Heat dissipation

Life span of
the electrical machines

Industrial Electrical Engineering and Automation

Previously
Energy loss in
magnetic circuits
q=ChB2f+Ce(Bf)2

Energy loss
in electric
circuits
qe=J2

Energy loss in
mechanic circuits
q=
Avo R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Radiative
cooling

Avo R
Design of Electrical Machines

Th
He erm
at al
sou cir
r ce cu i
s, t an
he d
at th
sin erm
ks a l
an de
d h si g
eat n
flo
w.

Next

Conduction
cooling
Convection
cooling

Industrial Electrical Engineering and Automation

Evaluation of thermal loading

Heat transfer
Input: heat sources and
cooling conditions
Outcome: temperature
distribution

Computational tools
Analytic, empiric, numeric
FEA, CFD, lumped circuits
for heat transfer and fluid
flow

Material characterization
Sub-model validation
Avo R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Complexity
Electrical machine is
A complex 3D electromagnetic structure
A complex spatial fluid dynamic structure with cooling
medium

In order to determine the temperature distribution

A good estimate of losses has to be known
Properties of the cooling process has to be known
The thermal characteristics and properties has to be known

An optimized thermal design can help increase

machine rated power substantially
Avo R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Thermal design
Good estimate of losses
the spatial and temporal
distribution of heat sources
Waveform of a loss origin
Distribution of heat sources
Duty cycle operational
cycle time often much
shorter than thermal time
constant
Short time operation
Intermittent

Avo R

Thermal characteristics of
materials
Temperature dependence
Temperature limits

Heat dissipation thermal

circuit and cooling system
Thermal efficiency
Cooling conditions (normal,
forced)

Maximum allowed loading

according to the thermal
limits at cooling capability

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Thermal circuit heat carrier

A good electric
conductor is usually
also a good thermal
conductor
Interested in hotspots:
100% conductor in the
middle of winding
Heat is taken from endwindings: conduction,
convection or both
Avo R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Thermal circuit thermal contacts

A bad electric conductor
is usually also a bad
thermal conductor
No air-gaps in electrical
circuit, many air-gaps in
thermal circuit
Thermal contact
between stator core and
housing
0.1 mm +5K
0.2 mm +10K
Avo R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Design target - Thermal limits

The most critical component in the electrical machine is

insulation and temperature dependent is magnet.
Insulation lifetime is shortened radically if temperature
exceeds the limit and that is due to accelerated oxidation
process in the insulation material.
-=100K -> lifetime
Avo R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Temperature dependence
Materials temperature dependence is taken account
with material thermal coefficients D
U coil

Avo R

U 0coil 1  D Ucoil -coil  -0coil 

BRmagn

BR 0 magn 1  D Brmagn -magn  -0 magn 

H Cmagn

H C 0 magn 1  D Hcmagn -magn  -0 magn 

Design of Electrical Machines

10

Industrial Electrical Engineering and Automation

Heat transfer
Steady state and transient
Heat transfer problem
according to temperature
(potential) and heat balance
between source, sink and
storage

Avo R

Ox

w 2w 2w 2O
O


Q
y
z
wx 2
wy 2
wz 2

Ox

www O y 2  Oz 2  Q
2
wx
wy
wz

Uc p

wwt

heat transfer convectiondiffusion equation

Uc p

w  k-  Uc p-u  Q
wt

incompressible NavierStokes equations for fluid

dynamics
wu
 U u  u p  K 2 u  F
wt
u 0

Design of Electrical Machines

11

Industrial Electrical Engineering and Automation

Equivalent circuit relations

Relation

Electrical
circuit

Magnetic
circuit

Thermal
circuit

Potential

U=El

NI=Hl

-=Gl

Flow

I=JA

=BA

Q=qA

R=1/l/A

R=1/l/A

R=1/l/A

U=IR

NI=R

-=QR

Resistive
element
Ohms Law
Avo R

Design of Electrical Machines

12

Industrial Electrical Engineering and Automation

Equivalent circuit

Avo R

Design of Electrical Machines

13

Multi-physics FEM
Industrial Electrical Engineering and Automation

u6

Different problems in physics

share the same geometry

u5
N 3 (x 3 ,y 3 )
-3

Calculate for a single element

u4

u3

-2
u2

-1

N 2 (x 2 ,y 2 )

u1

N 1 (x 1 ,y 1 )

J  x, y, z, t  o p cu
oB x, y, z, t  o p fe
Avo R

The variation of loss origin

RMS power loss
MEAN temperature

A field equation is solved for

the finite size of volume
boundaries suppose to
specify a potential (essential),
flow naturally given.

Design of Electrical Machines

14

Industrial Electrical Engineering and Automation

Thermal modelling example I

Determine heat sources in regions

Specify cooling conditions over cooling surfaces
Find heat balance i.e. temperature distribution

Avo R

Design of Electrical Machines

15

Industrial Electrical Engineering and Automation

Thermal modelling example II

Calculating flux (and current) density waveform

Estimating losses densities in the symmetric part of machine

Calculating temperature distribution according to heat sources and sinks

Avo R

Design of Electrical Machines

16

Industrial Electrical Engineering and Automation

Thermal modelling example III

Avo R

Design of Electrical Machines

17

Thermal model
 k sa

 k sa
0

k wsa
 k ws

 k ws
k mws

 k ms
 k mw

 k ms

 k mw

k mw

Industrial Electrical Engineering and Automation

k sa

-amb
-surf
-win
- pm

-amb

0
0
Qwin
Q pm

-surf

Geometry of a PMSM

Material & thermal loading

Winding
Permanent magnets

-win

Surface & cooling

Natural convection

-pm

Temperature nodes
Nodes of interest

Thermal circuits
Heat transfer rather than flow
network

Thermal resistances
Focus on thermal air-gaps

Avo R

Design of Electrical Machines

18

Industrial Electrical Engineering and Automation

Model development
Sorces and loads
Conductor losses
Convection cooling

2D heat transfer
Approximate rating
Extraction of elements

3D heat transfer
Extrucion from 2D
Focus on end turns

Heat exchange through endturns

Thermal conduction

Avo R

Design of Electrical Machines

19

Industrial Electrical Engineering and Automation

Thermal circuit cooling circuits

Natural and Forced
Integrated cooling as a
result of machine
integrated construction
Slotted stator operates
as a cooling circuit
Directly cooled heat
sources

Cooling capability
Maximize the cooling
surface area
Improve cooling medium
parameters and velocity

Smallest temperature
rise is the goal when
designing a thermal
circuit

Cooling ducts, cooling

jackets, cooling channels
Avo R

Design of Electrical Machines

20

Industrial Electrical Engineering and Automation

Cooling Concepts

Structure
Where the energy conversion,
heat transfer and temperature
drop (-) takes place

Heat sources
Energy converted to heat

Cooling sources
Heat dissipation

Cooling concepts
arrangement of heating and
cooling sources
Indirect Cooling (high -)
Direct cooling (low -)

Avo R

Design of Electrical Machines

21

Industrial Electrical Engineering and Automation

Thermal conductivity
l

-1

-2

OA
l

-1  -2 

A
l

-1  -2 

Conduction is heat transfer by diffusion in a

stationary medium due to a temperature gradient.
The medium can be a solid, a liquid or gas
Diffusion through the substance

Avo R

Design of Electrical Machines

22

Industrial Electrical Engineering and Automation

Thermal conductivity
Material
Air

[W/m0K]
0.025-0.035

Material

[W/m0K]

Cast iron

40-46

Nomex

0.11

Stainless-steel

25-30

Kapton

0.12

Laminated iron

20-40

Mica

0.4-0.6

Copper

360

Bonding epoxy

0.64

Aluminum

Avg.ins.system

0.2

NdFeB

SmCo

10

Avo R

Design of Electrical Machines

200-220

23

Industrial Electrical Engineering and Automation

Modeling a winding

Oeff

Ocond Oins
Oins k f  Ocond 1  k f 

Lkf

Oeff

Ocond

L 1  k f

Oins

L Oins k f  Ocond 1  k f

Ocond Oins

Equivalent thermal conductivity of a winding is given

by the filling factor of the conductor strands (copper
in this example) and the thermal conductivity of the
medium between the conductor strands
Avo R

Design of Electrical Machines

24

Industrial Electrical Engineering and Automation

Convection
l
hot
1 -1
-2

A
2

Q
Q

-amb
Q x

D 2 A-2  -amb 
A
1

D1
qn

-hot  -amb 

D2

n k-  h-  - amb 

Convection is heat transfer between either a hot

surface and a cold moving fluid or a cold surface and
a hot moving fluid. Convection occurs in liquids and
gases
Movement of the substance
Avo R

Design of Electrical Machines

25

Industrial Electrical Engineering and Automation

Transport of heat
Ph
U c '-

5 25

W
K m2

Q - the required flow rate, m3/s, Ph - required

cooling power, W, - the density of the heat
carrier, kg/m3, c - the specific heat capacity,
J/kgC, - - the temperature difference between
incoming and outgoing temperature C
Natural convection

7.8 20 v 0.60.78 Forced cooled plane surface by air speed v

Ploss
Acool

Avo R

1 2.5

kW
m2

Empirical cooling capability

Design of Electrical Machines

26

Industrial Electrical Engineering and Automation

Radiation
l
hot
1 -1
-2

A
Q

-amb
Q x

-2 4 - amb 4
c rad A


100 100

D 2 rad

-2 4 -amb 4
c rad


100 100

-2  -amb

Radiation is heat transfer between cooling surface A

at temperature -2 and ambience at temperature -amb
via electromagnetic waves

Avo R

Design of Electrical Machines

27

Industrial Electrical Engineering and Automation

Transient heat flow

l
hot
1 -1

A
2 -2

QP

QS

QP

QD

Heating time constant

Temperature rise during
the transient heating

d- 
dt Rth

C th

V U c

-amb

Steady state temperature

Avo R

QS  Q D

d A D 2 dt

-m

P Rth

W th

C th Rth

- -amb

Design of Electrical Machines

P
A D 2
V U c
A D 2

W
 th

 -m  -amb  1  e t

28

Industrial Electrical Engineering and Automation

Transient heat flow

Rth

-1

-2 Thermal model representing

a physical model

Mathematical formulation

Cth

Many simplifications and

approximations

Heat is not internally

generated in the body

d
-1
dt

-av
Avo R

P - 2  -1 1


C th
Rth
C th

Losses are applied to

specific node-point

-2  -1
2
Design of Electrical Machines

29

Industrial Electrical Engineering and Automation

Home assignment 3
PMSM model based on
lumped equivalent circuits
Magnetic
thermal

Core loss modelling

Data input
Models

Thermal limits and

peak/nominal operation
points

Avo R

Design of Electrical Machines

30

Industrial Electrical Engineering and Automation

Thermal circuit at steady state

Node points i, Qi [W], -i [K]

5. Coil loss and temperature
4. Tooth loss and temperature
6. Yoke loss and temperature
7. 8. Ambience temperature

Thermal conductivity
elements Gij [W/K]

Avo R

From coil to tooth G54

From coil to yoke G56
From tooth to yoke G46
From yoke to ambience G67

Design of Electrical Machines

31

Industrial Electrical Engineering and Automation

Summary
Thermal constrains and
dependences
Thermal circuits, heat
sources and cooling options
Heat transfer model and
modelling

Do
Hc

Learning skills from the

assignments
B

Avo R

Design of Electrical Machines

32