EJ2210 Analysis of Electrical Machines

Lecture 3 Oskar Wallmark Associate Professor, PhD

Laboratory of Electrical Energy Conversion Royal Institute of Technology Stockholm, Sweden

May 4, 2012

Outline I

Stator Windings Basic Winding Data Mush Windings Diamond Windings

Rotor Windings

Insulation Systems

Basic Winding Data

The number of conductors per slots ns can be computed as ns = int Here, Uf N1 = 2 LDf B where Uf is the (rms) phase voltage. N1 cs qf11 .

Recall also the fundamental winding factor f11 : f11 = 1 sin(/6) ysp sin q 6q sin 6q

where ysp is the pitch length in number of slots.

Mush Windings (sv. plocklinding)

< 700 V, < 450 kW, p = 24, 400 mm.

Slot Shapes

Slot a is a standard slot. Slot shape c provides the most copper area but:

Corners may not be accurately lled with conductors. The life time of the punching tool may be shorter due to the small corner radius.

Catalog Geometry

Typical catalog geometry data (semi closed slots):

Slot Contents

Insulated slot area Yis is found as (double layer winding) Yis = Yis 1 + Yis 2 Yis 1 = Yis 2 (r ds )2 2 (h1 2ds dm ) (bs 1 2ds ) + (r bs 1 /2)(h1 2ds dm )

where h1 = hs hsys hkil r .

Slot Contents

The slot ll factor Fs is found as

2 + N d2 Ns Np1 dis p 2 is 2 1 Yis dis = dcu + is

Fs =

where Ns is the number of conductors per slot, Np1 is the number of parallel strands with diameter dis 1 , dcu is the copper diameter and is is the double layer thickness of the copper coating.

The coating increases the copper strand diameter with around 5% (2.4 mm) to 7% (0.9 mm). Theoretical maximum of Fs for round conductors in a rectangular slot is Fs = /4 0.785.

An experienced winder can obtain somewhat higher ll factors than what obtained with winding machines.

Coil Dimensions

Figure: Two- and three-cross windings with concentric coils.

Single layer windings are suitable for automatized winding machines (one phase can be nished before the next phase is inserted). Single layer mush windings often do not have equal but concentric coils (saves space and copper and are easier to wind). Three-cross reduces axial length and average coil length compared to two-cross.

Coil Dimensions

Half the average coil length L1 : L1 L + (R1 + R2 )/2 (ysp + 2)s R1 = ysp s /2, R2 = 2 is the (smallest) coil pitch in slots, s is the slot

where ysp pitch (m).

Coil Dimensions

Approximate axial length (one side) of the end winding Lys : Lys = 1 ysp s + q 2 2 b

where b the widest slot width (note: slightly dierent from eq. (3.6)). ysp for the innermost (smallest) coil should be used.

Coil Dimensions

Insertion of coils in a small machine with a mush winding.

Coil Dimensions

Brazing of coil ends (left) and impregnation of the winding by soaking (right).

Diamond Windings (sv. formlinding)

> 700 V, > 500 kW, p > 4, 400 mm. Coils manufactured before insertion. Rectangular strands with larger areas than strands in mush windings.

Diamond Windings (sv. formlinding)

The diamond winding is most often a double layer winding. All coils have the same pitch (i.e., not concentric coils). Often short pitched to reduce impact of 5th and 7th harmonic.

Diamond Windings (sv. formlinding)

One sided axial length Lys and half average coil length L1 to be estimated.

Diamond Windings (sv. formlinding)

Assuming R1 R2 = R , trigonometry (do it yourself) yields: Lys = h + Lstraight + x tan + (2R + b ) 1 sin cos 2x 1 sin L1 = + 2(2R + b ) /2 + 2Lstraight + L. cos cos

Diamond Windings (sv. formlinding)

Spreading (left) and insulation (right) of a diamond winding.

Diamond Windings (sv. formlinding)

Coil insertion.

Diamond Windings (sv. formlinding)

Slot wedges (left) and braced diamond coil ends (right).

Rotor Windings

Cast Al rotors most common type for up to 400 mm shaft heights. Slots closed prevents Al to come out on the rotor surface, reduces permeance variations but increases slot leakage (less starting torque). Rotor a: Double cage rotor suitable for grid operation (high starting torque due to high resistance at grid frequency). Rotor b: Grid operation, lower losses but also lower starting torque. Rotor c: Suitable for inverter supply.

Rotor Windings

No insulation in casted rotors. However, the Al oxide layer adds some insulation. Very high ll factor compared to the stator winding ( 1). The rotor bars can also be inserted (Al or Cu). Wound rotors uncommon though used in doubly-fed induction generators (wind turbines).

Rotor Windings

The rotor is often skewed. Reduces noise and torque ripple. Single skew by one stator slot pitch most common. Slightly increased stray losses (due to inter-bar currents). The stator can also be skewed.

Insulation Systems

The insulation shall:

1. Separate conductors electrically from each other and ground. 2. Arrange the E-eld distribution so that partial discharges (PD) do not occur (high voltage machines). 3. Mechanically secure the conductors. 4. Transport the heat generated by the copper losses to cooler parts of the machine (Chapter 6). 5. Endure handling during manufacturing and installation. 6. Withstand thermal stresses during transient and steady state conditions.

Insulation Systems

Slot content in a high-voltage winding.

Insulation Systems

Class A E B F H

Hot spot temp ( C) 105 120 130 155 180

Rule of thumb: Insulation lifetime halved for every 10 C rise of temperature. Often, the temperature rise is given with respect to an ambient temperature of 40 C.

Partial Discharges (PD)

PD can result in cavities trapping gas inside the insulation. Occurs when voltage across the cavity exceeds the ignition voltage. Electrical corona discharge transformed into heat. Small local sparks aecting the material where they occur.

PD Protection (sv. sp arglimskydd)

Impossible to t the winding so that it completely lls the slot. PD protection made up by thin, low-resistive material most in contact with the stator core. All the voltage is built up within the insulation PD between the coil and the lamination is avoided.

PD Protection (sv. andglimskydd)

Close to the coil ends, large E-elds can arise resulting in PD. An enamel with voltage dependent resistivity (decreases with applied voltage) evens out the E-eld distribution PD is avoided.

Insulation Testing

Resistance between terminal-earth and terminal-terminal is measured (dc voltage/dc current). Healthy insulation MG. Insulation fault k. High voltage (kV) is added for 1 minute at grid frequency (50 or 60 Hz). Resistance between terminal-earth and terminal-terminal is measured again.

What Have We Learnt?

We have discussed the basics of mush and diamond windings. We have reviewed the basics of dierent rotor slot designs. We have discussed the basics of insulation systems. Dont forget to read about two-speed motors (Dahlander winding).

Friendly Reminder

Has your interest in the design of electric machinery deepened?

EJ2221 Design of Permanent-Magnet Synchronous Machines. 7.5 ECTS credits. Electromagnetic and thermal design. Finite element modeling (Cedrat-Flux).

Friendly Reminder

What about power electronic modulation?

EJ2311 Modulation of Power Electronic Converters 6 ECTS credits. Theoretical tools for evaluating dierent voltage modulation methods. Two-, three- and multilevel voltage modulation. Impact on electric machinery. Applications overview (HVDC, railway traction).