Experimentally validated numerical model of thermal and flow processes within the permanent magnet brushless direct current motor

Melka, Bartłomiej; Smołka, Jacek; Hetmańczyk, J.; Buliński, Zbigniew; Makieła, D.; Ryfa, Arkadiusz

doi:10.1016/j.ijthermalsci.2018.04.029

Cited by 16 publications

(4 citation statements)

References 28 publications

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“…Our data improve on the literature, which only contains studies on single motors. For example, reference [43] conducted detailed experimental Particle Image Velocimetry (PIV) and computational fluid studies on the thermal and flow processes of a single fixed-size brushless DC motor. However, these results are of little use for conceptual designers who seek heat transfer data for a broad range of devices, which could vary in size and aspect ratio.…”

Section: Novel Contributionsmentioning

confidence: 99%

Heat Transfer Models and Measurements of Brushless DC Motors for Small UASs

Saemi,

Whitson,

Benedict

2024

Aerospace

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Heat transfer affects a motor’s sizing, its performance, and, ultimately, the overall vehicle’s range and endurance. However, the thermal literature does not have early-stage models for outrunner brushless DC (BLDC) motors found in small unmanned aerial systems (UASs). To address this gap, we have developed a non-dimensional heat transfer model (Nusselt correlation). Parametric experiments of four different-sized BLDC motors under load in Reynolds-matched wind tunnel tests generated data for model correlation. The motors’ aspect ratios (diameter/length) ranged from 0.9 to 1.5. The freestream Reynolds number of the axial flow over the motors ranged from 20,000 to 40,000. The rotational Reynolds number ranged from 10,000 to 20,000. The results showed that aspect ratio had the largest influence on heat transfer, followed by rotational and freestream Reynolds numbers. A steady-state model used the correlation to predict the motor’s ambient temperature differential within 10 K of experimental data. A case study applied the correlation to predict a hypothetical motor’s continuous torque in different environments. The correlation enables conceptual designers to capture thermally-driven trade-offs in early design stages and reduce costly revisions in later stages.

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Section: Novel Contributionsmentioning

confidence: 99%

Heat Transfer Models and Measurements of Brushless DC Motors for Small UASs

Saemi,

Whitson,

Benedict

2024

Aerospace

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“…To calculate the loss, the magnetic flux density is divided into radial and tangential components, and each component is converted into multi-order odd harmonics by Fourier decomposition. The magnetic field of the winding is approximately to a multi-order sinusoidal alternating magnetic field for the calculation Finally, the analytical calculation model of the eddy current loss of a single conductor is as follows [15][16][17]:…”

Section: Eddy Current Loss Of a Single Wirementioning

confidence: 99%

Investigation of Eddy Current Loss and Structure Design with Magnetic-Thermal Coupling for Toothless BLDC High-Speed PM Motor

Zhao

et al. 2022

Machines

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Brushless direct current (BLDC) permanent magnet (PM) synchronous motors are in high demand for ventilator applications owing to their high speed, high efficiency, and other significant features. However, it has become an important problem in eddy current loss calculations with high-speed motors, which leads to low motor (ventilator) life and PM demagnetization. This paper focuses on the eddy current loss calculation and the structure improvement design for the two-pole 90 W, 47,000 r/min toothless BLDC motor. First, the influencing factors of eddy current loss are comprehensively investigated, and a multiparameter improvement methodology is proposed accordingly. Second, by finite element analysis (FEA), the effective winding length ratio and the number of parallel wires were mainly researched for the winding, and the influence on the eddy current loss and the efficiency was determined, providing a reference for BLDC high-speed motors. This study has resulted in a 34.75% reduction in the winding losses, and a 4.6% increase in the efficiency of the improved model compared with the original design. Third, the new rotor structure is proposed, saving PM volume 15% more than original. THD of gap flux density is decreased 20.97%; the eddy current loss in the new rotor is decreased 22% more than original. Furthermore, by coupling simulation of the magnetic–thermal field, the maximum temperature of winding of the improved model is 13.4% lower than that of the original model at the thermal steady state. Finally, the electromagnetic and thermal properties simulation results were verified by testing the prototype. It is of great significance to the structure design and efficiency improvement of the BLDC high-speed motor.

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“…Thermal anemometry is useful for solving problems in the nuclear industry when studying the convective boiling of liquids [ 28 ] or when obtaining data on gas dynamics in the vertical core channels of prismatic reactors [ 29 ]. HWAs and various sensor configurations are also used in the design of the ventilation ducts of residential buildings [ 30 ], the development of electric motors [ 31 ], the study of the hydrodynamics of offshore pipelines [ 32 ], and so on. Equally, thermal anemometry is actively used to solve classical as well as fundamental scientific problems, such as heated impact jets [ 33 ] and the structure of the aerodynamic wake after impacting objects with different geometries [ 34 , 35 ].…”

Section: Introductionmentioning

confidence: 99%

A Thermal Anemometry Method for Studying the Unsteady Gas Dynamics of Pipe Flows: Development, Modernisation, and Application

Plotnikov

2023

Sensors

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A detailed study of the gas-dynamic behaviour of both liquid and gas flows is urgently required for a variety of technical and process design applications. This article provides an overview of the application and an improvement to thermal anemometry methods and tools. The principle and advantages of a hot-wire anemometer operating according to the constant-temperature method are described. An original electronic circuit for a constant-temperature hot-wire anemometer with a filament protection unit is proposed for measuring the instantaneous velocity values of both stationary and pulsating gas flows in pipelines. The filament protection unit increases the measuring system’s reliability. The designs of the hot-wire anemometer and filament sensor are described. Based on development tests, the correct functioning of the measuring system was confirmed, and the main technical specifications (the time constant and calibration curve) were determined. A measuring system for determining instantaneous gas flow velocity values with a time constant from 0.5 to 3.0 ms and a relative uncertainty of 5.1% is proposed. Based on pilot studies of stationary and pulsating gas flows in different gas-dynamic systems (a straight pipeline, a curved channel, a system with a poppet valve or a damper, and the external influence on the flow), the applications of the hot-wire anemometer and sensor are identified.

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Experimentally validated numerical model of thermal and flow processes within the permanent magnet brushless direct current motor

Cited by 16 publications

References 28 publications

Heat Transfer Models and Measurements of Brushless DC Motors for Small UASs

Heat Transfer Models and Measurements of Brushless DC Motors for Small UASs

Investigation of Eddy Current Loss and Structure Design with Magnetic-Thermal Coupling for Toothless BLDC High-Speed PM Motor

A Thermal Anemometry Method for Studying the Unsteady Gas Dynamics of Pipe Flows: Development, Modernisation, and Application

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