Experimentally validated numerical model of thermal and flow processes within the permanent magnet brushless direct current motor

In this paper, a numerical model describing the heat transfer and air flow inside and outside the casing of the permanent magnet brushless direct current (PM BLDC) motor is presented. In the model, a conjugate heat transfer including the heat conduction with heat sources in windings, magnets, bearings, natural and forced convection and radiation phenomena within internal and external air domain were analysed. The complex geometrical model included windings, a magnet circuit, a rotor with neodymium magnets, a PCB electronic plate, plastic covers, internal air between solid parts as well as a portion of the external air. The validation process of the developed model was realised on the basis of the velocity and temperature fields. The experimental data were recorded by 7 constant temperature anemometers at 4 levels above the motor housing, Laser Doppler Anemometry sensors in two axes inside the rear portion of the motor and 25 thermocouples fixed inside and outside the motor. The experimental and numerical tests were performed for 4 motor loadings and 3 rotational speeds. The average temperature error for the internal point was of 9 K, while that of the external points was of 2 K. The velocity field was very well predicted close to the housing wall in terms of horizontal and vertical components. A slightly worse agreement was found for the vertical component, especially in the vicinity of the shaft. The results were consistent for all the considered motor loadings and rotational speeds.