Electricity and Control May 2025

Drives, motors + switchgear

Keeping motors cool, finding the right solution CWIEME takes place 3 to 5 June this year in Berlin, Germany. The coil winding, insulation and electrical manufacturing exhibition is organised by the Hyve Group. Ahead of the event, Nicola Acampora, Head of Sales at the Hyve Group, shared a comparative evaluation of electric motor cooling systems.

The need for cooling Electric motors generate heat due to energy losses during operation – the more stress, the more the machine radi ates heat that needs to be removed. This makes it crucial to be aware of the operational temperature and how to keep it within an optimal range. If unchecked, the heat can lead to short- and long-term degradation of the electric motor. Excessive heat can warp mechanical components or damage bearings, leading to immediate operational issues. There is also a significant di”erence in performance under ‘hot’ conditions, which means finding the right cooling system for electric motors is key to ensuring their energy e”iciency. The longer an electric motor is subject to inadequate cooling, the shorter its operational lifespan, as wear and tear will be accelerated. Prolonged exposure to high tem peratures can cause deterioration in insulation materials, posing a risk to continuing operation and safety. Without su”icient insulation material, electrical shorts can cause failure of the entire machine, and flammable components may be continuously exposed to high temperatures. Is simple best? A rotary fan is the simplest method to dissipate hot air surrounding an electric motor, promoting convection that allows cooler air to replace it. An uncomplicated layout reduces the number of com ponents and potential failure points, ensuring greater reli ability and ease of troubleshooting. Installation and main tenance are also easier and cost-e”ective, requiring fewer resources to be committed to start and keep such systems running. A lightweight design also makes this solution ide al for fast-changing or mobile tasks.

by the e”iciency of liquid cooling.

Decisions Making the choice will oŽen come down to each system’s limita tions and challenges. Staying with liquid cooling, the complexity produces a higher initial investment that might not be appropriate for smaller pro jects. Additionally, higher levels of expertise are needed to perform maintenance checks and repairs. Depending on the fluid used, liq uid cooling can also be sensitive to extreme temperatures, where there are risks of freezing or evaporation. This makes liquid cool ing appropriate in applications such as high-performance indus trial machinery or electric vehicles where high thermal dissipation is required in a relatively consistent environment. Air cooling provides comparatively lower performance, which might not keep up with electric motors that produce high heat in tensity. If the design requires tight or enclosed spaces where air currents are harder to generate, a fan-based system will not oper ate e”ectively. A generally hot operational environment may also make it hard to generate the necessary convection to cool down the electric motor. Simple air cooling lends itself to lightweight, simple designs like portable power tools and drones. Practical experience under application conditions will provide the most valuable reference data to help the decision-making pro cess, although this is not always available for new projects. That is when it’s important to talk to industry experts and learn about modern, proven solutions. The global coil winding, insulation and electrical manufactur ing event, CWIEME Berlin, is a melting pot of ideas that inspires start-ups as well as industry leaders. This is an environment that facilitates conversation and the exchange of ideas among practi tioners and professionals who have overcome operational tem perature challenges to keep motors cool.

For more information visit: https://berlin.cwiemeevents.com/home

Cool, compact and consistent Liquid cooling, as an alternative, takes advantage of the high heat capacity in fluids like water and cer tain oils to absorb the heat energy emitted by electric motors. This can be done by funnelling the cooling system through the heat source itself or via a jacket that covers the entire component, which greatly improves the cooling e”iciency. The more direct heat dis sipation method also allows more control over the temperature, regu lating the environment of the elec tric motor to a consistent level. De sign flexibilities like compactness and shape are also made possible

CWIEME is the exhibition for coil winding, insulation and electrical manufacturing.

14 Electricity + Control MAY 2025