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ISSN : 2458-925X
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Volume 6, Issue 11, November 2020
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Paper Title Pages Artificial Neural Network And Time Series Modeling Of Predicted Future Production With Lentil
Produc on In Turkey And Analysis Authors: Senol Çelik
3564‐3568 Liquid Cooling Model Of Axial Bldc Motor
Authors: Kristyadi Tarsisius; Marsono; Sahril Sayuti 3569‐3573
Design And Development Of A Third Generation Balanced Scorecard Prototype That Facilitates Strategic Implementa on In Automo ve Organiza ons
Authors: Braulio López Morales; Roberto Baeza Serrato
3574‐3580
Journal of Multidisciplinary Engineering Science Studies
ISSN: 2458‐925X (Online) Vol. 6 Issue 11, November ‐ 2020
Journal of Multidisciplinary Engineering Science Studies (JMESS) ISSN: 2458-925X Vol. 6 Issue 11, November - 2020
www.jmess.org
JMESSP13420691 3569
Liquid Cooling Model Of Axial Bldc Motor
Kristyadi Tarsisius Institut Teknologi Nasional Bandung Jl. PHH. Mustofa no 23 Bandung Indonesia
Email: [email protected]
Marsono
Institut Teknologi Nasional Bandung Jl. PHH. Mustofa no 23 Bandung Indonesia
Email : [email protected]
Sahril Sayuti
Institut Teknologi Nasional Bandung Jl. PHH. Mustofa no 23 Bandung Indonesia
Email :[email protected]
Abstract— Brushless DC motors (BLDC) is electric motor with high efficiency and excellent controllability, and are widely used in many applications. This paper explains the analysis of a 5 kW liquid cooling BLDC motor numerically. This motor is an axial BLDC motor which is composed of a stator consisting of an armature and a magnetic rotor. Numerically analysis show that cooling temperature have significant effect on power and efficiency of motor. Lower of cooling temperature produce higher motor power and efficiency. Low temperature liquid cooling motor can produce maximum power up to 6 kW and up to 88.0 % of efficiency, while air cooling motor can produce maximum power up to 3.5 kW and up to 55.0% efficiency. From above calculation it can be concluded that proper cooling process can increase efficiency up to 33 %.
Keywords—Axial, BLDC, rotor, stator, windings
I. INTRODUCTION
Brushless DC motors (BLDC) is electric motor with high efficiency and excellent controllability, and are widely used in many applications. The BLDC motor has power-saving advantages relative to other motor types [1]. This paper describes the modeling of heat transfer and cooling processes in liquid-cooled BLDC motors. Many studies have shown that the working temperature of an electric motor affects the performance of the motor. Temperature affects maximum power and efficiency. The higher the motor temperature, the maximum power will decrease and result in decreased efficiency [2].
This is because increasing temperature reduces the insulation resistance of the windings, generates thermal stress, and reduces efficiency [3].
One method to reduce the operating temperature of the BLDC motor is liquid cooling. In general, liquids have a higher thermal conductivity than air, which increases the rate of heat transfer from the motor to the surrounding air [4].
II. MOTORDESCRIPTION
In this modeling, the BLDC motor used is the axial type BLDC which consists of the main components of the rotor, stator, bearings and casing. The motor stator consists of a copper wire wound on a core (armature).
Armature core is made from pure iron powder with 99% Fe content mixed with carbon fiber resin as the bounding. The stator winding (armature) uses copper wire coated with an insulator with a total diameter of 0.6 mm. The rotor on the BLDC motor consists of 12 pairs of permanent magnets. The magnets used in axial Brushless DC motors are neodymium types which are strong magnets that have a very wide range of applications [5,6].
Figure 1. shows a stator which consist of a core and copper windings forming a core and armature unit.
Figure 1 Stator consist of core and armature A rotor piece consist of 8 pairs of neodymium magnet is shown in Figure 2.
Figure 2 Magnetic rotor
Journal of Multidisciplinary Engineering Science Studies (JMESS) ISSN: 2458-925X Vol. 6 Issue 11, November - 2020
www.jmess.org
JMESSP13420691 3570
General arrangement of the BLDC motor to be analyzed is described at Figure 3.
Shaft
Liquid Cooler
Liquid cooler
Rear bearing Front bearing
Magnetic rotor Armature (stator)
Casing wall
Figure 3 General arrangement of BLDC motor to be analyzed.
This motor has a nominal power of 5 kW and can generate maximum power of up to 7 kW at maximum speed 6000 rpm which electric input power of 60 V DC Maintaining the Integrity of the Specifications
III. NUMERICALANALYSIS
A. MODEL FORMULATION
This paper discusses liquid cooling process in a 5 kW BLDC motor. The motor input is electric power at voltage 60 V with 90% rate efficiency and operated of about 2000-6000 rpm. The motor consirt of an armature and single magnetic rotor. MAXWELL criteria is aplied for simulation do Electromagnetic losses such as coreloss and copper losses, while losses due to bearing friction are neglected [7]. Heat Generation on BLDC Motor Losses that occur in Electric Motors can be classified as resistive losses, Eddy current and hysterisis. Mechanical power of rotor is calculated based on Torque. In the case of Eddy curent below equation can be used [8]:
ܲ௬ ൌ ܭ଼
గ
మమ
ఉ (1)
where f is the frequency of the flux variation, Bm is the peak flux density, βm is the arc of the tooth and width of the mast respectively in the electric radians, Ke is the curve of the fit constant calculated from the data of the loss of the laminate.
The hysteresis is modelled using below equation [9]:
ܲൌ ܭ݂ఈܤఉ (2)
where f is the frequency of the flux variation, Bm is the peak density of the flux Kh, Ke, α, β is the fit curve calculated from the data of the loss of the laminate.
Resistive model for heat transfer is described based of the following figure:
Core and armature Magnetic Rotor Casing Air gap
Air gap
Air gap Casing
Qin
R1 R2 R3 R4
R5 R6
R7 R8 R9 R12
R14 R13 R11 R10
Liquid cooler
Air
Air
Air
Figure 4. Liquid cooled motor thermal circuit model
Figure 4 shows the thermal circuit of liquid cooled motor, where heat generate from from core and armature is transferred to atmospheric air axially and also transferred to liquid cooler radially. Symbol R is represent thermal resistance of material and described as following:
x R1, R9 and R 14 are radiative thermal resistance from casing surface to surrounding air.
x R2, R8, R11 and R13 are conductive in casing wall.
x R3, R6, R7 and R 10 are air gap convective thermal resistance
x R4 and R5 are conductive in magnetic rotor x R12 is convective in liquid cooler.
In this model air gap between the armature/core and casing, and air gap between core/armature and magnetic rotor uses Silicone Thermal Grease with a thermal conductivity of 6.2 W / mK as thick as 0.5 mm [10,11].
The magnitude of heat transfer Q from the Core and winding armature to the atmospheric air through air gap and liquid cooler depends on the convection coefficient where calculated based on following equation[12]:
ൌ ሺ െ ሻ (3)
Journal of Multidisciplinary Engineering Science Studies (JMESS) ISSN: 2458-925X Vol. 6 Issue 11, November - 2020
www.jmess.org
JMESSP13420691 3571
Where A is surface area, Ts is surface
temperature and Ta is atmospheric temperature.
h is convection coefficient that described as [12]:
݄ ൌ
ሺͲǤͳͳሻሾͲǤͷܴ݁ଶ ܩܲሿǤଷହ (4) where :
k is thermal conductivity D is diameter
Re is Reynolds number Gr is Grasoft number Pr is Prantl number
Ts is Temperature of surface (casing and core) Ta is air or liquid temperature
Model of mechanical power of Rotor
Rotor rotation is governed by the mechanical equation below [13]:
ܬௗఠ
ௗ௧ ൌ ܶെ ܶ ܦఠ (5) Where Jm is the total moment of inertia ω is the rotor speed; Te is the electromagnetic torque, D is the damping coefficient and TL is the torque required to drive the load.
B. CALCULATION PROCEDURE
The purpose of the simulation is to calculate the power and efficiency of the motor. Electrical energy is supplied to the motor with 60 V of voltage and 85 A of current. The input energy is transferred to mechanical energy (Pmech) and Electrical losses described above. The all parameter are calculated based on numerical using commercial software. The heat source of motor is on the winding and core where heatflux are transferred axially and radially.
C. CALCULATION RESULT
Result of calculation using numerical analysis based on commercial software was focused on effect of cooling media on the motor performance. In the first stage temperature distribution inside motor is calculated. In this case, 5 KW BLDC motor was cooled by water and set as 20oC. In this condition, thermal conductivity of water is 12 W/mK [12]. Numerical simulation result temperature distribution of motor radially and axially. It is shown in Figure 5 and Figure 6.
Figure 5 show that on motor casing radially the temperature distribution relatively symmetric, but in motor armature is seem higher temperature. Highest temperature occur at motor armature where in this point energy input is converted. Similar situation is shown in Figure 6 where temperature distribution at axial direction relatively balance from front to rear of the motor.
Figure 5 Water cooled Motor temperature distribution at radial direction
Figure 6. Cross section temperature distribution on water cooled BLDC motor
Journal of Multidisciplinary Engineering Science Studies (JMESS) ISSN: 2458-925X Vol. 6 Issue 11, November - 2020
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Figure 7 . Effect of cooling temperature to motor power.
Similar calculation using various water temperature and motor speed. Water temperature is set as 20oC, 22oC, 24oC, 50oC, 60 oC and 70oC and motor speed is varied form 1500 rpm to 3500 rpm
Based on numerical analysis, based on previous calculation procedure, motor power and efficiency can be summarized in Figure 7 to Figure 9. In this figure, effect of cooling temperature on motor power is explained. Figure 7 show that higher cooler temperature cause lower power. This is in line with the theory described in the introduction, that the higher the temperature causes the magnetic strength to decrease, causing the motor power to decrease. Low cooling temperature is capable of producing maximum motor power as shown in the motor specifications, 20oC water cooling can produce 6 kW motor power. In Figure 8 and Figure 9 show a close correlation regarding motor performance by type of cooling. Liquid cooler have higher heat transfer rate and provides a greater cooling rate so that the stator and rotor temperatures are relatively low, result in higher motor power (Figure 8). As power increases, the water cooledmotor efficiency is also higher than air-cooled motors. This can be seen in the Figure 9. From Figure 8 and Figure 9, it can be seen that liquid cooling motor can produce maximum power of 5.2 kW and up to 88.0
% of efficiency, while air cooling motor can produce maximum power up to 3.5 kW and up to 55.0%
efficiency
Figure 8. Motor power based on cooler type at various speed.
Figure 9. Motor power based on cooler type at various speed.
IV. CONCLUSSION
Numerical analysis of Effect of cooling temperature on 5 kW axial BLDC motor power and efficiency were presented. The motor power was calculated based on input power minus losses power and efficiency was calculated based power input and power output. Using commercial software calculation show that cooling temperature have significant effect on power and efficiency of motor. Lower of cooling temperature produce higher motor power and efficiency. Low temperature liquid cooling motor can produce maximum power up to 6 kW and up to 88.0 % of efficiency, while air cooling motor can produce maximum power up to 3.5 kW and up to 55.0%
efficiency. From above calculation it can be concluded that proper cooling process can increase efficiency up to 33 %.
ACKNOWLEDGMENT
This research paper is funded from Indonesia Government in “Penelitian Terapan Unggulan Perguruan Tinggi”scheme year 2019.
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4699
Liquid Cooling Model Of Axial Bldc Motor
By Tarsisius K
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PAPER ID 68015553
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PRIMARY SOURCES
HaiShun Sun, Ju Liu, JinYu Wen, ShiJie Cheng, Cheng Luo, LiangZhong Yao. "Participation of large-scale wind
power generation in power system frequency regulation", Chinese Science Bulletin, 2013
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