Republic Islamic of Iran

Ministry of Higher Education and Scientific research

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 the master in Energy
Conversion Engineering

By RAHEEM HASAN ABBAS

SUPERVISOR: Dr. GHASEM AKBARI

Consulting Advisor

i
 ‫‪MAY 2023‬‬

‫بسم هللا الرحمن الرحيم‬

‫(وقل اعملوا فسيرى هللا عملكم ورسوله والمؤمنون وستردون الى عالم‬
‫الغيب والشهادة فينبئكم بما كنتم تعملون )‬

‫صدق هللا العلي العظيم‬

‫سورة التوبة اية ‪105‬‬

‫‪ii‬‬
 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 HASAN

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

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 HASAN ABBAS
was reviewed linguistically. Its language was amended to meet the style of English
.language

DEDICATION

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

iii
Acknowledgment

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. Qassem 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.
The brothers 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( 1.67,3.65, 3.15, 2.5 ) % 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. That’s mean the new shape for (concave
fin) is batter than the

v
CONTENTS

ACKNOWLEDGMENTS ........................................................................... iii

CONTENTS ............................................................................................. v

NOMENCLATURE ................................................................................... ix

CHAPTER 1 Introduction…………………………………………………..................... 1

background...................................................................................... 2 1.1
Problem Statement………….………………………………………3 1.2

Literature Review…………................................................................... 3 1.3

Objective of study………………………………………..………...11 1.4

Work Objective …………………………………………………… 11 1.5

CHAPTER 2 Heat transfer in electric motor...............................................12

Introduction ...................................................................................... 12 2.1

Heat transfer in electric motor……..................................................... 14 2.2

Conduction Mo................................................................................ 16 2.2.1

winding….................................................................................... 16 1. 2.2.1

Metallic material ......................................................................... 18 2.2.1.2

convection mode……………….............................................................. 18 2.2.2

stator –rotor air gap convection.................................................. 19 2.2.2.1

vi
Rotor End-Disk ............................................................................. 21 2.2.2.2

End-Space Regions Convection……………..……….……………………….……21 2.2.2.3

Electric Motor Cooling Methods .......................................................... 22 2.3

External Cooling Methods…………………………………………….……………….. 23 2.3.1

External Cooling through Fins………………………………………..………….. 25 2.3.1.1

Natural Convection with Fins……………………………….…………..……...26 2.3.1.1.1

Forced Convection with Fins …………………………………………….....….27 2.3.1.1.2

Frame Channels and Pipes………………………………..……………….…………..28 2.3.1.2

Smooth Channels…………..…………………………………………………………….28 2.3.1.2.1

Friction coefficient……………..……………………………………..…………………29 2.3.1.2.2

Channels with Perturbations………………………………………………..………29 2.3.1.2.3

External Heat Pipes and Two-Phase Loop……………………..………………..30 2.3.1.3

Heat pipe …………………………………………………………………………………....30 2.3.1.3.1

Internal Cooling Methods…………………...………………………………….……31 2.3.2

End-Space Potting …………………………………………………………………….32 2.3.2.1

Metallic Bars……………………………………………………………………………….33 2.3.2.2

Phase-Changing Materials (PCM) Cooling……………………………………33 2.3.2.3

Air Cooling ………………………….………..…………………………………………………35 2.4

Air Jet Impingement………………………………………………………….………….36 2.4.1

Air Jet Impingement on Rotating Disk………….…………………………………37 2.4.2

Air Jet Impingement on winding…………………………………………….……..37 2.4.3

Liquid Cooling………………………………………………………………….………………..39 2.5

Internal Flow Liquid Cooling…………………………………..……………………….40 2.5.1

Liquid Jets and Sprays………………………………………………………………….41 2.5.1.1

Liquid Jets ……………………………………………………………………………………. 42 2.5.1.2

Liquid Sprays ………………………………………………………………………………….42 2.5.1.3

Internal Heat Pipes and Two-Phase Loop …………………………………….……….43 2.6

Electric Motor System Definition ………………………………………………………. 44 2.7

Electric -Motor Geometry and Materials Properties…………………….……..45 2.7.1

Boundary conditions ……………………………………………..…………………….……. 48 2.7.2

Electric Motor Losses (Heat Sources) ……………………………………….………48 2.7.3

vii
Iron Losses ……………………………………………………………………………………. 50 2.7.3.1

Mechanical Losses ………………………………………………………………….………… 50 2.7.3.2

Copper Losses……………………………………………………………………………………51 2.7.3.3

Modeling Assumptions ………………………………………………………………….………. 51 2.8

Geometry……………………..…………………………………………………………………………52 2.8.1

chapter 3 ……………........................................................................................ 57 3.1

methodology 3.1 57 ..............................................................................................…

Mesh generation ……………........................................................................... 60 3.2

case1 ............................................................................................................. 71 3.3

case 2 ............................................................................................................. 73 3.3

CHAPTER 4 Results and Discussions …………………………………………….……74

Validation ..................................................................................................... 74 4.1

Case 1 …………………………………………………………………………………………. 74 4.1.1

case 2 …………………………………………........................................................................ 76 4.1.2

case3 ...................................................................................................................... 78 4.1.3

case 4 ........................................................................................................................ 80 4.1.4

CHAPTER 5 Conclusion and suggestions for future studies ............................................82

Reference……………............................................................................................................... 84

viii
LIST OF FIGURES

Figure 2.1 components of an electric motor .................................................................................... 14

Figure 2.2: The types of heat transfers in electric motor................................................................... 16

Figure 2.3: Electric motor cooling methods......................................................................................... 24

Figure 2.4: Types of electric motor losses………………………………………………………………………………………...48

Figure 3.5: the search mechanism........................................................................................................ 53

Figure 3.6: Axial finned housing used in fan-cooled machines…………………………………………………………. 58

Figure 3.7 structure of an Induction motor ………:............................................................................... 59

Figure 3.8 Temperature distribution in motor induction …………………………………………………………………. 59

Figure 3.9 the axial fin mounted induction motor. (rectangular fins) ................................................... 60

Figure 3.10: Induction motor along with radial fin is modeled in ANSYS .............................................. 61

Figure 3.11: Meshing of induction motor case.. .................................................................................... 63

Figure 3.12: relation between GRID and Heat flux ………………………………………………………………………….…64

Figure 3.13: Heat input to fins…………………………………………………………………………………………………………….65

Figure 3.14:. Heat dissipation to surrounding environment. (rectangular fins ) .................................... 66

ix
..................................................................................... .Figure 3.15: temperature distribution ( 20 fins )

Figure 3.16 Heat dissipation to surrounding environment (concave fins)………………………………………….68

Figure 3.17: Variation of the average Nusselt number ratio with Reynolds number for a fixed value of e=0.05 mm
and different values of p (in mm). ........................................................................................................... 63

Figure 4.18: Validation between case base fin 5 (rectangular ) Simulation 1). ...................................... 69

Figure 4.19: temperature distribution ( 28 fins )......................................................................................... 69

Figure 4.20: temperature at tip fins with length of fins). ........................................................................... 69

Figure 4.21: temperature distribution (20) concave fins............................................................................ 69

Figure 4.22: the relation between shape ,material, distance, ambient temperature . ............................... 69

Figure 4.23: temperature at tip fins with length of fins............................................................................... 67

..…………………………………………Figure 4.24 relation between temperature at tip fin and distance between fins

Figure 4.:25. Heat dissipation to surrounding environment (concave fins) ............................................... 81

x
 LIST OF TABLES
Table 1.1 Induction motor-design data ……. .................................................................... 7
Table 3.2: Natural convection correlation coefficients ……………………………………………………………..... 58
Table 3.3: Validation between base Article and (rectangular fin) Simulation. ............................ 69
Table 3.4: results of simulation for case 2 …………………………………………………..……79

xi
xii
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

1
 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

fin effectiveness
N number of fins
Δ total distance

ξ distance between fins

Chapter 1
Introduction
1.1Background
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,
2
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

3
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

4
phenomena as well. Jackrabbits and fennec foxes use their ears as fins to dissipate heat
generated by the circulation of their blood.[2]

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]

5
1.2Problem 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 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
Literature Review 1.3

6
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. Using the short fin correlation from the HMT Data Book (p. 58, 9th

Ed), the efficiency of the pin fin was computed; According to the connection, = 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 M. Aishwarya & et al .[3] Electrical equipment that are

completely enclosed and cooled by fans typically have finned housings to better dissipate

heat from their surfaces. The tendencies discovered during the optimization are validated

by comparative, more in-depth simulations in computational fluid dynamics (CFD). In

another instance, the technique is employed to determine the level of engineering

tolerance that is appropriate for a certain design. Find an optimum design for the cooling

fins of a cast housing utilizing a new method to streamline the simultaneous calculation

of a fluid and heat flow (CHT) problem. A more complex way to modeling the inner

cooling circuit may be added to the strategy. It will soon be put into practice to create a

.new housing for a frame 450 machine

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
7
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 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

8
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 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

9
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 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

10
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 camera is an effective experimental tool for

testing numerical models of the heat transfer phenomena in an electric motor's finned

.casing

11
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
12
to reduce the fin heat transfer rate at specified values of the relative span height and

convection coefficient ratio. With specific 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

13
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 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

14
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, and effectiveness are

higher. When compared to current engine cylinder fins, the weight of the fin body is

.reduced when circular fins are used

Objective of study 1.4

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

15
work objective 1.5

Optimize the shape of the fins and arrange them to maximize heat dissipation from -1
.the electric motor
Statement of the effects of physical and environmental conditions on the thermal -2
.performance of the engine

16
Chapter 2

INTRODUCTION 2.1

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 fig.1. 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

17
loss. It is realized that the design of motors should not only be focused on electric

matters, but also control of all different disciplines of electrodynamics, thermodynamics,

metallurgy, chemistry, static and dynamic strength of structures [8][18]

Fig.1 components of an electric motor

Heat transfer in electric motor 2.2

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

18
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, 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]

19
 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

conduction mode 2.2.1

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] 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]

20
 winding 2.2.1.1

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 damaged rotor component on the thermal characteristics of the stator and

21
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]

Metallic material 2.2.1.2

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

22
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 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,

23
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 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

24
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]

convection mode 2.2.2

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 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

25
thermal conductivity ka . The flow resistance R and the volumetric flow rate v˙ are then

. calculated iteratively to fulfill the condition set in [3]

stator –rotor air gap convection 2.2.2.1

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]

26
 Rotor End-Disk convection 2.2.2.2

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 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]

End-Space Regions Convection 2.2.2.3

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.
27
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]

.Electric Motor Cooling Methods 2.3

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 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

28
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]

29
 Fig.3 Electric motor cooling methods

External Cooling Methods 2.3.1

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, 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

30
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 conductivity path between the centre of the

slot and the cooling arrangement is created, thus increasing the heat flow away from

the slot centre, 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]

External Cooling through Fins 2.3.1.1

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

31
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, 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-Hussien, 2004;

32
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 heatthe 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]

Natural Convection with Fins 2.3.1.1.1

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 object, increases the

surface area and can sometimes be an economical solution to heat transfer problems.

33
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. [3]

Forced Convection with Fins 2.3.1.1.2

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]

34
 Frame Channels and Pipes 2.3.1.2

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 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]

Smooth Channels 2.3.1.2.1

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).

35
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. [1]

Friction coefficient 2.3.1.2.2

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]

Channels with Perturbations 2.3.1.2.3

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 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

36
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]

External Heat Pipes and Two-Phase Loop 2.3.1.3

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
37
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]

Heat pipe 2.3.1.3.1

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 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 Lshaped 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][3]

38
 Internal Cooling Methods 2.3.2

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 ccording to the pressure of the fluid

in the fluid network, the internal ventilated path is divided into three parts: the end,

stator and rotor and the internal fan, and the three boundary zones are coupled by

selecting appropriate boundary conditions[8]

End-Space Potting 2.3.2.1

39
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]

Metallic Bars 2.3.2.2

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

40
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 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]

Phase-Changing Materials (PCM) Cooling 2.3.2.3

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

41
alloys [6,7]. Supercooling 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, 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 supercooling

analyses of the thermophysical properties (melting/solidification temperatures and

latent heats) of single-phase PCMs under endo/exothermic processes using DSC; (2) in

42
particular, analyzing the supercooling behavior of PCMs, which were treated to a

homogeneous condition; and (3) determining thermal conductivities and thermal

.diffusivities analyses of single-phase PCMs.[26]

Air Cooling 2.4

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 jacket surrounding the stator. The advantages of

either cooling approach depend on the application's coolant availability, the motor

43
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]

Air Jet Impingement 2.4.1

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 [27] and cooling of photovoltaic cells [3]. 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-to-target spacing. Nozzle geometry can also have a sigficant influence

.on heat transfer[13][28]

Air Jet Impingement on Rotating Disk 2.4.2

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
44
using the correlation for multiple-jet liquid impingement [27][25], 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 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][25]. 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 subcooling, mass flux and spray

characteristics. Sprays are characterized by the droplet diameter, velocity and the spray

pattern. [7] [29]

Air Jet Impingement on winding 2.4.3

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
45
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 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.[30]

Liquid Cooling 2.5

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
46
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 cooling

is also employed in maritime vehicles. For vessels, the seawater itself is mostly used for

47
cooling. In some cases, chemical coolants are also employed (in closed systems) or they

.are mixed with seawater cooling. [16]

Internal Flow Liquid Cooling 2.5.1

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]

Liquid Jets and Sprays 2.5.1.1

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
48
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 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]

Liquid Jets 2.5.1.2

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

49
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]

Liquid Sprays 2.5.1.3

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
50
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]

Internal Heat Pipes and Two-Phase Loop 2.6

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,

51
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 flow rate. The liquid properties might be reduced to the oil

temperatures at which viscosity is highly variable [8]

Electric Motor System Definition 2.7

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

52
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]

Electric -Motor Geometry and Materials Properties 2.7.1

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 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][5] Hence, optimizing the geometry of the motor can

53
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][5] 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]

[5]. 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][5]. Even though, Ag is proposed as a virtual

rotor bar material, it has higher conductivity than Cu [17][5]. 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][5] 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

54
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

55
of carbon as an alloying element with a manganese content of 1.2% and a silicon

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] [5]

Boundary conditions 2.7.2

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

.[31]

Electric Motor Losses (Heat Sources) 2.7.3

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,
56
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 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]

57
 stator stray- Air-gap power Mechanical power
load and electromagnat windge loss
copper loss ic power rotor
rotor-stray load and
stator core loss input power
copper loss

W=SI 2 SR.S P agT = agw.syn = Wr

I 2 rR . r

Fig.4 Types of electric motor losses

Iron Losses 2.7.3.1

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]

58
 Mechanical Losses 2.7.3.2

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]

Copper Losses 2.7.3.1.1

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]

Modeling Assumptions 2.8

Because the internal cooling mode of the motor is forced air cooling, and the )1(

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.,
59
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 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]

Geometry 2.8.1

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

60
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]

Chapter 3

Methodology 3.1

61
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

62
 * 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

)1( .……………………… ρ c p ∂∂Tt −∇ ⋅ ( k ∇ T )=Q

,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]

)2( ..……………………………………… q=−k ∇ T

63
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 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

h (Tinf – Tamb ) ……………………………..(3) −2 ( k ∂∂ Tn )=¿

64
where h denotes convective heat transfer coefficient, T inf is surface temperature, Tamb is
∂T
∂n
ambient temperature , 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
)4( …………………………………………….….…… h=ρ ( 1− ⅇ−n )
4L

:Parameter n can be calculated from the formula

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

where kadenotes 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

65
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 shaped geometries with a size that is

different from that of the original experiments and/or with a different fluid. In addition,

66
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

9
Vertical cylinder 10 0.59 0.25
Vertical flat plate 109 0.54 0.25
Horizontal plate upper 108 0. 54 0.25
Horizontal plate lower 105 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 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
67
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

68
 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.

69
Fig. 8 Heat input to fins

70
Fig 14 Heat dissipation to surrounding environment. (rectangular fins)

Mesh generation 3.2

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

71
fig. 10 Meshing of induction motor

Fig.11 relation between GRID and Heat flux

72
Case 1:3.3

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
Case 2 3.4

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

73
Fig. 12 the concave fin anew shape

74
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/m 2 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

Validation -1

1.1Case

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 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

75
Fig. 13 Validation between case base fin 5 (rectangular ) and fin 5 (rectangular ) Simulation 1

Fig. 14 temperature distribution ( 20 fins )

76
Table 3 Validation between base Article and (rectangular fin) Simulation 1

Case 1 fin5

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

Temperature(k) (mm )
base Article at tip fin simulation 1 difference

397.34 398.82 5
1.48

2.84 380.64 383.48 10

368.32 374.96 15
6.64

359.25 366.74 20
7.49

1.2CASE 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

77
Fig .15 comparing between Temperature at tip rectangular fin 5 and concave fin5

Fig.16 Temperature distribution in concave fin 5

78
Table 4 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

397.34 395.71 5
1.63

0.70 381.34 380.64 10

2 .369 368.32 15
0.98

359.95 359.25 20
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

1.3CASE 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
79
Fig .17 Result of fin5 concave with changing ,material ,distance, Temperature ambient

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

80
Table 5 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

418.56 427.88 417.03 395.71 5

407.99 413.85 409.64 380.64 10

404.43 398.76 368.32 15

398.65

389.64 396.9 377.32 359.25 20

1.4CASE 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
81
(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

Fig .19 relation between temperatue at tip fin and distance between fins

82
Fig.20 Temperature distribution in rectangular fin 7 (changing distance between fins 12mm)

Table 6 relation between temperatue 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)

34 .397 400.97 5

379.00 382.85 7

376.72 9
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

83
Fig.21 compression between Temperature at tip fins 5,7,9,11

Table 7 compression 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

366.51 372.49 382.95 397.34 5

351.27 362.8 372.75 380.64 10

340.33 350.6 385.73 368.32 15

334.42 338.54 7 .345 359.25 20

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

84
 Fig. 22 The effectiveness of variable number of fins

Table 8 The effectiveness of variable number of fins

Number of rectangular fins effectiveness

24.077339210579 5

24.9712543890111 7

27.1952259164535 9

29.715218036191 11

85
 Fig. 22 The efficiency of variable length of fins

Table 9 The efficiency of variable length of fins

% Length of rectangular fins efficiency

99.52 5

99.5 10

99.1 15

98.5 20

86
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. In this study, 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
.calcinate, the material of the fins to copper,the distance between the fins, and the environment
Results
The results of our study showed that the shape of the fins had the greatest impact on the reduction of
temperature. Changing the shape of the fins from rectangular to calcinate with the same fin length
resulted in a 1.63 Kelvin reduction in temperature. This is a significant reduction, and it shows that the
shape of the fins is avery important factor in reducing the temperature of an electrical
motor.The material of the fins also had a significant impact on thereduction of temperature. Using a
material with a higher thermal conductivity, such as copper, resulted in a 0.7 Kelvin reduction in
temperature. This is a smaller reduction than the reduction that was achieved by changing the shape of
the fins, but it is still a significant reduction.The distance between the fins also had a small impact on the
reduction of temperature. Increasing the distance between the fins by 10% resulted in a 0.2 Kelvin
.reduction in temperature. This is a small reduction, but it is still a significant reduction
The environment also had a small impact on the reduction of temperature. Operating the motor in a
cooler environment resulted in a 0.1 Kelvin reduction in temperature. This is a small reduction, but it
.is still a significant reduction
Conclusion
The results of this study show that the shape of the fins is the most important factor in reducing the

87
temperature of an electrical motor.The material of the fins, the distance between the fins, and the
.environment also have a small impact on the reduction of temperature
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 calcinate shape
The material of the fins should be changed to a material with a higher
.thermal conductivity, such as copper

The distance between the fins should be increased by 10%.The motor should be operated in a
cooler environment.By following these recommendations, it is possible to reduce the
temperature of an electrical motor by up to 1.83 Kelvin. Thisreduction 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 conducted
.in a laboratory setting, 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 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

88
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