1
Calculation and Analysis of Stator
Temperature for High Voltage Generator
Prototype with Rated Load
GE Baojun, CHANG Weibin, TAO Dajun
Abstract—High voltage generator is a new type of generator.
In order to determine if the innovational structure of high voltage
generator can satisfy the requirement of high voltage generator
with rated load, the temperature of the high voltage generator is
analyzed and calculated. The electromagnetic of high voltage
generator is analyzed with FEM, and the 2D model of
electromagnetic field is proposed to calculate the loss of high
voltage generator. According to the basic laws of heat transfer
and the differential equation of heat conduction and its boundary
conditions, 3D physical model of temperature for high voltage
generator is established. According to the theory of fluid
similarity, heat release coefficient of every part in stator is
derived; the temperature field distribution of stator is obtained.
Then, the correctness of the analysis is proved by the experiment.
The conclusion of this paper provides certain theoretical
significance and practical value for the reliable design and
operation of high voltage generator.
KEY WORDS: high voltage generator; rated load ；
electromagnetic; temperature.
I. INTRODUCTION
A new type of high voltage generator is developed in order
to reduce the production costs, improve efficiency and
minimize environmental impact [1-2]. Cross-linked
polyethylene (XLPE) cables are used in the high voltage
generator instead of conductor windings of conventional
generators, so the output voltage 30～35kV has been break.
The temperature of XLPE cable is limited less then
90 °C when the high voltage generator run with rated load [3-
4]. Insulation life of windings could be affected if the
temperature of XLPE cable is higher then 90 °C , thus the
useful life and reliability of generator would be affected. So it
Project Supported by Natural Science Foundation of China (50577012)
GE Baojun was born in 1960. He received his Ph.D. degree from Harbin
Institute of Technology, Heilongjiang Province, China. Dr. GE is now a
Professor of Harbin University of Science and Technology. He mainly studies
on basic theory and application technology of large electromechanical energy
Conversion Device.
Chang Weibin was born in 1982. He is a master student in Harbin
University of Science and Technology; he studied on the basis theory and
electromagnetic calculation of large generator.
Tao Dajun was born in Hubei Province of China, on March 5, 1982. He
got his master’s degree from the Harbin University of Science and
Technology, and now is a doctoral student; he studied on the basis theory and
electromagnetic calculation of large generator.
is important that the analysis of temperature field for high-
voltage generator is used to determine the temperature of
XLPE cable to meet the requirements.
A 2D electromagnetic field model and a 3D temperature
model of stator are established, and the boundary conditions
are given, during the process of the geometry figure and
material properties of the high voltage generator are
considered, and then stator temperature of the high voltage
generator 130kW prototype is analyzed and calculated by the
finite element method. By solving the electromagnetic fields
and temperature fields of high voltage generator with rated
load, the electromagnetic field distribution and the
temperature distribution are obtained, and the results is
analyzed.
II. ELECTROMAGNETIC FIELDS CALCULATION OF HIGH
VOLTAGE GENERATOR WITH RATED LOAD
A. Calculation model and solved region of electromagnetic
fields
The end effect of generator is not considered in order to
simplify electromagnetic fields calculation; it is considered
that the electromagnetic fields are uniformly distributed along
axial. A quarter is taken when creating model, because the
electromagnetic fields are symmetrical distribution, as show in
Fig.1
B A
C
Fig. 1. 2D model of electromagnetic field for high voltage generator
In order to establish differential equations of inside
magnetic field for high voltage generator and determine the
solved region and boundary conditions of finite element, the
follows assumptions are presented [5-8]:
1)The fillet of stator slot and stator sector piece, partial
fillet of magnetic pole punching and chamfering edge are
simplified.
2)The end effect of generator is neglected, and the
 2

electromagnetic field is uniformly distributed along axial, so field is the region between two adjacent teeth. The solving
current density vector J and magnetic potential A only have region is shown as follow in Fig.4. S1 is the cooling
axial components. surface, S2 is the surface insulation.
3)The outer surface of stator circle and the inner surface of
rotor circle are zero-vectors surface.
Based on the above assumptions, according to the solved S1
region of electromagnetic field of high voltage generator,
using magnetic vector AZ expression, the field contents the
boundary value problem: S1
⎧ ∂ ⎛ 1 ∂AZ ⎞ ∂ ⎛ 1 ∂AZ ⎞
⎪ ⎜ ⎟+ ⎜ ⎟ = −J Z
⎪ ∂x ⎝ μ ∂x ⎠ ∂y ⎝ μ ∂y ⎠
⎪ S2
⎨ AZ AB = 0 (1) S1
⎪
⎪ AZ AC = − AZ BC Fig. 3. The 3D model of temperature for high voltage generator
⎪
⎩ For convenience of calculation, the following assumptions
where, J Z is current density. μ is material permeability are presented
1)Considering the generating structure, the upper and lower
B. Electromagnetic field calculation of high-voltage end surface of stator, the inside and outside surface of stator
generator under load operation core are the cooling surface.
When calculating various losses of high voltage generator 2)Since the generator is symmetry along the direction of
with rated load, firstly, generator of constant non-linear 2D the circular, the tooth center of surface is insulation surface.
magnetic field should be solved. B. The 3D steady heat conduction equation of stator in
When generator run with rated load, generator three-phase heterosexual media in Cartesian coordinate
composite magnetic motive force amplitude value is
In Cartesian coordinate, the 3D steady heat conduction
IN equation of various heterosexual media of stator is:
Fam = 1.5Fm = 1.35 K (2)
p
∂ ⎛ ∂T ⎞ ∂ ⎛ ∂T ⎞ ∂ ⎛ ∂T ⎞
where, I is phase current effective value; N is serial turn of ⎜ kx ⎟ + ⎜ ky ⎟ + ⎜ kz ⎟ = −q (3)
∂x ⎝ ∂x ⎠ ∂y ⎝ ∂y ⎠ ∂z ⎝ ∂z ⎠
each phase of windings; K is coefficient of windings; p is
where, T is temperature; k x ， k y ， k z are conduction
number pair of magnetic pole of rotor.
So, the generator with rated load is only decided by the coefficient of x , y , z respectively. q is heat density If the
current value of stator [9]. border S is consisted by cooling surface S1 and insulation
The current rated value of stator for 130kW high voltage
surface S2 ,the boundary conditions of S1 and S2 are:
generator is given and the electromagnetic field distribution of
∂T
high voltage generator with rated load is calculated by the -k n = a (T − T f ) (4)
finite element. Fig.2 is the electromagnetic field distribution of ∂n S1
high voltage generator with rated load. ∂T
=0 (5)
∂n S2

where, n is border normal vector； a is heat release coefficient

； T f is environment temperature. kn is conduction coefficient
of n respectively.
C. Heat release coefficient of stator
For the prototype is axial ventilated, the heat release
coefficient of the upper and lower end surface of stator are
Fig. 2. The magnetic lines of force for high voltage generator with rated load given by empirical formulas [10-11]:
Ud
III. TEMPERATURE FIELD CALCULATION OF HIGH VOLTAGE Re = (6)
v
GENERATOR WITH RATED LOAD
ad
Nu = (7)
A. The calculative regions of temperature field and λ
fundamental suppose. where, Re is the Reynolds number of fluid; U is velocity of
The axial flow ventilation cooling action is adopted in the flow in ventilation groove; v is viscosity coefficient of fluid;
130kW high voltage generator. As the high voltage generator where, d is equivalent diameter of ventilation grooves; Nu is
is symmetry along radial, the solved region of temperature Nu number; λ is conduction coefficient of fluid.
 3

For heat release of fluid when axial ventilation shows where, K d is the increase coefficient of loss; GFe is the
turbulent motion, it can be list the follow equation: weight of stator; PFe10/50 is the unit’s loss of iron; B is
Nu = 0.59 Re0.47 ε (8)
magnetic flux density of stator.
where, ε is correction coefficient.
Calculating the iron loss of stator yoke, take K d = 1.3 ,
In this way, the heat release coefficients of the two end
surfaces of stator are given: α =1.3 , B is magnetic flux density of stator yoke.
λ Calculating the iron loss of stator yoke, take K d = 1.7 ,
a = 0.59 Re0.47 ε (9) α =2 , B is magnetic flux density of 1/2 stator teeth.
d
The heat release of stator surface changes better because of
windward, so heat release coefficient of windward stator is IV. RESULTS ANALYSIS OF STATOR TEMPERATURE FIELD
α1 = 1.1α , the heat release of stator surface changes worse COMPARED WITH THE EXPERIMENTAL
because of leeward, so heat release coefficient of leeward Through the above electromagnetic calculations of high
is α 2 = 0.9α . voltage generator, losses of each part of cores are got. Heat
release coefficient value of each part is derived by the heat
Tangential movement of rotor has impact on the cooling
release coefficient formulas. Then, 3D temperature field
medium which is in air-gap, in addition, the retardative effect
model is solved. The results are shown in fig4 to fig9, which
of inner circle surface of stator have impact on the cooling
represent temperature field distributions of high voltage
medium, so heat release coefficient of inner circle surface can
generator prototype under rated operating.
be expressed as follow equation:

aδ = 28（ 1 + wδ0.5） (10)

where, wδ is the average wind speed of air gap;

( 0.5u2 )
2
wδ = + C2 (11)
where, u2 is speed of rotor circle; C is axial wind speed.
The heat release coefficient of outside surface of stator yoke
is: Fig. 4. The temperature distribution of stator windward for high voltage
generator
⎛θ ⎞
α 3 = 14（ 1 + 0.5 Wi） ⎜ ⎟ 3 (12)
⎝ 25 ⎠
where, Wi is wind speed of stator’s yoke outside surface; θ is
the temperature of stator’s yoke surface.
According the calculations of empirical formulas (6) to (12),
the table1 representing heat release coefficients of every part
in stator is obtained.
Table1 Heat release coefficients of every part in stator
α1 α2 α3 αδ Fig. 5. The temperature distribution of stator leeside for high voltage
generator
176.493 144.502 104.25 190.713
D. The calculate of heat source
The heat sources mainly is divided into copper loss of
stator windings and iron loss of stator, and iron loss of stator
can be divided into iron loss of tooth and iron loss of yoke
[12].
1）copper loss of stator
Fig. 6. The temperature distribution of stator for high voltage generator
The stator winding loss can be obtained by its current value:
PCu = 3I N2 Ra (13)
where, I N is phase current;
2）iron loss of stator
The magnetic hysteresis and eddy current loss is produced
in stator during main field alternative; iron loss of stator is
expressed as follows: Fig. 7. The temperature distribution of stator coil for high voltage generator
2 α
⎛ B ⎞ ⎛ fN ⎞
pFe = K d GFe PFe10/50 ⎜ ⎟ ⎜ ⎟ (14)
⎝ 10000 ⎠ ⎝ 50 ⎠
 4

Fig. 8. The temperature distribution of stator tooth for high voltage
Generator
Fig. 9. The temperature distribution of stator yoke for high voltage generator
Fig.4 to fig.9 represent the temperature field distributions
of stator surface, stator winding, stator core tooth and yoke of
high voltage generator with rated load, the positions of the
highest and the lowest temperature can be found in the figures
obviously. The highest temperature of stator 3D temperature
field is located in copper conductor of stator winding because
the high voltage generator with rated load produces great loss
of stator winding and heat conduction performance of the
main insulation layer of stator winding copper is very poor,
the temperature value ranges from 28.6 °C to 33.5 °C , and it is
close to the test temperature 27.5 °C of the prototype. The
two end surfaces of stator, outer surface of stator yoke and
inside surface of stator tooth are cooling surface, cooling
effect is better, so the lowest temperatures are located in the
two end surfaces of stator and inside surface of stator tooth.
The heat is mainly concentrated in the stator windings and
teeth, so temperature of stator yoke is lower than stator tooth.
[5] Sun Yutian. The Moving Problem in the Dynamic FEM of Electric
Machines Large electrical Machine and Hydraulic turbine .1997，(6)：
35~39 (in Chinese).
[6] Chen Shiyuan, "AC motor's magnetic field finite element analysis"
Harbin: Harbin Engineering University Press ,1998,pp.146~148
[7] Yan Chengjun, Liu. Ruifang, Hu. Minqiang. "A New Method to Deal
with The Motion Problem in Electromagnetic Field Finite Element
Analysis" Proceedings of the CSEE, vol. 23, no. 8, pp. 163~167, 2003.
[8] Tang Yunqiu, "Electrical machinery inside the electromagnetic field"
2nd ed., Beijing: Science Press 1997, pp.123~142.
[9] Zhou Degui, "Synchronous generator to run Technology and Practice"
Beijing: china electric power press. 2004.
[10] Li Weili, "Calculation of Rotor Temperature Field For Hydro-Generator
as well as the Analysis on Relevant Factors ".Proceedings of the CSEE
vol. 22, no. 10, pp. 85~90,2002. (in Chinese).
[11] Ding Shunnian, "Large motor heating and cooling" Beijing: Science
Press, 1992, pp.126~167.
[12] Tang Yunqiu, Shi Nai, "Electrical machinery," 2nd ed., Beijing:
Mechanical Industry Press, 2005, pp.148-153, 229-247.
VII. BIOGRAPHIES
GE Baojun was born in 1960. He received his Ph.D. degree from Harbin
Institute of Technology, Heilongjiang Province, China. Dr. GE is now a
Professor of Harbin University of Science and Technology. He mainly studies
on basic theory and application technology of large electromechanical energy
Conversion Device.
CHANG Weibin was born in 1982. He is a master
student in Harbin University of Science and Technology;
he studied on the basis theory and electromagnetic
calculation of large generator.
TAO Dajun was born in Hubei Province of China, on
March 5, 1982. He got his master’s degree from the
Harbin University of Science and Technology, and now
is a doctoral student; he studied on the basis theory and electromagnetic
calculation of large generator.

V. CONCLUSION
The electromagnetic field and stator temperature field of
high voltage generator are calculated by finite element method
in this paper and numerical calculation results of stator
temperature field is obtained, the value is close to the test
temperature of the prototype. The temperature of stator
winding meets the requirement of Polyethylene cables
(XLPE). The method that this paper used can also be used in
other types of generators, which can help the accuracy of the
temperature calculation for generator manufacture.

VI. REFERENCES
[1] Ge Baojun, Zhang Dakui, Liang Yanping, "Powerformer and its Recent
Development," Proceedings of the CSEE, vol. 20, no 7, pp. 26-28, Jan.
2005(in Chinese).
[2] Ge Baojun, Zhang Dakui, Zhou Chuiyou, Song Fuchuang,
"Powerformer--A nascent electric power generation equipment for the
21st century," Automation of Electric Power Systems, vol. 4, no 1, pp.
1-3, Apr. 2004. (in Chinese).
[3] Mats Leijon, "PowerformerTM —A Radically New Rotating Machine".
ABB Review, no. 2, pp. 21~26.1998.
[4] Marguerite Touma-Holmberg, Kailash Srivastava, "Double winding,
high-voltage cable wound generator: Steady-state and fault analysis,"
IEEE TRANS. Energy Conversion, vol. 19, no. 2, pp. 245-246 Jun.
2004.