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This study presents a detailed methodology for non-intrusive measurement of cooling air mass flow rate that enables an overall machine evaluation. This approach enables the simultaneous measurement of air mass flow with shaft torque at differing operating points while minimising the change in air flow introduced by the measurement system. The impact of geometric parameters in the designed system is investigated using a detailed 180° computational fluid dynamics (CFD) model. Special attention was paid to minimising their influence on pressure drop, the mass flow rate through the machine, and measurement uncertainty. Based on the results of this investigation, the system was designed and manufactured, and the experimentally measured data was used to validate the CFD predictions. For the as optimal identified configuration, the flow rate is predicted to decrease by 2.2% relative to unrestricted operation. The achieved measurement uncertainty is ± 2.6% at synchronous speed.

Here, a typical small low-voltage totally enclosed fan-cooled (TEFC) motor (output power ∼10 kW) has been studied using computational fluid dynamics. The complexity of the end-winding geometries, often consisting of several insulated copper strands bound together, provides a challenge to the modelling and analysis of heat transfer and fluid flow phenomena occurring in the end region, which typically is an area of most interest for thermal management. Approximated geometries are usually employed in order to model the end windings to reduce the analysis time and cost. This paper presents a comparison of two cases, a typical simplified geometry and a more realistic geometry of end windings, and uses these cases to highlight the challenges and impact on predicted heat transfer. A comparison of the two models indicate that the different representations of end winding geometries can affect the heat dissipation rate through the outer housing by up to 45%.

A novel experimental rig for analysing intensive liquid cooling of highly power-dense electrical machine components has been developed. Coupled fluid flow and heat transfer have been modelled, using computational fluid dynamics (CFD), to inform the design of a purpose-built enclosure for optimising the design of submerged oil jet cooling approaches for electrical machine stators. The detailed modelling methodology presented in this work demonstrates the value in utilising CFD as a design tool for oil-cooled electrical machines. The predicted performance of the final test enclosure design is presented, as well as examples of the sensitivity studies which helped to develop the design. The sensitivity of jet flow on resulting heat transfer coefficients has been calculated, while ensuring parasitic pressure losses are minimised. The CFD modelling will be retrospectively validated using experimental measurements from the test enclosure.