Int. J. Computer Applications in Technology, Vol. 30, Nos.

1/2, 2007 47

Fan-shape optimisation using CFD and genetic

algorithms for increasing the efficiency of electric
motors

Noel León-Rovira*
Center for Innovation in Design and Technology,
Tecnológico de Monterrey,
Campus Monterrey. Ave. Eugenio Garza Sada # 2501,
Colonia Tecnológico, CP 64841 Monterrey, Mexico
E-mail: noel.leon@itesm.mx
*Corresponding author

Eduardo Uresti
Center for Artifitial Intelligence,
Tecnológico de Monterrey,
Campus Monterrey. Ave. Eugenio Garza Sada #2501,
Sucursal de Correos ‘J’, Colonia Tecnológico,
CP 64841 Monterrey, Mexico
E-mail: euresti@itesm.mx

Waldo Arcos
Center for Innovation in Design and Technology,
Tecnológico de Monterrey,
Campus Monterrey. Ave. Eugenio Garza Sada # 2501,
Colonia Tecnológico, CP 64841 Monterrey, Mexico
E-mail: waldo.arcos@gmail.com

Abstract: The electric motor efficiency represents the effectiveness with which the motor
converts electrical energy into mechanical energy. As the energy losses are converted into heat,
which is dissipated by the motor frame aided by internal and external fans, a better cooling
system adds up to better efficiency. In recent years, improvements in motor efficiency have been
achieved but at higher costs. By using Genetic Algorithms (GAs), changes are introduced to the
fan shape looking for a better aerodynamic performance. The evaluation of the achieved fan
efficiency with the modified shapes is performed with Computational Fluid Dynamics (CFD)
simulation software.

Keywords: shape optimisation; genetic algorithms; shape parameterisation; CFD.

Reference to this paper should be made as follows: León-Rovira, N., Uresti, E. and Arcos, W.
(2007) ‘Fan shape optimisation using CFD and genetic algorithms for increasing the efficiency of
electric motors’, Int. J. Computer Applications in Technology, Vol. 30, Nos. 1/2, pp.47–58.

Biographical notes: Noel León-Rovira is a Professor at the Center for Innovation in Design
and Technology at Mexico’s Tecnológico de Monterrey. He holds a Degree in Mechanical
Engineering, as well as a PhD in Mechanical Engineering (Summa cum Laude), both from the
Dresden University of Technology, Germany. He also made Postdoctoral studies on design
methodology and computer-aided design. He is the Director of the Research Program
Creativity, Inventiveness and Innovation in Engineering. He specialises in product design, design
methodology and computer-aided engineering.

Eduardo Uresti is a Professor at the Center for Intelligent Systems at Mexico’s Tecnológico de
Monterrey. He holds a degree in Mathematics, a master degree in Mathematics and a PhD in
Computer Science. He has served as professor in the Physics and Mathematics School (ESFM) of
the National Politechnical Institute (IPN) and also in the Physics and Mathematics Faculty at
UANL Mexico. His current interests include the use of genetic algorithms for multi-modal and
multi-objective optimisation (new algorithms and their applications) and the application of
Artificial Intelligent strategies in teaching and learning.

Copyright © 2007 Inderscience Enterprises Ltd.

48 N. León-Rovira, E. Uresti and W. Arcos
Waldo Arcos received the BS Degree in Mechanical with Minor in Electrical Engineering from
the Autonomous University of Nuevo León, Nuevo Leon, Mexico, and the Master’s Degree in
Manufacturing Systems from Tecnológico de Monterrey, Nuevo Leon, Mexico, in 2002 and
2006, respectively. He is currently responsible for the mechanical and electrical design of electric
motors in an electric motors company.
1 Introduction
Improving the energy use in electric motors is relevant
because improved efficiency leads to slower growth in
electricity demand. In the following sections, a way is
shown of obtaining a higher efficiency of electric motor
with a better heat dissipation that is achieved by a better fan
aerodynamic performance.
Losses due to electrical resistance in electric motors take
the form of heat, which has to be dissipated. Improvements
in motor efficiency are achieved by reducing losses.
In electric motors, reduction of losses is achieved in various
ways, such as higher core-steel grade, higher slot fill, slots
redesign and reduced windage design. All these options
have been used throughout the years, but even though
these methods have achieved increments in electric
motor efficiency, the consequence has incremented total
motor costs. The objective of achieving higher efficiency
through fan-shape optimisation using GAs is obtaining
the same benefits but without increasing the costs. GAs
have been successfully applied in other shape optimisation
cases for optimising aerodynamic shapes (Marco et al.,
2004; Obayashi et al., 2000a; 2000b; Olhofer et al., 2001;
Kelner et al., 2005). In this case, the application starts from
a shape optimisation of a fan, which used at first only
straight-line blades’ cross sections.
Using CFD software, it is possible to simulate the
effect of changing the fan blades’ shapes with GAs.
However, for optimisation purpose, the CFD simulation
time required is tremendous. In a recent study, Kelner
et al. (2005) relate a study where the CFD simulation
time was greatly reduced, based on the differentiation
and high-order Taylor-series expansion of the discretised
Reynolds-Averaged Navier–Stokes (RANS) equations
around an independently computed reference flow solution.
In the present study, the simulation time was reduced
taking advantage of the periodicity of the geometry,
simulating only one-eighth of the fan rotor. Moreover, in
order to reduce the total computational time, two different
commercially available CFD packages were compared and
the one which require less computational time was used.
The objective is to increase the efficiency of a Total
Enclosed Fan-Cooled (TEFC) induction motor, using
the same raw materials and manufacturing processes.
The electrical design of the motor is not subject of analysis.
2 Innovation as concept optimisation
Based on former publications, it may be stated that
product innovation may also be implicit as “optimisation
not restricted to parametric variation” but extended
to ‘constrained concept variations’. As has been shown
in several case studies, an extended parametric optimisation
is achieved by adding shape and topology as possible search
directions. This extended optimisation has been achieved by
allowing shape variation substituting the original shapes,
which were based on straight lines and arcs, with spline
curves (Leon et al., 2004).
The current fan blade profile has two identical
parallel straight lines. The new fan blade design proposed in
this paper, although starting from the same straight
profiles, is represented by splines, shape of which may be
modified for finding new profiles beyond the limits
than would be possible using only straight-line profiles.
New constraints have been added to the GA that restricts the
minimum permitted thickness of the fan blade profile to
avoid possible flexion due to the air impact over the
fan blades.
3 Basic thermal consideration
Thermal issues affect the performance of a motor. The coil
temperature rise, that is, the temperature difference of stator
coil over an ambient temperature, depends on two factors:
• the temperature gradient between stator coil and
housing for conductive heat flow, which can be
solved analytically
• the temperature difference between housing and air for
heat flow by convection and radiation.
For a TEFC machine, the problem of heat transfer from
housing to air for a given temperature gradient is associated
with the aerodynamic flow pattern. This part is difficult
to solve analytically, and, because of this, an empirical
relation has been established, based on data available from
test results.
Conduction of losses inside the motors is particularly
important in areas that include air gaps and voids, for
example inside the coil insulation between conductors and
cores and between the stator core and housing of totally
enclosed motors. A totally enclosed machine is one so
enclosed as to prevent the free exchange of air between the
inside and the outside of the case, but not sufficiently
enclosed to be termed airtight. There are different types of
enclosures and its use depends upon the application and the
working environment. For this research, a TEFC electric
motor enclosure is used. In this type of enclosure, an
external fan pulls air in through a fan cover and blows it
over the external motor surface. Heat transfer occurs by
forced convection.
 Fan shape optimisation using CFD and genetic algorithms
4 Genetic Algorithms (GAs)
GAs are search algorithms based on the mechanics of
natural selection and natural genetics. They combine
survival of the fittest among string structures with a
structured yet randomised information exchange to form
a search algorithm with some of the innovative flair of
human search. In every generation, a new set of artificial
creatures (strings) or individuals is created using the fittest
as parents. While randomised, GAs are no simple random
walk. They efficiently exploit historical information to
speculate on new search points with expected improved
performance (Goldberg, 1989).
Normally, when a GA is used for function optimisation,
each individual in the population represents a point in the
search space of the problem to be solved. The aptitude of an
individual is closely related to the value of the function in
the point being represented by the individual. Different
types of GAs have been proposed, from the simple GA
(Goldberg, 1989) to others with special selection schemes
as Genitor (Whitley, 1989). In the simple GA, the whole
population is replaced by a new set of individuals each
generation. The new set of individuals is produced in pairs.
In order to produce two new individuals, a pair of parents is
selected from the current population. Those individuals with
a better aptitude have more chances of being selected. Once
a pair of individuals is selected, crossover and mutation are
applied. The crossover consists of constructing a pair of new
individuals by taking parts of the genetic material from both
parents. The expected effect is the combination of the
characteristics present in both parents. In the simplest case,
the genetic material of an individual consists of the string
and the crossover consists of randomly taking a point in
which both parents can simultaneously be divided and
then joining the first part of the first parent with the second
part of the second parent. The second individual can be
constructed with the remaining parts of the genetic
material of the parents. Mutation consists of making
changes in the genetic material in both resulting new
individuals. Compared with the simple GA, Genitor has
some differences, as it produces one new individual each
generation, which replaces the worst individual in the
current population. As in the simple GA, two parents are
selected, but they are selected according to their ranking
in the population: the whole population is ordered according
to the value of the function evaluation.
In some GA applications, it may be more convenient to
use a real vector as genetic material instead of a string
of characters (Wright, 1991; Barone et al., 2002; Bleier,
1998; Capello and Mancuso, 2003; Chapman, 2004;
Goldberg, 1989; Eshelman and Schaffer, 1993), in
such applications, the use of different crossover operators
is required.
5 AC motor losses
Electric motor efficiency is a measure of the effectiveness
with which a motor converts electrical energy to mechanical
49
energy. It is defined as the ratio of power output to
power input or as the ratio of output to output + losses
(http://www.reliance.com/mtr/b7087_5/b7087_5_2.htm.):
Output Output
Motor Efficiency = = .
Input Output + losses
AC motor losses are classified in components.
Electrical losses are converted into heat, which is dissipated
by the motor housing aided by internal or external fans.
Stator and rotor losses are caused by current flowing
through the motor winding and are proportional to the
squared current times the winding resistance (I2R).
Hysteresis and eddy current losses are confined to the
laminated core of the stator and rotor and can be reduced by
utilising steels with low core loss characteristics, as found
in high-grade silicon steel. Friction and windage losses are
due to all sources of friction and air movement in the
motor and may be appreciable in large high-speed
or TEFC motors. The stay load losses are due mainly to
high-frequency flux pulsations, caused by design and
manufacturing variations (http://www.reliance.com/mtr/
b7087_5/b7087_5_2.htm.).
There are two basic ways for increasing the efficiency of
an electric motor based on its fan characteristics. One way
is by minimising windage losses while maintaining the
airflow rate. In that case, the rest of the losses will not be
benefited. The efficiency increase is due only to the
reduction of windage losses. Another way to boost electric
motor efficiency is by increasing the airflow rate provided
by the fan, without increasing the energy required for
driving the fan. This way will benefit the rest of the
losses mentioned earlier, while the windage losses remain
constant.
Fan size augmentation is a straightforward way for
increasing airflow (Bleier, 1998). However, fan size is
constrained by the space available in the fan cover and it
increases the energy required for driving the fan. By varying
the shape of the fan blades, the fan efficiency can be
enhanced in such a way that the airflow is increased and a
better cooling effect reduces the stator losses, core losses
and rotor losses without increasing the energy absorbed for
driving the fan. Therefore, shape variations generated with
GAs may be useful in achieving best results considering the
size constraints.
6 Identifying the influence of the fan
performance
For better identifying the effect of increasing the fan
efficiency, two preliminary experiments were made: the first
was a laboratory test and the second was an analytical
calculation. In the first case, a motor was tested in a
laboratory, eliminating the energy consumption of the
fan by using an external fan cooling system. The internal
fan was removed from the motor; therefore, the fan energy
consumption was zero (an ideal situation). The efficiency
increase measured was 1.09%.
50 N. León-Rovira, E. Uresti and W. Arcos
In the second case, the airflow was increased in the
analytical model by 50%, without considering any increase
of the energy consumption of the fan. The efficiency
increase calculated was 1.35%. It became evident that the
efficiency of the motor could be more benefited through
efficiency augmentation of the fan.
7 Simulation using CFD simulation software
integrated into 3D CAD system with meshing
capabilities
Two commercial CFD simulation programs were compared.
In the first case, a 3D CAD system for modelling
the geometry and CFD software with dedicated mesh
generation software were used. The analysis time was
approximately 4 h. Then the same case study was performed
using CFD simulation software integrated into a 3D CAD
system with meshing capabilities. The analysis time was
about 40 min. The second package was selected, as it
performed the analysis up to ten times faster than the first
with similar results.
Taking advantage of the periodicity of the geometry,
only one-eighth of the fan geometry was modelled.
This way the total computational time is reduced
accordingly.
The geometry was constructed as a single blade centred
within the region divided by two even adjacent passages.
Figure 1 (a) 3D CAD geometry and (b) mesh model in CFD program
(a)
(b)
The mesh was generated inside of the 3D CAD system
using an interface provided by the CFD software. The grid
is set up with periodic boundaries on either side of the
domain. The upstream boundary is defined by velocity and
the downstream boundary by pressure. The single blade
centred is assumed to be rotating, while the two even
adjacent passages are stationary. The z-axis is used
as a rotation axis for the reference frame. The fan spins
clock-wise (looking from the positive end of the z-axis) at
constant rotational speed. The fan rotation speed is defined
by the motor at full load. The standard k –ε turbulence
model (Abbott, 1989) and sea-level conditions were used.
The 3D CAD model and the mesh generated are shown in
Figure 1.
The simulations were performed based on the
defined boundary conditions. The simulation stops after
convergence criteria are met. The convergence criteria are
shown in the Figure 2. Each curve should become horizontal
as criterion that the convergence was reached. A guideline
followed is that the quantities in the calculation progresses
change <5% over the last 20% of the total iterations.
Figure 3 shows the velocity vectors as found at the
midspan of the rotational area. The velocity vector plot
provides insight into the behaviour of the flow around the
fan blade. This analysis is the basis for finding the
variations of blade profiles that increase the airflow.
The pressure distribution on the blade is shown in
Figure 4.
 Fan shape optimisation using CFD and genetic algorithms 51

Figure 2 Plot curve convergence

Figure 3 Velocity vectors (second simulation)

Figure 4 Pressure distribution on the blade

52 N. León-Rovira, E. Uresti and W. Arcos
The contour plots illustrate the pressure rise on the
fluid caused by the fan blade. Positive pressure values
occur on the surface, where the fan blade pushes the
air and negative pressures (suction) on the other
surface.
7.1 Profile modification
As the purpose of this paper is to look for new designs that
increase the efficiency of the electric motor using shape
optimisation through GAs, the blade profiles are required to
Figure 5 Fan profile modification
Figure 6 (a) Velocity vectors (profile curve-simulation) and (b) pressure distribution on the blade (profile curve simulation)
(a)
be modified during the optimisation run. For a first trial, the
straight profile of the fan blade was substituted by a curved
profile as shown in Figure 5.
This analysis shows an increment in the velocity
vector’s magnitude. The results are shown in Figure 6.
The velocity vector’s magnitude was increased 4.7%
with respect to the current design. The increment of the
parameters measured shows that it is possible to get higher
airflow provided by the fan over the motor. By increasing
the airflow the electric motor efficiency can be improved,
as was discussed in Section 5.
 Fan shape optimisation using CFD and genetic algorithms
Figure 6 (a) Velocity vectors (profile curve-simulation) and (b) pressure distribution on the blade (profile curve simulation) (continued)
(b)
8 Representation of fan blade for optimisation
Shape optimisation deals with variations of the form: find
a shape (in two or three dimensions) that is optimal in a
certain sense, while satisfying certain requirements and
constraints. In the present case study, as was already
mentioned, advantage was taken of the periodicity
of the geometry and only one fan blade was simulated.
In order to simplify the shape optimisation problem,
only the profile half way up the fan blade will be modified,
as shown in Figure 7. The fan blade profile analysed
in Section 7 will be codified below as chromosome in
the GA.
Figure 7 Fan blade profile
The population is represented by individuals with
different fan profile shapes, where each fan profile shape is
53
evaluated and represents a possible solution. Following
a strategy adopted by several researches (Lamping, 2003;
Leon et al., 2004, 2005; Marco et al., 2004; Michalewicz,
1992; Obayashi et al., 2000a) and the concepts studied in
the preceding sections, the shape parameterisation is
based on B-spline curves. B-splines are commonly used
to define curved bodies and profiles. In some cases
(Marco et al., 2004), Bézier curves are used, and the
parameters constituting the chromosome are coded as binary
string. The smoothness properties of Bézier curve permits to
avoid non-feasible shapes by the crossover operator.
In this case study, non-feasible shapes are controlled
by using constraints added in the GA, which are discussed
briefly in the last paragraph of this section. Six control
points are used in this case to control the whole fan profile
shape modification by the crossover operator, as shown in
Figure 8.
Figure 8 Control points along the profile
54 N. León-Rovira, E. Uresti and W. Arcos

The control points shown above (P1–P6) are defined done yet automatically (because actual CFD software lacks
by their x- and y-coordinates, respectively; thus, scripting capabilities), it was necessary to use an evaluation
P1 = (x1, y1), …, P6 = (x6, y6). For simplifying the shape team. The evaluation team was a group of specialists
parameterisation, the x values are fixed, and only the y- (volunteer Master degree students in the Computer-Aided
coordinates are allowed to vary. This way, P1 = y1, P2 = y2, Engineering course), where the simulation results of each
…, P6 = y6 represent the search space, while Pi, Pi′, Pf and population member was assigned for evaluation to one
Pf′ are fixed. Several approaches have been proposed person of this team.
for controlling the geometry through control points; for
example, in Obayashi et al. (2000a), the airfoil geometry is Figure 9 Process flow diagram from Genetic Algorithms
split into a mean camber line and thickness distribution.
Some points are used for the camber line and other points
are used for the thickness distributions. In this case, the
extreme points have to be fixed to avoid a new fan blade
profile being thinner than the current profile. Therefore, the
chromosome will be represented only by the y-coordinates:
 
Chromosome =  y1 , y2 , y3 , y4 , y5 , y6  .
 
Upper
 
Lower
 

The GA introduces changes on the position of the control

points, resulting in profile variations. Traditionally, GAs use
binary numbers to represent such strings: a string has a
finite length, and each bit of a string can be either 0 or 1.
For real-valued function optimisation, however, it is more
natural to use real numbers (as might be done with evolution
strategies or evolutionary programming), as suggested in
Obayashi et al. (2000b), where the length of the real-number
strings corresponds to the number of design variables. Real-
number coding is used here.
Genitor is the GA selected for sampling the search
space, but in this case individuals of the population are not
removed. In order to keep the selection pressure high, the
selection bias parameter is dynamically set to be 1.5 in a
growing population. In the present investigation, the
operator BLX-α is used (Goldberg, 1989):
New = α × P1 + (1 – α) × P2
where P1, P2 are the parents, New is the new individual GA depends on the data reported after the evaluation from
and α is a random number in the real interval [–0.5, 1.5]. each new individual has been done. Thus, it was constructed
Mutation operations consist of adding to the new individual using PHP language where it runs on a web server,
a vector of small random numbers. taking PHP code (GA) and a MySQL database as input
Normally, in a real application, some individuals and creating a web page to manage the information of the
produced by the GA correspond to impossible simulation.
configurations and such individuals receive reduced When a new evaluation is reported to the GA by any
evaluations or penalties. In this case, such individuals were member of the team, the PHP script stores the information
mapped to valid individuals by swapping the corresponding parameter and images related to the simulation process into
y-coordinates, in order to preserve the restrictions y1 > y6, the databases. A new individual is created, and the new
y2 > y5 and y3 > y4, and minimum permitted thickness. parameters (six control points) are sent via e-mail to the
Individuals with smaller thickness are considered invalids team member with less evaluations pending.
by the GA. In order to assure that evaluations in the CFD
package are consistent, a step-by-step manual was created
and provided to each team member and exercises were
9 Evaluation procedure performed before starting with the actual evaluation.
Using the GA described, the process flow is constituted Figure 10(a) shows how the members of this team report the
by the steps shown in Figure 9. An initial population of results obtained in the analysis. All data obtained in the
25 individuals was generated, which were seeded. As the analysis were saved in the databases and it can be easily
evaluation process is complicated and the cycle could not be retrieved as a web page.
 Fan shape optimisation using CFD and genetic algorithms 55

Figure 10 (a) Report of results and (b) GA population

(a)

(b)
56 N. León-Rovira, E. Uresti and W. Arcos
Figure 10(b) shows some individuals of the GA population
in the web page. The best fan profile design generated
by the GA is shown into the red circle. It will be discussed
in the next section. The web page can be accessed in
the following link http://lizt.mty.itesm.mx/~euresti/genetico/
home.htm.
10 Results
The best fan profile generated by the GA presents a
significant increase in the velocity vector’s magnitude of
9.4%, with respect to the current design, while the profile
curve presented in Section 7.1 had an increment of 4.7%.
Due to the time limits, the GA was not run until its final
convergence; however, the best fan profile obtained from
Figure 11 (a) Velocity vectors (profile generated by GA) and (b) pressure distribution on the blade (profile generated by GA)
(a)
(b)
GA shows that introducing changes in the profile
it is possible to get a better aerodynamic performance than
the results obtained by former profile curves. The results are
shown in Figure 11.
In Figure 12, the changes in the new fan profile
generated by GA are shown. This kind of variation obtained
by GA optimisation procedures is finer than the changes
obtained by trial and error variations of experienced
designers, who commonly do not have the patience and
time for such minimal changes. The use of splines for
changing profiles that are initially modelled with only
circular arcs and lines seems to be a better solution for
shape optimisation by using genetics algorithms
for controlling the geometry through control points
(Lamping, 2003).
 Fan shape optimisation using CFD and genetic algorithms
Figure 12 (a) Original profile and (b) profile generated by GA
11 Conclusions
Although requiring experimental validation, the results
obtained by simulation indicate that optimising the fan blade
shape through GAs increases the airflow in the motor.
This improvement can be achieved by small shape
modifications. The obtained shapes are not more expensive
to manufacture than the original ones, as the fan is produced
by injection moulding and the cost increment of the mould
is negligible. The economic benefits obtained through
efficiency increment may be substantial. The present
research represents a step forward towards a new way of
increasing the efficiency of TEFC induction motors through
shape optimisation, using genetic algorithms and CFD
techniques.
Acknowledgements
The authors acknowledge the support received from
Tecnológico de Monterrey through grant number CAT043,
Research Chair Creativity and Innovation in Engineering of
the Center for Innovation in Products and Technology
(CIDYT) to carry out the research reported in this paper.
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Websites
http://www.usmotors.com/.
http://www.reliance.com/mtr/b7087_5/b7087_5_2.htm.