Induction Motor Design (3-Phase)

OUTPUT EQUATION: - It gives the relationship between electrical rating and physical dimensions
(Quantities)

Output of a 3 phase IM is
Q 3VPh1 I Ph1 Cos 103 KW (1)
Where
VPh1= Input phase voltage
IPh1= Input Phase current
Cos Input power factor
Efficiency of motor
Or equation (1) can be written as
Q 3(4.44 K pd 1 f 1 N Ph1 ) I Ph1 Cos 10 3 KW (2)
(VPh1 4.44 K pd 1 f 1 N Ph1 )
Where
f = frequency of supply =PN/120
P =No of Poles
N =Speed in RPM
Kpd1= Winding factor =0.955
D
1 B P L B L
P

B = Average value of fundamental flux density
P =Pole pitch = D
P
D = Inner diameter of stator
L = Length of the IM
Total No of Conductors on Stator 3 2 N Ph1 6 N Ph1
Toal Ampere Conductors on Stator 6 N Ph1 I Ph1
Total Ampere conductors is known as total electric loading
Specific electric loading

It is defined as electric loading per meter of periphery, denoted by ac .
6 N Ph1 I Ph1
ac
D

Or ac D
N Ph1 I Ph1
6
Putting the values of f, 1 & NPh1IPh1 in equation 2 we get

NP D ac D
Q 3 4.44 0.955 ( ) ( B L) ( ) Cos 10 3 KW
120 P 6

Q (17.4 10 5 B ac Cos ) D 2 LN

Or Q CD 2 LN KW

Where

C Output Co efficient 17.4 10 5 B ac Cos

CHOICE OF MAGNETIC LOADING ( B ):

( B is average value of fundamental flux density in the air gap)

1. Magnetizing current : Lower B

2. P.F : Lower B

3. Iron Loss : Lower B

4. Heating & Temp rise : Lower B

5. Overload Capacity : Higher B
We know
VPh1 4.44 K pd 1 f 1 N Ph1

If voltage is constant so for Higher B , Nph1 will be less.
And we know
Leakage reactance N Ph 1
2
Leakage Reactance
Isc is more Dia of circle diagram Overload Capacity

6. Noise & Vibration : Lower B

7. Size : Higher B

8. Cost : Higher B

Range of B = 0.3 to 0.6 Tesla

CHOICE OF SPECIFIC ELECTRIC LOADING:

1. Copper Losses : Lower ac

2. Heating & Temp Rise : Lower ac

3. Overload Capacity : Lower ac

If ac
N
Ph1
And we know
Leakage reactance N Ph1 Leakage reac tan ce
2

Isc is more Dia of circle diagram Overload Capacity

4. Size : Higher ac

5. Cost : Higher ac

Suitable values of ac are

ac =10,000 to 17,500 Amp Cond/meter up to 10 KW
=20,000 to 30,000 Amp Cond/meter up to 100 KW
=30,000 to 45,000 Amp Cond/meter > 100 KW

MINI AND MAXI VALUE OF C:

We know

C 17.4 10 5 B ac Cos
 Cmin 17.4 10 5 0.30 10000 0.80 0.85 ( let Cosmin 0.80 & min 85%)
Cmin 0.35
Cmax 17.4 10 5 0.60 45000 0.85 0.88 ( let Cosmax 0.85 & max 88%)
Cmin 3.5

EFFECT OF SPEED ON COST AND SIZE OF IM:

Q
D2L Represents the volume of Machine
CN
So for higher speed IM volume is inversely proportional to speed.
Hence High speed means less volume that is low cost

ESTIMATION OF MAIN DIMENSIONS (D, L):

We know
Q
D2 L (1)
CN
L
1 : Good Overall Design
P

1 1.25 : for Good PF ( 2)
1. 5 : for higher

1.5 2.0 : Overall Economical Design

Solving equation (1) & (2) we can find out D & L.

LENGTH OF AIR GAP:

0.2 DL mm
Note: D & L are in Meters
min 0.25 mm
For medium rating machines
2 3 mm

EFFECTIVE LENGTH OF MACHINE:

Generally
l1= l2= l3=. = ln l1 l2 l3 ln

Let bv
nv =No of ventilating ducts L
bv = Width of one ventilating duct
(Generally for every 10 cm of core length there used to be 1 cm ventilating duct)

Gross Iron length

l = l1+ l2+ l3+. +ln
Actual Iron length
li =Ki*l

Where Ki =Stacking factor

=0.90 to 0.92
Overall length
L = l + nv*bv
Effective length
Le L nv bv'
5
bv' bv
Where bv =Effective width of ventilating duct (< bv due to fringing)
5

DESIGN OF STATOR:

(1) Shapes of stator slots

May be (i) Open Slot
(ii) Partially Closed Slot

(2) No of Stator Slots S1:

Slot pitch
D
sg1 15 20 mm
S1
D
S1

So sg 1

For 3-Phase IM having P-poles

S1 3q1 P
S1
q1 No of slots per pole per phase
Where 3P
Winding may be integral (q1 is integer) or fractional (q1 is fractional) slot winding.
If q1 is fractional, say
x
q1
y
Then for windings to be symmetrical it is essential that the denominator y should be such that the
no of pole pair is divisible by y.
If double layer winding is to be use then y should be divisible by 2.

Hence S1 is estimated.

(3) Estimation of total No of turns per Phase (Nph1), Total no of conductors (Z1) & No of conductors
per slots (Nc1):

We know
VPh1 4.44 K pd 1 f 1 N Ph1 (1)
VPh1
So N Ph1 (2)
4.44 K pd 1 f 1

Where
D
1 B P le B le (3)
P
Z1 3 2 N Ph1 6 N Ph1 (4)
 Z1
N c1 (5)
S1
N c1 must be an integer and divisible by 2 for double layer windings. If not an integer make it
integer
and hence find the corrected value of N c1 that is N c1,corrected . Also find out the corrected values of
Followings
Z1,corrected Using equation (5)
N Ph1, corrected Using equation (4)
1,corrected
Using equation (1)

B corrected Using equation (3)

(4) Sectional area of stator conductor (Fc1):

Per phase stator current

Q 103
I Ph1
3VPh1 Cos
I Ph1
FC1 mm 2
So 1

Where 1 Current density 3 4 A / mm 2

From ICC (Indian Cable Company) table, find dc corresponding to Fc1

SWG | Fc1 (mm) | dc (mm) | doverall (mm)

50 | | 0.025 |
25 | | 0.5 |
1 | | 7.62 |

(5) Stator slot design:

Let
nv = No of conductors vertically
nh = No of conductors horizontally
So Nc1= nv*nh ------------------------- (1)
nv
3 5 ( 2)
nh
Solving equation (1) & (2) find out nv & nh.

Height of slot b01

hs1 = nv*dc + 3*0.5 + 3.5 + 1.5 + 2 mm (0.5 mm is insulation thickness and
2 mm for slack1.5 mm Tooth lip
& tolerance)
Width of the slot
bs1 = nh*dc + 2*0.5 + 2 mm 3.5 mm
(0.5 mm is insulation Wedgeand
thickness
2 mm for slack & tolerance)
Slot opening
2 0.5 mm
b01 bs1 hs1
5

Ratio
hs1
35
bs1

bs1

Partially closed slot for 400Volts IM

Thickness of insulation
With mica or leatheroid insulation for small rating machines
KV 0.4 1.1 3.3 6.6 11 15
mm 0.5 0.75 1.5 2.5 4 5.5

With improved insulation (Semica Therm)

KV 2 3 6 10 16 25
mm 1.1 1.4 1.8 2.8 4.0 6.0
Thickness = 0.215 KV +0.7 mm
Advantages of Semica Therm:
(a) Much better heat is dissipated for higher rating machines due to less thickness of wall
insulations.
(b) Insulation occupies little less space in the slot.

(6) Length of mean turns (Lmt1)

Lmt1 2 L 2.3 P 0.24 L Coil Span

D < Pole pitch
Where P Pole pitch
P

(7) Resistance of stator winding per phase (RPh1)

One Turns
6 L
RPh1 0.021 10 mt1 N Ph1
Fc1
(8) Total copper loss in the stator winding
3 I Ph
2
1 RPh1

(9) Flux density in stator tooth

hy
Slot
Yoke
Teeth
Maximum flux density in stator tooth should not exceed 1.8T; otherwise iron losses and
magnetizing current will be abnormally high. (So if flux density >1.8T, change slot dimensions)
rd
1
Mean flux density in the stator tooth is calculated at of tooth height from the narrow end of the
3
stator tooth.
rd
1
Dia of stator at of tooth height from narrow end
3
1
D1 D hs 2
3
ht 3
rd
1
Slot pitch at of tooth height from narrow end
3
D1
ht
1 3
sg ht
3
S1
rd
1
Width of the tooth at of tooth height from narrow end
3
b1 1 bs
t ht sg ht
3 3
rd
1
Area of one stator tooth at of tooth height from narrow end
3
b1 K il
t
3
ht (Where li = ki l=Actual iron length)

Area of all the stator teeth under one pole

S
A 1 Area of one tooth No of teeth per pole 1
t ht
3 P
S
b 1 K il 1
t ht
3 P
1
D 3 hs 2 S
bs K il 1
S1 P

 So mean flux density in teeth
1
B1
t ht
3
A1
t ht
3

(10) Depth (Height) of stator yoke (hy):

Flux through stator yoke is half of the flux per pole
1
B y hy K i l
2
Where By = flux density in yoke
= 1.3 to 1.5 T
/2
So hy 1
By K il

(11) Outer dia of IM (Do):

Do D 2hs 2hy

(12) Estimation of iron losses:

Corresponding to flux density in tooth Bt 1 h find out iron loss per Kg from the graph given
t
3
So B 1 pit W / Kg
on page 19, fig 18. t ht
3

Iron loss in teeth

= pit* density * volume of iron in teeth
= pit* 7600 * volume of iron in teeth
Corresponding to flux density in yoke B y find out iron loss per Kg from the graph given on page
19, fig 18. So By piy W / Kg
Iron loss in yoke
= piy* density * volume of iron in yoke
= piy* 7600 * volume of iron in yoke
Total iron losses Pi = Iron loss in teeth + Iron loss in yoke
Pi
So IC
3VPh1

ROTOR DESIGN:

(1) Estimation of rotor no of slots (S2)

If S1= S2, cogging will take place and slot selection also affects noise & vibrations. So as a general
rule to avoid crawling, cogging and keeping noise & vibrations low, following slot combinations are
selected

1 2
q1 q2 1, , .........
3 3
1 2
q2 q1 1, , .........
3 3
Where, q1 & q2 are no of slots per pole per phase for stator and rotor respectively.
So No of rotor slots
S 2 3q2 P
(2) Estimation of rotor no of turns, conductors etc

(a) Wound rotor IM:

We may keep
VPh 2 N Ph 2
0.5 0.6
VPh1 N Ph1
 So No of turns per phase on rotor
N Ph 2 (0.5 0.6) N Ph1
Total no of conductors on rotor
Z 2 6 N Ph 2
Conductors per slot for rotor
Z
NC 2 2 Make it (NC2) integer if not and divisible by 2 for 2 layer winding. Hence find
S2
out correct value of NC2, NPh2 & Z2 i.e. NC2,Corrected NPh2,Corrected Z2,Corrected

(b) Cage rotor IM:

No of rotor bars
Z 2bar S2

(3) Rotor current (IPh2)

It is assumed that 85% of ampere turns get transferred to the rotor.
Ampere turns on stator 3 I Ph1 N Ph1

(a) Wound rotor IM:

Ampere turns on rotor 3 I Ph2 N Ph2
So 3 I Ph2 N Ph2 0.85 3 I Ph1 N Ph1
0.85 I Ph1 N Ph1
Or I Ph2
N Ph2
(b) Cage rotor IM:
S
Ampere turns on rotor I 2bar 2
2
S
So I 2bar 2 0.85 3 I Ph1 N Ph1
2
0.85 6 I Ph1 N Ph1
Or I 2bar
S2
End ring current
S I
I 2 endring 2 2bar
P
(4) Size of rotor conductors:
(a) Wound rotor IM:
X-sectional area of rotor conductor
I
FC 2 Ph 2
2
Where 2 = Current density in rotor winding
= 4 to 5 A/mm2
(Higher than stator current density because rotor is rotating so cooling
is increased hence, 2 is more)
SWG or strip conductors may be used.

(b) Cage rotor IM:

X-sectional area of rotor bar
I 2bar
FC 2bar
bar
Where bar = Current density in rotor bar
= 5 to 7 A/mm2
(Higher than stator & wound rotor because rotor conductors are
bare that is no insulation so better heat conduction resulting in
better cooling so is more)
 If round bars are used then dia of bar
2
FC 2 bar d 2bar
4
4 FC 2bar
Or d 2bar

X-sectional area of rotor endring

I 2 endring
FC 2 endring
bar
Current density in end ring is same as current density in bar.

(5) Flux density in rotor tooth

(Note: This is same as flux density in stator tooth)
rd
1
Dia of rotor at of tooth height from narrow end
3
2
D1 D 2 ht 2 2
3
ht 2 3
rd
1
Slot pitch at of tooth height from narrow end
3
D1
ht 2
1 3
sg 2 ht 2
3
S2
rd
1
Width of the tooth at of tooth height from narrow end
3
b 1 1 bS 2
t 2 ht 2 Sg 2 ht 2
3 3
rd
1
Area of one stator tooth at of tooth height from narrow end
3
b 1 Ki l
t 2 ht 2
3

Area of all the stator teeth under one pole

S
A 1 Area of one tooth No of teeth per pole 2
t 2 ht 2
3 P
S
b 1 K il 2
t 2 ht 2
3 P
2
D 2 3 ht 2 2
b K l S2
s2 i
S2 P

So mean flux density in teeth
1
B 1
t 2 ht 2
3
A 1
t 2 ht 2
3

(6) Rotor copper loss

(a) Wound rotor:

Length of mean turns of rotor
Lmt 2 2 L 3.5 P

DC resistance per phase at 75 0 C

Lmt 2
RPh 2, 75o C 0.021 10 6 N Ph 2
Fc 2
 We dont take the ac resistance because the rotor current frequency is very small (f2=sf)
So Rotor cu loss 3I Ph
2
2 RPh 2

(b) Cage rotor: Do D 2hs 2hy

6 L ( m) D
Resistance of one bar 0.021 10
FC 2 bar ( m 2 )
Cu loss in bars S 2 I 22bar Resistance of one bar
Resistance of end ring
d2bar
( D 2 2d 2bar )(m)
0.021 10 6 2d2bar
FC 2 endring (m 2 )
Cu loss in end rings
2 I 22endring Resistance of one endring
Total cu loss = Cu loss in bars + Cu loss in end rings

Rotor Cu Loss
Slip S
Rotor Input Power
Rotor Cu Loss D 2 2d 2bar
S
Mech Power Output Losses
D 2
Losses = Rotor Iron Loss (Negligible) + Rotor Cu loss + F & W loss
F & W loss up to 5% for small motors
3% to 4% for medium motors
2% to 3% for large motors

S up to 5% for small motors

2.5% to 3.5% for medium motors
1% to 1.5% for large motors

EFFECTIVE AIR GAP LENGTH ( ' ) :

Rotor

'

Stator

Effective air gap length

' K C1K C 2
Where K C1 Cartor ' s Coefficient for stator
Sg1 D
K C1 & Sg1
Sg1 K 01b01 S1
K C 2 Cartor ' s Coefficient for rotor
Sg 2 ( D 2 )
KC 2 & Sg 2
Sg 2 K 02b02 S2
K01 & K02 are constants

MMF REQUIRED IN AIR GAP AT :

1
H B
0 AT/m
 1
AT ' B '
0 30
0

FLUX DENSITY DISTRIBUTION:

Flux density at 300 from direct axis

= flux density at 600 from inter-polar axis
B30 0 B60 0 Bm1 Cos300
So
3
B
2 2

1.36 B

For all practical purposes this value is modified to

B30 0 1.35 B

ESTIMATION OF MAGNETIZING CURRENT & NO LOAD CURRENT (Im & Io):

S.No Part Length of path Flux at ATpole-pair

density (AT/m)
1 Stator Yoke ly By aty ATy

2 Stator Tooth 2ht1 B 1 at2ht1 AT2ht1

t ht 1
3

3 Air Gap 2 ' B300 at 2 ' AT2 '

4 Rotor Tooth 2ht2 B1 at2ht2 AT2ht2
t ht 2
3

5 Rotor Yoke lry Bry atry ATry

ATpole-pair = AT30 =

AT30 ATy AT2ht1 AT2 ' AT2ht2 ATry

AT30
AT for one pole
2
So no load current
P 1 Pi
I m AT30 IC
2 1.17 K d 1 N Ph1 3VPh1
No load current
Io I C2 I m2
No load power factor
IC
Coso
IO
ESTIMATIONS OF IDEAL BLOCKED ROTOR CURRENT:
Total resistance referred to stator
2
K d 1 N Ph1
R01 R1 R '
2 Where R '
2
R2
K d 2 N Ph 2
Total leakage reactance referred to stator
2
X 01 X 1 X 2' K d 1 N Ph1
Where X '
2
X2
K d 2 N Ph 2
 VPh1
I sc , Ideal
R012 X 012
R01
Cossc
R X 012
2
01

ESTIMATION OF LEAKAGE REACTANCE:

Leakage reactance consists of Leakage flux

1. Stator slot leakage reactance
2. Rotor slot leakage reactance
(a) Wound rotor or
(b) Cage rotor Slot leakage Reactance
3. Overhang or end turns leakage reactance Over Hang
Leakage flux
4. Zigzag leakage reactance

Zigzag leakage flux L

Rotor

Stator

Zigzag leakage Reactance Over Hang Leakage Reactance

For cage rotor IM Zigzag leakage reactance is small and may be ignored.
5. Differential or harmonic leakage reactance

1. Stator slot leakage reactance:

Assumptions are
(i) Permeability of iron is infinity so NO MMF is consumed in iron path.
(ii) Leakage flux path is parallel to slot width

Let
Ic1 = Conductor current (A)
Zc1 = No of conductors per slot
Z1 = Total No of conductors
NPh1 = Turns per Phase
P = No of poles
q1 = Slot / Pole /Phase
(a) For 1-Layer winding
Total amp conductors in slot =Ic1 Zc1
Consider an elementary path of thickness dx at a distance of x as shown in the figure. Let dx be the
leakage flux through the elementary path of thickness dx & height x.
MMF at distance x

Z c1 I c1
Mx x ------ (1)
h1
A Ldx
Permeance 0 L 0 b ----- (2)
s1

So
d x Mx Permeance of the path
 Z c1I c1 Ldx
d x x 0 ---- (3)
h1 bs1

b01
h4

h3

h2 Zc1Ic1

h1
dx Mx

bs1
Stator slot MMF Distribution

Leakage flux linkages associated with this elementary path

d x No of Conductors with which it is associated d x
Z Z I Ldx
d x C1 x c1 c1 x 0 ---------- (4)
h1 h1 bs1
So flux linkages in height h1
h1 2
L x
h1 0 Z I 0 h1 dx
2
C 1 c1 ------------------- (5) (Integrating equation 4 from 0 to
bs1
h1)
h1
h1 0 Z C21 I c1 L ------------------- (6)
3bs1

Leakage flux linkages in height h2

h
h 2 0 Z C21 I c1 L 2 ------------------- (7)
bs1

Leakage flux linkages in height h3

2h3
h 3 0 Z C21 I c1 L ------------------- (8)
(bs1 b01 )

Leakage flux linkages in height h4

h
h 4 0 Z C21I c1L 4 ------------------- (9)
b01

Total slot leakage flux

h1 h 2h3 h
s1 0 Z C21I c1L 2 4 ----------- (10)
3bs1 bs1 (bs1 b01 ) b01

Slot leakage inductance will be

 s1 h h 2h3 h
Ls1 Z C21L 0 1 2 4 --------- (11)
I C1 3bs1 bs1 (bs1 b01 ) b01

Ls1 s1 Z C21L s --------- (12)
I C1
Where
h1 h 2h3 h
s 0 2 4 Specific slot permeance
3bs1 bs1 (bs1 b01 ) b01
No of slots per phase =Pq1

Slot leakage inductance per phase

Ls1 / Phase Pq1 Z C21 L s
---------- (13)
Total No of conductors
Z1 Z c1.3q1.P 6 N Ph1
2 N Ph1
So Z C1 Put in above equation
Pq1
2
2 N Ph1
So Ls1 / Phase Pq1 L s
Pq1
2
N Ph h h 2h3 h
Or Ls1 / Phase 4 0 1
L 1 2 4 -------- (14)
Pq1 3bs1 bs1 (bs1 b01 ) b01
Slot leakage reactance per phase (1-Layer)
X s1 2fLs1 / Phase
2
N Ph h h 2h3 h
X 1 X s1 8f0 1
L 1 2 4 -------- (15)
Pq1 3bs1 bs1 (bs1 b01 ) b01

(b) For 2-Layer winding

Same as 1-Layer winding

Slot leakage reactance per phase (2-layer)

N2 2h1 h h 2h4 h
X 1 X s1 8 f 0 Ph1 L 2 3 5 -------- (16)
Pq1 3bs1 4bs1 bs1 (bs1 b01 ) b01

b01
h5

h4
h3 Zc1Ic1

h1 I C1
Z c1
2
h2

h1

bs1
2-Layer stator slot MMF Distribution
2. Rotor slot leakage reactance(X2)

(a) Wound rotor: Estimated in the same manor as for stator.

(b) Cage rotor:
W0 = b02 = (0.2 to 0.4) d2bar
h = 1 to 3 mm
Rotor reactance per phase
N2
X 2 8 f Ph 2 L r ----------------- (17)
Pq2
Where
r Rotor Specific Permeance
h
r 0 0.623
W0
Rotor resistance referred to stator
2
K d 1 N Ph1
X
'
2
X 2
K d 2 N Ph 2
Where
S2
N Ph 2
26
3. Overhang leakage reactance(X0):

2
N Ph
X 0 8 f 1
l0 0 -------------- (18)
Pq1

Where
0 Overhang Specific Permeance
P2
0 0 K s
l0 sg
l0 = Length of conductor in overhang
Ks = Slot leakage factor
P Pole Pitch
sg Slot Pitch
4. Zigzag leakage reactance (Xz):

5 1 1
Xz X m 2 2 --------------- (19)
6 S P1 S P 2
Where
VPh1 S1 S2
Xm S P1 & SP2
Im P P

5. Differential or Belt or Harmonic leakage reactance (Xh):

It is ignored for cage rotor but considered for wound rotor IM. It is due to the fact that spatial
distribution of MMFs of the primary and secondary windings is not the same; the difference in the
harmonic contents of the two MMFs causes harmonic leakage fluxes.

X h X m ( K h1 K h 2 ) ----------------- (20)
 Where
Kh1 & Kh2 are the factors for stator & rotor

Hence
Total leakage reactance referred to the stator side

X 01 X 1 X s1 X 2' X 0 X z X h

CONSTRUCTION OF CIRCLE DIAGRAM FROM DESIGNED DATA:

We should know following for drawing the circle diagram
a. No load current and no load power factor
b. Short circuit current and short circuit power factor

Steps to draw the circle diagram are (See the figure on next page)

1. Draw horizontal (x-axis) and vertical (y-axis) lines.

2. Draw I at an angle 0 from vertical line assuming some scale for current.
0

3. Draw Isc at an angle sc from vertical line.

4. Join AB, which represents the o/p line of the motor to power scale.
5. Draw a horizontal line AF, and erect a perpendicular bisector on the o/p line AB so as to meet the
line AF at the point O. Then O as center and AO as radius, draw a semi circle ABF.
6. Draw vertical line BD; divide line BD in the radio of rotor copper loss to stator copper loss at the
point E.
7. Join AE, which represent the torque line.

Determination of design performance from above circle diagram

1. Power scale can be find out from current scale
Power in watt per Cm = Voltage x Current per Cm
2. Full load current & power factor
Draw a vertical line BC representing the rated o/p of the motor s per the power scale.
From point C, draw a line parallel to o/p line, so as to cut the circle at pint P. Join OP which
represents the full load current of the motor to current scale. Operating power factor can also be
found out.

3. Full load efficiency

Draw a vertical line from P as shown in above figure.
PL = O/p Power
PX = I/p Power
PL

PX
4. Full load slip
Rotor Cu loss
Slip
Rotor Input Power
LS

PS
5. Starting torque
Line BE represents the starting torque of the motor in synchronous watts to power scale
We can also draw maximum torque and maximum power output from circle diagram.
(Not shown in above diagram)