Thermal Analysis of Flux Switching Permanent Magnet Generator

Flux-switching permanent-magnet (FSPM) generators are gaining prominence in renewable energy applications due to their robust rotor structure and high-power density. However, thermal management remains a critical challenge, as excessive heat can degrade insulation and permanent magnet (PM) properties. This study presents a comprehensive thermal analysis of a 12-slot/10-pole FSPM generator using 3D Computational Fluid Dynamics (CFD) via ANSYS Icepak. Electromagnetic losses, including copper, core, and eddy-current losses, were integrated into the finite-volume formulation to solve for conduction, convection, and radiation effects. Simulation results identify the primary hotspots in the central axial region of the armature windings, reaching a peak steady-state temperature of 78 °C. The rotor and PMs exhibit strong thermal coupling, stabilizing within a range of 69 °C to 78 °C. Transient analysis confirms that all components reach thermal stability after approximately 90 minutes. The findings demonstrate that peak temperatures remain well below the critical limits for NdFeB magnets and Class F insulation, validating the thermal reliability of the proposed design for long-term operation.