EJ2210 Analysis of Electrical Machines

Lecture 6I
Oskar Wallmark
Associate Professor, PhD
Laboratory of Electrical Energy Conversion
Royal Institute of Technology
Stockholm, Sweden
May 4, 2012
Outline I
Insulation Classes and Temperature Limits
Introduction to Thermal Modeling of Electric Machinery
Heat Transfer
LP Thermal Models
Insulation Classes and Temperature Limits

Standard motors are normally designed for a maximal ambient

temperature of 40

C.

Temperature typically measured in

C and temperature
dierence measured in K.
Insulation Classes and Temperature Limits

Denition of stall time:

Time for the rotor or stator to reach a limiting temperature

while the rotor is at standstill.

For shaft heights less than 200 mm, the stator typically
reaches a temperature limit rst.

For shaft heights larger than 200 mm, the rotor typically
reaches a temperature limit rst.
Brostroms Formula

Empirical based formula for calculating steady state rotor and

stator temperatures.

The temperature rise in the stator

s
is approximated as

s
= K
cs
_
P
Cu,1
(P
Cu,1
+ P
Cu,2
+ P
Fe
). (1)

Eq. (1) can be solved by iteration in order to consider

temperature dependency of the stator resistance.

The temperature rise in the rotor

r
is approximated as

r
= K
cr
_
P
Cu,2
(P
Cu,1
+ P
Cu,2
+ P
Fe
).

K
cs
and K
cr
are empirically based cooling constants.
Heat Transfer

Heat can transfer in and between dierent mediums through:

Thermal conduction.

Thermal convection.

Thermal radiation.
Thermal Conduction

Thermal motion diusing through the substance.

The substance can be in solid, liquid or gas form.

Fouriers law (empirically based) states that

q

= T (2)
where q

is the heat ux vector (W/m

2
) and is the thermal
heat conductivity (W/(mK)).

If the heat is transferred the distance l in the x-direction only

and through the area A, from temperature T
1
to temperature
T
2
, we have from (2)
q

x
=
P
A
=
T
x

T
2
T
1
l
(3)
where P is the heat rate in the x-direction (W).
Thermal Conduction

Eq. (3) can be re-expressed as

P =
T
1
T
2
R
where R =
l
A
is referred to as the thermal resistance
(compare with electrical circuits).

Also, the material is characterized by the specic heat

capacity c (Ws/(kgK)) which is a measure of how much
energy is required to increase 1 kg of the material with 1 K.
Thermal Conduction

Here C =Vc where V is the volume (m

3
), the density
(kg/m
3
).

Note that the heat was not generated within the body. We
will soon see how that case will be tackled.
Thermal Conduction

Thermal conduction governed by the heat equation.

The heat equation is obtained by combining Fouriers law with

the principle of energy conservation.

For a constant , the heat equation can be expressed as

c

T
t
=
2
T +
q

where is the material density (kg/m

3
), c the specic heat
capacity (Ws/(kgK)) and q the internally generated power
density (W/m
3
).

Recall that
2
T =

2
T
x
2
+

2
T
y
2
+

2
T
z
2
is cartesian
coordinates.
Thermal Convection

Convection is when heat is transferred between a surface and

a uid due to intermingling of the uid immediately adjacent
to the surface with the remainder of the uid due to uid
motion.

Newtons law of cooling states that

P = A
cool
(T
1
T
2
)
where is the heat transfer coecient (W/(m
2
K)), A
cool
the
cooling cross sectional area (m
2
), T
1
the temperature of the
object (K) and T
2
the uid temperature (K).
Thermal Convection

Hence, thermal convection can also be modeled by

introducing the thermal resistance R=1/(A
cool
) (K/W).

depends on several factors including shape and dimensions

of the ow channel and whether the ow is laminar or
turbulent.
Thermal Radiation

Heat can also be transferred by radiation (heat transfer from

sun to earth ).

Thermal radiation can also be modeled as a (non linear)

thermal resistance.

Radiation is generally a minor source of heat transfer in

electric machinery.
LP Thermal Models

The LP thermal models now presented are very simplied

Simple to implement.

Requires calibration with experimental data.

Reduced validity far away from operating points calibrated

with experimental data.
LP Thermal Models Stator Winding

A simple model for predicting the steady-state stator

temperature T
1
is shown below.
P
1
= P
cu1
+ 0.2 (P
h
+ P
stray
)
P
2
= P
cu2
P
3
= P
fe
+ 0.8 (P
h
+ P
stray
)
Here, P
h
is the total harmonic losses (W) and P
stray
is the
total stray losses (W).
LP Thermal Models Stator Winding

The stator temperature is found as

T
1
= P
1
R
1
+ (P
1
+ P
2
+ P
3
) R
x
n
0.78
(4)
where n is the rotor speed (rpm) and the exponent 0.78 is
(often) applicable for motors equipped with shaft mounted
fans.

The resistances R
1
and R
x
can be deduced by applying (4) on
two test with dierent loss conditions.

Compare with Brostr oms formula

T
1
= K
cs
_
P
cu1
(P
cu1
+ P
cu2
+ P
fe
).
LP Thermal Models Rotor Temperature

For shaft heights larger than 200 mm, the stall time is
typically limited by the rotor overheating.

Heat is transferred both radially and axially (relatively

complicated).

A relatively simple method for predicting the rotor

temperatures (as function of time) will be presented now.

Assumption 1: No heat is transferred to the ambient air.

Assumption 2: No heat is transferred to the shaft.

LP Thermal Models Rotor Temperature

1 : Short circuit ring and end of rotor bars.

2 : Rotor bars (width b

c
, height h
c
).

3 : Rotor teeth + a ring under the teeth.

4 : Rotor back.
LP Thermal Models Rotor Temperature

Simplied thermal network:

Note that the thermal resistances in the circuit are computed

as R
12
=Y
1
12
, R
23
=Y
1
23
and R
34
=Y
1
34
.

Warning! This model was conceptually challenging for the

lecturer (recall that the heat transfer is two-dimensional)!
LP Thermal Models Rotor Temperature

P
bar
=3
2
R
bar
I
2
21

is the impedance reduction factor between the stator and

rotor (eq. (4.16) in the course book).

R
bar
is the bar resistance (eq. (4.7) in the course book).

21
is the rotor current reduced to the stator side.

Note the typos in eqs. (6.10)(6.11) in the course book!

P
SCR
=P
cu2
3
2
R
bar
I
2
21
.
LP Thermal Models Rotor Temperature

Dynamic system (

T =dT/dt):

T
1
=
P
SCR
+ (T
2
T
1
)Y
12
C
1
(5)

T
2
=
P
bar
+ (T
1
T
2
)Y
12
+ (T
3
T
2
)Y
23
C
2
(6)

T
3
=
(T
2
T
3
)Y
23
+ (T
4
T
3
)Y
34
C
3
(7)

T
4
=
(T
3
T
4
)Y
34
C
4
. (8)

Eqs. (5)(8) can be easily solved in Matlab (compare with

Task 2).
LP Thermal Models Rotor Temperature

Thermal capacitances C
1
C
4
are relatively easy to compute
from C = V c.

Region 1 : Short circuit ring and end of rotor bars:

C
1
= 2 (D
SCR
A
SCR

SCR
c
SCR
+ l
y
A
bar

bar
c
bar
Q
r
) .

Region 2 : Rotor bars:

C
2
= (L
bar
2l
y
) A
bar

bar
c
bar
Q
r
.
Region 3 : Rotor teeth + concentric ring:
C
3
= L
_
Q
r
h
s
b
t
+
_
_
D 2h
s
2
_
2

_
D 2(h
s
+ b
t
)
2
_
2
__

fe
c
fe
.

Region 4 : Rotor back - concentric ring:

C
4
= L
_
_
D 2(h
s
+ b
t
)
2
_
2

_
D
i
2
_
2
_

fe
c
fe
.
LP Thermal Models Rotor Temperature

There is a very small eective air distance between the rotor

bars and the rotor teeth.

The thermal conductance between the rotor bars and rotor

teeth Y
23
=R
1
23
is approximated as
Y
23
= A
23

23
/l
bt
A
23
= L(2h
c
+ b
c
)Q
r
where
23
is the heat conductivity of air and l
bt
the eective
average air-gap distance between the rotor bars and rotor
teeth (determined experimentally).

l
bt
0.1 mm for cast Al rotor cages, l
bt
0.2 mm for bar Al
rotor cages and l
bt
0.5 mm for bar Cu rotor cages.

Note the typo in eq. (6.27) in the course book!

LP Thermal Models Rotor Temperature

Thermal conductance between the rotor teeth to the inner of

the rotor.

The corresponding rotor surface that the heat transfers

through is approximated as
A
34
= L (D 2(h
s
+ b
t
)) .

The eective length (in the radial direction) that the heat
passes l
e
is approximated as
l
e
=
1
2
_
D
2

D
i
2
h
s
b
t
_
+
1
3
(h
s
+ b
t
).

Resulting thermal conductance:

Y
34
= R
1
34
=

34
A
34
l
e
.
LP Thermal Models Rotor Temperature

Heat generation from rotor bars to short circuit ring is more

complex as the heat is generated internally (in the rotor bars).

Note that the temperature is equal to the same temperature

T
s
on both axial ends of the rotor bars.

Bar length=2a.

How should the thermal resistance be computed taking the

internal heat generation into account?
LP Thermal Models Rotor Temperature

Start with the heat equation

c

T
t
=
2
T +
q

Assume steady state condition

T
t
=0.

Consider heat conduction in the x-direction only

2
T
y
2
=

2
T
z
2
=0.

Result:

2
T
x
2
=q where q is the internal generated heat
power in the bars [W/m
3
].

Note: In eq. (6.18) in the course book, the symbol P should

be replaced with q.
LP Thermal Models Rotor Temperature

Temperature distribution T(x) found from integration

T(x) =
q
2
x
2
+ C
1
x + C
2
where C
1
and C
2
are constants.

At x =0 we have dT/dx =0C

1
=0 (stems from Fouriers
law).

At x =a we have T =T
s
C
2
=T
s
+
qa
2
2
.

Resulting temperature distribution:

T(x) =
qa
2
2
_
1
x
2
a
2
_
+ T
s
.

Average temperature

T:

T =
1
2a
_
a
a
T(x)dx =
qa
2
3
+ T
s
.
LP Thermal Models Rotor Temperature

The distance from x =a to point where average temperature

T is reached is found by solving

T(x) =

T x =
a

3
=
l
2

3
.

From the above, we can argue that the eective length to be

used in the thermal conductance l
e
=
l
2

3
.

In the course book, it is argued that l

e
=
l
6
+
3
4
(l
y
h
c
)
where the factor
3
4
is empirically determined.

Corresponding area A
12
=b
c
h
c
Q
r
.

Resulting thermal conductance:

C
12
= 2

12
A
12
l
e
where the factor 2 is due to the fact that the model includes
the two bar ends.
What Have We Learnt?

We have learnt about dierent insulation classes.

We reviewed the, empirically based, Brostr oms formula for

calculating stator and rotor average temperature.

We discussed heat conduction in terms of Fouriers law, the

heat equation and thermal resistances.

We discussed heat convection and saw that it too could be

modeled as a thermal resistance.

We discusses simplied LP thermal models for the stator and

rotor.

Now, lets discuss more advanced aspects of thermal

modeling!
EJ2210 Analysis of Electrical Machines
Lecture 6-II
Shagh Nategh
PhD student
Laboratory of Electrical Energy Conversion
Royal Institute of Technology
Stockholm, Sweden
May 4, 2012
Outline I
Thermal Eects in Electric Machines
Traditional Thermal Sizing of Electric Machines
Useful table
Modern Thermal Modeling of Electric Machines
LP Modeling
Numerical Methods
Combination of Analytical and Numerical Methods
Electric Machines Cooling Approaches
Totally Enclosed
Totally Enclosed Fan Cooled
Housing Water Jacket
Oil Spray Cooling
Summary
Thermal Eects in Electric Machines

Lifetime of insulation materials

Insulation classes

10 K increase in temperature can reduce the lifetime by 50 %

0 20 40
0
50
100
150
K
%
L
i
f
e
t
i
m
e
Lifetime Vs excess temperature
Thermal Eects in Electric Machines

Electromagnetic performance of the materials used in the

electric machines changes with temperature, e.g., PMs
-2 -1.5 -1 -0.5 0
x 10
6
-2
-1
0
1
H (kA/m)
B

(
T
)
20 C
60 C
180 C
150 C
120 C
100 C
80 C
Irreversible change in the
flux density

Cooling system design

Complex duty cycle applications

Dierent thermal time constants for rotor, winding.

Traditional Thermal Sizing of Electric Machines

Single parameter thermal model

Housing heat transfer coecient

Winding current density (produced losses in the winding)

Double-parameter thermal model (rotor is included)

Traditional Thermal Sizing of Electric Machines

Useful table
Cooling condition Heat transfer coe. (W/m
2
C) Current density (A/mm
2
)
Totally enclosed (natural convection) 510 1.55
TEFC (Forced convection) 10300 510
Liquid cooled (Forced convection) 5020000 1030

The complex thermal behavior of an electric machine can not

be modeled by a resistance (inaccurate results)

Wide range of possible values

Average not maximum temperatures are calculated

Where to concentrate cooling system design eorts

Results in

Oversized electric machine or its cooling system (not cost

ecient)

Poor cooling system

Lower eciency (due to the higher losses)

Shorter lifetime

Protection problems

Undesired electromagnetic performances (due to the changes

in materials, e.g., PMs)
Modern Thermal Modeling of Electric Machines

Analytical methods

Lumped parameter (LP) modeling

Numerical methods

Finite element analysis (FEA)

Computational uid dynamics (CFD)

Combination of analytical and numerical methods

LP+FEA

FEA+CFD
LP Modeling

Heat transfer Ohms law

R
P
T1
T2
P =
T
R
P = Power [W]
T = Temperature [

C]
R = Thermal resistance [

C/W]

Analytical modeling of heat transfer

Conduction
R =
L
k A
A = Cross sectional area, L = Length,
k = Thermal conductivity of medium

Radiation
R =
1
h A
h = Heat transfer coecient
Analytical modeling of heat transfer

Convection
R =
1
h A
h= Heat transfer coecient [W/m
2

C]

Dimensionless Numbers
R
e
(Reynoldsnumber ) = vD
h
/
G
r
(Grashof number ) = g
2
D
h
3
/
2
P
r
(Prandtl number ) = c
p
/k
N
u
(Nusseltnumber ) = hD
h
/k
=uid dynamic viscosity [kg/s m]
=uid density [kg/m
3
]
k=thermal conductivity of the uid [W/m

C]
c
p
=specic heat capacity of the uid [kJ/kg

C]
v=uid velocity [m/s]
=surface to uid temperature [

C]
=coecient of cubical expansion of uid [1/

C]
D
h
=hydraulic diameter [m]
Analytical modeling of heat transfer

General form of convection for natural convection

N
u
= a(G
r
P
r
)
b
a and b are constants

General form of convection for forced convection

N
u
= aR
e
b
P
r
c
a, b and c are constants

Mixed convection
h
mixed
3
= h
forced
3
+ h
natural
3
(1)
Example: LP Model of a Water Cooled Electric Machine
Ambient
Coolant
Hs
Hs(R) Hs(F)
Ec(R)
Ec(F)
Es(R)
Sht(R)
Es(R)
Es(F)
Sht(F)
Es(F)
Brn(F) Brn(R)
Sht
Plt
Yk
Tth
St-Br
Sl-Wl (n)
Wnd
E-Wnd(F) E-Wnd(R)
Hs
Sht
Yk
Tth
St-Br
Sl-Wl (1)
Wnd
Rd-Cv Cd
Cd
Cd
Cv
Cd Cd
Cv
Cd Cv
Rd-Cv Cd Cd Cd
Cd
Cd
Cv
Cd Cd
Cv
Cd Cv
Rd-Cv Cd
Cd
Cd
Cd
Cd
Cd
Cd
Cv-Cd
Cd
Cd
Cd
Cd
Cd
Cd
Cv-Cd
Axiallayern Axiallayer 1
Rd-Cv
Rd-Cv Rd-Cv
Cv Cv Coolant Cv Coolant Coolant Cv
Cv
Es(F)
Cv
Cv
Cv Es(R)
Activepartofmachine
Cv
Cv Es(F) Rotor Rotor
Cd Cd
(F) Front Hs Housing
(R) Rear Plt Plate
Cd Conduction Sht Shaft
Cv Convection Sl-Wl Slot wall
Rd Radiation St-Br Stator bore
Brn Bearing Yk Stator yoke
Ec End cap Tth Stator tooth
Es End space Wnd Winding
E-Wnd End winding
LP Modeling

Advantages

Easy to be implemented

Quick run

Disadvantages

Modeling of complex structures, e.g., active winding, end

winding, bearing and rotor
Copper, wire ins. &
impregnation (coil 1)
Coil divider
Liner 2
Copper, wire ins. &
impregnation (coil 2)
Slot insulation
Liner 1
Wedge
x
y
z

Modeling convection and radiation

Numerical Methods

FEA

Modeling convection and radiation using boundary conditions

CFD
Numerical Methods

FEA

Eective approach for calculating hot-spot temperature

Modeling complex structures

Modeling convection and radiation using boundary conditions

Modeling is very time consuming

CFD

Accurate modeling of convection

Modeling is time consuming

Running is time consuming

Combination of Analytical and Numerical Methods

LP+FEA (1)

Here you should model all parts of the machine in your FE

software !!!
Combination of Analytical and Numerical Methods

LP+Partial FEA (2)

Simpler FEA

More advanced LP modeling

Ambient
Coolant
Hs
Hs(R) Hs(F)
Ec(R)
Ec(F)
Es(R)
Sht(R)
Es(R)
Es(F)
Sht(F)
Es(F)
Brn(F) Brn(R)
Sht
Plt
Yk
Tth
St-Br
Sl-Wl (n)
Wnd
E-Wnd(F) E-Wnd(R)
Hs
Sht
Yk
Tth
St-Br
Sl-Wl (1)
Wnd
Rd-Cv Cd
Cd
Cd
Cv
Cd Cd
Cv
Cd Cv
Rd-Cv Cd Cd Cd
Cd
Cd
Cv
Cd Cd
Cv
Cd Cv
Rd-Cv Cd
Cd
Cd
Cd
Cd
Cd
Cd
Cv-Cd
Cd
Cd
Cd
Cd
Cd
Cd
Cv-Cd
Axial layer n Axial layer 1
Rd-Cv Rd-Cv Rd-Cv
Cv Cv Coolant Cv Coolant Coolant Cv
Cv
Es(F)
Cv
Cv
Cv Es(R)
Cv Cv Es(F) Rotor Rotor
Cd Cd
Winding
Rotor
Combination of Analytical and Numerical Methods

Stator including winding

Step 1 Step 2 Step 3
Step 4
Step 5
79
96
113
130
62
45
70
85
100
115
130
1 1
1 1 1
1 1
1 2 2 2 2
2 2 2 2
2 2 2
2 2
2 2 2
2 2 2 2
2 2 2
3 3 3 3 3
3 3
3 3
3 3
3
3 3
3 3
3 3 3
3 3 3 3
3
4 4 4 4
4 4 4 4
4 4
4 4
4
4 4
4
4 4
4
4
4 4 4 4 4
4 4 4 5 5 5 5
5 5
5
5
5 5
5 5 5 5 5
5 5 5 5 5 5
Combination of Analytical and Numerical Methods

Rotor
Block 1
Block 2
Block 3
Magnet 1
Magnet 2
Magnet 3
Block 4
Magnet 4
Block 5
Air gap
Stator Bore
Block 1
Block 2
Block 3
Block 4
Block 5 Magnet 1
Magnet 2
Magnet 3
Magnet 4
Combination of Analytical and Numerical Methods

Results (90 Nm, 1500 rpm)

Steady-state
Machine part Meas. (

C) LP model (

C) Rel. error (%)

Active winding 91.1-99.2 88.5-122.5
End winding (R) 120.8 120.4 0.33%
Outlet coolant 34.8 35.1 0.86%
Bearing 41.8 41.5 0.72%
Magnet 1 61.3 61.4 0.16%
Magnet 2 61.4 61.8 0.65%
Magnet 4 61.8 62.0 0.32%

Transient
0 20 40 60 80 100
0
20
40
60
80
100
120
140


Experiment
Thermal model
End winding
Max. Magnet
Bearing
Time (min)
T
e
m
p
e
r
a
t
u
r
e
(

C
)
Electric Machines Cooling Approaches

Totally enclosed

Natural convection (horizontal n channel)

N
u
= 0.00067G
r
P
r
(1 e
(7640/G
r
P
r
)
0.44
)
1.7
h = N
u
k/s
k: thermal conductivity of air [W/m

C]
s: n spacing [m]
Electric Machines Cooling Approaches

Totally enclosed fan cooled (TEFC) electric machine

Component Air velocity (pu)
Endcap (R) 1.0
Housing (R) 0.9
Housing (Act) 0.7
Housing (F) 0.6
Endcap (F) 0.5
Flange 0.2
Air velocity (v) Heat transfer coecient (h) Thermal
resistance between the machine cooling surface and air (R)
Electric Machines Cooling Approaches

Forced convection
h =
C
p
D
h
v
(4L)(1 e
m
)
m =
0.1448L
0.946
D
h
1.16
(k/(C
p
v))
0.214
D
h
= Hydraulic diameter = 4 channel area / channel perimeter
L = Axial length of cooling n
Electric Machines Cooling Approaches

Fin design
Electric Machines Cooling Approaches

Housing water jacket

Channels conguration

Channels connection

Series

Parallel
Electric Machines Cooling Approaches

Convection
R
e
= D
h
v/
D
h
= 4 channel cross sectional area / channel perimeter

If R
e
< 2300: The ow is laminar
N
u
= 3.66 + [0.065(D
h
/L)R
e
P
r
]/[1 + 0.04((D/L)R
e
P
r
)
2/3
]
D=Channel diameter

If R
e
> 3000: The ow is turbulent
N
u
= (f /8)(R
e
1000)P
r
/[1 + 12.7(f /8)
0.5
x(P
r
2/3
1)]
f=Friction factor
Electric Machines Cooling Approaches

Oil spray cooling

Eective cooling for rotor and end winding

Application: Traction drives

Summary

Thermal design can be as determinant as electromagnetic

design in the performance of an electric machine

Traditional thermal sizing is not accurate enough and modern

approaches are needed

Combination of numerical and analytical methods enables

accurate thermal modeling

There is not a good or a poor cooling system !!!

The cooling system should be chosen based on the application,

operating condition and machine design