Vol. 337 No. 4 (2026)
DOI https://doi.org/10.18799/24131830/2026/4/5153
Simulation of the thermal behaviour of a wound rotor induction motor employed in electric drives of mining complexes using COMSOL Multiphysics
Relevance. In the mining and processing industry, the electric drives are exposed to harsh operating conditions, including high ambient air temperatures, dust, and cyclic overloads. These conditions significantly increase the requirements for reliability and thermal stability of the drive, necessitating accurate thermal modeling to assess the thermal reserve. Wound rotor induction motors, commonly used in doubly-fed induction machine, are subject to increased thermal stress, especially in the rotor winding. These conditions significantly affect the reliability and thermal lifespan of the machine and require accurate modeling to assess its thermal reserve. Aim. To develop a 2D thermal model of the 4AK160M4U3 asynchronous motor in COMSOL Multiphysics 6.0, to investigate the temperature distribution under nominal operation (continuous duty, S1) for different values of ambient air temperature, and to provide a baseline for further research into the thermal state of the machine under the implementation of energy-efficient control strategies in doubly-fed induction motor systems. Methods. Electromagnetic losses were calculated using the Rotating Machinery, Magnetic module, with the Bertotti model applied for M530-50A electrical steel. These losses were then transferred to the Heat Transfer in Solids module using a multiphysics coupling. The simulation accounted for actual material properties, ideal thermal contacts between metals, a thin Kapton H insulation layer, and convective cooling of the motor housing with an air flow velocity of 12 m/s. Results and conclusions. At an ambient air temperature of 25°C, the maximum temperature in the rotor winding reached 118.5°C; at 40°C, it increased to 137.9°C. The temperatures of the stator and housing ranged from 83 to 105°C. The results indicate that under elevated ambient conditions, the motor operates close to the thermal limit of insulation class F. It is therefore recommended to use insulation class H and to upgrade the cooling system in order to ensure reliable performance in mining and mineral processing environments. The developed model provides a validated computational basis for further studies focused on the thermal behavior of wound rotor machines in energy-efficient control applications.
For citation: Tutaev G.M., Bezborodov E.S. Simulation of the thermal behaviour of a wound rotor induction motor employed in electric drives of mining complexes using COMSOL Multiphysics. Bulletin of the Tomsk Polytechnic University. Geo Assets Engineering, 2026, vol. 337, no. 4, pp. 17-25.
Keywords:
wound rotor induction motor, doubly-fed induction motor, insulation class, overheating, cooling system, thermal model, COMSOL Multiphysics
References:
1. Dmitrievskii V., Prakht V., Valeev E., Paramonov A., Kazakbaev V., Anuchin A. comparative study of induction and wound rotor synchronous motors for the traction drive of a mining dump truck operating in wide constant power speed range. IEEE Access, 2023, vol. 11, pp. 68395–68409. DOI: 10.1109/ACCESS.2023.3292244.
2. Ostrovlyanchik V., Popolzin I., Kubarev V., Marshev D., Qu Q. Operation modes of frequency converter in the rotor circuit of induction motor drive of a mine hoist. E3S Web Conferences, 2021, vol. 330. DOI: 10.1051/e3sconf/202133003009.
3. Tutaev G.M. Double inverter-fed induction motor like multifreedom control object. Elektrichestvo, 2013, vol. 10, pp. 48–51. (In Russ.)
4. Sonin Yu.P., Gulyaev I.V. Double inverter-fed induction motor. Saransk, Ogarev Mordovia State University Publ., 1998. 68 p. (In Russ.)
5. Ostrovlyanchik V., Popolzin I., Kubarev V., Marshev D., Qi D. Modeling of induction motor drive of a mine hoist on the basis of a doubly-fed electric machine. E3S Web Conferences, 2021, vol. 330. DOI: 10.1051/e3sconf/202133003008.
6. Gebauer M., Blejchař T., Brzobohatý T., Nevřela M. Conjugate heat transfer model for an induction motor and its adequate FEM model. Symmetry, 2023, vol. 15, pp. 1294. DOI: 10.3390/sym15071294.
7. Tutaev G.M., Bezborodov E.S. The theory of decision-making in problems of energy-efficient electric drive control with a double inverter-fed induction motor. Bulletin of the South Ural State University. Ser. Power Engineering, 2024, vol. 24 (1), pp. 51–58. (In Russ.) DOI: 10.14529/power240106
8. Bezborodov E.S. Development of a mathematical model of a wound rotor induction machine in COMSOL Multiphysics® to assess energy parameters in static mode. Bulletin of the South Ural State University. Ser. Power Engineering, 2024, vol. 24 (4), pp. 30–36. (In Russ.) DOI: 10.14529/power240404.
9. Wang Q., Hao L., Zhang H., Wei H., Sun G., Huang Z., Wu Y., Hu J., Coombs T. Optimisation and loss analyses of pulsed field magnetisation in a superconducting motor with cryocooled iron cores. Supercond. Sci. Technol., 2025, vol. 38, no. 3, pp. 035013. DOI: 10.1088/1361-6668/ada830
10. Wen J., Zheng J. Numerical analysis of the external wind path for medium-size high-voltage asynchronous motors. Applied Thermal Engineering, 2015, vol. 90, pp. 869–878. DOI: 10.1016/j.applthermaleng.2015.07.065.
11. Yang F., Sun Y., Yang J., Zhang S., Liu H., Tang Y. Effect of forced convection cooling on overload performance of permanent magnet synchronous motor for industrial robot. International Communications in Heat and Mass Transfer, 2025, vol. 161, pp. 108527. DOI: 10.1016/j.icheatmasstransfer.2024.108527.
12. Li X., Zhao X., Zhang Z., Avelin A., Liu S., Li H. Selecting cooling methods for electric motors. Applied Thermal Engineering, 2025, vol. 274, pp. 126554. DOI: 10.1016/j.applthermaleng.2025.126554.
13. Wyczółkowski, R., Bagdasaryan, V., Strycharska, D. Experimental and theoretical studies of the thermal contact conductance for bundles of round steel bars. Materials, 2023, vol. 16, pp. 6925. DOI: 10.3390/ma16216925.
14. Wang Y., Sun X., Kang H., Ma X., Zhang T. Thermal contact resistance and heat transfer enhancement mechanisms at non-smooth contact interfaces. Journal of Thermal Science, 2025, vol. 34, pp. 465–497. DOI: 10.1007/s11630-025-2086-5.
15. Boglietti A., Cavagnino A., Staton D.A., Popescu M. Impact of different end region cooling arrangements on endwinding heat transfer coefficients in electric motors. 2009 35th Annual Conference of IEEE Industrial Electronics. Portugal, Porto, 2009. pp. 1168–1173. DOI: 10.1109/IECON.2009.5414657.
16. Konda Y.R., Ponnaganti V.K., Reddy P.V.S., Singh R.R., Mercorelli P., Gundabattini E., Solomon D.G. Thermal analysis and cooling strategies of high-efficiency three-phase squirrel-cage induction motors – a review. Computation, 2024, vol. 12, pp. 6. DOI: 10.3390/computation12010006.
17. Varghese J., Schlautman J., Chen Y., Bhunia S., Srinivasan C. 3D CHT simulation of oil-cooled electric motors: a comparative study of standard and paperless designs. SAE Technical, 2025, pp. 8181. DOI: 10.4271/2025-01-8181.
18. Wang X., Wang Y., Lai X., Wang G., Sang C. Investigation of heat stress and thermal response in deep hot-humid underground environments: a field and experimental study. Building and Environment, 2025, vol. 270, pp. 112506. DOI: 10.1016/j.buildenv.2024.112506.
19. Madhavan S., Devdatta P.B.R., Konda Y.R., Gundabattini E., Mystkowski A., Palka R., Wardach M., Prajzendanc P. Thermal management analyses of induction motor through the combination of air-cooling and an integrated water-cooling. Sci Per, 2023, vol. 13, pp. 10125. DOI: 10.1038/s41598-023-36989-2.
20. Pandey G.K., Sikha S.S., Thakur A., Yarlagadda S.S., Thatikonda S.S., Baiju suja B., Mystkowski A., Dragašius E., Gundabattini E. Thermal mapping and heat transfer analysis of an induction motor of an electric vehicle using nanofluids as a cooling medium. Sustainability, 2023, vol. 15, pp. 8124. DOI: 10.3390/su15108124.
21. Bergfried C., Abdi Qezeljeh S., Roisman I.V., De Gersem H., Hussong J., Späck Leigsnering Y. Thermal finite-element model of electric machine cooled by spray. Energies, 2025, vol. 18, pp. 84. DOI: 10.3390/en18010084.
