کنفرانس بین المللی ماشین و محرکه های الکتریکی

صفحه اصلی / The 5th International Conference on Electrical Machines and Drives

Thermo‑Fluid Feasibility Analysis of Alternator Rotor Winding Replacement via Computational Fluid Dynamics

نویسندگان :

Omid Mahdavi keshavar¹ Ehsan Mohammadian² Hadi Zarafshani³

1- Thermal Design Specialist, R&D Department, MAPNA Generator Engineering and Manufacturing Co. (PARS), Karaj, Iran 2- Head of Thermal Design Group, R&D Department, MAPNA Generator Engineering and Manufacturing Co. (PARS), Karaj, Iran 3- Thermal Design Specialist, R&D Department, MAPNA Generator Engineering and Manufacturing Co. (PARS), Karaj, Iran

کلمات کلیدی :

Thermo‑fluid،CFD،Alternator،Winding،Edgewise،Side-Winding،Separator

چکیده :

Industrial heavy‑duty alternators operate under extreme loading condition, where airflow capacity must be optimally balanced with insulation reliability and cooling efficiency. Optimising such systems demands accurate prediction of airflow distribution, pressure drop, and alternator temperature under operational loads. A Computational Fluid Dynamics (CFD) and coupled thermal analysis workflow using CFX and Steady-State Thermal modules of the ANSYS software was developed to evaluate the thermo‑fluid feasibility of replacing the Edgewise rotor winding with a Side-Winding configuration in an alternator. CFD simulations across 2000–3600 CFM determined alternator (system) curves and operating condition. The replacement of the rotor winding type from the Edgewise type to Side-Winding configuration required integrating winding separators into the rotor assembly, which alter the alternator’s internal flow dynamics. Their inclusion increases overall pressure drop, reducing the volumetric airflow of rotor part and impacting cooling performance. Fluid flow simulation conducted to quantified this effect by derivation of system‑curve correlations and determined operating conditions based on the fan and system curves. Thermal analysis incorporated and results indicated a maximum rotor temperature of  151.38 °C, within insulation/thermal (H/F) limits. The study demonstrates that the Modified Rotor meets all specified thermal and hydraulic criteria, providing a reproducible CFD–thermal methodology for industrial alternator optimization under demanding operational conditions.