Fabrication and test results of low‐voltage alternator with improved efficiency and reduced temperature rise using polyester nanocomposite insulation

Abstract This study reports the test results of a total of 16 low‐voltage (415 V) 15 and 30 kVA alternators manufactured using optimized polyester resin nanocomposites. These tests consist of the open‐circuit characteristics (OCC), short‐circuit characteristics (SCC), voltage regulation, and temperature rise tests. The test results obtained are reported in terms of efficiency, voltage regulation, OCC and SCC curves, and temperature rise in stator and rotor windings. The results show that the temperature rise in the windings reduced significantly and the efficiency improved marginally using polyester resin nanocomposite insulation. Finally, the calculations show that the reduction in temperature rise can double the life of the alternator. Notably, the manufactured alternators passed all the performance tests as per the test standards, without adversely affecting its performance. For the insulation design of any low‐voltage rotating machine utilizing polyester resin as its base insulation, a similar approach can thus be adopted. Highlights Fabrication of alternator prototype using polyester nanocomposite insulation. Alternator prototype fabrication using standard industry manufacturing process. Reduction in temperature rise in stator and rotor windings by 10 °C. Enhancement in alternator efficiency by 3%–4%. Polyester nanocomposite insulation doubles the service life of alternator.