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Electrical Engineering in Japan, Vol. 147, No.

2, 2004
Translated from Denki Gakkai Ronbunshi, Vol. 123-D, No. 4, April 2003, pp. 392–400

Loss Calculation of Induction Motors Considering Harmonic Electromagnetic


Field in Stator and Rotor

KATSUMI YAMAZAKI
Chiba Institute of Technology, Japan

SUMMARY The magnetic fields in induction motors include


many time harmonics caused by the phase band, stator and
A method of loss calculation for induction motors is rotor slot ripple, even when the motors are driven by
proposed. The combined 3D–2D time-stepping finite ele- sinusoidal power supplies [4]. When the motors are driven
ment analysis is carried out to obtain the copper loss and by inverters, the time harmonics of the power supply are
the time variation of the magnetic field in the motor. The superimposed and the time variation of the magnetic field
iron loss is calculated approximately considering the time becomes more complex. These time harmonic fields induce
variation of the magnetic field direction and the minor harmonic losses at the stator windings, the rotor conductor,
hysteresis loops caused by the time-harmonic fields using and the stator and rotor cores. Among these harmonic
practical computer resources. The proposed method is ap- losses, it has become well known over the last few decades
plied to four types of induction motors, which are the solid that the stator surface loss caused by rotor slot ripple and
rotor induction motors with/without slot and the cage in- the rotor surface loss caused by stator slot ripple are rela-
duction motors with/without skew. The measured and the tively large and not negligible [5]. Furthermore, these har-
calculated total losses and the iron losses agree well in all monics have become more marked due to the recent design
cases. The differences of the loss distributions of each trends of smaller size and higher output. Consequently,
motor are also compared and investigated. © 2004 Wiley numerical electromagnetic field analyses, which have been
Periodicals, Inc. Electr Eng Jpn, 147(2): 63–73, 2004;
developed rapidly owing to progress in computers, have
Published online in Wiley InterScience (www.interscience.
been expected to be a powerful method of calculating the
wiley.com). DOI 10.1002/eej.10305
characteristics of motors with consideration of the effects
of these harmonic fields.
However, one problem remains, that is, the calcula-
Key words: induction motor; finite element tion of the losses generated at the stator and rotor cores,
method; harmonic field; iron loss; copper loss; surface loss; which are called iron losses. Iron losses can be classified as
eddy current loss; hysteresis loss. eddy current loss and the hysteresis loss. Accurate calcula-
tion of the eddy current loss requires a dense finite element
mesh, which uses huge amounts of computer resources,
1. Introduction because the stator and rotor cores are composed of lami-
nated electromagnetic steel having a thickness below 0.5
In this paper, we propose and investigate a method of mm. On the other hand, there are few reports of accurate
calculating the losses of induction motors involving iron modeling of hysteresis in core materials considering the
loss, considering the effects of the slot harmonics and the time harmonics of the magnetic field caused by slot ripple.
rotational magnetic field. Furthermore, not only the strength of the magnetic field
Motors account for nearly 50% of total electrical vector in the motor but also the direction of the vector varies
power consumption in advanced industrialized countries. with time. To consider this effect accurately, modeling of
Improvements of the efficiency of the motors are highly the vector magnetic property in the presence of a rotational
desirable from the viewpoint of environmental problems magnetic field [6] is required. In this case, enormous
[1–3]. Accordingly, many studies on the losses of the amounts of data on the core material must be provided for
motors have been reported in recent years. the electromagnetic field analyses.

© 2004 Wiley Periodicals, Inc.


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From these points of view, many studies on approxi-
mate and practical methods of calculating iron losses have
been reported, which utilize the nonlinear time-stepping
finite element method based on the scalar magnetic charac-
teristics. In addition, investigations of direct calculation
methods that take account of hysteresis phenomena and the
exact characteristics of the core material are still continu-
ing. However, so far as I know, there are few reports on the
calculation of the total loss of induction motors including
the stator and the rotor surface losses, with comparison to
measurement results. It is still unclear how great the losses
generated in each part of the induction motor are.
In this paper, I propose a method of calculating the
losses generated in the stators and the rotors of induction
motors, considering the variation of the direction of the
magnetic field vector and losses due to minor hysteresis Fig. 1. Outline of loss calculation.
loops caused by the harmonic magnetic field. The proposed
method is applied to four types of induction motors,
namely, solid rotor induction motors with and without slots,
and cage induction motors with and without skew. The
validity of the proposed method is verified by comparison 2.2 Finite element analysis
of the measured and the calculated total losses with iron
losses. The losses of each motor are also compared and The governing equation of the electromagnetic field
investigated to clarify the differences in the generation of in the induction motors, which is based on the scalar mag-
each loss component, which are influenced by the struc- netic characteristics, and the primary voltage equation are
tures of the rotor cores, such as the use of a solid or as follows:
laminated core, the presence or absence of slots, and the (1)
presence of absence of skew.

(2)
2. Calculation Method
where A is the magnetic vector potential, Js is the stator
current density, Jr is the rotor current density, n is the
2.1 Outline of calculation method reluctivity, vs and is are the stator voltage and current, Rs is
the stator winding resistance, and Φs is the linkage flux of
Figure 1 shows the outline of the procedure used to the stator winding.
calculate the losses. The procedure consists of two steps. Using Eqs. (1) and (2), the nonlinear time-stepping
First, the electromagnetic field analysis of the induction finite element analysis considering the nonlinear magnetic
motor is carried out by using nonlinear time-stepping finite characteristics of the core and the movement of the rotor is
element analysis considering the nonlinear magnetic char- carried out. As a result, the primary copper loss W1 and the
acteristics of the core and the harmonics caused by rotor secondary copper loss W2 are obtained as follows:
movement. At this step, the eddy currents and hysteresis
phenomena in the stator and rotor cores are neglected (3)
because it can be assumed that their effect on the total
electromagnetic field is relatively small. From this step of
the finite element analysis, the copper losses of the stator
and the rotor are obtained with consideration of the harmon- (4)
ics. Next, in the second step, the iron loss considering the
harmonics is calculated from the time-series data of the
stator and the rotor flux density at each point in the motor where T is the analysis period.
as obtained in the first step. The details of the first step of As mentioned before, the eddy currents and hystere-
the finite element analysis and the second step of the iron sis phenomena in the stator and the rotor cores are neglected
loss calculation are described below. in the finite element analysis because it can be considered

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that their effect on the total electromagnetic field is rela- It can be considered that the first term on the right-
tively small. This approximation corresponds to neglect of hand side of Eq. (5) is obtained from Eq. (6) with the
the iron loss current in the equivalent circuit of the induction following approximation [19]:
motor. In this case, the primary current may be slightly
underestimated when the primary voltage is given.
(7)

2.3 Method for iron loss calculation


Therefore, in this paper, the eddy current is calculated on
The iron loss per unit weight in case of a single-fre- the basis of Eq. (6) to take the harmonics of the magnetic
quency alternating magnetic field can be expressed ap- flux density and the time variation of the vector direction
proximately as follows [17]: into account. In this case, the eddy current loss Wie can be
calculated as follows from the eddy current coefficient Ke
(5) in Eq. (5) and the time series data of the flux density
distribution obtained by the finite element method:
where f is the frequency, and Ke and Kh are the constant
obtained by the Epstein frame test.
The first term on the right-hand side of Eq. (5) is the
eddy current loss wie and the second term is the hysteresis
loss wih. However, the real magnetic field in the rotating
machine can be considered to be complex. It includes many (8)
harmonics, especially near the air gap. Furthermore, the
direction of the magnetic field vector is not constant.
where ∆t is the time interval and N is the number of
There are several detailed investigations of the effect
iterations (number of samples).
of variation of the magnetic field vector [18, 19]. From
Using Eq. (8), we can calculate the eddy current loss
experimental results on the differences between the iron
including harmonics without Fourier transformation and an
losses caused by the alternating and rotational magnetic
array to hold the time variation of the flux density at each
fields, it was concluded that the iron loss caused by the
point in the motor.
rotational magnetic field can be regarded as approximately
equal to the sum of the losses caused by the alternating 2.3.2 Calculation of hysteresis loss including
fields in two directions into which the rotational field is
harmonics
decomposed when the sum of the two alternating fields is
less than 2T. Therefore, in this paper, the total iron loss is When the magnetic field includes harmonics, the
assumed to be the sum of the losses caused by the two hysteresis loss also increases due to the generation of minor
components of the flux density Br, Bθ (radial and tangential hysteresis loops. To calculate the hysteresis loss including
components in the rotating machine) that are parallel to the minor loops, the following assumptions are introduced.
laminated steel plates. The detailed methods of calculation
of the eddy current and hysteresis losses are described (1) All local maxima and minima in the time variation
below. of the flux density cause minor hysteresis loops.
(2) All hysteresis loops are similar in shape.
2.3.1 Calculation of eddy current loss (3) The total hysteresis loss corresponds to the sum
including harmonics of the areas of all hysteresis loops.
It is well known that the eddy current loss per unit
Using these assumptions, the hysteresis loss Wih can be
weight wie can be expressed as follows when the flux calculated as follows:
density is parallel to the steel plate:

(9)
(6)

where NE is the number of finite elements in the core, ∆Vi


where h is the thickness, D is the density, σiron is the is the volume of the i-th finite element, Nipr and Npi θ are the
conductivity of the steel plate, and κ is a coefficient express- number of peaks in the time variation of the r and θ
ing the difference between the classical theory and the real components of the flux density on the i-th finite element,
eddy current loss. and Bijmr, Bijmθ are the amplitudes of each hysteresis loop.

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Table 1. Specifications of analyzed motors

Fig. 2. Determination of amplitudes of major and minor mittees of IEE Japan, namely, the Research Committee on
hysteresis loops. Electromagnetic Field Analysis for the Virtual Engineering
of Rotating Machines (1998–1999) and the Research Com-
mittee on Electromagnetic Field Analysis for Three-Di-
mensional CAE of Rotating Machines (1999–2001). The
stators of all models are identical. Two types of the solid
Figure 2 shows the outline of the method of determin- rotors were built, without slots and with 34 slots. They were
ing Bijmr, Bm
ij
θ. The result of Eq. (9) includes not only the loss made from S45C carbon steel. The overhang at the ends of
due to the major hysteresis loop but also the losses of the the solid rotors from the stator was 4 mm. In addition, two
minor loops. This method does not require a Fourier trans- types of die-cast aluminum cage rotors were built, without
formation or an eddy current loss calculation. Only the local skew and with one rotor slot pitch skew. The core material
maximum and minimum in the time variation of the flux of the cage rotors was 50A1300, identical to the stator core.
density at each finite element need be stored in the computer The core length was 42 mm, also the same as the stator. In
memory. addition, the stator and the rotor core were built by laser cut
processing. The stator lamination was fixed only with bolts,
3. Analyzed Motors and Application of Proposed without using a frame.
Method
3.2 Application of combined 3D–2D finite
3.1 Specification of analyzed motors element method

Figure 3 shows the cross-sectional dimensions of the As mentioned in Section 2.2, the nonlinear time-step-
analyzed motors. Table 1 gives the specifications. The ping finite element method considering the harmonics and
motors are the induction motor K-models and the solid rotor the nonlinear magnetic characteristics of the core should be
induction motor models which have been studied by com- applied to calculate the primary and secondary copper

Fig. 3. Cross sections of stator and rotor of analyzed motors.

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Table 2. Coefficients of iron loss

depending on the slip frequency. The conductivities to be


utilized in the 2D nonlinear time-stepping analyses can be
obtained by multiplying these coefficients by the real con-
ductivity shown in Fig. 1. In addition, the number of time
Fig. 4. Coefficients for modifying conductivity of solid steps of the time-stepping analysis is set as 256 in one cycle
rotor. of the power supply.

3.3 Determination of iron loss coefficient for


iron loss calculation
losses considering the harmonics and the time-series data
As mentioned in Section 2.3, the coefficients of the
of the flux density at each point of the motor cores. But 3D eddy current loss Ke and the hysteresis loss Kh in Eqs. (8)
analysis is also needed because the secondary currents are and (9) are needed in order to calculate the losses of the
strongly influenced by the end effects of the rotor [21–24]. cores. In this paper, these coefficients are obtained from the
However, 3D nonlinear time-stepping analysis requires a catalogue data on 50A1300 electromagnetic steel plate as
very long calculation time. From these points of view, follows.
combined 3D–2D finite element analysis [23, 24] is applied Dividing each hand of Eq. (5) by f yields
to the motors. In this analysis, the voltage drop of the end
parts of the rotor conductor is estimated by approximate 3D (10)
analysis that is as simple as possible. The result of the 3D
analysis gives the coefficient that modifies the conductivity Figure 5 shows the relationship between f and wi/f obtained
of the rotor conductor for the 2D nonlinear time-stepping from the iron loss curve and the high-frequency iron loss
analysis. The characteristics of the motors are then calcu- curve in the catalogue data. The relationship is almost
lated by modified 2D analysis. linear. Thus, Ke and Kh can be obtained from the slope and
The modified coefficient of the conductivity of cage the intercept. The results are shown in Table 2, which also
conductors is calculated as 0.37, which is constant due to shows Kh of the S45C carbon steel that is used for the solid
the slip frequency. Figure 4 shows the calculated coeffi- rotors.
cients for solid rotors. The results vary between 0.3 and 0.6,
4. Measured and Calculated Results

4.1 Current and loss characteristics due to


rotational speed

Figures 6 and 7 show the measured and calculated


primary current and the total loss due to the rotational speed
of the motor. In the calculation of the total loss, the me-
chanical loss is estimated as

(11)

where d is the diameter of the rotor, l is the core length, and


v is the velocity on the surface of the rotor. This expression
has been obtained from various experiments and is widely
Fig. 5. Determination of coefficients of iron loss. used in the design of rotating machines [17]. The estimated

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Fig. 6. Experimental and calculated speed–current Fig. 7. Experimental and calculated speed–loss curve.
curve.

Fig. 8. Flux distribution, time variation of flux density, and loss distribution of solid rotor induction motor without slot.

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mechanical loss of the analyzed motors is 3.2 W, which is sinusoidal. In particular, the variation at the stator teeth is a
relatively small in proportion to the total loss because the nearly radial alternating field. On the other hand, the vari-
analyzed motors are small four-pole machines. Although ation at the rotor surface includes time harmonics caused
the calculated results for the solid rotor with slots and for by stator slot ripple due to the movement of the rotor. In this
cage induction motors at low speed slightly overestimate case, the locus of the flux density shows a harmonic rota-
the total loss compared with the measured results, the other tional field. The harmonics rapidly decrease from the sur-
results agree well with the measured results. Thus, the face to the inside of the rotor, where the magnetic field is
validity of the calculation method is verified. almost a DC field at synchronous speed. As a result, the
losses concentrate on the rotor surface.
4.2 Space and time variation of flux density On the other hand, in the case of the solid rotor with
and loss distribution slots in Fig. 9, time-harmonic magnetic fields also appear
at the stator because of the movement of the rotor slot due
Figures 8 to 11 show the space and time variation of to the rotation of the rotor. These harmonics are especially
the flux density and the loss distribution at the stator and marked at the stator surface, where the locus of the flux
rotor when the rotor is at synchronous speed. They show all density reveals complex variation. The harmonics caused
cases of the solid rotor with and without slots and the cage by stator slot ripple also appear at the rotor surface, and also
rotor with and without skew. in the case of the solid rotor without slots in Fig. 8. The
In the case of the solid rotor without slots in Fig. 8, losses concentrate at the rotor surface, including the sides
the variation of the flux density at the stator is nearly of the slots.

Fig. 9. Flux distribution, time variation of flux density, and loss distribution of solid rotor induction motor with slot.

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Fig. 10. Flux distribution, time variation of flux density, and loss distribution of cage rotor induction motor without skew.

The results for the cage rotor without skew in Fig. 10 neglecting the harmonics are also plotted for comparison.
also show time harmonics at the stator and the rotor core The experimental iron loss defined by the classical electric
near the air gap because of slot ripple. The losses also machine theory is
concentrate at the rotor surface. In addition, the figure
shows the generation of the harmonic secondary currents (12)
induced by stator slot ripple at the rotor conductor. The
currents concentrate at the surface due to the skin effect.
where Wnoload is the total no-load loss.
In the case of the cage rotor with skew in Fig. 11, the
The iron loss defined by Eq. (12) includes not only
harmonic secondary currents decrease compared with the
the losses generated at the core but also the harmonic
cage rotor without skew in Fig. 9 because of the effect of
secondary copper losses generated at the rotor conductor.
the skew. As a result, the loss density at the rotor conductor
The experimental and calculated results of each mo-
decreases. The figure shows the generation of the rotor core
losses not only at the surface but also relatively deep inside, tor in Fig. 12 show good agreement, verifying the validity
because of the deep penetration of the harmonic magnetic of the proposed calculation method. Among the calculated
field. This effect can be attributed to a decrease in harmonic results, the case of the cage rotor with skew shows the
secondary currents, which produce a reaction field against largest calculation error, with a calculated value 14% less
the slot harmonics. than the experimental result. It can be considered that this
Figure 12 shows the experimental and calculated iron error is caused by neglect of the inter-bar currents in the
losses at synchronous speed. The results calculated while calculation.

70
Fig. 11. Flux distribution, time variation of flux density, and loss distribution of cage rotor induction motor with skew.

Fig. 12. Experimental and calculated results of iron losses.

71
The results for all motors indicate a large contribution (2) The rotor losses are generated by slot harmonics
of rotor losses to total iron losses. This can be explained by even when the rotor is at synchronous speed. In this case,
the results shown in Figs. 8 to 11, which reveal relatively the losses concentrate particularly at the rotor surface.
large harmonic losses of the rotors even at synchronous (3) The iron loss defined by the classical electric
speed. The results calculated without consideration of the machine theory includes harmonic secondary copper losses
harmonics underestimate the losses by 40 to 70% as shown generated at the rotor conductor.
in Fig. 12 because they do not consider rotor losses. (4) When the iron loss is calculated without consid-
Let us discuss the components of the rotor losses. In eration of these losses generated in the rotor core and at the
the case of the solid rotor, the components are the harmonic conductor, the results often underestimate the losses com-
eddy current and the hysteresis losses generated in the S45C pared with the experimental results.
carbon steel. On the other hand, in the case of the cage rotor,
the components are eddy currents and hysteresis losses in Further work is required in order to develop a more
the 50A1300 electromagnetic steel sheet and harmonic accurate general-purpose calculation method which takes
secondary copper losses generated in the aluminum of the account of the stress of the core and includes material
rotor conductor. When the rotor is skewed, the harmonic modeling based on the vector magnetic properties. Further
secondary copper losses decrease, but the losses of the work is also required in order to calculate the inter-bar
electromagnetic steel sheet increase. This effect of the skew currents of the cage rotors with skew.
can be explained by the results shown in Fig. 11. In the case
of the skewed rotor, the reaction field against the slot
Acknowledgments
harmonics decreases because of the decrease in harmonic
secondary currents. As a result, the harmonic magnetic
I thank the members of the Research Committee on
fields penetrate deeply into the rotor core.
Advanced 3D Electromagnetic Field Analysis for Rotating
Next, let us consider the stator losses. In the case of
Machines, IEE Japan, for providing valuable advice, mate-
the solid rotor without slots, the calculated stator loss
rials, and measurement data.
neglecting the harmonics is almost identical to the result
The content of this paper is derived from papers
obtained when considering the harmonics. For the other
presented at the Joint Technical Meeting on Static Appara-
motors, the calculated results neglecting the harmonics
tus and Rotating Machinery, numbers SA-01-32, RM-01-
underestimate the stator losses by 10 to 20%. This result
100 and the Technical Meeting on Rotating Machinery,
can be explained by Fig. 8. In the case of the solid rotor
RM-01-142, of IEE Japan.
without slots, the time variation of the flux density at the
stator is almost sinusoidal. On the other hand, the variations
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AUTHOR

Katsumi Yamazaki (member) received his M.E. degree in electrical engineering from Waseda University in 1989. From
1989 to 1992, he worked in the Medical Engineering Laboratory of Toshiba Corp. From 1992 to 1997 he was a research associate
in the Department of Electrical, Electronic and System Engineering, Teikyo University. In 1997, he became a lecturer in the
Department of Electrical Engineering, Chiba Institute of Technology, and has been an associate professor since 1999. He is
mainly engaged in the electromagnetic field analysis of rotating machines. From 1996 to 1998 he was an adjunct lecturer at
Utsunomiya University. He received a paper presentation award of IEE Japan in 1998. He holds a D.Eng. degree.

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