Screw compressors use electric motors to drive the male screw rotor. They are cooled by the suction refrigerant vapor that flows around the motor. The thermal conditions of the motor can dramatically influence the performance and reliability of the compressor. The more optimized this flow path is, the better the motor performance. For that reason it is important to understand the flow characteristics around the motor and the motor temperatures. Computational fluid dynamics (CFD) can be used to provide a detailed analysis of the refrigerant's flow behavior and motor temperatures to identify the undesirable hot spots in the motor. CFD analysis can be used further to optimize the flow path and determine the reduction of hot spots and cooling effect. This study compares the CFD solutions of a motor cooling model to a motor installed with thermocouples measured in the lab. The compressor considered for this study is an R134a screw compressor. The CFD simulation of the motor consists of a detailed breakdown of the stator and rotor components. Orthotropic thermal conductivity material properties are used to represent the simplified motor geometry. In addition, the analysis includes the motor casings of the compressor to draw heat away from the motor by conduction. The study will look at different operating conditions and motor speeds. Finally, the CFD study will investigate the predicted motor temperature change by varying the vapor mass flow rates and motor speed. Recommendations for CFD modeling of such intricate heat transfer phenomenon have thus been proposed.
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