Electrical Workshop II

INDUCTION MOTOR WINDING

 Contents
• Introduction to Induction motor;
• Three phase induction motor winding types and arrangement;
• Design of three phase induction motor winding types;
• Winding of coils using manual winding machine;
• Assembly of the winding to the stator of the motor and finally
performing all necessary tests that are done by maintenance
personnel 2
 Introduction to Induction Motor
Three-phase induction motors are the most common and
frequently encountered machines in industry;
• Simple design, low-price, easy maintenance
• Wide range of power ratings: fractional horsepower to 10 MW
• Run essentially as constant speed from no-load to full load
• Its speed depends on the frequency of the power source
• Requires a variable-frequency power-electronic drive for optimal speed
control

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 Construction of IM
• An induction motor has two main parts
A stationary stator
• Consisting of a steel frame that supports a hollow, cylindrical core
• Core, constructed from stacked laminations, having a number of evenly spaced
slots, providing the space for the stator winding
A revolving rotor
• Composed of punched laminations, stacked to create a series of rotor slots, providing
space for the rotor winding
• One of two types of rotor windings
• Conventional 3-phase windings made of insulated wire (wound-rotor) » similar to
the winding on the stator
• Aluminum bus bars shorted together at the ends by two aluminum rings, forming a
squirrel-cage shaped circuit (squirrel-cage)
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Two basic design types depending on the rotor design
• Squirrel-cage: conducting bars laid into slots and shorted at both ends by
shorting rings.
• Wound-rotor: complete set of three-phase windings exactly as the stator.
Usually Y-connected, the ends of the three rotor wires are connected to 3
slip rings on the rotor shaft. In this way, the rotor circuit is accessible.

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 Squirrel cage rotor

Wound rotor

Notice the slip rings

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 Principle of Operation
• A Rotating Magnetic field (RMF) is set up in the stator when a 3- Phase supply
is given.
• This rotating magnetic field cuts the rotor windings and produces an induced
voltage in the rotor windings.
• Due to the fact that the rotor windings are short circuited, for both squirrel cage
and wound-rotor, and induced current flows in the rotor windings.
• The rotor current produces another magnetic field.
• A torque is produced as a result of the interaction of those two magnetic fields.
 ind  kB R  B s
Where ind is the induced torque and BR and BS are the magnetic flux densities of
the rotor and the stator respectively
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Rotating Magnetic Field
• Balanced three phase windings, i.e. mechanically
displaced 120 degrees form each other, fed by
balanced three phase source
• A rotating magnetic field with constant magnitude
is produced, rotating with a speed

120 fe
nsync  rpm
P
Where
• fe is the supply frequency and
• P is the no. of poles and
• nsync is called the synchronous speed in rpm
(revolutions per minute)
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Rotating Magnetic Field

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 Induction motor speed
At what speed will the IM run?
• Can the IM run at the synchronous speed, why?

• If rotor runs at the synchronous speed, which is the same speed of the rotating magnetic
field, then the rotor will appear stationary to the rotating magnetic field and the rotating
magnetic field will not cut the rotor.

• So, no induced current will flow in the rotor and no rotor magnetic flux will be produced
so no torque is generated and the rotor speed will fall below the synchronous speed

• When the speed falls, the rotating magnetic field will cut the rotor windings and a torque
is produced
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 Induction motor speed
• So, the IM will always run at a speed lower than the synchronous speed.
• The difference between the motor speed and the synchronous speed is called
the Slip
nslip  nsync  nm

Where nslip= slip speed

nsync= speed of the magnetic field
nm = mechanical shaft speed of the motor

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 The Slip
n sync  n m
s 
n sync
Where, s is the slip
Notice that : if the rotor runs at synchronous speed

s=0
if the rotor is stationary

s=1
 Slip may be expressed as a percentage by multiplying the above eq. by
100, notice that the slip is a ratio and doesn’t have units 12
 Frequency
• The frequency of the voltage induced in the rotor is given by
𝑃 × 𝑛𝑠𝑙𝑖𝑝
𝑓 =
120

Where fr = the rotor frequency (Hz)

P = number of stator poles
nslip = slip speed (rpm)
P  (ns  nm )
fr 
120
P  sns
  sfe
120 13
What would be the frequency of the rotor’s induced voltage at any speed
nm?
f r  s fe
When the rotor is blocked (s=1) , the frequency of the induced voltage is
equal to the supply frequency.

On the other hand, if the rotor runs at synchronous speed (s = 0), the
frequency will be zero.

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 Torque
• While the input to the induction motor is electrical power, its output is
mechanical power and for that we should know some terms and quantities
related to mechanical power.
• Any mechanical load applied to the motor shaft will introduce a Torque on
the motor shaft.
• This torque is related to the motor output power and the rotor speed
Pout 2 nm
 load  N.m and m  rad / s
m 60

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 Horse Power
• Another unit used to measure mechanical power is the horse power.

• It is used to refer to the mechanical output power of the motor.

• Since we, as an electrical engineers, deal with watts as a unit to measure

electrical power, there is a relation between horse power and watts

hp  746 watts

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Power flow in induction motor

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Power Relations
Pin  3 VL I L cos  3 Vph I ph cos

PS C L  3 I 12 R 1
PAG  Pin  (PSCL  Pcore )
PRCL  3 I R 2 2
2

Pconv  PAG  PRCL  in d 

Pc o n v
m
Pout  Pconv  ( Pf  w  Pstray )
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Components of 3-phase Induction Motor
1. Frame
2. Stator
3. Stator Winding
4. Rotor
5. Rotor Winding
6. Cooling Fan
7. Bearings Frame:
Frame: provides mechanical support to the stator and rotor.
• It is made from casting materials.
Stator:
• It is stationary part of induction motor. It consists stator winding
• It is housed on the motor frame.
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Rotor:-
• It is the rotating part of the induction motor.
• It is housed on the shaft of the induction motor.
• It has two ends, one is called Driving end and another is called non
Driving end.
• Mechanical load is connected on driving end while cooling fan is
connected on non-driving end.
• Both the ends are connected with bearings for free rotation means of
reduced friction losses.
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Assembly of 3-Phase Induction Motor

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 Three Phase winding in Induction Machine
• In a three phase alternators, three different sets of windings are arranged in the
armature (stator) slots in such a way that there exists a phase difference of
between the induced e.m.f in them.

• Each set of windings is for each phase of three phase induced e.m.f.

• Thus the three phase induced e.m.f has three different e.m.f given by,

𝑹 𝒎

𝒀 𝒎

𝑩 𝒎
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 AC Winding Terminologies
1. Conductor:- The part of the wire, which is under the influence of
the magnetic field and responsible for the induced e.m.f. is called
active length of the conductor. The conductors are placed in the
stator slots.
2. Turn :- A conductor in one slot, when connected to a conductor in
another slot forms a turn. So two conductors constitute a turn.
• Two conductors connected in series and separated from each other by a pole
pitch so that the emf induced will be additive.

Turn
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3. Coil :- As there are number of turns, for simplicity the number of turns are
grouped together to form a coil. Such a coil is called multi-turn coil. A coil
may consist of single turn called single turn coil.

4. Coil Side :- Coil consists of many turns. Part of the coil in each slot is called
coil side of a coil.

Multi-turn coil
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5. Pole Pitch:- It is center to center distance between the two adjacent poles.
• For one rotation of the conductors, 2 poles are responsible for electrical
of e.m.f, 4 poles are responsible for electrical of e.m.f and so on.
• 1 pole is responsible for electrical of induced e.m.f so electrical is
also called one pole pitch.
• Practically how many slots are under one pole which are responsible for
electrical, are measured to specify the pole pitch.
Example:- Consider 2 pole, 18 slots armature of an alternator. Then under 1 pole
there are 18/2 i.e. 9 slots. pole pitch is 9 slots or electrical. means 9 slots are
responsible to produce a phase difference of between the e.m.f.s induced in
different conductors.
• Number of slots/pole is denoted as ‘n’

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6. Slot angle (β) :- The phase difference contributed by one slot in degrees electrical
is called slot angle β.
• As slots per pole contributes electrical which is denoted as 'n',
• we can write, 1 slot angle(β) = /n

• Note : This means that if we consider an induced e.m.f in the conductors which are placed in
the slots which are adjacent to each other, there will exist a phase difference of β in between
them.
• While if e.m.f. induced in the conductors which are placed in slots which are 'n' slots distance
away, there will exist a phase difference of in between them.
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7. Coil span:- Coil span is the distance between two coil sides measured in
terms of slots.
• Coil span = winding pitch/slot angle;
• For full pitched winding /slot angle. 27
 AC Windings
Generally open windings except when delta connected.
• Classification:
• Based on:
• Supply: 1- Φ & 3 - Φ
• Placing: Concentrated and Distributed
• No. of layers: Single and Double layer
• End connection: Lap, wave and concentric
• The pitch: Full pitched and short pitched
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 Types of Three Phase Winding
In general, the types of three phase winding used in a-c machines are,
1. Single layer and double layer
2. Full pitch and short pitch
3. Concentrated and distributed.
Single layer and double layer
• If a slot consists of only one coil side, winding is said to be single layer.
• While there are two coil sides per slot, one at the bottom and one at the top the
winding is called double layer.
A lot of space gets wasted in
single layer hence in practice
generally double layer winding is
preferred.
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 Full pitch and Short pitch
 Full Pitch
• If coil side in one slot is connected to a coil side in another slot which is one
pole pitch distance away from first slot, the winding is said to be full pitch
winding and coil is called full pitch coil.
• Example:- In 2 pole, 18 slots alternator, the pole pitch is n = 18/2 = 9 slots.
• So if coil side in slot No. 1 is connected to coil side in slot No. 10 such that
two slots No. 1 and No. 10 are one pole pitch or n slots or electrical
apart, the coil is called full pitch coil.
 Coil Span:- It is distance on the periphery of the
armature between coil sides of a coil.
 It is usually expressed in terms of number of slots
or degrees electrical.
 So if coil span is 'n' slots or electrical the
coil is called full pitch coil. 30
Short Pitch
• If coils are used in such a way that coil span is slightly less than a pole pitch
i.e. less than electrical, the coils are called, short pitched coils or
fractional pitched coils.
• Generally coils are shorted by one or two slots.
• So in 18 slots, 2 pole alternator instead of connecting a coil side in slot No. 1 to
slot No.10, it is connected to a coil side in slot No. 9 or slot No. 8, coil is said
to be short pitched coil and winding is called short pitch winding.

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• Advantages of Short Pitch Coils (Chording)
In actual practice, short pitch coils are used as it has following advantages

a) The length required for the end connections of coils is less i.e. inactive length
of winding is less. So less copper is required. Hence economical.

b) Short pitching eliminates high frequency harmonics which distort the

sinusoidal nature of e.m.f, Hence waveform of an induced e.m.f is more
sinusoidal due to short pitching.

c) As high frequency harmonics get eliminated, eddy current and hysteresis

losses which depend on frequency also get minimized. This increases the
efficiency.
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Concentrated and distributed Winding
• In three phase alternators, there are three different sets of windings,
each for a phase.
• So depending upon the total number of slots and number of poles,
we have certain slots per phase available under each pole.
• This is denoted as ‘m’
• m = Slots per pole per phase
= n/Number of phases
= n /3 (generally no. of phases is 3)
• For example:- in 18 slots, 2 pole alternator we have;
• n = 18/2 = 9
• m = n/3 = 9/3 = 3
• So we have 3 slots per pole per phase available.
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• Now let 'x' number of conductors per phase are to be placed under one pole. And we
have 3 slots per pole per phase available. But if all 'x' conductors per phase are
placed in one slot keeping remaining 2 slots per pole per phase empty the winding
is called concentrated winding.
• So in concentrated winding all conductors or coils belonging to a phase are placed in
one slot under every pole.
• But in practice, an attempt is always made to use all the slots per pole per phase
available for distribution of the winding.
• So if 'x' conductors per phase are distributed amongst the 3 slots per phase
available under every pole, the winding is called distributed winding.
• So in distributed type of winding all the coils belonging to a phase are well
distributed over the 'm' slots per phase, under every pole.
• Distributed winding makes the waveform of the induced e.m.f more sinusoidal in
nature. Also in concentrated winding due to large number of conductors per slot,
heat dissipation is poor.
• Key Point:- So in practice, double layer, short pitched and distributed type of
winding is preferred for the alternators.
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Pitch factor or coil span factor (Kc)
• In practice short pitch coils are preferred. So coil is form by connecting one coil
side to another which is less than one pole pitch away. So actual coil Span is less
than . The coil is generally shorted by one or two slots.
• Key point :- The angle by which coils are short pitched is called angle of short
pitch denoted as ‘α’.
• α = angle by which coils are short pitched. As coils are shorted in terms of
number of slots i.e. either by one slot, two slots and so on and slot angle is β,
then angle of short pitch is always a multiple of the slot angle β.
• α = β x Number of slots by which coils are short pitched.
• or — Actual coil of the coils.
• Key Point:- Now the factor by which,
induced e.m.f. gets reduced due to short
pitching is called pitch factor or coil span
factor denoted by Kc. Kc = Cos(α/2) 35
Distribution Factor (Kd)
• Similar to full pitch coils, concentrated winding is also rare in practice.
• Attempt is made to use all the slots available under a pole for the winding
which makes the nature of the induced e.m.f. more sinusoidal. Such a winding
is called distributed winding.
• Key Point:- The factor by which there is a reduction in the e.m.f. due to
distribution of coils is called distribution factor denoted as ‘Kd'.

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• Example 1: Draw the developed/winding diagram for full pitch
stator winding of a three phase, 4 pole, 24 slots alternator. Assume
single layer winding, Lap winding and of distributed type.
• Note: This example will explain all the winding terminologies discussed
earlier.
Solution: p = 4, 24 slots, 3-phase
• n = slots per pole = 24/4 = 6
• m = slots per pole per phase = 6/3 = 2
• β = slot angle = /n = /6 =
• Full pitch coils are to be used so if phase 1 say, R is started in slot
1, it is to be connected to a coil in slot 7 so that coil span will be 6
slots i.e. 'n' slots i.e. 1 pole pitch.
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• As distributed winding is to be used, both the slots per pole per phase (m = 2)
available are to be used to place the coils.
• And all coils for one phase are to be connected in series. So from slot No.7 we
have to connect it to coil slot No.2 and slot No.2 second end to slot No.8 and so
on.
• After finishing all slots per phase available under first pair of pole, we will
connect coil to Slot No.13 under next pole and winding will be repeated in
similar fashion. starting end Rs and final end Rf winding for R-phase are taken
out finally. Connections for R-phase only are shown below.

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• Now we want to have a phase difference of between 'R' and 'Y. Each slot contributes
as β = .
• So start of ‘Y’ phase should be apart from start of 'R' i.e. 4 slots away from start of
R. So start of 'Y' will be in slot 5 and will get connected to slot No.11 to have full pitch coil.
• Similarly start of 'B' will be further apart from 'Y' i.e. 4 slots apart start of 'Y' i.e. will
be in slot No.9 and will continue similar to 'R.
• Finally all six terminals of three sets will be brought out which are connected either in star
or delta to get three ends R, Y and B outside to get three phase supply. The entire winding
diagram with star connected windings is shown as;

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Example 2: Draw the developed winding diagram of a 3 phase induction motor with 18 slots, 2
poles, single layer, full pitched winding with delta connection.
Soln:- Pole pitch (n) = no. of conductor / pole = 18/2 = 9
• No. of slots per pole per phase (m) = 18/(2 x 3) = 3
• Slot angle (β) = 180/ pole pitch = 180°/9 = 200
• Full pitched winding = coil span = 180°
• Coil span = winding pitch/slot angle = 180/20 = 9 slots
Winding Table
Phase 1st pole 2nd pole
R 1 + 9 = 10 11+ 9 = 20 (2)
3 + 9 = 12

Y 7 + 9 = 16 17 + 9 = 26 (8)
9 + 9 = 18

B 13 + 9 = 22(4)
5 + 9 = 14 15 + 9 = 24 (6)
 Connections: Rs = 1, Ys = 1 + 120/slot angle = 1+120/20 = 7; Bs = 1 + 240/slot angle = 1+ 240/20 = 13

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Winding Diagram

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Windings Connection of Induction Motor
Stator Windings: Rotor Windings:
• Star connected • It is wound as rotor bars and
• Delta connected short circuited at both the ends
through end rings.

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What data you need?
- Line to line voltage (V),
- Frequency (Hz),
- Star or delta connection,
- Number of poles or rpm,
- All other nameplate data if available,
- Stator slots,
- Core internal diameter (mm),
- Core external diameter (mm),
- Core length,
- Number and width of air vents if exist,
- Back-iron (mm),
- Tooth-width (mm)
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Materials needed for Motor winding
• Copper wire
• Isolate paper (for insulation)
• Stator lacing thread (for tying windings)
• Spray Lubricant
• Motor lacquer (for smoothing)

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 Thank you
for
your Attention!!

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