energies

Article
Coupled Fluid-Thermal Analysis for Induction
Motors with Broken Bars Operating under the
Rated Load
Ying Xie * ID
, Jinpeng Guo, Peng Chen and Zhiwei Li
School of Electrical & Electronic Engineering, Harbin University of Science and Technology,
Harbin 150080, China; guojinpeng_1992@163.com (J.G.); chenp_7@163.com (P.C.);
lzw1067010086@163.com (Z.L.)
* Correspondence: ying.xie@hrbust.edu.cn; Tel.: +86-0451-8639-1678




Received: 3 July 2018; Accepted: 25 July 2018; Published: 3 August 2018


Abstract: Thermal stress of the rotor in a squirrel cage induction motor is generated due to the
temperature rise, it is also one of the factors causing the broken bar fault because the structure of
the rotor would be destroyed if the stress of the rotor bars exceed the strength limit. The coupled
fluid-thermal analysis for the induction motor with healthy and broken bar rotors is performed
in this paper. Much concern has been committed to establishment of the fluid model on the basis
of computational fluid dynamic (CFD) theory. The heat field of the prototypes is analysed so that
the effect of the asymmetrical rotor on the motor heat performance can be investigated in depth.
Eventually, the efficiency of the presented model and method, for the totally enclosed fan cooled
(TEFC) induction motor, can be verified through experimental results. In addition, this paper reports
a quantitative analysis of the heat flux distribution of the fault rotor, and the heat flux density of the
bars is investigated in detail. Then, the part most likely to break in the rotor as a result of the thermal
load is identified.

Keywords: induction motors; finite element method; computational fluid dynamic (CFD) method;
thermal field; fluid field; broken bars fault

1. Introduction
As a key performance parameter of electrical machines, the temperature rise has been of wide
concern in the industrial field. The temperature rise can limit the rated power and reduce the motor
efficiency, and it also imposes special demands on the material of the motor. Therefore, in the process
of the motor design, the temperature limits should be calculated and checked for satisfying the
requirements of functionality and safe. If the operating temperature exceeds the insulation material
working limit of the motor [1], it will cause an accelerated aging effect or even failure of insulation [2,3],
and then machine life expectance can be seriously affected [4]. Accordingly, it is vital to plot the
thermal map of the electric machine, working in the most severe condition.
As well known, the accuracy of thermal analysis greatly depends on the heat transfer coefficient
on heat transfer surfaces, so it is essential for designers to get an accurate analysis of the fluid
field. However, inner and outer environment of the motor is complex, in some conventional
methods [5–7], the fluid model is usually simplified, or the fluid velocity on heat transfer surfaces is
regarded as constant, so the corresponding heat transfer coefficient is also constant. These studies
provide good ways to fluid field analysis, but the continuity of the fluid field distribution is not
included. In view of this problem, reference [8] proposed a coupled calculation of fluid and
thermal field for high speed motor considering tooth slots effects, and [9] proposed analysis of the
electromagnetic-fluid-thermal field in a permanent magnet linear motor. The permanent magnet motor

Energies 2018, 11, 2024; doi:10.3390/en11082024 www.mdpi.com/journal/energies

Energies 2018, 11, 2024 2 of 17

with high speed of 60,000 r/min is discussed in [10], according to computational fluid dynamic (CFD)
theory, the parameters of the equivalent thermal circuit can be obtained. For an air-cooled disc type
electrical machine, the measurement and simulation of stator heat transfer were performed in [11] and
the CFD analysis was introduced. The CFD (computational fluid dynamic) analysis and the thermal
equivalent circuit model have been established for a totally enclosed fan cooled (TEFC) induction motor,
and the simulation data are compared with experimental data measured by sensors [12]. Moreover,
many fluid analyses of the motor are based on local fluid field, very little research has addressed the
complete fluid space, especially for small and medium size induction motors.
In addition, apparent thermal stresses can be observed with the temperature rise of motors.
It frequently leads to cage fracture in the joint of the bars and the rings and accompanying asymmetric
rotor operation, which is a serious accident in the running state of the motor. The thermal field
distribution research on asymmetry rotor can provide some references for the prevention and diagnosis
of fault. With the increase of rotor bar failures, it has received some attention from researchers. In [13],
an innovative method of fault diagnosis for the induction motor with broken bars fault is proposed.
A new methodology was introduced in [14], which integrates vibration and current analysis by
associating signal spectrum analysis to improve the detectability for the motor, under the mechanically
loaded and unloaded running state respectively. Reference [15] evaluated the internal faults of the
induction motor with the squirrel cage by the finite element method as well as discrete wavelet
transform. Reference [16] presented an experimental research of the fault rotor motor, regarding time
frequency evolution effects, and the fault factor can be obtained. The detection methods for induction
motor with rotor bar fault are proposed in [17,18], and different diagnostic mediums are compared in
two studies. The purpose of [19] is to report the effect of partially fault rotor bar based on experimental
research in induction motor. The running characteristics of the motor under different operating
conditions are obtained by discrete wavelet transform analysis. The effect of saturation level due to
rotor bars fault in induction motor was introduced in [20], by means of fundamental electromagnetic
laws and finite element modelling. Obviously, the existing studies works relating to thermal analysis
of the motor with broken bar is still much less than those associated with other aspects.
Considering the aforementioned issues, in this paper, the coupled fluid-thermal analysis of the
prototype running under normal and faulty conditions is performed. To effectively simulate the fluid
field, the 3D model for the prototype motor and the fluid domains are built, and the coupled model
is solved by CFD simulation. The software “ANSYS” was used to analyze the induction motor with
healthy and faulty rotor. The 3D geometry model construction of the induction motor is studied
by commercial software ANSYS ICEM (15, ANSYS Inc., Canonsburg, PA, USA) programs, and the
calculation of the coupled fluid-thermal field, including meshing, solving and post-processing is
achieved by commercial software ANSYS FLUENT (15, ANSYS Inc., Canonsburg, PA, USA). In the
stage of pre-processing, the outer approximate infinite fluid field and 3D finite element construction
model are established, with the ventilation structure and characteristics of heat transfer taken into
account. In the light of Newton’s heat transfer law and Fourier’s theorem, the heat transfer coefficients
of the motor can be obtained, and the steady thermal field of the motor running at full capacity is
computed. The calculated results are close to the experimental data, and the analytical method in the
paper proved to be valuable can provide references for the other middle and small induction motors.

2. Basic Parameters of the Motor and Laboratory Testing Platform

The major data of the prototype motor are listed in Table 1. The air velocity of fluid field and
temperature of the motor are also tested in the laboratory under healthy and broken bar conditions.
The test flat has been shown in Figure 1, and the same rotors, including one healthy rotor and two faulty
rotor are prepared for the test purpose. The motor used for experimental study is a three-phase
induction motor, 50 Hz, 2 poles, 1.1 kW, and the healthy squired cage rotor is made of 16 bars.
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Energies 2018, 11, x FOR PEER REVIEW 3 of 17

KA41L Hot-wire Anemometer

KA41L Hot-wire Anemometer

Raynger ST30 Infrared Thermometer

Raynger ST30 Infrared Thermometer

(a) (b)

Figure
Figure 1. The
1. The laboratory
laboratory test
test
(a) setupand
setup andthe
the broken
broken bar
barrotors:
rotors:(a)(a)
The laboratory
The (b)test test
laboratory setup; (b) the
setup; (b) the
broken bar rotors.
broken bar rotors.
Figure 1. The laboratory test setup and the broken bar rotors: (a) The laboratory test setup; (b) the
broken bar rotors. Table 1. Basic parameters of the prototype motor.
Table 1. Basic parameters of the prototype motor.
Parameter Value Parameter Value
Table 1. Basic parameters
Rated power 1.1 KW of the prototype
Stator motor.
outer radius 120 mm
Parameter Value Parameter Value
Rated voltage 380 V Stator inner radius 67 mm
Parameter
Ratedofpower Value
1.1 KW Stator Parameter Value
Number stator slots 18 Rotorouter
outer radius
radius 120
66.4 mm
mm
Ratedvoltage
Rated power 1.1 KW
380 V Stator
Stator outer
inner radius
radius 67 120 mm
Number of rotor slots 16 Air-gap length 0.3mm
mm
Rated
Number ofvoltage
stator slots 380
18 V Stator
Rotor inner
outer radius
radius 66.467mmmm
Number of stator slots 18 Rotor outer radius 66.4 mm
The air velocity of rotorthe axial direction
along 16 Air-gap
on shell length
surface can be accessed0.3 mm by a hot wire
Number of rotor slots 16 Air-gap length 0.3 mm
anemometer during the experiment as shown in Figure 1. In order to evaluate the heat behaviour of
the
The induction
air air motor,
velocity alonga complete
the axial thermal
directionevaluation
on shell of the prototype motor fitted
by awith thermistor is
The velocity along the axial direction onsurface can be accessed
shell surface can be accessed hot wire
by aanemometer
hot wire
carried
during out in the
the experiment laboratory,
as shown so the temperature
in Figure in
1. Ininorder all
to 1.the spots
evaluate of interest can be obtained. The
anemometer during the experiment as shown Figure In orderthe to heat behaviour
evaluate the heatofbehaviour
the induction
of
temperature on the motor shell is measured by an infrared thermometry probe.
motor, a complete
the induction thermal
motor, evaluation
a complete of the
thermal prototype
evaluation motor
of the fitted with
prototype thermistor
motor fitted withisthermistor
carried out
is in
thecarried
laboratory, insothe
out and
3. Model thelaboratory,
temperature
Fundamental so in
thealltemperature
Equations the spots ofin
interest
all thecan be of
spots obtained.
interest The
can temperature
be obtained. onThethe
motor shell is measured
temperature by an
on the motor infrared
shell thermometry
is measured probe.thermometry probe.
by an infrared
3.1. CFD Model and Temperature Measured Positions
3. Model and
3. Model Fundamental
and FundamentalEquations
Equations
The 3D model of the prototype motor is employed in the paper, as shown in Figure 2.
Meanwhile
3.1.3.1.
CFD Model the Temperature
and presented model is intended to calculate the fluid and temperature field. The
CFD Model and TemperatureMeasured
MeasuredPositions
Positions
structured grids and unstructured grid are adopted in the paper. The motor is meshed by structured
The
grid 3D
The model
due3D of the
to model
complex prototype
ofstructures, motor
and
the prototype is employed
themotor
external
is fluid in the in
space
employed paper,
is the as
meshed shown
by the
paper, inshown
Figurein2. Figure
as unstructured Meanwhile
grids. 2.
theMeanwhile
presented model is mesh
There are 3,160,630 intended
the presented cells
modelto the
in calculate the fluid
is simulations.
intended and temperature
to calculate the fluid field. The structured
and temperature grids
field. and
The
unstructured grid are
structured grids andadopted in thegrid
unstructured paper. The motor
are adopted is meshed
in the by motor
paper. The structured grid due
is meshed to complex
by structured
structures, and the external fluid space is meshed by the unstructured grids. There are 3,160,630
grid due to complex structures, and the external fluid space is meshed by the unstructured grids. mesh
There
cells aresimulations.
in the 3,160,630 mesh cells in the simulations.

Figure 2. 3D model of the motor.

Figure2.
Figure 2. 3D
3D model
model of
of the
the motor.
motor.
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Due
Due to to the
the irregular
irregular arrangement
arrangement of of the
the winding
winding in in the
the stator
stator slots,
slots, the
the model
model must
must bebe
Due tobased
simplified the irregular
on the arrangement
following of the winding
hypotheses [21]: in the stator slots, the model must be simplified
simplified based on the following hypotheses [21]:
based on the following hypotheses [21]:
1.
1. The
The stator
stator winding
winding has has aa good
good dipping
dipping process.
process.
1.
2. The stator winding has a good dipping process.
2. Insulated lacquer on the stator winding surface
Insulated lacquer on the stator winding surface is is uniformly
uniformly distributed.
distributed.
2. The
3. Insulated lacquer on the stator winding surface isisuniformly distributed. the stator core.
3. The equivalent insulation layer in the stator slots is tightly
equivalent insulation layer in the stator slots tightly connected
connected with
with the stator core.
3. The
4. Thethermal
equivalent insulation
difference of layer
all in thein
winding stator
a slotsslot
stator is tightly
can be connected
neglected. with the stator core.
4. The thermal difference of all winding in a stator slot can be neglected.
4. The thermal difference of all winding in a stator slot can be neglected.
Based
Based on on the
the above
above hypothesis,
hypothesis, all all copper
copper wires
wires cancan be
be equivalent
equivalent treated
treated as
as aa copper
copper bar
bar
Based
placed in on
the the above
stator slothypothesis,
center. Theall copper
insulating wires can
paper, be equivalent
impregnating treated
varnish, as a copper
varnish bar placed
film of the
placed in the stator slot center. The insulating paper, impregnating varnish, varnish film of the
in the stator slot
copper center. The insulating paper, impregnating varnish, varnish filmlayer.
of the copper and the
copper andand the
the air
air between
between wires
wires are
are dealt
dealt with
with anan equivalent
equivalent insulating
insulating layer. TheThe equivalent
equivalent
air between
method is wires in
shown arethe
dealt with an
Figures 3 equivalent
and 4. The insulating heat
equivalent layer.conduction
The equivalent method
coefficient ofisthe
shown in the
insulation
method is shown in the Figures 3 and 4. The equivalent heat conduction coefficient of the insulation
Figures 3 be
layer and 4. The equivalent heat conduction coefficient of the insulation layer can be calculated by
layer can
can be calculated
calculated by by Equation
Equation (1)
(1) [21].
[21].
Equation (1) [21]. n


n n
δδ∑

λλλ == = i=1 ,, ,
i =1
i
δi
i
eq
eq n i =1 (1)
(1)

((δ∑δ (λλδi))/λi )
eq n n
i i
i =1 i i
i =1 i =1

where, λeqeq is
is equivalent heat
heat conduction coefficient
coefficient of thethe insulation layer
layer in the stator slots, δi is
where, λeq is equivalent
equivalent heat conduction
conduction coefficient of of the insulation
insulation layer in in the stator slots, δi is
equivalent thickness of each insulating material (δ1(δis thickness of of
the slotslot
wedge, the value is 0.5 mm,
equivalent thickness
thickness ofof each
each insulating
insulating material
material (δ11 isis thickness
thickness of the
the slot wedge,
wedge, the
the value
value isis 0.5
0.5
δ2 is thickness
mm, of theof
airthe
gapair
between slot wedge and stator core, thecore,
valuetheis 0.15 mm, δ3 ismm,
thickness
δ
mm, δ2 is thickness of the air gap between slot wedge and stator core, the value is 0.15 mm, δδ33 is
2 is thickness gap between slot wedge and stator value is 0.15 is
of the enameled
thickness of the wire insulation
enameled wire and impregnating
insulation and varnish, the value
impregnating is 0.96
varnish, mm),
the λi is average
value 0.96 mm),thermal
λ i is
thickness of the enameled wire insulation and impregnating varnish, the value is 0.96 mm), λi is
conductivity of each
average material. each material.
average thermal
thermal conductivity
conductivity of of each material.

Figure 3. The sketch map of the equivalent stator slots.

Figure 3. The sketch map of the equivalent stator slots.

Figure 4. The structure in the modeling of the equivalent stator slots

Figure 4.
Figure 4. The
The structure
structure in
in the
the modeling
modeling of
of the
the equivalent
equivalent stator
stator slots.
slots

Furthermore,
Furthermore, because
because of
of the
the low
low heat
heat conduction
conduction coefficient
coefficient of of air,
air, the
the thermal
thermal contact
contact
Furthermore,
resistance because of the low heat conduction coefficient of air, the thermal contact resistance
resistance of the assembly space between the stator and the frame cannot negligible, and it has
of the assembly space between the stator and the frame cannot negligible, and it has aa
of the
great assembly space between the stator and the frame cannot negligible, and it has a great effect on
great effect
effect on
on the
the thermal
thermal analysis
analysis of
of the
the motor.
motor. The
The thermal
thermal contact
contact resistance
resistance is is defined
defined as
as follows
follows
the thermal analysis of the motor. The thermal contact resistance is defined as follows [22]:
[22]:
[22]:
δδ
Rc R=c == δ ,,,
R (2)
c λAλλ AAaaa
(2)

where,
where, R Rccc is
is the
is the thermal
the thermal contact
thermal contact resistance,
contact resistance, δδδ is
resistance, is the
is the gap
the gap length
gap length between
length between the
between the stator
the stator and
stator and motor
and motor frame,
motor frame,
frame,
the value is 0.5 ×
× 10
10 −m,
−4 4 m,
λ is
λ the
is heat
the heatconduction
conduction coefficient
coefficient of
ofthe
theair,
air, A
A a is
is the
the contact
contact area
area between
between
a
the value is 0.5 × 10−4 m, λ is the heat conduction coefficient of the air, Aa is the contact area between
the
the stator
stator and motor
and motor frame.
motor frame. The
frame. The material
Thematerial properties
materialproperties
propertiesare are isotropic,
areisotropic, and
isotropic,and
andthethe
thelistlist
listofof material
material
of material properties
properties is
properties
is
is given
given
giveninin Table
Table
in Table2. 2.
2.
Energies 2018, 11, 2024 5 of 17

Table 2. Properties of material.

Density Specific Heat Thermal Conductivity Viscosity

Material Type Name
(kg/m3 ) (j/kg−k ) (w/m−k ) (kg/m−s )
Fluid Air 1.225 1006.43 0.0242 1.7894 × 10−5
Solid Slot wedge 2150 1200 0.5
Solid Steel 7650 502.48 48
Solid Iron core 7900 477.3 46
Solid Equivalent insulation 1850 1700 0.287
Solid Copper 8978 381 398
Solid Aluminum 2719 871 202.4

The test points of the temperature A to G given in Figure 2, which generally report the temperature
rise of the motor. The rotor temperature can be obtained from the sensor A planted in rotor bar. The aim
of sensor B is to get the air-gap temperature, but actually it can be only mounted on stator wedge to
obtain temperature of the air-gap near the stator. The sensors C and D are inserted inside two stator
slots center respectively, and one is near the junction box and the other is placed in the opposite side of
the junction box. E, F, G are three measured points of the motor frame. It should be noted that all test
positions are located in the middle of the motor along the axial direction.

3.2. Fundamental Equations of the Fluid and Thermal Field

The fundamental equations governing fluid flow are solved for calculating the fluid field in this
paper. As the range of the Reynolds number is greater than 2300, the turbulence equation is also
required to describe the fluid flow. According to the CFD theory, the standard k-ε equation can be
written as follows [23]:
"  #
∂ ∂ ∂ µt ∂k
(ρk) + (ρkui ) = µ+ + Gk − ρε, (3)
∂t ∂xi ∂x j σk ∂x j
" #
ε2

∂ ∂ ∂ µt ∂ε ε
(ρε) + (ρεui ) = µ+ + C1ε Gk − C2ε ρ , (4)
∂t ∂xi ∂x j σε ∂x j k k

where, Cµ , C1ε and C2ε are constants, µt = ρCµ (k2 /ε) is turbulence viscous coefficient,
Gk = µt ((∂ui /∂x j ) + (∂u j /∂xi ))(∂u j /∂xi ) is turbulent generation ratio, and σk and σe are turbulence
Prandtl number (Pr number) of the k equation and the ε equation, respectively.
Besides, 3D heat transfer equations are required for the temperature calculation [24,25]:

∂ ∂T ∂ ∂T ∂ ∂T
(λ x ) + (λy ) + (λz ) = −q, (5)
∂x ∂x ∂y ∂y ∂z ∂z

∂T 
= 0, (6)
∂n S j

∂T 
− λ  = α ( T − T f ), (7)
∂n SS
where T is the temperature, Tf is the fluid temperature, q is the heat generation per unit volume, α is the
surface heat transfer coefficient, λx , λy , λz are the coefficient of thermal conductivity in x, y, z direction
respectively, n is the unit normal vector of the solution domain boundary, Sj and SS are adiabatic
surface and heat-dissipating surface respectively. The initial data α is constant, and it is variable on the
heat transfer surface when numerical solutions are convergent.
Energies 2018,
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adiabatic surface
adiabatic surface andand heat-dissipating
heat-dissipating surface
surface respectively.
respectively. The
The initial
initial data
data αα is
is constant,
constant, and
and itit is
is
Energies 2018, 11, 2024 6 of 17
variable on the heat transfer surface when numerical solutions are convergent.
variable on the heat transfer surface when numerical solutions are convergent.

Fundamental Assumptions
3.3. Fundamental
3.3. Assumptions
To simplify
To simplify calculation,
calculation, some
some reasonable
reasonableassumptions
assumptionsare
areproposed
are proposedas
proposed asfollows
as follows[26]:
follows [26]:
[26]:
1.
1. Thermal resistance
Thermalresistance
Thermal resistanceofof windings
ofwindings
windingsisis neglected
isneglected because of
neglectedbecause of its
its good
good heat
heat conducting
conducting properties.
properties.
2.
2. The thermal
Thethermal
The contact
thermalcontact resistances
contactresistances between
resistancesbetween
betweenthe the rotor
rotor core
core and
and rotor
rotor bars
bars is
is negligible.
negligible.
3.
3.
3. Stray
Stray loss
Strayloss is focused
lossisisfocused
focusedonon the
onthe tooth
thetooth tip
toothtip of
tipof stator
ofstator and
statorand rotor.
androtor.
rotor.

3.4. Boundary
3.4. Boundary Conditions
Conditions
The coupled
The coupledfluid-thermal
coupled fluid-thermal
fluid-thermal modelmodel
model are adopted
are are adopted
adopted inpaper,
in thisin this and
this paper,
paper, and the
the and
thermaltheboundary
thermal conditions
thermal boundary
boundary
conditions
of of heat
heat transfer
conditions of heat transfer
surfaces
transfer cansurfaces
be got can
surfaces canthe
by be got
be got by
fluid byfield
the fluid
the fluid field
field calculation.
calculation. calculation. Compared
ComparedCompared to traditional
to traditional
to traditional
empirical
empirical
equations, equations,
the the
temperature temperature
results results
obtained obtained
through through
CFD CFD
simulation
empirical equations, the temperature results obtained through CFD simulation are more accurate. simulation
are more are more
accurate. accurate.
In this
In this section,
section, the the fluid
fluid domains
domains of of the
the motor
motor were
were specially
specially considered,
considered, so so that
that they
they are
are closer
closer
to the
to the real
real fact,
fact, asas shown
shown in in Figure
Figure 5, 5, the
the motor
motor is is placed
placed in in an
an approximate
approximate infinite
approximate infinite fluid
infinite fluid space.
fluid space.
space.
Considering the calculation
Considering the calculation time
Considering time
time and and accuracy,
and accuracy,
accuracy,and and
andthe the
the20 20 times
20times volume
timesvolume of
volumeofofthethe motor
themotor
motorwas was chosen,
waschosen,
chosen, it
it it
is
is appropriate
is appropriate
appropriate for
forfor the
thethe computational
computational
computational domain.
domain.
domain. TheThe
The external
external
external fluid
fluid space
fluid space consists
consists
space consists of two
of two
of two parts:
parts: one
oneone
parts: is
is the
is
the rotating
the rotating
rotating fluidfluid domain
domain
fluid domain thatthat is formed
is formed
that is formedbybyby aa 360
a 360 360 degree
degree
degree sweepofof
sweep
sweep ofthe
thefan
the fanblade
fan blade(see
blade (seeFigure
(see Figure6)
Figure 6) and
and the
the
other is
other is the
the rest
rest of
of the
the fluid
fluid space.
space.

Figure 5.
Figure 5. The
The model
model of
of external
external fluid
fluid domain
domain of
of the motor.
the motor.
motor.

Figure 6. Rotating
Figure Rotating fluid domain
domain of fan.
fan.
Figure 6.
6. Rotating fluid
fluid domain of
of fan.

Figure 77 is
Figure is the
the section
section diagram
diagram of of air-gap
air-gap fluid
fluid field,
field, and
and itit is
is divided
divided into
into two
two regions,
regions,
Figure 7 is the section diagram of air-gap fluid field, and it is divided into two regions, including
including the
including the rotary
rotary and
and stationary
stationary fluid
fluid region.
region. The
The rotary
rotary fluid
fluid region
region isis close
close to
to the
the rotor,
rotor, and
and the
the
the rotary and stationary fluid region. The rotary fluid region is close to the rotor, and the stationary
stationary fluid region is close to the stator. On the basis of the reference coordinate
stationary fluid region is close to the stator. On the basis of the reference coordinate system, the system, the
fluid region is close to the stator. On the basis of the reference coordinate system, the motive fluid
domain and the rotor rotate synchronously, and the speed is given as a relative speed. The detailed
boundary conditions of the fluid field are given in Table 3.
Energies 2018, 11, x FOR PEER REVIEW 7 of 17

motive fluid11,domain
Energies 2018, 2024 and the rotor rotate synchronously, and the speed is given as a relative speed.
7 of 17
The detailed boundary conditions of the fluid field are given in Table 3.

Figure
Figure7.7.The
Thesection
sectiondiagram
diagramof
ofair-gap
air-gapfluid
fluidfield.
field.

Table
Table3.3.Boundary
Boundaryconditions
conditionsof
ofcomputational
computationalfluid
fluiddynamic
dynamic (CFD)
(CFD) simulation.
simulation.

Boundary/Cell Zone Condition

Boundary/Cell Zone Condition
in Pressure-inlet Ptotal = 0 Pa
inout Pressure-inlet
Pressure-outlet Ptotal
Ptotal = 0=Pa0 Pa
outwall Pressure-outlet
Stationary wall P
No slip0 Pa
total =
wall
inner wall of stator Stationary wall
Stationary wall NoNo slip
slip
inner wall of stator Stationary wall No slip
outer wall of rotor Moving wall No slip
outer wall of rotor Moving wall No slip
interface
interface Interface
Interface - -
rotating fluid domain
rotating fluid domain Angular velocity
Angular velocity 2830 rad/min
2830 rad/min

3.5. Losses
3.5. Losses
As well known the losses, in an induction motor bring about the temperature rise, which can
As well known the losses, in an induction motor bring about the temperature rise, which can cause
cause significant thermal stress, and the total losses of the motor can be given by the following
significant thermal stress, and the total losses of the motor can be given by the following Equation [26]:
Equation [26]:
P = PPcu
=P+cu P
+alPal++ PPFe + PΩ + P∆ ,
Fe + PΩ + PΔ ,
(8)
(8)

where,PPcucuisiswinding
where, winding loss, PalPisal bar
loss, is bar
loss,loss, PFe
PFe is is core
core P isPmechanical
loss, loss, Ω is mechanical
loss, Ploss, P∆ isloss.Based
 is stray stray loss.
Based on the results of electromagnetic field calculation, the losses can be obtained
on the results of electromagnetic field calculation, the losses can be obtained [27,28]. The rotor [27,28]. The rotor
core
core loss is relatively small and hence it can be ignored in Equation (8).
loss is relatively small and hence it can be ignored in Equation (8).
4. Results and Discussion
4. Results and Discussion
According to the above analysis, the coupled fluid-thermal field of the motor is calculated and the
According
simulation to the
results above analysis,
are analysed the coupled
in this section. fluid-thermal
The absolute steadyfield of thebased
pressure motor is calculated
solver is adopted andin
the simulation results are analysed in this
this paper, and the solving time is about six hours. section. The absolute steady pressure based solver is
adopted in this paper, and the solving time is about six hours.
4.1. Fluid Field Results
4.1. Fluid Field Results
As can be seen from the Figure 8, the 3D fluid distribution on the shell surface, from the figure,
the fluidcan
As be seen from
continuous the Figure
distribution 8, be
can theseen.
3D fluid
The distribution
air velocity on the shell surface, from theto
surface appears figure,
show
the fluid continuous
a significant variationdistribution canand
along the axis, be seen. Thevalue
the max air velocity on the located
of air velocity shell surface
in theappears
fan side,to
it show
is abouta
significant variation along the axis, and the max value of air velocity located in the
10 m/s. The average air velocity on the shell surface is 4~5 m/s. Besides, the fluid status inside and fan side, it is
about
outside10of
m/s.
theThe average
junction boxair velocity on
is obviously the shellunder
different surface is 4~5
rated m/s.
load, all Besides, the fluidwhy
of these explain status
theinside
motor
and outside of
temperature the junction
distribution boxthe
along is obviously different
axial and radial underisrated
direction load, all of these
not symmetrical. explain
The air whyalong
velocity the
motor
the path l1 was measured during the experiment, and the 19 testing points was selected (see Figureair
temperature distribution along the axial and radial direction is not symmetrical. The 9),
velocity along
and the test datathearepath l1 waswith
compared measured during results
the calculated the experiment, and10.the 19 testing points was
in the Figure
selected (see Figure 9), and the test data are compared with the calculated results in the Figure 10.
Energies 2018, 11, 2024 8 of 17
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Energies 2018, 11,2018,
x FOR 11,PEER
FORREVIEW
PEER REVIEW 8 of 17
Energies 2018, 11, x FOR PEER REVIEW 8 of 17

Figure 8.8.3D
3Dfluid
FigureFigure fluid field distribution on the
theshell
shell surfaceofofthe
themotor.
motor.
8. 3D field
fluiddistribution on
field distribution on the surface
shell surface of the motor.
Figure8.8.3D
Figure 3Dfluid
fluidfield
field distribution
distribution on
on the
theshell
shellsurface
surfaceofofthe
themotor.
motor.
19 19

l1 l1 1919

ll11
1 1
1
1

FigureFigure
9. Air 9.
velocity measured
Air velocity positions
measured on theon
positions motor frame.frame.
the motor
Figure 9. Air velocity measured positions on the motor frame.
Figure 9. Air velocity measured positions on the motor frame.
Figure 9. 12
Air velocity
12 measured positions on the motor frame.
12 Simulation
Simulation
10
12 10 Experiment
Experiment
Simulation
10
Velocity/(m/s)

Simulation
Velocity/(m/s)

8 8 Experiment
10
Experiment
Velocity/(m/s)

8
6
Velocity/(m/s)

8 6
6
4 4
6
4
2 2
4
2
0 0
20 0 5 5 10 10 15 15 20 20
0
0 Air5velocity measurement
Air velocity points
10 measurement
15 points 20
0 Air5velocity measurement points
FigureFigure
10. Comparison 0 of air of
10. Comparison velocity
air velocity in10simulation
in simulation 15
and experiment 20 along
along
and experiment the path
the11.
path 11.
Air velocity
Figure 10. Comparison of air velocity measurement
in simulation andpoints
experiment along the path 11.
Figure 10. Comparison of air velocity in simulation and experiment along the path 11.
Figure 11
Figureshows
11 2D
shows streamlines
2D of
streamlines outer
of fluid
outer field
fluid of the
field ofmotor,
Figure 10. Comparison of air velocity in simulation and experiment from
the motor, thethe
from
along figure,
the the air
figure,
path 11. thegets
air gets
into fan
intocover
Figure and
fan11cover itand
shows will
2Ditbe affected
streamlines
will by
ofthe
be affected byrotating
outer fluid
the of theof
field
rotating offan,
thethen
the the
motor,
fan, then air
from flows
the out along
the flows
air figure, the
air heat
thealong
out gets
the heat
Figure
radiation
into fan 11
fins
cover
radiationshows
at high
and it 2D
will
fins at 2D
highstreamlines
velocity,
be which
affected of
leads
by
velocity, which outer
theto fluid
the
rotating
leadsfluid field
forced
of the
to thefield of
heat
forced the
fan, motor,
exchange
then on
the from
airshell
flowsthe figure,
surface
out of
along the
the air
motor.
the gets
heat
Figure 11 shows streamlines of outer of heat exchange
the motor, from on the
shellfigure,
surfacethe
of the
air motor.
gets
into fan cover
radiation finsand
at it will
high be affected
velocity, which by theto
leads rotating
the of the
forced heat fan, then the
exchange on air flows
shell out of
surface along
the the heat
motor.
into fan cover and it will be affected by the rotating of the fan, then the air flows out along the heat
radiation fins at high velocity, which leads to the forced heat exchange on shell surface of the motor.
radiation fins at high velocity, which leads to the forced heat exchange on shell surface of the motor.

FigureFigure
11. 2D11.
streamlines of outer
2D streamlines fluid field
of outer fluidof theof
field motor.
the motor.
Figure 11. 2D streamlines of outer fluid field of the motor.
WhenWhen
fluid fluid
comecome
to thetoload
the side
load of theofmotor,
side the velocity
the motor, reduces
the velocity rapidly
reduces due to
rapidly thetokinetic
due the kinetic
energy
Whendecrease,
energyfluid caused
decrease, by
come Figure
to
caused open
the load
11.by environment.
2Dside
openof the motor,
environment.
streamlines Meanwhile,
thefluid
of outer velocity the
Meanwhile, obvious
reduces
field of thethe vortex
rapidly
obvious
motor. due phenomenon
to thephenomenon
vortex kinetic
Figure 11. 2D streamlines of outer fluid field of the motor.
energy decrease, caused by open environment. Meanwhile, the obvious vortex phenomenon
When fluid come to the load side of the motor, the velocity reduces rapidly due to the kinetic
energy decrease, caused by open environment. Meanwhile, the obvious vortex phenomenon
Energies 2018, 11, 2024 9 of 17

Energies 2018, 11, x FOR PEER REVIEW 9 of 17

When fluid come to the load side of the motor, the velocity reduces rapidly due to the kinetic
energy
appears decrease,
Energies 2018,
at caused
11, x FOR
region andby
V1PEER open
REVIEW
V2, which environment.
will lead to Meanwhile,
the energythe obvious
loss of fluid vortex
medium phenomenon
and is oneappears
9 of
of17the
at Energies
region 2018,
V1 11,
and x FOR
V2, PEER
which REVIEW
will lead to the energy loss of fluid medium and is one of the main 9 of 17
reasons
main reasons for vibration noise. Except for outer fluid field, the inner fluid field also is key to the
forappears
vibration
temperature
at region
noise.
rise
V1 andfor
Except
calculation.
V2,outer
The
which
TEFC
willfield,
fluid lead to
induction thethe energy
inner
motor fluid loss
field
is adopted
of also
fluidismedium
keypaper,
in this
and
to the is one of therise
temperature
so theoneinner and
appears
main reasons at region V1 and V2, which will lead to the energy loss of fluid medium and is key of the
the
calculation.
outer fluid Thefor
field are
vibration
TEFC
relatively
noise. motor
induction Exceptisfor
separate, and
outer fluid
adopted
the fluid inflowfield,
this the inner
paper,
inside
fluid
so motor
the the innerfield
is andalsoouter
completely
is to
fluid
caused field
main reasonsrise
temperature forcalculation.
vibration noise. The Exceptinduction
TEFC for outermotor fluid field, the inner
isisadopted fluid
in this field so
paper, also is inner
the key toand theby
are relatively
thetemperature
rotor rotation.separate,
Figure and the
12 gives fluidthe flow inside
3D induction the motor
fluid distribution incompletely
the air-gap. caused
The by the
result rotor
shows rotation.
that air
outer12 fluid riseare
field calculation.
relatively The TEFC
separate, and the fluid motor
flowTheis adopted
inside in thisis
the shows
motor paper, so the
completely inner
caused and
by
Figure
velocity gives
adjacent the
to 3D fluid
rotor distribution
surface can reachin the
about air-gap.
10 m/s, and result
it is close that
to air velocity
tangential speed adjacent
of the
outer
the fluid
rotor field are
rotation. relatively
Figure 12 givesseparate,
the 3Dand fluidthedistribution
fluid flow inside in the the motorThe
air-gap. is completely
result shows caused
that airby
to rotor
rotor. surface can reach about a10stationary,
m/s, and and it is itclose to tangential speed of themovement
rotor. Moreover,
the Moreover,
rotoradjacent
velocity rotation.since stator
toFigure
rotor 12 is
gives
surface thereach
can 3D fluidabout 10has m/s,aand
distribution strong
in the effect
it isair-gap.
close to on
The fluid
result shows
tangential speedthatof in the
air
the
since stator
air-gap. is a
Therefore, stationary, and it has a strong effect on fluid movement in the air-gap. Therefore, the air
velocity
rotor. adjacent the
Moreover, since airstator
to rotor velocity
is a changes
surface can reachgreatly,
stationary, about
and it10 that
has is,
m/s, it shows
and
a strong it is an obvious
close
effect to fluid
on decline
tangential
movement trend
speed inofalong
the
the
velocity
theair-gap. changes
radialMoreover,
rotor. direction. greatly, that is, it shows an obvious decline trend along the radial direction.
Therefore,since the airstator is a changes
velocity stationary, and itthat
greatly, hasis,a itstrong
showseffect on fluid
an obvious movement
decline in the
trend along
air-gap.
the radialTherefore,
direction. the air velocity changes greatly, that is, it shows an obvious decline trend along
the radial direction.

Figure
Figure 12.
12. 3D
3D fluid
fluid field
field distribution
distribution in
in the
the air-gap.
air-gap.
Figure 12. 3D fluid field distribution in the air-gap.
Figure 12. 3D fluid field distribution in the air-gap.
As shown in Figure 13, l2 is an axial path on the rotor surface, including the rotor core and the
AsAsshown
shownininFigure Figure13,
13,l2l2isisananaxial
axial path
path on the
the rotor
rotorsurface,
surface,including
includingthe the rotor
rotor corecoreandandthethe
end-ring. The variation of air velocity along the path l2 is shown in Figure 14. From it, it is clear that
end-ring. As
end-ring. shown
The in
Thevariation Figure
variationofofair 13, l2 is
airvelocity an axial
velocity along path on
along the path the
path l2 rotor surface,
l2 isisshown including
shownininFigure
Figure14. the
14.From
Fromrotor
it,it, core
it is
it is and
clear
clear the
that
that
the fluid field is generally symmetrical in the axial direction. The air speed on the rotor core surface
end-ring.
thethe
fluid field
fluid The
is isvariation
field generally
generallyofsymmetrical
air velocity along
symmetrical in thethe
in the path
axial l2 is shown
direction.
direction. Thein
The air
air Figure
speed
speed 14. From
ononthethe it, itcore
rotor
rotor iscore
clear that
surface
surface
hasthe
almost
fluid no change,
field and asymmetrical
is generally substantial in fluctuation can be found
the axial direction. in speed
The in
air the end-ring segment,
on thesegment,
rotor core which is
surface
hashas almost
almost nonochange,
change, andaasubstantial
and substantial fluctuation
fluctuation can
can be befound
found inthetheend-ring
end-ring segment, which
which is is
attributed
has to
almost violent
no turbulence
change, and a in the
substantialconfluence of
fluctuation the
can air
be gap and
found in the
the end cavity.
end-ring segment, which is
attributed to violent turbulence in
attributed to violent turbulence in the confluence the confluence of the air gap and the end cavity.
air gap and the end cavity.
attributed to violent turbulence in the confluence of the air gap and the end cavity.

Figure 13. 3D
Figure 3D model of the rotor.
Figure 13.
13. 3D model
model of
of the
the rotor.
rotor.
Figure 13. 3D model of the rotor.
1010
10

9.5
9.5
Velocity/(m/s)

9.5
Velocity/(m/s)
Velocity/(m/s)

9 rotor core
9 rotor core
9 rotor core
8.5 end-ring
8.5 end-ring
8.5 end-ring
8
8 80 20 40 60 80 100
0 0 2020 40
Axial 60
40 length/mm60 80
80 100
100
Axial
Axiallength/mm
length/mm
Figure 14. Fluid velocity distribution on rotor surface along axial.
Figure
Figure 14.
Figure Fluid
14.
14. Fluidvelocity
Fluid velocitydistribution
velocity distribution on
distribution on rotor
rotor surface
rotor surface along
surfacealong axial.
alongaxial.
axial.
The accuracy of thermal analysis depends on the model. As a consequence, it also depends on
theThe accuracy
The accuracy
obtained
The accuracy of
ofofthermal
thermal
coefficient analysis
analysis
of heat
thermal depends
transfer
analysis related on
depends
depends to
on the
the model.
oninternal
the and As
model.
model. As aaa consequence,
consequence,
external ititalso
heat exchange
consequence, it also depends
ofdepends
also the onon
motor,
depends on
the the obtained
obtained
including coefficient
coefficient
natural and ofof heat
heat
forced transfer
transfer related
related
convection. In to
to
this internal
internal
paper, and
a external
external
numerical heat
heat exchange
exchange
algorithm of of
of
heat the
themotor,
motor,
transfer
the obtained coefficient of heat transfer related to internal and external heat exchange of the motor,
including
including
coefficient natural
natural
is and andforced
proposed, forcedconvection.
according convection.
to Newton’sInIn this
thisof
law paper,
paper,
cooling numerical
a and
numerical
Fourier’salgorithm
algorithm
law of heat ofofconduction.
heat
heattransfer
transfer
coefficient
coefficient is proposed,
is proposed, accordingtotoNewton’s
according Newton’slaw lawof of cooling
cooling and
and Fourier’s
Fourier’slaw
lawofofheat
heatconduction.
conduction.
Energies 2018, 11, 2024 10 of 17

including natural and forced convection. In this paper, a numerical algorithm of heat transfer coefficient
is proposed, according to Newton’s law of cooling and Fourier’s law of heat conduction.
Energies 2018, 11, x FOR PEER REVIEW 10 of 17
After getting the initial fluid field, the initial heat transfer coefficient can be obtain, from which
the heat field
Afterofgetting
the motor can be
the initial determined
fluid by the
field, the initial Equations
heat (5)–(7). On
transfer coefficient canaccount of the
be obtain, fromtemperature
which
of allthe
nodes,
heat field of the motor can be determined by the Equations (5)–(7). On account (9),
a new heat transfer coefficient can be determined according to Equation and the
of the
temperature
temperatureof allofnodes willabe
all nodes, calculated
new again
heat transfer based oncan
coefficient it: be determined according to Equation
(9), and the temperature of all nodes will be calculated again based on it:
λ( T − Tw )
αi = (T − T )  ,
λ (9)
αi∆X
= Tw −wT f ,
ΔX (Tw − Tf )
(9)

where i is the
where i isnumber of iterations,
the number αi is αcoefficient
of iterations, of heat transfer for the ith iteration, λ is the thermal
i is coefficient of heat transfer for the ith iteration, λ is the
conductivity
thermal of cooling medium,
conductivity of coolingTw ismedium,
the surface Tw temperature
is the surfaceoftemperature
solid locatedofon the fluid-solid
solid located on interface,
the
Tf is the averageinterface,
fluid-solid temperature
Tf is the fluid, ∆X
ofaverage is the distance
temperature of ΔX
of fluid, twoiselements center,
the distance of twoand it depends
elements center,on the
meshand it depends
generation on the mesh
strategies, generation strategies,
T is temperature T iswith
at position temperature
distance at ∆X fromwith
ofposition the distance of ΔX
body surface.
from the body surface.
Equations (10) and (11) are used to identify whether the heat transfer coefficient and temperature
Equations
are acceptable. The(10) and (11)
iteration are usedif the
is stopped to identify whether
heat transfer the heat and
coefficients transfer coefficient meet
temperatures and the
temperature are acceptable. The iteration is stopped if the heat transfer coefficients and temperatures
two convergence conditions of (10) and (11), otherwise the iteration continues, and the chart of the
meet the two convergence conditions of (10) and (11), otherwise the iteration continues, and the
iterative method is shown in Figure 15.
chart of the iterative method is shown in Figure 15.

Figure 15. The chart of the iterative method.

Figure 15. The chart of the iterative method.

(αi+1 −αi )
<ε , (10)

 ( α i +1 − αi +α1 )  1
i 
 < ε1, (10)

 α i +1
Energies 2018, 11, 2024 11 of 17
Energies 2018, 11, x FOR PEER REVIEW 11 of 17

( )
Energies 2018, 11, x FOR PEER REVIEW   11 of 17
 TT (k(+k +11))
−−TTk k 
<ε<

( k +11))  2 , ε2 (11) (11)

TTT((kk +
( +1)
)

k 
 −T
( k +1)
< ε2 , (11)
where Tk T
where is the
isk the temperatureobtained
temperature obtained at the kkTtimes,
at the times,ε1ε1and and ε2 εare
2 areresidual
residualerror.To
error.getToa get
morea more
precision
precision heatheat transfer
transfer coefficient,
coefficient, the environmental
the environmental temperature
temperature was chosen
was chosen as theas the temperature
initial initial
where Tk isofthe
temperature temperature
fluid field. The obtained
heat at thecoefficient
transfer k times, εdistribution
1 and ε2 areofresidual
the motorerror.To
is get a more
displayed in 16a,b.
of fluid field. The heat transfer coefficient distribution of the motor is displayed in Figure
precision
Figure 16a,b.heat
The transfer
calculatedcoefficient, the environmental
results of fluid field can provide temperature was chosen
accurate boundary as the
conditions forinitial
the
The calculated results of fluid field can provide accurate boundary conditions for the thermal field
temperature
thermal of fluid field.
field calculation. FromThetheheat transfer
results, it iscoefficient
revealed that distribution
the fluid of the distribution
field motor is displayed
has littlein
calculation.
Figure From
16a,b. the
The results, it
calculated is revealed
results of that
fluid the
field fluid
can field
provide distribution
accurate
change before and after the broken bar fault, so only the results of fluid field about healthy motor
has
boundary little change
conditions before
for the and
afterwere
the broken
thermal field
reported. bar fault, so
calculation. only
From the
the results
results, ofit fluid
is field
revealed about
that healthy
the fluid motor
field were reported.
distribution has little
change before and after the broken bar fault, so only the results of fluid field about healthy motor
were reported.

(a) (b)
Figure 16. Heat transfer coefficient distribution of the motor: (a) Heat transfer surfaces distribution of
Figure 16. Heat transfer coefficient (a) distribution of the motor: (a) Heat(b) transfer surfaces distribution of
the stator and frame; (b) Heat transfer coefficient distribution of the rotor.
the stator and frame; (b) Heat transfer coefficient distribution of the rotor.
Figure 16. Heat transfer coefficient distribution of the motor: (a) Heat transfer surfaces distribution of
4.2. Thermal Field
the stator Results
and frame; (b) Heat transfer coefficient distribution of the rotor.
4.2. Thermal Field Results
In this section, 3D steady thermal field of the motor operating at the full load is studied. Figure
4.2. Thermal Field Results
17a–c shows
In this the temperature
section, 3D steady distribution
thermal fieldof the of motor
the with
motor healthy cage, one
operating at andthe two
fullbroken
load isbars
studied.
In this
respectively. section,
From the3D steady
figures, thermal
the thermalfield of
field the
of motor
the operating
motor can
Figure 17a–c shows the temperature distribution of the motor with healthy cage, one and two beat the full
divided load
into is
two studied.
regions,Figure
thebroken
17a–c shows the stator
temperature distribution of the motoriswith healthy cage, one and two broken bars
barsrotor part and the
respectively. From the part, and
figures, thethe
rotor temperature
thermal field of much highercan
the motor thanbethe stator
divided temperature.
into two regions,
Because of the existence of the fan and the junction box, the temperature distribution of regions,
respectively. From the figures, the thermal field of the motor can be divided into two the motorthe
the rotor part and the stator part, and the rotor temperature is much higher than the stator temperature.
rotor part and the stator part, and the rotor temperature is much higher
shows obvious asymmetry along the axial and circumferential direction. Due to the good cooling than the stator temperature.
Because of the
Because existence
ofthe
thetemperature
existenceof of
thethefan and
fan and the
theisjunction
junction box, the
box, thetemperature
temperature distribution of motor
the motor
conditions, of motor frame the lowest, relative to the otherdistribution
parts. of the
shows obvious
shows obviousasymmetry
asymmetry along
along the
theaxial
axialand and circumferential direction.
circumferential direction. Due Due to the
to the goodgood cooling
cooling
conditions, the temperature
conditions, the temperature of of
motor
motor frame
frameisisthe the lowest, relativetotothe
lowest, relative theother
other parts.
parts.

(a) (b)

(a) (b)

(c)

Figure 17. Temperature distribution of the motor: (a)

(c) Healthy motor cage; (b) One-broken-bar fault;
(c) Continuous two-broken-bars.
Figure
Figure 17. Temperature
17. Temperature distributionofofthe
distribution themotor:
motor: (a)
(a) Healthy
Healthymotor
motor cage; (b)(b)
cage; One-broken-bar fault;fault;
One-broken-bar
(c) Continuous two-broken-bars.
(c) Continuous two-broken-bars.
Energies 2018, 11, 2024 12 of 17
Energies 2018, 11, x FOR PEER REVIEW 12 of 17

Energies 2018, 11, x FOR PEER REVIEW 12 of 17

The rotary
The rotary magnetic
magnetic field
field is createdbybythe
is created thestator
stator current,
current, which
whichbrings
bringsa power
a powerlossloss
at the
at same
the same
time, time,
and Theand stator
stator winding
winding temperature
temperature riserise caused
caused by by
thethe loss
loss is isalways
alwaysconcerned.
concerned. Figure
Figure 18
rotary magnetic field is created by the stator current, which brings a power loss at the same 18 gives
gives the
the
temperaturetemperature of the stator winding in different cases. The highest temperature of the stator
time, andofstator
the stator winding
winding in different
temperature cases.
rise caused byThe
the highest temperature
loss is always of the
concerned. stator
Figure winding
18 gives
winding with healthy cage is◦ about 76 °C and it increases obviously in case of faulty condition which
with healthy cage is of
the temperature about 76 C winding
the stator and it increases
in differentobviously
cases. Thein highest
case of temperature
faulty condition
of thewhich
stator will
will result in insulation aging. Besides, because of the asymmetric cooling condition on the shell
resultwinding with healthy
in insulation aging.cage is about
Besides, 76 °C and
because it increases
of the obviously
asymmetric coolingin case of faulty on
condition condition
the shellwhich
surface,
surface, the temperature of the stator winding close to the junction box is higher than other
will result
the temperature in insulation aging. Besides, because of the asymmetric cooling condition on the shell
windings. of the stator winding close to the junction box is higher than other windings.
surface, the temperature of the stator winding close to the junction box is higher than other
windings.

(a) (b)
(a) (b)

(c)
(c)
Figure 18. Temperature distribution of the equivalent stator winding: (a) Healthy motor cage; (b)
Figure 18. Temperature distribution of the equivalent stator winding: (a) Healthy motor cage;
One-broken-bar fault; (c) Continuous two-broken-bars.
Figure 18. Temperature
(b) One-broken-bar fault; (c)distribution
Continuousoftwo-broken-bars.
the equivalent stator winding: (a) Healthy motor cage; (b)
One-broken-bar fault; (c) Continuous two-broken-bars.
The temperature distributions of the rotor with healthy bars and broken bars are given in
Figure
The 19. Compared
temperature with otherof
distributions parts rotor
of the with
motor, the rotor temperature is bars
the highest. Dueinto the 19.
The temperature distributionsthe
of the rotor healthy
with bars
healthy and broken
bars and broken are
barsgiven Figure
are given in
good
Compared thermal conductivities of the bars and rotor core, there is minimal temperature changes of the
Figurewith other parts
19. Compared of the
with othermotor, thethe
parts of rotor temperature
motor, is the highest.
the rotor temperature Due
is the to theDue
highest. goodto thermal
the
entire rotor
conductivities ofcan
thebe observed.
bars and rotor core,
good thermal conductivities of the barsthere is minimal
and rotor temperature
core, there is minimalchanges of the
temperature entireofrotor
changes the can
be observed.
entire rotor can be observed.

(a) (b)
(a) (b)

Two broken bars

Two broken bars

(c)
(c)

Figure 19. Temperature distribution of the rotor: (a) Healthy motor cage; (b) One-broken-bar fault;
(c) Continuous two-broken-bars.
Energies 2018, 11, x FOR PEER REVIEW 13 of 17

Figure 19. Temperature distribution of the rotor: (a) Healthy motor cage; (b) One-broken-bar fault;
Energies
(c) 2018, 11, 2024 two-broken-bars.
Continuous 13 of 17

It can be seen from the whole rotor solving region that the lowest temperatures are located at
It can be seen from the whole rotor solving region that the lowest temperatures are located at
broken bars, as shown in Figure 19b,c. Despite there is no currents pass through the broken bars, as
broken bars, as shown in Figure 19b,c. Despite there is no currents pass through the broken bars,
well as no aluminium losses are produced. Based on the magnetic field calculation results [27–29], it
as well as no aluminium losses are produced. Based on the magnetic field calculation results [27–29],
isit revealed
is revealed that thethe
that current
currentandandthethe
aluminium
aluminium losses ininthe
losses therotor
rotorbar
baradjacent
adjacenttotothe
thefaulty
faultybars
bars
increase
increase obviously. The current distribution of rotor bars for different cases is shown in Figure20a.
obviously. The current distribution of rotor bars for different cases is shown in Figure 20a.
But in fact, there are little temperature differences between the healthy bars and broken
But in fact, there are little temperature differences between the healthy bars and broken bars, even the bars, even
the
wholewhole rotor,
rotor, duedue to the
to the goodgood thermal
thermal conductivity
conductivity properties
properties of the
of the rotor
rotor materials.
materials.

350 350
One broken bar Two broken bar
300 The health bars 300 The health bars

250 250
Current(A)

Current(A)
200 200

150 150

100 100

50 50

0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Bar number Bar number

(a) (b)
Figure 20. The current distribution: (a) Healthy motor cage and one-broken-bar fault; (b) Healthy
Figure 20. The current distribution: (a) Healthy motor cage and one-broken-bar fault; (b) Healthy
motor cage and continuous two-broken-bars.
motor cage and continuous two-broken-bars.

The temperature of some representative measured points is listed in Table 4, and the test values
The temperature
and calculated of some
values are representative
compared. Because it measured points
took a long timeisto
listed
do thein Table 4, and the
temperature test values
experiments,
andchange
the calculated values temperature
of ambient are compared. Because
must to be it took a longIntime
considered. this to do the
paper, thetemperature experiments,
ambient temperature at
the change of ambient temperature must to be considered. In this paper, the ambient temperature
above three cases are 20.5 °C, 16.5 °C, 17 °C respectively. From the data in Table 4, it is cleared that at
above three cases are 20.5 ◦ C, 16.5 ◦ C, 17 ◦ C respectively. From the data in Table 4, it is cleared that the
the temperature rise is closely related to the broken bar number, that is, it increases rapidly with
temperature
increase rise isbar
of broken closely related
number. In to the broken
addition, the bar number,values
calculated that is,ofittemperature
increases rapidly with
rise are increase
similar to
the test values at measurement point, and the accuracy of the simulation results is proved. the test
of broken bar number. In addition, the calculated values of temperature rise are similar to
values at measurement point, and the accuracy of the simulation results is proved.
Table 4. Comparison of the temperature value of the measured points (°C).
Table 4. Comparison of the temperature value of the measured points (◦ C).
Measured Test Calculated Test Calculated
Motor Condition
Positions Value
Measured Value Temperature-Rise
Calculated Test Temperature-Rise
Calculated
Motor Condition Test Value
A Positions91.1 93.1 Value 70.6Temperature-Rise Temperature-Rise
72.6
A 91.1 93.1 70.6
Healthy rotor (the B 68.1 69.4 47.6 48.972.6
B 68.1 69.4 47.6 48.9
Healthy rotor (the ambient
ambient C C 76.6 76.676.0 76.0 56.1 56.1 55.555.5
Temperature 20.5 ◦ C)
Temperature 20.5 °C) D D 73.9 73.973.6 73.6 53.4 53.4 53.153.1
F 51.2 49.2 30.7 28.7
F 51.2 49.2 30.7 28.7
A 89.2 91.1 72.7 74.6
A B 89.2 68.091.1 70.1 72.7 51.5 74.653.6
One broken bar (the ambient
One broken bar (the B C 68.0 77.370.1 74.9 51.5 60.8 53.658.4
Temperature 16.5 ◦ C)
D 74.3 72.5 57.8 56.0
ambient C F 77.3 50.374.9 48.3 60.8 33.8 58.431.8
Temperature 16.5 °C) D A 74.3 99.372.5 100.2 57.8 82.3 56.083.2
F B 50.3 74.448.3 76.7 33.8 57.4 31.859.7
Two broken bars (the ambient
C 83.9 79.8 66.9 62.8
Temperature 17 ◦ C) A 99.3 100.2 82.3 83.2
D 79.5 77.3 62.5 60.3
Two broken bars (the B F 74.4 53.476.7 51.1 57.4 36.4 59.734.1
ambient C 83.9 79.8 66.9 62.8
Temperature 17 °C) D 79.5 77.3 62.5 60.3
Figure 21 shows the temperature rise distributions of the motor along the radial direction for the
F 53.4 51.1 36.4 34.1
three cases described above. It is indicates that the change of the temperature rise is visible. Except for
the temperature increase due to the fault, there is subtle difference in radial temperature distribution
tendencies of the motor for the three different cases. There is a large temperature difference between
Energies2018,
Energies 2018,11,
11,xxFOR
FORPEER
PEERREVIEW
REVIEW 14of
14 of17
17

Figure 21
Figure 21 shows
shows the
the temperature
temperature rise rise distributions
distributions of of the
the motor
motor along
along the
the radial
radial direction
direction for
for
the three
the three
Energies cases
2018,cases
11, 2024described above.
described above. ItIt is
is indicates
indicates that
that the
the change
change of of the
the temperature
temperature rise rise is
is visible.
visible.
14 of 17
Except for
Except for the
the temperature
temperature increase
increase duedue toto the
the fault,
fault, there
there isis subtle
subtle difference
difference inin radial
radial temperature
temperature
distribution tendencies
distribution tendencies of of the
the motor
motor for for the
the three
three different
different cases.
cases. There
There isis aa large
large temperature
temperature
the rotor and
difference between
difference stator
between the owing
the rotorto the
rotor and poor
and stator thermal
stator owing
owing toconductivity
to the
the poor of
poor thermal air, and the
thermal conductivity same
conductivity of situation
of air, andalso
air, and theexists
the same
same
between
situation the
situation also stator
also exists and motor
exists between
between the shell because
the stator
stator and of the
and motor contact
motor shell thermal
shell because
because of resistance.
of the
the contact
contact thermal
thermal resistance.
resistance.

90
90
Healthyrotor
Healthy rotor
80
80 Onebroken
brokenbar
bar
One

℃))
Temperature-rise ((℃
70
70 Two broken
Two brokenbars
bars

Temperature-rise
60
60
rotor
rotor
50
50
winding
winding
40
40
statorcore
stator core
30
30
frame
frame
20
20
0.01
0.01 0.02
0.02 0.03
0.03 0.04
0.04 0.05
0.05 0.06
0.06 0.07
0.07
Radiallength
Radial length(m)
(m)

Figure 21.
Figure 21.Temperature
Temperature rise
rise distributions
distributions of
of the
the motor
motor along
along the
the radial
radial direction
direction for
forthe
the three
three cases.
cases.
Figure 21. Temperature rise distributions of the motor along the radial direction for the three cases.

Figure 22
Figure 22 displays
displays the
the heat
heat flux
flux distribution
distribution of of the
the rotor
rotor ring
ring and
and bar,
bar, from
from which,
which, the
the heat
heat flux
flux
Figure
distribution 22of displays
the rotor the heat
appears flux
to distribution
be uneven, and of the
heat rotor
flux ring
value and
of bar,
the from
ring
distribution of the rotor appears to be uneven, and heat flux value of the ring is slightly larger than iswhich,
slightlythe heat
larger flux
than
distribution
that of
that rotorof
of rotor the rotor
bars.
bars. Thereappears
There is fairly
is tohigh
fairly be uneven,
high andin
heat flux
heat flux inheat
theflux
the valueof
junction
junction ofthe
of thebars
the ring and
bars is slightly
and largerwhere
the rings,
the rings, than that
where the
the
of rotor
broken bar
broken bars.
bar faultThere is fairly
fault frequently high
frequently occurs. heat flux in
occurs. Meanwhile, the
Meanwhile, when junction
when broken of the
broken bar bars and
bar fault the rings,
fault happens,
happens, the where
the heat the
fluxbroken
heat flux value
value
bar
of fault
of the
the frequently
joint
joint adjacentoccurs.
adjacent to fault
to faultMeanwhile,
bars goes
bars when
goes up broken
up greatly,
greatly, bar fault
which
which willhappens,
will probablythe
probably heatin
result
result flux
in value of the
aggravation
aggravation ofjoint
of the
the
adjacent
broken bar
broken to fault
bar fault.
fault.bars goes up greatly, which will probably result in aggravation of the broken bar fault.

(a)
(a) (b)
(b)

(c)
(c)

Figure 22.
Figure
Figure 22. Heat
22. Heat flux
Heatflux distribution
fluxdistribution ofofthe
distributionof the rotor:
therotor:
rotor: (a)(a)
(a) Healthy
Healthy motor
motor
Healthy cage;
cage;
motor (b)(b)
(b)
cage; One-broken-bar
One-broken-bar fault;
fault;
One-broken-bar (c)
(c)
fault;
Continuous
Continuous two-broken-bars.
two-broken-bars.
(c) Continuous two-broken-bars.

5. Conclusions
5.
5. Conclusions
Conclusions
In this
In
In this paper,
this paper, the
paper, the research
the research developed
research developed aaa CFD
developed CFD model
CFD model for
model for coupled
for coupled fluid-thermal
coupled fluid-thermal calculation
fluid-thermal calculation of
calculation of the
of the
the
medium
medium
medium small small induction
small induction
induction motormotor with
motor with healthy
with healthy
healthy and and broken
and broken
broken barbar fault
bar fault rotors. The
rotors. The
fault rotors. fluid
The fluid field
fluid field and
field and
and thethe
the
thermal
thermal field have been analyzed around the squirrel cage with or without
thermal field have been analyzed around the squirrel cage with or without the broken bar fault.
field have been analyzed around the squirrel cage with or without the
the broken
broken bar
bar fault.
fault.
Compared with
Compared
Compared with the
with the healthy
the healthy case,
healthy case, the
case, the growth
the growth of
growth of these
of these quantities
these quantities is
quantities is not
is not obvious
not obvious in
obvious in the
in the one
the one broken-bar
one broken-bar
broken-bar
case but
case
case but they
but they increase
they increase greatly
increase greatly in
greatly in two
in two adjacent
two adjacent broken
adjacent broken bars,
broken bars, and
bars, and the
and the thermal
the thermal field
thermal field distributions
field distributions are
distributions are
are
asymmertrical
asymmertrical in
in the
the condition
condition of
of fault
fault cases.
cases. The
The calculated
calculated results
results of
of temperature
temperature
asymmertrical in the condition of fault cases. The calculated results of temperature regarding the fluid regarding
regarding the
the
field are compared with the test results, shows the accuracy and rationality of the model. Furthermore,
Energies 2018, 11, 2024 15 of 17

the number of broken bar has great influence on the motor temperature rise, and it quickly increases
with the number of broken bars increasing. There is fairly high heat flux in the joint of the rings and
the bars, where is the most likely part of broken bar fault. The heat flux of the joint adjacent to broken
bar increases greatly when broken bar fault happens, and it explains why adjacent fractured bars are
always found in the faulty motor.

Author Contributions: X.Y. supervised all process; G.J. implemented simulation; C.P. analyzed the data;
L.Z. checked paper format.
Acknowledgments: This work was supported in part by National Natural Science Foundation of China (51107022);
The Heilongjiang Province Science Fund for Distinguished Young Scholars(JC2016010); Program for Scientific &
Technological Innovation Talents in Harbin (RC2014QN007005).
Conflicts of Interest: The authors declare no conflict of interest.

Abbreviations
λeq equivalent heat conductivity of the insulation layer in the stator slots, W/m·k
δi equivalent thickness of each insulating material, m
λi average thermal conductivity of each material, W/m·k
Rc thermal contact resistance, Ω
δ gap length between the stator and motor frame, m
λ heat conductivity, W/m·k
Aa contact area between the stator and motor frame, m2
Gk turbulent generation ratio
µt turbulence viscous coefficient, Pa·s
Cµ , C1ε , C2ε constants
σk turbulence Prandtl number (Pr number) of the k equation
σε turbulence Prandtl number (Pr number) of the ε equation
T temperature, K
Tf fluid temperature, K
q heat generation per unit volume, J/m2 ·s
α surface heat transfer coefficient, W/m2 ·k
λx , λy , λz thermal conductivity in x, y, z direction respectively, W/m·k
n unit normal vector of the boundary
Sj adiabatic surface
SS heat transfer surface
Pcu winding loss, W
Pal bar loss, W
PFe core loss, W
PΩ mechanical loss, W
P∆ stray loss, W
i number of iterations
αi coefficient of heat transfer for the th times iteration, W/m2 ·k
TW surface temperature of solid located on the fluid-solid interface, K
∆X distance of two elements center, m
Tk temperature obtained at the k times, K
ε1 , ε2 residual error

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