CFD-based Temperature Field Analysis and Lifetime Prediction of Brushless DC Motor

More than one-third of motor accidents are caused by failures in the motor insulation system, making motor insulation the weakest link in motor reliability. Thermal stress is one of the most important factors causing gradual insulation deterioration and eventually failure. In this paper, the three-dimensional temperature field model of the motor is established in Ansys Fluent, and the steady-state temperature field distribution of the motor in the air medium is calculated based on the computational fluid dynamics method, and the maximum temperature rise of the stator insulation is determined. A constant thermal stress accelerated aging test is performed on the motor stator insulation material, and a lifetime prediction model of the motor is established based on the Wiener process, which can accurately predict the lifetime of the motor insulation affected by temperature and improve the operational reliability of the motor.