Method of efficient thermal management of rotor in a high power generator

A method of manufacturing a rotor for a generator, comprising:

• winding a wire bundle about rotor poles of a rotor,
• wherein:
• the rotor defines a rotor body and the rotor poles extend in a radial outward direction from the rotor body;
• and
• each rotor pole defines a pole body and pole circumferential side surfaces that are spaced apart from each other in a circumferential direction about the rotor body, and
• positioning a wire separator between coil windings while winding the wire bundle to divide the coil windings in the wire bundle into subsets of wire bundles;
• wherein:
• positioning a wire separator within the wire bundle includes:
• forming, between adjacent coil windings of the wire bundle and the wire separator, an edge cooling channel;
• and
• forming, between adjacent coil windings of the wire bundle, an intra-bundle cooling channel,
• wherein the intra-bundle cooling channel is at a location spaced apart from the wire separator, inner and outer circumferential boundaries of the wire bundle and inner and outer radial boundaries of the wire bundle, and
• wherein the edge cooling channel is larger than the intra-bundle cooling channel;
• wherein:
• positioning the wire separator between the coil windings includes
• positioning a radial wire separator within the wire bundle that extends in the radial outward direction between the inner and outer radial boundaries of the wire bundle;
• and
• positioning a plurality of circumferential wire separator within the wire bundle that extend in the circumferential direction between the inner and outer circumferential boundaries of the wire bundle and are spaced apart from each other in the radial outward direction within the wire bundle,
• whereby the wire separator forms at least three of the subsets of wire bundles.