Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings
This paper investigates innovative methods for enhancing heat transfer efficiency in high-power permanent magnet electrical machines. The objectives are to quantify the effects of increasing the air speed, increasing the turbulence intensity, and introducing the spacing between windings on cooling p...
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-03-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/14/6/2658 |
| _version_ | 1797242161035476992 |
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| author | Xiang Shen Xu Deng Barrie Mecrow Rafal Wrobel Richard Whalley |
| author_facet | Xiang Shen Xu Deng Barrie Mecrow Rafal Wrobel Richard Whalley |
| author_sort | Xiang Shen |
| collection | DOAJ |
| description | This paper investigates innovative methods for enhancing heat transfer efficiency in high-power permanent magnet electrical machines. The objectives are to quantify the effects of increasing the air speed, increasing the turbulence intensity, and introducing the spacing between windings on cooling performance. The cooling of stator windings is studied through experimental wind tunnel testing and Computational Fluid Dynamics (CFD) modelling. The CFD model is validated against wind tunnel measurements to within 4 Kelvin (K). The results demonstrate that each enhancement method significantly improves the cooling capability. Increasing the air speed from 10 m/s to 40 m/s reduces the winding hotspot temperature by 34%. Introducing a high turbulence intensity of 40% leads to a 21% lower hotspot temperature compared to 0.5% turbulence intensity. Creating a 1.5 mm spacing between coils also substantially improves convection and conduction heat transfer. Overall, combining these optimised design parameters yields over a 40% reduction in hotspot temperature compared to the original design. This research provides practical guidance for maximising heat transfer efficiency in high-power permanent magnet machines, without increasing complexity. The findings will lead to higher machine efficiency, reliability, and longevity for aerospace and other applications. |
| first_indexed | 2024-04-24T18:34:49Z |
| format | Article |
| id | doaj.art-c2dce443e64f4ee483271e98957805e2 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-04-24T18:34:49Z |
| publishDate | 2024-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-c2dce443e64f4ee483271e98957805e22024-03-27T13:20:22ZengMDPI AGApplied Sciences2076-34172024-03-01146265810.3390/app14062658Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator WindingsXiang Shen0Xu Deng1Barrie Mecrow2Rafal Wrobel3Richard Whalley4Department of Mechanical and Construction Engineering, Northumbria University, Newcastle upon Tyne NE1 8ST, UKSchool of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UKSchool of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UKSchool of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UKSchool of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UKThis paper investigates innovative methods for enhancing heat transfer efficiency in high-power permanent magnet electrical machines. The objectives are to quantify the effects of increasing the air speed, increasing the turbulence intensity, and introducing the spacing between windings on cooling performance. The cooling of stator windings is studied through experimental wind tunnel testing and Computational Fluid Dynamics (CFD) modelling. The CFD model is validated against wind tunnel measurements to within 4 Kelvin (K). The results demonstrate that each enhancement method significantly improves the cooling capability. Increasing the air speed from 10 m/s to 40 m/s reduces the winding hotspot temperature by 34%. Introducing a high turbulence intensity of 40% leads to a 21% lower hotspot temperature compared to 0.5% turbulence intensity. Creating a 1.5 mm spacing between coils also substantially improves convection and conduction heat transfer. Overall, combining these optimised design parameters yields over a 40% reduction in hotspot temperature compared to the original design. This research provides practical guidance for maximising heat transfer efficiency in high-power permanent magnet machines, without increasing complexity. The findings will lead to higher machine efficiency, reliability, and longevity for aerospace and other applications.https://www.mdpi.com/2076-3417/14/6/2658stator windingsthermal designair coolingCFD modellingexperimental testing |
| spellingShingle | Xiang Shen Xu Deng Barrie Mecrow Rafal Wrobel Richard Whalley Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings Applied Sciences stator windings thermal design air cooling CFD modelling experimental testing |
| title | Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings |
| title_full | Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings |
| title_fullStr | Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings |
| title_full_unstemmed | Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings |
| title_short | Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings |
| title_sort | enhancing heat transfer efficiency in permanent magnet machines through innovative thermal design of stator windings |
| topic | stator windings thermal design air cooling CFD modelling experimental testing |
| url | https://www.mdpi.com/2076-3417/14/6/2658 |
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