Thermal Performance of Mini Cooling Channels for High-Power Servo Motor with Non-Uniform Heat Dissipation

展开
  • 1. Institute of Precision Guidance and Control, Northwestern Polytechnical University, Xi’an 710072, China
    2. College of Petroleum Engineering, Xi’an Shiyou University, Xi’an 710065, China

网络出版日期: 2023-11-28

基金资助

This study was supported by the National Natural Science Foundation of China (Grant No. 52106112, 52007153) and Natural Science Basic Research Plan of Shaanxi Province in China (Program No. 2022JM-185).

版权

Science Press, Institute of Engineering Thermophysics, CAS and Springer-Verlag GmbH Germany, part of Springer Nature 2023

Thermal Performance of Mini Cooling Channels for High-Power Servo Motor with Non-Uniform Heat Dissipation

Expand
  • 1. Institute of Precision Guidance and Control, Northwestern Polytechnical University, Xi’an 710072, China
    2. College of Petroleum Engineering, Xi’an Shiyou University, Xi’an 710065, China

Online published: 2023-11-28

Supported by

This study was supported by the National Natural Science Foundation of China (Grant No. 52106112, 52007153) and Natural Science Basic Research Plan of Shaanxi Province in China (Program No. 2022JM-185).

Copyright

Science Press, Institute of Engineering Thermophysics, CAS and Springer-Verlag GmbH Germany, part of Springer Nature 2023

摘要

作为飞行器重要执行机构,大功率伺服电机工作性能受到飞行器环境下散热能力的显著制约。在高功率运行状态时,散热能力不足将导致伺服电机出现过热烧毁或产生其它安全隐患。本文根据伺服电机的非均匀发热特性,设计了一种变通道密度的微小通道冷却结构,并以飞行器推进系统低温燃料——超临界甲烷作为冷却工质,开展伺服电机的微小通道再生冷却热沉研究。构建了变密度冷却通道的数值模型以分析其传热机理和热性能,探究不同非均匀热流比的影响,力图抑制电机的过高温升和非均匀温度分布。针对变密度冷却通道的构型特点,采用壁面增强的k-ε RNG模型以精确模拟通道歧管处的复杂湍流特性和通道内的二次流影响。计算结果表明,电机热流比给微小通道热沉的热性能带来显著影响,高热流比会导致严重的非均匀温度分布,而根据电机热流分布设计相应冷却通道密度,可匹配非均匀热流实现传热强化,改善电机散热性能和均温性,控制其工作温升。该方案在所有流动区域中均为混合对流模式,传热系数峰值可达常规直通道的2-4倍。同时,歧管所处的湍流混合状态使得冷却工质和壁面在不同热流比下各自的温差较小,但此时浮升力影响仍不可忽略。热阻R和努塞尔数Nu受热流比、总热流和入口流速等参数的影响显著,效能因子η则还受到运行压力的明显影响。

本文引用格式

WANG Tianhu, GAO Zhigang, BAI Junhua, WANG Zhiqiang, QIAO Keqiang, LI Peng . Thermal Performance of Mini Cooling Channels for High-Power Servo Motor with Non-Uniform Heat Dissipation[J]. 热科学学报, 2023 , 32(2) : 650 -661 . DOI: 10.1007/s11630-023-1761-7

Abstract

High-power servo motor is widely employed as a necessary actuator in flight vehicles. The urgent problem to be solved restraining the working performance of servo motor is no longer the torque and power, but the heat dissipation capability under high-power working conditions, which may cause the overheat, even burn down of motor or other potential safety hazards. Therefore, a structure of mini cooling channels with appropriate channel density is designed in accordance with the non-uniform heat flux of servo motor in this paper. Combined with the regenerative cooling method, the cryogenic fuel supercritical methane is served as the coolant, which is easy to be obtained from the propulsion system, and the heat from the servo motor can be transported to the combustion for reusing. According to the actual working cases of servo motor, a numerical model is built to predict the thermal performance of cooling channels. In order to better represent the secondary flow of coolant in the cooling channels, especially the turbulent mixed flow in the manifold, the k-ε RNG model with enhanced wall treatment is employed resulting from its precise capacity to simulate the secondary and wall shear flow. On this basis, the heat transfer mechanism and thermal performance of cooling channels, as well as the influence of various heat flux ratios are investigated, which can offer an in-depth understanding of restraining excessive temperature rise and non-uniformity distribution of the servo motor. By the calculation results, it can be concluded that under the adjustment of the channel density according to the corresponding heat flux, the positive role of the appropriate channel density and the manifolds on heat transfer is manifested. Moreover, the maximum temperature difference of heating wall can be kept within an acceptable range of the servo motor. The heat transfer coefficient in the manifold is nearly 2–4 times higher compared with that in the straight cooling channels. The effect of buoyancy force cannot be neglected even in the manifold with turbulent mixed flow, and the pattern of heat transfer is mixed convection one in all the flow regions. The thermal resistance R and overall Nusselt number Nu are affected remarkably by all the operation parameters studied in the paper, except the pressure, while the overall thermal performance coefficient η demonstrates differently. The strong impact of heat flux ratio is implied on thermal performance of the cooling channels. Higher heat flux ratio results in the stronger non-uniform temperature distribution. Meanwhile, only tiny temperature differences of the fluid and inner wall in manifolds among various heat flux ratios are demonstrated, resulting from the positive effect of mixture flow on heat transfer.

参考文献

[1] Liu X.D., Chen H., Zhao J., et al., Research on the performances and parameters of interior PMSM used for electric vehicles. IEEE Transactions on Industrial Electronics, 2016, 63(6): 3533–3545.
[2] Xu Y.M., Ai M.M., Yang Y., Heat transfer characteristic research based on thermal network method in submersible motor. International Transactions on Electrical Energy Systems, 2018, 28(3): 1–16.
[3] Ahmed F., Kar N.C., Analysis of end-winding thermal effects in a totally enclosed fan cooled induction motor with die cast copper rotor. IEEE Transactions on Industry Applications, 2017, 53(3): 3098–3109.
[4] Lu Q.F., Zhang X.M., Chen Y., et al., Modeling and investigation of thermal characteristics of a water-cooled permanent-magnet linear motor. IEEE Transactions on Industry Applications, 2015, 51(3): 2086–2096.
[5] Boglietti A., Carpaneto E., Cossale M., et al., Stator winding thermal models for short-time thermal transients: Definition and validation. IEEE Transactions on Industrial Electronics, 2016, 63(5): 2713–2721.
[6] Gyftakis K.N., Sumislawska M., Kavanagh D.F., et al., Dielectric characteristics of electric vehicle traction motor winding insulation under thermal ageing. IEEE Transactions on Industry Applications, 2016, 52(2): 1398–1404.
[7] Chen M.Z., Zhuang W.H., Deng S., et al., Thermal analysis of the triple-phase asynchronous motor-reducer coupling system by thermal network method. Journal of Automobile Engineering, 2020, 234(12): 2851–2861.
[8] Jiao Z.X, He P., Yan L., et al., Hybrid thermal modeling of tubular linear oscillating motor based on sectionalized equivalent thermal circuit. International Journal of Applied Electromagnetics and Mechanics, 2017, 54(4): 535–551.
[9] Kim C., Lee K., Thermal nexus model for the thermal characteristic analysis of an open-type air-cooled induction motor. Applied Thermal Engineering, 2017, 112: 1108–1116.
[10] Jussila H.K., Mityakov A.V., Sapozhnikov S.Z., et al., Local heat flux measurement in a permanent magnet motor at no load. IEEE Transactions on Industry Applications, 2013, 60(11): 4852–4860.
[11] Le T.D., Kim J.H., Kim D.J., et al., Design of indirect closed-cycle cooling scheme coupled with a cryocooler for a 3-MW-class high-temperature superconducting synchronous motor. IEEE Transactions on Applied Superconductivity, 2016, 26(4): 5204904.
[12] Dong B.T., Wang K., Han B.C., et al., Thermal analysis and experimental validation of a 30 kW 60000 r/min high-speed permanent magnet motor with magnetic bearings. IEEE Access, 2019, 7: 92184–92192.
[13] Sikanen E., Nerg J., Heikkinen J.E., et al., Fatigue life calculation procedure for the rotor of an embedded magnet traction motor taking into account thermomechanical loads. Mechanical Systems & Signal Processing, 2018, 111: 36–46.
[14] Jie D.S., Thermal performance analysis of motor based on motor-CAD. AIP Conference Proceedings, 2019, 2073(1): 020049.
[15] Wang D., Liang Y., Li C., et al., Thermal equivalent network method for calculating stator temperature of a shielding induction motor. International Journal of Thermal Sciences, 2020, 147: 106149.
[16] Mroz J., Temperature field of a double squirrel-cage motor during startup. IEE Proceedings-Electric Power Applications, 2005, 152(6): 1531–1538.
[17] Liang D.W., Zhu Z.Q., Zhang Y.F., et al., A hybrid lumped-parameter and 2-D analytical thermal model for electrical machines. IEEE Transactions on Industry Applications, 2021, 57(1): 246–258.
[18] Kim C., Lee K.S., Yook S.J., Effect of air-gap fans on cooling of windings in a large-capacity, high-speed induction motor. Applied Thermal Engineering, 2016, 100: 658–667.
[19] Baraiiski M., Polak A., Thermal diagnostic in electrical machines. Przeglad Elektrotechniczny, 2011, 87(10): 305–308.
[20] Xie Y., Guo J.P., Chen P., et al., Coupled fluid-thermal analysis for induction motors with broken bars operating under the rated load. Energies, 2018, 11(8): 2024.
[21] Bonnett A.H., Operating temperature considerations and performance characteristics for IEEE 841 Motors. IEEE Transactions on Industry Applications, 2001, 37(4): 1120–1131.
[22] Jing T.T., He G.Q., Li W.Q., et al., Flow and thermal analyses of regenerative cooling in non-uniform channels for combustion chamber. Applied Thermal Engineering, 2017, 119: 89–97.
[23] Xu Y.Y., Zhang B.Y., Feng G.H., Research on thermal capacity of a high-torque-density direct drive permanent magnet synchronous machine based on a temperature cycling module. IEEE Access, 2020, 8: 155721–155731.
[24] Pei Z.L., Zhao J.W., Song J.C., et al., Temperature field calculation and water-cooling structure design of coreless permanent magnet synchronous linear motor. IEEE Transactions on Industry Electronics, 2021, 68(2): 1065–1076.
[25] Tuckerman D.B., Pease R.F.W., High-performance heat sinking for VLSI. IEEE Electron Device Letters, 1981, 2(5): 126–129.
[26] Adham A.M., Mohd-Ghazali N., Ahmad R., Thermal and hydrodynamic analysis of microchannel heat sinks: A review. Renewable and Sustainable Energy Reviews, 2013, 21: 614–622.
[27] Zhuang D.W., Yang Y.F., Ding G.L., et al., Optimization of microchannel heat sink with rhombus fractal-like units for electronic chip cooling. International Journal of Refrigeration, 2020, 116: 108–118.
[28] Jing T.T., He G.Q., Li W.Q., et al., Flow and thermal analyses of supercritical hydrocarbon fuel in curved regenerative cooling channel around cavity in rocket based combined cycle engine. Applied Thermal Engineering, 2018, 145: 423–434.
[29] Gao Z.G., Bai J.H., Zhou J., et al., Numerical investigation of supercritical methane in helically coiled tube on regenerative cooling of liquid rocket electromechanical actuator. Cryogenics, 2020, 106: 103023.
[30] Jing T.T., He G.Q., Qin F., et al., An innovative self-adaptive method for improving heat sink utilization efficiency of hydrocarbon fuel in regenerative thermal protection system of combined cycle engine. Energy Conversion and Management, 2018, 178: 369–382.
[31] Lee P.S., Ho J.C., Xue H., Experimental study on laminar heat transfer in microchannel heat sink. Conference on Thermal & Thermomechanical Phenomena in Electronic Systems IEEE, 2002, pp. 379–386.
[32] Tikadara A., Paulb T.C., Oudaha S.K., et al., Enhancing thermal-hydraulic performance of counter flow mini-channel heat sinks utilizing secondary flow: Numerical study with experimental validation. International Communications in Heat and Mass Transfer, 2020, 111: 104447.
[33] Kandlikar S.G., Fundamental issues related to flow boiling in mini-channels and microchannels. Experimental Thermal and Fluid Science, 2002, 26: 389–407.
[34] Gao Z.G., Zhou J., Wang T.H., et al., Heat transfer analysis of supercritical methane on a cooling channel of electromechanical actuator under various flight acceleration overloads. ASME Journal of Thermal Science and Engineering Applications, 2022, 14: 041005.
[35] Gao Z.G., Wang T.H., Yang Y.X., et al., Heat transfer analysis of supercritical methane in microchannels with different geometric configurations on high power electromechanical actuator. ASME Journal of Electronic Packaging, 2022, 144: 041014.
[36] NIST Reference Fluid Thermodynamic and Transport Properties Database (REFPROP). 
https://www.nist.gov/srd/refprop.
[37] Metais B., Eckert E.R.G., Forced, mixed and free convection regimes. Journal of Heat Transfer, 1964, 86(2): 295–300.
文章导航

/