GRD Journals- Global Research and Development Journal for Engineering | Volume 5 | Issue 6 | May 2020 ISSN- 2455-5703
Flow and Thermal Analysis of a Two Pole TETV Motor using CFD Sireesha Baile Senior Engineer COE-Computational Fluid Dynamics Lab, Corporate R & D Bharat Heavy Electricals Limited
Pavitran Dynampally Deputy Manager COE-Computational Fluid Dynamics Lab, Corporate R & D Bharat Heavy Electricals Limited
Abstract Ventilation studies in Motors with complicated geometry are generally carried out with analytical methods during design stage. However, analytical methods do not provide comprehensive information of flow and temperature fields inside the motor at a system level. Therefore, CFD techniques are being extensively employed by motor manufacturers to analyze motor cooling systems. In the present work, Flow & Heat transfer analysis of Totally Enclosed Tube Ventilated (TETV) motor was carried out using ANSYS CFX. The complete fluid domain was modelled and heat loss data was defined on heat generating components. The ventilation flow circuit and calculated temperatures on critical components have been studied and end winding temperatures are compared with physical test data. The CFD results were within 5% of the tested data. Keywords- Motors, CFD, Computational Fluid Dynamics, Thermal Analysis, Electrical Machines
I. INTRODUCTION Modern electric motors have more complicated mechanical and electromagnetic structures over conventional motors for gaining better performance, higher operation reliability and efficiency. The improvements are being primarily aided by modern simulation tools and high performance computers. Computational Fluid Dynamics (CFD) techniques are being extensively used for this purpose. As motor designs and processes grow in sophistication, motor-cooling problems have become too complex to solve analytically. This led engineers to perform numerical simulations to gain insight into the details of fluid flow and heat transfer processes in motors [1]. T.Bäuml et al. [2] presented the thermal simulation models for a totally enclosed fan cooled induction machine using thermal equivalent circuits. As motor manufacturers are targeting to make motors compact, heat generation problems in electric motors increased. Limited cooling capabilities cause degradations of the motor performance and operation reliability. CFD has played an important role to understand and overcome these problems by aiding designer to gain detailed insights of physical aspects of motor cooling. The flow fields and temperature distributions even in the most inaccessible locations of a complex motor geometry parts can now be quantified and visualised from the detailed results of CFD simulation [1]. Most of the previous studies in the ventilation and cooling of the motors have been carried out on a section of the parts. The rotor and stator parts are analysed separately by considering a sector by applying symmetry and periodic boundary conditions [3]. Sector analysis was primarily done due to meshing and computational time constraints [4]. Similar methodologies have been used by various researchers to carry out the ventilation studies in electrical machines [4-17]. Marco et al. [5] carried out thermal analysis by considering a 60° sector for a PM machine using STAR CCM+. Maxmilian et al. [6] conducted heat transfer studies based on CFD inside electrical machines by taking a section of the stator and applying periodic boundary conditions. Shanel et al. [7] has carried out thermal analysis on a 90° sector citing to computational limitations. Unai et al. [8] presented a review for thermal design and analysis of electrical machines using different tools. The ability of CFD tools to simulate fluid flow and heat transfer for overall machines is emphasized. Anderson et al. [9] has carried out CFD study of forced air cooling and windage losses in a high speed electric motor. Complete 360° model was considered for the analysis, however, only flow analysis was carried out. Lukasz et al. [10] carried out CFD analysis in an electric motor by considering one quarter of the model and making many geometric simplifications such as modelling end winding region as a torus, not modelling the air gaps in the rotor, etc., Pirooz et al. [11] presented a predictive CFD approach assessed for the flow of cooling air in a generator by considering a one half sector of the model. Hettegger [12] performed CFD simulations on an electrical machine by considering 1/8th of the rotor model, 1/10th of the stator and stator end windings. D.-D.Dang et al. [13] carried out a CFD analysis in a hydro generator rotor-stator system with a simplified model of 20° sector for the rotating domain and 5° sector for stationary domain Maximilian et al. [14] performed numerical analysis of heat transfer and flow of one periodic stator duct model. Moradnia et al. [15] in his work discussed the flow analysis in an electric generator model, performing simulations on a half scale model. Kral et al. [16] compared two methods of numerical analysis for a totally enclosed fan-cooled induction machine. In the present work, flow and heat transfer studies in a two pole “Totally Enclosed Tube Ventilated (TETV)” motor is performed using CFD by considering the entire motor (360°). Complete motor analysis is carried out to avoid the inherent uncertainties involved with sector analysis. Moreover, the advancements in computational hardware and improvements in commercial CFD solvers have enabled to analyse the entire motor [17].
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