Induction Motor Design (3-Phase)

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

KVA rating of 3-phase IM is given by

H ..P  0.746
KVA 
Cos  
KVA  3  VPh1  I Ph1 10 3                (1)
Where
E Ph1 = VPh1= Input phase voltage
IPh1= Input Phase current

Equation (1) can be written as

KVA  3(4.44  Kw  f  1  N Ph1 )  I Ph1  10 3        (2)
(E Ph1  VPh1  4.44  Kw  f  1  N Ph1 )
Where
f = frequency of supply =P×Ns/2
P =No. of Poles
Ns =Speed in RPS
KW = Winding factor = Kp*Kd =0.955
Kp = Pitch Factor
Kd = Distribution Factor
1 = Flux per pole
N Ph1 = No. of turns per phase
   D
1  B  P  L  B L
P

B = Average value of fundamental flux density

‘ B ’ is also called Specific Magnetic Loading
 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

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 Induction Motor Design (3-Phase)

Specific Electric Loading

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

Putting the values of f, 1 & NPh1IPh1 in equation (2) we get


Ns  P   D ac    D
KVA  3  4.44  Kw  ( )  ( B  L)  ( )  10 3
2 P 6
 
KVA  (10.955  Kw  B  ac 10 3 ) D 2  L  Ns

KVA  Co  D 2  L  Ns

Where
 
CO  Output Co  efficient  10.955  Kw  B  ac  10 3


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 w  f  1  N Ph1

If voltage is constant so for Higher B , Nph1 will be less.
And we know
Leakage reactance  N Ph 1  Leakage Reactance 
2

 Isc is more  Dia of circle diagram   Overload Capacity 


6. Noise & Vibration : Lower B

7. Size : Higher B

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 Induction Motor Design (3-Phase)


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   NPh1 
And we know
Leakage reactance  N Ph
2
1  Leakage reac tan ce 

 Isc is more  Dia of circle diagram   Overload Capacity 


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

EFFECT OF SPEED ON COST AND SIZE OF IM:

KVA
D2L   Represents the volume of Machine
C o  Ns
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
KVA
D2L                     (1)
C o  Ns
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.

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 Induction Motor Design (3-Phase)

EFFECTIVE LENGTH OF MACHINE:

Generally
L1= L2= L3=………. = Ln L1 L2 L3 Ln

Let bv
nv =No of ventilating ducts Lt
bv = Width of one ventilating duct
(Generally for every 18 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
Lt = L+ nv × bv

DESIGN OF STATOR:

(1) Shapes of stator slots

May be (i) Open slot
(ii) Semi-enclosed slot

(2) No of Stator Slots SS:

Slot pitch
 D
 sg1 
Ss
 D
Ss   sg1 = 15 to 25mm (Open Slot)
 sg1
 sg1 ≤ 15mm (Semi-enclosed Slot)

For 3-Phase IM having P-poles

Ss  3q1 P
Ss
q1   No of slots per pole per phase
3P
Generally we take q1 = 3 to 5 (Distributed Winding)

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 Induction Motor Design (3-Phase)

(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 w  f  1  N Ph1              (1)
VPh1
So N Ph1               (2)
4.44  K w  f  1

Where
   D
1  B  P  L  B  L                (3)
P
Z1  3  2  N Ph1  6  N Ph1                (4)
Z1
N c1                 (5)
Ss
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

KVA  10 3
I Ph1 
3  VPh1
I
So Fc1  Ph1 mm 2
1
Where  1  Current density  3  4 A / mm 2

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 Induction Motor Design (3-Phase)

Standard size for area of conductor in market, find dc corresponding to Fc1

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

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

(5) Area of stator slot

N c1  Fc1
Area of stator slot = mm2
KS
⸫ ‘Ks’ is called Space Factor
Value of ‘Ks’ = 0.25 to 0.4

(6) 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
hs1 = nv×dc + 3×0.5 + 3.5 + 1.5 + 2 mm b01
Width of the slot
bs1 = nh×dc + 2×0.5 + 2 mm 1.5 mm Tooth lip
Slot opening
2 3.5 mm Wedge
b01  bs1
5
hs1
35 0.5 mm
bs1 hs1
Note:
(0.5 mm is insulation thickness and
2 mm for slack & tolerance)

bs1

Semi-enclosed slot

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 Induction Motor Design (3-Phase)

Thickness of insulation

With mica 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.

(7) Length of mean turns (Lmt1)

Lmt1  2 L  2.3  P  0.24 L Coil Span

 D ˂Pole pitch
Where  P  Pole pitch 
P

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

One Turns
Lmt1
RPh1  0.021  10 6   N Ph1
Fc1
(9) Total copper loss in the stator winding
 3 I Ph
2
1 RPh1
(10) Flux density in stator tooth

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 Induction Motor Design (3-Phase)

1
Flux density in stator teeth Bst  ⸫ Bst = 1.8 Tesla
Ss
 Li  Wst
P

⸫ ‘ Wst ’ is the minimum width of stator teeth

(11) Depth of stator core (dsc):

Flux through stator core is half of the flux per pole
1
 BSC  d sc  K i  L
2
Where Bsc = Flux density in stator core
= 1.3 to 1.5 T
1 / 2
So d sc  ⸫ ‘ K i ’ is called Stacking Factor
Bsc  K i  L
Value of ‘ K i ’ = 0.9

(12) Outer diameter of IM (Do):

Do  D  2d ss  2d sc

(13) Estimation of iron losses:

Corresponding to flux density in tooth B 1 find out iron loss per Kg from the
t ht
3

graph. So B 1  Pit W / Kg
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 Bsc find out iron loss per Kg from the graph.
So Bsc  Pic W / Kg
Iron loss in yoke
= Pis × density × volume of iron in yoke
= Pis × 7600 × volume of iron in yoke
Total iron losses Pi = Iron loss in teeth + Iron loss in yoke
Pi
So IC 
3  VPh1

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 Induction Motor Design (3-Phase)

LENGTH OF AIR-GAP:

Lg  0.2  2  DL mm

Note: D & L are in meters

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
S2  3q2 P
(2) Estimation of rotor no of turns, conductors etc

(a) Wound rotor IM:

We may keep
VPh2 N Ph2
  0.5  0.6
VPh1 N Ph1
So No of turns per phase on rotor
N Ph2  (0.5  0.6)  N Ph1
Total no of conductors on rotor
Z 2  6  N Ph2
Conductors per slot for rotor
Z
NC 2  2 Make it (NC2) integer if not and divisible by 2 for 2 layer
S2
winding. Hence find out correct value of NC2, NPh2 & Z2 i.e. NC2, Corrected NPh2, Corrected ¸
Z2, Corrected

(b) Cage rotor IM:

No of rotor bars
Z2bar  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

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 Induction Motor Design (3-Phase)

(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 2endring  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
FC 2bar  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  bar is more)
If round bars are used then dia of bar

FC 2bar   d 22bar
4

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 Induction Motor Design (3-Phase)

4  FC 2bar
or d 2bar 


X-sectional area of rotor endring

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

(5) Flux density in rotor tooth

1
Flux density in rotor tooth = Brt  ⸫ Brt = 1.8 Tesla
S2
 Li  Wrt
P
⸫ ‘ Wrt ’ is the minimum width of rotor tooth

(6) Depth of rotor core (drc)

Flux through rotor core is half of the flux per pole

1
 Brc  d rc  K i  L
2
Where ‘Brc’ = Flux density in rotor core
= 1.3 to 1.5 T
1 / 2
So d rc  ⸫ ‘ K i ’ is called Stacking Factor
Brc  K i  L
Value of ‘ K i ’ = 0.9
Outer diameter of rotor Dr = D ˗ 2×Lg
Inside diameter of rotor Di = Dr – 2×(drs + drc)

⸫ drs = Depth of rotor slot

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 Induction Motor Design (3-Phase)

(7) Rotor copper loss

(a) Wound rotor:

Length of mean turns of rotor
Lmt2  2 L  2.3 P  0.24

DC resistance per phase at 75 0 C

Lmt2
RPh2,75o C  0.021  10 6   N Ph2
Fc 2
We don’t take the ac resistance because the rotor current frequency is very small (f2=sf)
So Rotor cu loss  3I Ph
2
2 RPh2

(b) Cage rotor: Do  D  2d ss  2d sc

6 L ( m)
Resistance of one bar  0.021  10 D
FC 2bar (m 2 )
Cu loss in bars  S2  I 22bar  Resistance of one bar
Resistance of end ring
  ( D  2 Lg  2d 2bar )( m) d2ba
 0.021  10 6  r
FC 2endring (m 2 ) 2d2ba
r
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
D  2Lg  2d 2bar
Rotor Cu Loss
S D  2 Lg
Mech Power Output  Losses

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

Page 12
 Induction Motor Design (3-Phase)

ESTIMATIONS OF IDEAL BLOCKED ROTOR CURRENT:

Total resistance referred to stator
2
K N 
R01  R1  R '
2 Where R   w1 Ph1  R2
'
2
 K w2 N Ph2 
Total leakage reactance referred to stator
2
X 01  X1  X 2' K N 
Where X   w1 Ph1  X 2
'
2
 K w2 N Ph2 

VPh1
I sc , Ideal 
R012  X 012
R01
Cossc 
2
R01  X 01
2

INTRODUCTION TO 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

Page 13
 Induction Motor Design (3-Phase)

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 I0 at an angle 0 from vertical line assuming some scale for current.
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.

Page 14
 Induction Motor Design (3-Phase)

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)

Page 15