
analysis .

fig. 10 Meshing of induction motor

53
Fig.11 relation between GRID and Heat flux

Table 3 Relation between Grid (element ) and Heat flux for simulation1
H. flux (w/m2) Grid (elements)

13874 53781

14441 81270

15218 100536

15788 175560

17574 206206

17854 272844

18292 325584

18363 357561

54
3.3 Case 1
A simulation was made for the first case with 20 fins on the body of the
electric motor, with lengths of 5, 10, 15, and 20 mm. The relationship between
( heat Flux and Grid (elements)) shows that the best case with a size of
(0.0012)mm, and it is considered a reference for the four simulations of fin 5,
Since the results are close between the previous work and the new
simulation .Therefore, according to the available data, the simulation can be
continued with a change in a shape. And material and ambient conditions for the
purpose of improving heat dissipation from the electric motor to the outside
environment and improving its performance.

3.4 Case 2
The shape of the fin was changed to a concave shape, and simulation was
performed by ANSYS2021 R2 with all conditions constant, then a simulation
was performed by changing the type of metal from aluminum to aluminum
alloy, then simulation was performed by changing the distance between the fins,
then the ambient temperature with stability for other conditions.

Fig. 12 the concave fin anew shape

55
Chapter4
Results and Discussions
For the purpose of improving the thermal performance of the electric
motor and preventing it from being damaged as a result of continuous operation,
as in water filtration plants, an increase in the efficiency of cooling the motor is
studied by means of fins on the motor body, where the number of fins, their
height, the material they are made of, and the surrounding conditions are
controlled. With the help of ANSYS software, a three-dimensional steady-state
thermal study of the induction motor housing and the fins on the outer surface is
performed. First, a simulation of the previous work was carried out, and fin 5,
made of aluminum, with lengths of 5,10 ,15,20, was taken. The inner surface of
the casing was kept at a constant temperature of 127 °C (400.15 K), while the
rest of the outer surface, including the fins, was subjected to convection with a
heat transfer coefficient of 15 W/m2 K. The ambient temperature was 28 °C (301
K). (Kelvin) All examples were run to calculate the forced convection between
the surface of the housing and the surrounding air. Figure 5 depicts the results of
heat transfer from the inner surface to the outer surface, as well as the
convection on the surface of the uncovered induction motor housing.

1- Validation
1.1CASE 1
The electric motor simulation was carried out by A N S Y S 2021 R2
program and it was found that the temperature inside is 142°C(415.15)K , and
when the number of fins is 5,L 5 mm ( Rectangular) simulation was conducted
at an ambient temperature of 28°C(301.15)K . the temperature is at the top of
the fin 124.19°C (397.34) K. and when the number of fins is 5,L 10 mm
( Rectangular), the temperature is 107.8 C(380.95 K) , and when the number of
fins is 5,L 15 mm( Rectangular)The temperature is at the top of the fin 95.17°C
(368.32) K and when the number of fins is 5,L 20 mm ( Rectangular)The

56
temperature is at the top of the fin 86.1 °C (359.25) K as shown in
Table3 .when we compared the result that we obtained in this simulation with
the result of the base case we found the result its very near and the difference in
the result its (1.48,2.84, 6.64, 7.49 ) K.

Fig. 13 Validation between case base fin 5 (rectangular ) and fin 5 (rectangular )
Simulation

57
Fig. 14 temperature distribution ( 20 fins )

Table 4 Validation between base Article and (rectangular fin) Simulation 1

Case 1 fin5

Length of fin Minimum temperature (K) Minimumtemperature(K)

Temperature(k) (mm )

base Article at tip fin simulation 1difference

5 398.82 397.34
1.48

10 383.48 380.64
2.84

15 374.96 368.32
6.64

20 366.74 359.25
7.49

1.2 CASE 2
In the second case, and for the purpose of improving heat transfer to the
atmosphere, the shape of the fins was changed to be concave instead of
rectangular , and repeated the simulation by ANSYS 2021 R2 at same
boundary condition for fin 5 with length fin (5,10,15,20 )mm It was found that
the temperature of the fin5 L 5mm , 122.56 °C (395.71 K) ,107.49 C° (380.64
K),for Fin 5 L 10 mm ,95.17 C° (368.32 K) for Fin5 L 15 mm and 85.1 C°
(359.25K) for Fin5 L 20 mm by comparing the results, it was found that the
temperature of the concave fin5 with length of 5 mm at the tip fin (minimum
temperature) was less than the temperature of the rectangular fin5 also at tip fin .
That’s mean the new shape for (concave fin) is batter than the rectangular fin
shape by (1.63)K and the percentage of (1.3)% .as shown in figure 15 ,16 and
Table 4

58
Fig .15 comparing between Temperature at tip rectangular fin 5 and concave fin5 .

Fig.16 Temperature distribution in concave fin 5

59
Table 5 Comparing rectangular fin and concave fin
Case 2 fin5

Length of fin Minimum temperature (K) Minimum temperature(K)

Temperature(k) (mm )
at tip fin ( concave ) at tip fin ( rectangular)
difference

5 395.71 397.34
1.63

10 380.64 381.34
0.70

15 368.32 369. 2
0.98

20 359.25 359.95
0.70

and we note when we increase the number of fins to 7,9,11 fins with
length fins (5 mm) we found enhancement in the temperature at tip fins 111.8 C°
(384.95)K,99.34 C° (372.49)K,93.36 C° (366.51)K.

1.3 CASE 3
Simulations were repeated for the same fin under the same conditions, with changing
the type of metal from Aluminum to Aluminum Alloy there's found the Temperature its
154.32 C° (429.47 K) . The simulation was also repeated for the same fin under the same
conditions, with changing the distance between the fins from (20mm) to (15 mm) and the
result was 158.54 C° (431.69) K. Also re-simulating the same fin with changing the ambient
temperature to 35 C° (301.15) K and the result its been 156.28 C° (429.43) K the result of this
simulations explain the change in material is not useful in this case and also the change in
ambient temperature this is normal are shown in the table4. The figure also represents a
comparison of the results .

60
Fig .17 Result of fin5 concave with changing ,material ,distance, Temperature ambient

Fig.18 Temperature distribution in concave fin 5 (changing ambient Temperature.

61
Table 6 Result of fin5 concave with changing, material, distance, Temperature
ambient
Case 3 fin5 concave

Length of fin (mm) Minimum Temperature (K)

change shape change material change distance change Tem. ambient

5 395.71 417.03 427.88

418.56

10 380.64 409.64 413.85 407.99

15 368.32 398.76 404.43

398.65

20 359.25 377.32 396.9 389.64

1.4 CASE 4
simulation was made for an electric motor with different distances
between the fins. The fins were rectangular. The distance was chosen according
to the following law

N=Δ/ξ+1

When distance between fins is 20 mm the number of fins is 5 and the

temperature at the tip fin is 124.19 C° (397.34K) and When we decrease the
distance to (12 mm) between the fins the number of fins becomes 7 fins then the
simulation its worked we recorded this result 105.85 C °(379K) while recorded
this result 101.61 C° (374.76 K) when the distance between the fins is (9 mm)
and the fins becomes 9 fins this result are shown in table5 and figure 19 shows
results . we notce when we chang the distance between the fins for rectangular
fins the numer of fins will increse to 7 fins with distance (12mm) and to 9 fins
with distance (9mm) the temperature at the tip fin will inhanchcment but the
weight of motor will increase that’s lead to increase in the cost of the electric
motors.

62
Fig .19 Relation between temperatue at tip fin and distance between fins

Fig.20 Temperature distribution in rectangular fin 7 (changing distance between fins 12mm)

63
Table 7 Relation between temperatuer at tip fin and distance between
fins(rectangular)
Case 4

N0. of fins Maximum temperature (K) Minimum temperature(K)

at tip fin ( rectangular ) at tip fin ( rectangular)

5 400.97 397. 34

7 382.85
379.00

9 376.72
374.76

The last comparison its between rectangular fins,5,7,9,11 with

length( 5,10,15,20 )mm figure 21 and table 7 explained the relation between
them .and we shown when increase the number of fins the effectiveness and
volume of fins are increased and maximum temperature at the tip fin decreased
but the efficiency of the fins is decreased gradually .the overall weight of the
motor is amplified due to higher number of fins.

Fig.21 comparison between Temperature at tip fins 5,7,9,11

64
Table 8 comparison between Temperature at tip fins 5,7,9,11
Length of fin Maximum temperature(k) maximum temperature (k) maximum temperature (k) maximum temperature (k)

rectangular (mm) at tip fin 5 at tip fin 7 at tip fin 9 at tip fin 11

5 397.34 382.95 372.49 366.51

10 380.64 372.75 362.8 351.27

15 368.32 385.73 350.6 340.33

20 359.25 345. 7 338.54 334.42

Also we shown when increase the number of fins the effectiveness and
volume of fins are increased and maximum temperature at the tip fin decreased
but the efficiency of the fins is decreased gradually .the overall weight of the
motor is amplified due to higher number of fins.as shown in figure 22 and Table
8.

Fig. 22 The effectiveness of variable number of fins

65
Table 9 The effectiveness of variable number of fins
Number of rectangular fins effectiveness

5 24.077339210579

7 24.9712543890111

9 27.1952259164535

11 29.715218036191

Fig. 23 The efficiency of variable length of fins.

66
Table 10 The efficiency of variable length of fins
Length of rectangular fins efficiency %

5 99.52

10 99.5

15 99.1

20 98.5

67
Chapter5
Conclusion and Suggestions for Future studies
Electrical motors are used in a wide variety of applications, from
household appliances to industrial machinery. As the demand for electrical
motors continues to grow, it is important to find ways to improve their
efficiency and reduce their environmental impact. One way to do this is to
reduce the temperature of the motor.

Methods
The temperature of an electrical motor can be reduced by a number of
factors, including the shape of the fins, the material of the fins, the distance
between the fins, and the environment , we investigated the effects of these
factors on the reduction of temperature We conducted a series of calculations
and simulations to determine the impact of each factor. We used a base case
model of an electrical motor with rectangular fins made of Aluminum. We then
changed the shape of the fins to concave, the material of the fins to Aluminum
Alloy ,the distance between the fins, and the environment temperature.

Results
The results showed that the distance between the fins and the shape of
the fins had the good impact on the reduction of temperature. Changing the
shape of the fins from rectangular to Concave with the same fin length resulted
in a 1.63 K reduction in temperature. Changing the distance between of the fins
from 20 mm to (12 ,9)mm with the same fin length resulted in a (18,3.34) K
reduction in temperature This is a significant reduction, and it shows the
distance between the fins and the shape of the fins is a very important factor in
reducing the temperature of an electrical motor. When we changing the material
of fins there was not affected for reduction temperature also Operating the
motor in a hot environment that’s its normally.

68
Conclusion
The results show that the distance between the fins and the shape of the fins is
the most important factor in reducing the temperature of an electrical motor. The
material of the fins, it's not affected on the reduction of temperature, also
Operating the motor in a hot environment that’s its normally.

Recommendations
Based on the results of this study, the following recommendations can be
made:

 The shape of the fins should be changed from rectangular to concave shape.
 The distance between fins should be minimized, with increase number of
fins. The material of the fins should be changed to a material with a higher
thermal conductivity.
 The motor should be operated in a cooler environment.
 By following these recommendations, it is possible to reduce the
temperature of an electrical motor . This reduction in temperature can lead to
a number of benefits, including increased efficiency, reduced wear and tear,
and extended lifespan.

Limitations
This study was limited by a number of factors, including the following:

The study was carried out through simulation in ANSYS program, and the
results may not be generalizable to real-world applications.

The study only investigated a limited number of factors, and it is possible

that other factors may also have an impact on the reduction of temperature. The
study was conducted over a short period of time, and it is possible that the
results may not be sustained over a longer period of time. Despite these
limitations, the results of this study provide valuable insights into the factors that

69
can be used to reduce the temperature of an electrical motor. Further research
is needed to investigate the effects of other factors on the reduction of
temperature, and to confirm the results of this study over a longer period of time
also changing the thickness of fin.

70
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