Machine Dynamics23 - L9

01/08/2023
Sudan International University

Faculty of Engineering
Electrical & Electronic Engineering Dept.
Semester 9
Electrical Machines Dynamics

Lecture 9
Machine Heating and Cooling
Dr. Kamal Ramadan, UofK, 2017 1
Thermal modeling of machines

We have discussed several machine types,
and for each of them we have a
fundamental relationship
Pout = Pin − Ploss
 and also defined the efficiency by:
So, what happens to the power not converted to

useful output, i.e. the power loss Ploss?
 Our power loss from electrical, magnetic and
mechanical parts of the machine is always
translated to heat
Dr. Kamal Ramadan; UofK, 2018
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01/08/2023
 Then the temperature of the parts of the

machine will increase until they reached a
steady state.
 In steady state, the temperatures are
constant, and,
Ploss = Pdissipated
all parts of a machine have some practical
thermal limits (i.e. temperature limits),
particularly for electrical insulation of
conductors, bearings, and permanent magnet
demagnetization limits
This means that thermal design is a key part of
the design of the electrical machines
Winding insulation has an overall thermal

limit, due to the change of physical and
chemical properties, especially the melting
point
Different insulation classes by different
materials
Winding temperature is also one of the main
influences on machine lifetime
In general, each 10 Kelvin (or °C) increase in
the operating temperature of the machine
leads to a 50% reduction in its expected
lifetime before an insulation failure.
 This is actually a reliability issue (in broad
sense) Dr. Kamal Ramadan; UofK, 2018
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Thermal limits: winding insulation

Overall machine insulation class:
Overall machine insulation class: an example of

lifetime
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Thermal limits: magnets and bearings

 Permanent magnets
All PM’s have a Curie Point, i.e. a temperature
beyond which they demagnetize, and this depends
on temperature.
 The hotter a magnet gets, the less negative H (e.g.
from the stator windings) it takes to demagnetize
 Example of
temperature
variation for a
particular
grade of a
NdFeB magnet
Thermal limits: magnets and bearings

 Bearings
Bearings are used to allow rotation of the rotor
while remaining mechanically attached to the
motor structure.
 Bearings have seals, lubricants and tight
mechanical tolerances so also have thermal limits
(100°C to 200°C typically)
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Thermal management
 These limits mean that heat transfer is just as
important as electromagnetic and mechanical
design, and needs to be given an equal weighting
during the machine design process.
 Analysis of heat transfer and fluid flow is more
complex and more non-linear than
electromagnetic behavior.
 Just like Electromagnetics, thermal behaviors can
be modeled using special programs
 Lumped parameter thermal models are usually
employed alongside electromagnetic (and often
mechanical) models.
The permitted temperature rise of a motor

determines the achievable power density and
efficiency.
The figure show the result of heat analysis using
special software .
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01/08/2023
Parameters affecting temperature

distribution in machines:
Electromagnetic and mechanical (aerodynamic
and friction) losses
 Thermal conductivities of the materials
employed
 Heat capacitance of the materials employed
 Heat transfer between the different
components
 Heat transfer to cooling fluids (air, liquid)
 Thermal contact resistance between
components
 Other external influences
The effects of the above parameters on the

temperature distribution also vary with the
duty cycle.
 3 key issues to be considered (in sequence)
 Loss distribution [heat source]
What are the sources of loss (heat
generation)
 Heat removal [passive path]
Theories of cooling (heat dissipation)
 Temperature distribution in the machine
temperature]
Final assessment of thermal management
(temperature)
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Measuring temperature
Thermometer (e.g. thermistor, infrared
thermometer, or thermographic camera): This
method directly measures:
 the temperature, which is very simple. But it can
only measure the surface temperature of each
part of the motor.
 The maximum internal temperature and average
temperature cannot be obtained
Winding resistance:
The average temperature of the winding is
measured based on the model with resistance
temperature coefficient
Online
Observer
 Sensors
Offline
Direct detection of resistances
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01/08/2023
Inserted temperature sensor:

When assembling the motor, a thermocouple or
an inserted thermistor (e.g. PT100, PT1000) can
be buried in the place where the expected
working temperature is the highest.
 This method can measure the temperature close
to the hottest spot inside the motor
Iron or magnetic loss

Losses in the ferromagnetic stator and rotor cores,
caused by time variations of flux density
throughout the stator and rotor core, both from
the fundamental component and from harmonics
Hysteresis loss (empirical equation)
 Eddy current loss (empirical equation)
 Both depend on frequency and flux density; eddy

current loss is also dependent on material
thickness and resistivity (vary with temperature,
just like Pcopper)
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01/08/2023
Permanent magnets are ferromagnetic materials

with some inherent resistivity, and so also
experience eddy current losses (and are also
sometimes laminated to reduce these losses.
 Practical machines also have some mechanical

losses, typically represented as friction and
windage loss.
 Friction loss:
The friction force developed from moving contact
 This is mainly from the bearings that allow the
shaft to rotate, and from any sliding electrical
contacts that connect stator and rotor.
 Developed as heat at the friction surface
 For bearings, gives a loss that is proportional to
the speed of rotation.
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01/08/2023
Windage loss:
 As the rotor rotates, it will also cause the air
around it to move
 This is a complex system to analyze due to three
dimensional fluid flow, but to a large part depends
on the speed and aerodynamics of the rotor.
 e.g. a salient pole rotor (synchronous or SRM)
would have much greater windage losses than
non salient due to the large variation in the airgap
geometry.
 Some windage is frictional heat, some is kinetic
energy imparted to the air
Rating (duty)
 Rating (duty) has a huge impact on thermal
design.
 Rating (duty) is the proportion of time a machine
is designed to operate for.
 For example,
A linear motor designed to launch a 35 ton F35
from a carrier deck at 80m/s needs to output
80MW peak power (to give 1MN thrust at 80m/s);
With an 80% efficiency, the motor has 20MW of
thermal losses.
But there is 20 minutes of downtime between
launches, and the actual part of the motor at peak
power (the last part before takeoff) is only active
for around 0.1 of a second
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For example (cont’d):

So as Watts (W) = Joules (J)/s, this motor develops
20M J/s × 0.1s = 2M Joules of loss, but has 20
minutes to dissipate this.
So the continuous equivalent loss of the motor is
2MJ / (60s × 20) = 1.7kW continuous heat loss,
about the same as a domestic electric heater!
So these motors would work fine as designed.
But assuming the motors weigh around 10 tons,
the temperature increase would be ~ 2°C/s
(assuming they are largely steel), and so in
continuous operation would reach insulation
failure temperatures in less than two minutes
Heat removal
 Heat is removed by conduction, convection and
radiation.
 Radiation is generally small, but may be significant
 In some cases e.g. motors for vacuum / space
operation, it may be the main mechanism of loss
dissipation.
 Usually the most important mechanism is the
convection of air (unless liquid cooled) however
conduction may be significant with some
mounting methods that give a large area of the
machine in physical contact with its surroundings
(e.g. flange vs. foot mounting below)
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Different cooling arrangements

 There are different ways to cool motors
 This depends on the operating environment,
required torque density, availability of cooling
mechanisms, etc.
 Some common cooling mechanisms
Natural convection: many housing design
types, with
axial / circumferential fins:
 depending on machine orientation
Forced convection with fans
 Water jackets: stator/rotor water jackets
 Submersible cooling
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 Through ventilation via rotor and stator cooling

ducts
 Wet rotor & wet stator cooling
 Spray cooling, e.g. oil spray cooling of end
windings
 Direct conductor cooling, e.g. slot water jacket or
hollow conductors.
Whatever method is used, the cooling design
should be optimized during the motor design
process
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Dissipation methods: conduction

For a region of thickness tthick and area A
where
P: power dissipated (W)
ΔT: temperature difference across material thickness (°C)
k: thermal conductivity (W/m/°C), where most metals
have high k, and Insulation materials and most fluids
have low k
If we rearrange this equation
 So, we can define our thermal dissipation in terms

of a thermal resistance Rth, a thermal potential Δt
and a resultant power flow P
 Each of these components can be equated to
electrical circuit terms e.g. Δt and V, R and Rth, I
and P
Thermal conduction between materials is highly
dependent on surface contact resistance
 This is complex to calculate, and often based on
experimental data
Typical thermal
conductivity for
machine materials
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 Heat removal governed by
Where
• ΔT: temperature difference between cooling medium
(e.g.air) and the surface being cooled (e.g. frame)
• h: heat transfer coefficient (W/m2/°C)
• A: surface area
 h depends upon:
 The surface material
 The surrounding medium
 The relative velocity of cooling medium to the
surface
 The surrounding medium may be air or a liquid

(water / oil)
 The factor h can be found experimentally.
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End of Lecture 9
Thank You
16

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01/08/2023

Sudan International University

Electrical Machines Dynamics

Dr. Kamal Ramadan, UofK, 2017 1

Thermal modeling of machines

So, what happens to the power not converted to

 Then the temperature of the parts of the

Winding insulation has an overall thermal

Thermal limits: winding insulation

Dr. Kamal Ramadan; UofK, 2018

Overall machine insulation class: an example of

Dr. Kamal Ramadan; UofK, 2018

Thermal limits: magnets and bearings

Dr. Kamal Ramadan; UofK, 2018

Thermal limits: magnets and bearings

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

The permitted temperature rise of a motor

Dr. Kamal Ramadan; UofK, 2018

Parameters affecting temperature

The effects of the above parameters on the

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

Inserted temperature sensor:

Dr. Kamal Ramadan; UofK, 2018

Iron or magnetic loss

 Eddy current loss (empirical equation)

 Both depend on frequency and flux density; eddy

Permanent magnets are ferromagnetic materials

Dr. Kamal Ramadan; UofK, 2018

 Practical machines also have some mechanical

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

For example (cont’d):

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

Different cooling arrangements

Dr. Kamal Ramadan; UofK, 2018

 Through ventilation via rotor and stator cooling

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

Dissipation methods: conduction

Dr. Kamal Ramadan; UofK, 2018

 So, we can define our thermal dissipation in terms

 Heat removal governed by

 The surrounding medium may be air or a liquid

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

Dr. Kamal Ramadan; UofK, 2018

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