Design and Performance Analysis of Brushless DC Motor Cooling System for Low-Cost Manufacturing Process

Abstract

Thermal analysis on BLDC Motors is very important to be learned in order to obtain a low-cost motor design and have a high level of efficiency. The design of the existing motor cooling system uses a complex design that must use sophisticated machining tools and spend a lot of money in the manufacturing process. The purpose of this paper is to get the geometry of the cooling system on BLDC motor with simple manufacturing process thus saving the cost of production. The expected cooling system design is a simple geometry so that manufacturing can be done using 3-axis CNC machining. Design of cooling system using water-jacket with an additional cover. On this study, Author modeled the motor with Ansys Maxwell to obtain the heat source parameters of the motor geometry. Software Fluent is involved to perform the temperature simulation on the motor using the designed cooling system then validated with an experiment. Thermal analysis of this study compares motor performance with the use of water and oil. The flow rate compared to the radiator power efficiency.

Design of Cooling System on Brushless DC Motor to Improve Heat Transfers Efficiency

“…4, the results of the cooling system efficiency on the BLDC motor casing are shown. The resulting efficiency is 43.410% and an increase in efficiency compared to the previous literature review, the result is an increase in efficiency of 32.491% compared to Vu & Hwang, (2013) 38) ; an increase of 18.410% compared to Abdul Karim & Mohd Yusoff, (2014) 40) ; 42.610% increase in efficiency compared to Paine & Sentis, (2015) 39) ; 14.590% increase in efficiency compared to research Permana, (2016) 41) ; The results of the comparison of efficiency -3.790% to the research Mukhlisin et al, (2018) 43) , are negative because in the study they simulated at a speed of 5000 RPM while in this study the parameters were only 4000 RPM An increase in efficiency of 33.410% compared to Uta Nugraha et al, (2019) 47) ; an increase in efficiency of 40 46) and; 10.410% increase in efficiency compared to studies Tarsisius et al, (2020) 48) . Thus the results of the study experienced an increase in the average efficiency of the previous study of 17.348%.…”

“…The development of the cooling system aims to reduce heat on the outside and inside of the BLDC motor. Development can also be done by designing fans and water as cooling systems 47) , liquid cooling systems can also increase efficiency by 33% 48) . Heat transfer depends on the relative orientation of the heated cavity and the magnetic field lines.…”

Design and additive manufacturing of brushless electric motor components

“…The brushless direct current motor (BLDC) is a brushless electric motor that is controlled by a three-phase inverter [6]. Due to its outstanding performance, this kind of motor is the most widely used motor for electric vehicles.…”