Thermal Effects in the End-Winding Region of Electrical Machines

The main heat transfer mechanism in the end-winding region of electrical machines is convection. In order to increase the air motion, the rotor is equipped with a series of blades. Their geometry is reflected in the fanning factor, i.e., the ratio between the rotor peripheral speed and air velocity. An accurate calculation procedure for the fanning factor has not yet been given. Knowing its value is crucial for the determination of air velocity and heat transfer coefficient (HTC), as the latter describes the end-winding heat removal capability. In this study, the convective heat transfer phenomena between the end winding and air inside the end-winding region were analyzed, with the heat generated only in the end winding, mimicked with a custom designed coil, and air moved by the blades. The analysis was performed by experimental testing and computational fluid dynamics (CFD) modeling. Measurements data were used to build a reliable CFD model. Further on, CFD results were used to derive a generalized analytical equation for calculation of the end-winding HTC, related to blade geometry and rotor rotational speed. The developed analytical model significantly improves the quality of real-time lumped circuit thermal modeling of electrical machines and, thus, enriches this field of science