Experimental and Numerical Study of Windage Losses in the Narrow Gap Region of a High-Speed Electric Motor

Windage (drag) losses have been found to be a key design factor for high power density and high-speed electric motor development. Inducing axial flow between rotor and stator is a common method in cooling the rotor. Hence, it is necessary to understand the effect on windage while forced axial airflow is in present in the air gap. The current paper presents results from experimental testing and modeling of a high-speed motor designed to operate at 30,000 revolutions per minute (RPM) and utilize axial air cooling of 200 Liters per minute (LPM) to cool the motor. Details of the experimental apparatus and computational fluid dynamics (CFD) modeling of the small gap narrow region of the stator/rotor are outlined in the paper. The experimental results are used to calibrate the CFD model. Results for windage losses, flow rate of cooling air, power and torque of the motor versus mass flow rate are given in the paper. Trade studies of CFD on the effect of inlet cooling flow rate, and parasitic heat transfer losses on the Taylor–Couette flow coherent flow structure breakdown are presented. Windage losses on the order of 20 W are found to be present in the configuration tested and simulated.