20 1 3 International Conference on Electrical Machines and Systems, Oct.

26-29, 20 1 3 , Busan, Korea

Thermal-Flow Analysis and

Cooling Performance Enhancement of
a Totally Enclosed Fan-Cooled Motor
Sung-Hyun Moon \ Jang-Ho Yun 1 , Wan-Gi Kim 1 *, Ju-Pil Kim 2
I Electric Power Machinery Research Dept., Hyundai Heavy Industries, Korea
2
Hyundai Ideal Electric Co., USA
E-mail: wgkim@hhi.co.kr

Cooling performance of rotating machines is one of the critical

qualities determining product lifespan. As power density of the
machines is considerably increased, enhancement of the cooling
performance is required in order to secure thermal safety and
prevent failure such as dielectric breakdown. In this paper,
thermal-flow analysis using CFD (computational fluid dynamics)
was carried out to evaluate temperature rise of a TEFC (totally
enclosed fan-cooled) motor of which power density had been
improved. From the analysis result, we investigated flow
structures reducing cooling efficiency, such as bending loss,
reverse flow and flow separation. In order to attenuate these
negative phenomena, we modified cooling design for fan-cover,
frame and end-shield of the motor. As a result, temperature rise
of stator winding of the motor was decreased by 7.5%, from
97.4K to 90. 1K. For reference, an error rate of the analysis result
is 3.7% in comparison with the test result.
I.

INTRODUCTION

Cooling system of general motors is classified by

circulation structure, coolant type and circulation type. The
TEFC (totally enclosed fan-cooled) motor has totally enclosed
protection (IP54) grade and self-circulation air-cooled
(ICOA 1 ) system. Also the TEFC motor is being used in
various industries due to easy mounting and complete block
against external foreign substance.
Many studies on cooling performance enhancement of
motors have been continuously performed to increase power
density and insulation lifespan because electric losses
operating heat sources are also increased considerably.
Generally every time temperature of motor winding is
decreased by 1 0K, insulation lifespan is prolonged two times.
For this reason, temperature rise of motors is one of critical
qualities.
In this study, thermal-flow analysis using Star-CCM+, one
of CFD (computational fluid dynamics) common use
programs, was performed to evaluate cooling performance of
newly-developed TEFC motor. To verify an accuracy of the
analysis result, the temperature rise of stator winding was
compared with the test result. From the analysis result, we
investigated flow structures reducing cooling efficiency, such
as bending loss, reverse flow and flow separation. In order to
attenuate these negative phenomena, we improved structural
design for fan-cover, frame and end-shield of the newly
developed TEFC motor [ 1 ] .

II.

THERMAL-FLOW ANALYSTS

1) Analysis condition and numerical detail

Fig. 1 shows 3-dimensional analysis model composed of
stator core, stator winding, rotor core, squirrel cage, frame,
end-shield, internal/external cooling fan and fan-cover. Flow
over the TEFC motor can be divided into inner circulation
flow and outer stream flow, which are generated by self
rotating radial fan and axial fan, respectively.
Table 1 shows electric losses, calculated from electric
design, of 3 1 5frame 2poles high voltage motor. On the basis
of empirical data, we distributed stray load loss to each active
part and considered thermal resistance caused by winding
insulation [2] . Table 2 shows numerical detail for thermal
flow analysis. Rotating speed is 3 ,600rpm and ambient
temperature is 40 C. M RF (moving reference frame) scheme
is used to simulate rotation of the radial fan. On the other hand
P-Q curve is substituted for the axial fan. The k-e turbulence
model, which is derived from energy conservation between

Fig. 1 . 3-dimensional model for thermal-flow analysis

Table I . Electric losses of 3 1 5frame 2poles high voltage motor
Part

Losses (W)

Stator coil

4,590

Stator core

3 ,706

Squirrel cage

2,976

Stray load loss

2,050

Total

1 3 ,322

978- 1 -4799- 1447-0/1 3/$3 l .00 20 1 3 IEEE

2028

Table 2. Numerical detail for thermal-flow analysis

Numerical detail

Value

Rotating speed (rpm)

3 ,600

Simulation of internal fan

MRF

Simulation of external fan

P-Q Curve

Turbulence model

k-Epsilon

Ambient temperature CC )

40

Domain size (mm)

3 ,600L

1 ,8000

Grid distribution (mm)

3 - 64

Grid number (EAs)

6,200,000

Table 3. Temperature rise of stator winding

Data from

Averaged (K)

Maximum (K)

Analysis

89.6

97.4

Test

86.4

Fig. 2 shows pressure and velocity fields over the TEFC

motor, (a) and (b) are cases of existing model and improved
model, respectively. The first picture of fig. 2a shows pressure
field inside the fan-cover and pressure is increased by bending
loss and stagnation point. The second one of fig. 2a shows
velocity field around the end-shield and flow separation
severely occurs on the edge of end-shield. This phenomenon
induces ventilation area to be narrower and increase hydraulic
resistance. As you can see in the third one of fig. 2a, axial
velocity between frame and floor, reverse flow is generated
under the fan-cover. This phenomenon induces forward air
volume to be decreased. As shown in the last one of fig. 2a,
axial velocity under the frame is lower than both sides. This is
caused by high skin friction and narrow ventilation area [3 ] .
In order to suppress such negative flow structures
decreasing cooling performance of the TEFC motor, cooling
design of fan-cover, end-shield and frame was modified as
shown in fig. 3 .

turbulent kinetic energy (k) and turbulent dissipate rate (e), is

used. Computational domain size is 3 ,600mm (axial direction)
x 1 ,800mm (radial direction) and number of volume mesh is
about 6,200,000 EAs.

400

2) Temperature rise
Because the developed motor is squirrel cage induction
motor, evaluation standard of cooling performance is
temperature rise of stator winding insulated with type F grade.
In order to secure thermal safety and to increase insulation
lifespan, cooling design is usually progressed to satisfy
temperature rise limit of one-step lower insulation grade than
actual one. According to KS (Korean industrial standards),
temperature rise limits of type B insulation and type F
insulation are 90K and 1 1 5K at 041) am b i ent tem p erature,
respectively. So temperature rise of the developed motor has
to be satisfied with limit of type B insulation, less than 90K.
Table 3 shows temperature rise of stator winding. From the
analysis result, averaged and maximum values are 89.6K and
97.4K, respectively. Because local (maximum) temperature
rise exceeds 90K, cooling performance enhancement is
required. In the case of averaged temperature rise, an error rate
of analysis result is 3 .7% in comparison with test result,
meaning high numerical accuracy.
III.

20

10

o
v

(m/s)
10

-10

COOLING PERFORMANCE ENHANCEMENT

In this section, we derived improvement schemes for

cooling design of the developed motor by analyzing flow field
and verified improvement effect through CFD again.
1) Improvement schemes for cooling design
Air volume of fan is determined from equilibrium between
hydraulic resistance and pressure increase. In order to increase
cooling performance of the TEFC motor under same fan
specification, we modified cooling design in the direction to
decrease hydraulic resistance.

10

20

(a) Existing model

Axial v (m/s)

(b) Improved model

Fig. 2. Pressure and velocity fields over TEFC motor

2029

to=r=w=i=
tem=p
a=
e ra
t urerise__
T (.__s=t=
n=
n
d i=
g=

1 00
9

97.4

_ - ;.:- _

Average tl.T

----------------+----------90. 1
89.6
------..:
-+--- ------------------

90

--&-- Maximum tl.T

,'\- - - -

85

+-----------------8
1
. 8--

80 L----After- improvement

Before- im provement

Fig. 4. Stator winding temperature rise after improvement

IiJ

(a) Existing model

Air flow rate

Q (m3/s)

10 2
101

(b) Improved model

Fig. 3. Improved cooling design of TEFC motor

0.99
In order to decrease bending loss inside the fan-cover, air
guide plate was expanded up to stagnation point. To attenuate
flow separation at the edge of the end-shield, 45 degree
chamfer was applied to the edge. To block reverse flow under
the fan-cover, windbreak device was attached to fan-cover
bottom. To extend ventilation area between frame and floor,
sub-structure of the frame was flattened in parallel with the
floor.

0.97
0.96

Case

a : Before-improvement
b: Applying windbreak device
c: Applying windbreak device and chamfer
d: Applying windbreak device, chamfer and air-guide's expansion

Fig. 5. Variation for air flow rate of axial fan

2) Effect of improvement schemes

The effect of improvement schemes was investigated
through CFD and then it was determined that the existing
problems were attenuated as shown in fig. 2b. By expanding
the air-guide plate, overall pressure distribution inside the fan
cover was decreased. By applying the chamfer to the edge of
the end-shield, flow separation was delayed. By attaching the
windbreak device to fan-cover bottom, reverse flow under the
fan-cover was totally eliminated. By flattening sub-structure
of the frame, ventilation area was expanded and axial velocity
under the frame was increased.
After applying all of the improvement schemes, maximum
temperature rise of stator winding was decreased by 7.5%,
from 97.4K to 90. 1 K, as shown in fig. 4. Also we investigated
variation for air flow rate of external axial-fan (see fig. 5).
With the windbreak device (case b), air flow rate is decreased
by 1 .0% rather than expected because hydraulic resistance of
forward flow under the frame is higher than one of reverse
flow under the fan-cover. In cases of c and d, air flow rate is
increased by 1 .95% and 1 .8 1 % in comparison with case b and
c, respectively.

---

0.98

TV.

CONCLUSION

In this study, thermal-flow analysis using CFD was

performed to evaluate cooling performance of the totally
enclosed fan-cooled motor of which power density had been
improved. With analyzing flow field over the TEFC motor, we
investigated flow structures reducing cooling efficiency. In
order to attenuate these negative phenomena, we suggested
improvement schemes of cooling design as follows. The air
guide plate inside the fan-cover was expanded in order to
decrease bending loss. The chamfer at the edge of the end
shield was applied in order to delay flow separation on the
edge. The windbreak device under the fan-cover was attached
in order to block reverse flow. Finally, sub-structure of the
frame was flattened in order to increase ventilation area under
the frame. After applying all the improvement schemes to the
TEFC motor, maximum temperature rise of stator winding
was decreased by 7.5%, meaning that thermal safety and
product lifespan were enhanced.
REFERENCES
[I]

[2]
[3]

S . H. Moon, W . G . Kim, and K . W . Kim, "Electric design and thermal

analysis for totally enclosed fan-cooled motor, " HEMRl, I 1 -AB-089,
January 2012.
F. P. Incropera and D. P. DeWitt, Fundametals of Heat and Mass
Transfer, 4th ed., WILEY, 2006, pp. 1 3 9- 1 6 1
F. M. White, Fluid Mechanics, 3rd ed., McGRAW-HILL, 1 994, pp. 4 1 1 432.

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