Numerical Investigation of Optimal Air Flowrate for Cooling 600 W Brushless Direct-Current Motor

Abstract

Personal mobility devices have drawn growing attention to relieve the congestion of traffic and air pollution. The efficiency of electric motors is significant in terms of energy utilization, driving range, and lifetime of the devices. In this study, a brushless direct-current (BLDC) motor is numerically investigated to maximize the system efficiency. The inevitable energy losses in the motor are evaluated using heat sources generated in the motor components. The resulting copper and iron losses generate heat and decrease the motor efficiency. With these, the developed three-dimensional numerical model accurately predicts the temperature variations of the motor components in accordance with the experimental results. Numerical simulations are conducted by supplying air flow at a rate of 0 to 40 l/min. The results show that the decreased temperature at copper windings improves the efficiency of the motor as more air flowrate is supplied. Nonetheless, after the temperature at the copper windings reaches 42.5 °C at an air flow of 30 l/min, the temperature remains constant despite additional increase in the air flow. Through a comparison between the improved electrical work by cooling and the consumed energy to supply the air flowrate, the maximum efficiency of the air-cooled BLDC is found to be 86.3% with an optimal air flowrate of 30 l/min.