Simulation Visualization

Watch the oil injection cooling simulation in electric motor end winding geometry. This visualization demonstrates the complex multiphase flow patterns and thermal management in high-performance electrical equipment.

Advanced Solver Capabilities

Our team of PhD experts has developed a powerful custom solver specifically engineered for electric motor oil cooling applications, incorporating the latest VOF sharp interface technology to tackle complex multiphase flow and heat transfer challenges in electrical equipment cooling.

Key Capabilities:
  • Solid & Liquid Interaction
  • Sharp Interface Tracking
  • Smart Meshing (AMR)
  • Wetting Phenomena (Dynamic Contact Angle)
Advanced Features:
  • High Prandtl Fluids & CHT
  • Advanced Wall Boundary Treatment
  • Thermal Boundary Layer Optimization
  • Conjugate Heat Transfer

Computational Domain & Geometry

Geometry and Computational Domain - End Winding
Geometry and Computational Domain
The computational domain is simplified to focus only on the end winding section to highlight the effect of oil injection cooling. This approach allows for detailed analysis of the thermal-fluid interaction in the critical cooling region while maintaining computational efficiency.

Mesh Generation & Refinement

Overall Mesh - End Winding
Overall Mesh Structure
The overall mesh shows refinement level 3 at the oil injection outlet to better capture the critical domain. The mesh is relatively coarse with 1.7M cells for this demonstration. In real industry simulations, much finer meshes are used for superior results.
Internal Mesh Structure - End Winding
Internal Mesh Structure
The internal mesh structure shows detailed refinement at the interface between solid and fluid domains, especially in the fluid domain to better capture the thermal boundary layer when oil injects to the solid surface. This is critical due to the high Prandtl number of oil, where the thermal boundary layer is thinner than the hydrodynamic boundary layer.

Simulation Setup & Solver

Technical Specifications

Oil Injection Velocity: 1.5 m/s
Coolant Type: EC110 (Temperature-dependent properties)
Stator Radius: ~16 cm
Mesh Cells: 1.7M (Demo resolution)
Solver Technology: Custom solver for electric motor oil cooling
Interface Model: Latest VOF sharp interface technology
Wetting Phenomena: Dynamic contact angle model
Contact Angles: 20° receding, 30° equilibrium, 40° advancing

Simulation Results

Oil Distribution and Temperature Contour - End Winding
Oil Distribution and Temperature Contour
The results show the output of temperature distribution and oil pattern. This visualization demonstrates the effectiveness of oil injection cooling in managing thermal loads in the end winding region.
Temperature Distribution - End Winding
Temperature Distribution Analysis
This visualization hides the oil pattern to highlight the temperature distribution better, showing the effect of oil injection cooling on thermal management. The temperature contours clearly demonstrate the cooling effectiveness of the oil injection system.

Methodology & Approach

The simulation employs state-of-the-art computational fluid dynamics techniques to model the complex interaction between oil injection and heat transfer in electric motor end winding systems. The methodology includes:

Conjugate Heat Transfer

Seamless coupling of energy transfer between solid domain (temperature field) and liquid coolant (two-phase flow), capturing real-world physics accurately.

Sharp Interface Tracking

Utilizing the isoAdvector method to resolve the liquid-vapor interface with exceptional sharpness—eliminating blurry, diffused interfaces critical for precise multiphase phenomena prediction.

Smart Meshing

Intelligent focusing of high-resolution cells only where needed most—at critical liquid-vapor interfaces and thermal boundary layers—drastically reducing computational time while preserving accuracy.

Applications & Benefits

This advanced oil injection cooling simulation provides valuable insights for the design and optimization of high-performance electrical equipment, particularly in applications requiring efficient thermal management.

Key Applications:

  • Electric Motor Cooling Systems
  • Generator Thermal Management
  • High-Power Electrical Equipment
  • Industrial Cooling Applications

Engineering Benefits:

  • Optimized Cooling Performance
  • Reduced Thermal Stress
  • Enhanced Equipment Reliability
  • Improved Energy Efficiency
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