Training Module on Distribution Transformer Design and Testing

The module should be included the following points in addition

mentioned on the paper

 Transformer types depending upon the types of core

construction
 Transformer connections
 Definitions of basic parameters of transformer
 Core design and core dimensions
 Core stacking and building factors
 Core window height estimating
 Core assembly and building
 Overall dimensions of transformer
 Winding wires and strips
 Selection of winding wires and strips
 Winding strips arrangement selection
 Polarity of transformer
 Tapping and tap changing of transformer
 Equivalent resistance and reactance calculation
 Percentage impedance calculation
 Transformer tank body and radiators design and selection
 Bushing design and selection
 Basic Transformer design software training including
design software
 Transformer protection
 All industry standard tests of transformer
 Failure analysis and preventive maintenance
 Installation ; erection and commission of transformer
 As Case study current material in our industry CRGO
grade M23/0.23mm; specific loss at 1.7T=0.9w/kg and
how to use this material? Percentage impedance=4%
Rotor and stator in electric motor

Functionality, structure and

differences of rotors and stators
Prompted by megatrends such as climate change, the energy transition, and
the general increase in electrification of daily life, the number of electronic
devices and machines around us continues to grow. Electric bicycles, electric
scooters and even electric surfboards, but above all the electrification of the
car, are bringing the topic of e-mobility to the fore.

All of these applications require efficient and reliable electric motors.

Elementary components of electric motors are the rotor and stator. But what
tasks do the rotors and stators perform in electric machines, how do they
work and how are they manufactured?

To be able to go into this question in more detail, we first have to deal with
how an electric motor basically works.

How does an electric motor work?

Most electric motors are based on the principle of the so-called Lorenz force.
It is a force acting on a current-carrying conductor in the external magnetic
field.

If the direction of the current in the conductor changes with a certain

frequency, the movement of the conductor is caused in the magnetic field.
Due to the special design of an electric motor, the alternating current
generates a rotary motion that can be used as a drive.

In order for the magnetic field to be generated and conducted in a specific

way, ferromagnetic materials are used. These include iron, nickel, cobalt, as
well as certain alloys and non-metallic compounds (soft ferrites, many
permanent magnets).

Some electric motors use the so-called reluctance force to generate the
torque in the rotor. Here, the motion comes from the system striving for
minimum magnetic resistance (reluctance). The ferromagnetic, or more
precisely the soft magnetic materials are also used for these motors.

What is a rotor?
The rotor is the moving, or rather rotating part of the electric motor. The
rotor sits between the poles of the stator. It is often made of iron or iron alloy
and therefore also called iron core or magnetic core.

Since an iron core made of solid material is inefficient in terms of

performance due to high eddy current losses, a rotor is made of individual
laminations, also called rotor lamellas. This also applies to the stator
laminations. The stator and rotor laminations are punched from electrical
sheets or cut on the laser cutting machine, stacked to form magnetic cores,
joined together (e.g., glued, welded, riveted, etc.) and fitted with windings
(stator) or with permanent magnets (rotor). Depending on the design of the
electric motor, both the rotor and the stator can be provided with permanent
magnets or with windings.

Modern drive motors can reach speeds of 10,000 rpm and even considerably
higher. This generates considerable centrifugal forces in the rotor. For the
positioning and alignment of the magnets in the rotor, corresponding
openings known as magnet pockets are used.

In the magnetic pockets, the sensitive (brittle) magnets are safely protected
from the high centrifugal forces.
Statorpaket-Blechpaket-Elektroblech-TEPROSA

What is a stator?
The stator, also called the stator, is the immobile part of the electric
motor and the magnetic counterpart of the rotor. Its function is to guide the
magnetic field within the electric motor.

Stators can be equipped with permanent magnets as well as electromagnets.

The rotor rotates in the stator, or between the magnetic north and south
poles of the stator. One speaks of an internal rotor when the stator is firmly
connected to the outer housing of the electric motor and the rotor rotates in
the bore of the stator. In contrast, an electric motor is called an external
rotor when the stationary part (stator) of the machines is inside it and is
enclosed by the moving part (rotor or armature).

Construction of rotor and stator

.
Rotor and stator are usually constructed and manufactured in the so-called
laminated construction. This is referred to as the laminated construction
method because the magnetic cores (rotor core, stator core) are made of
individual metal sheets, also known as sheet laminations, each of which is
insulated from the other by a coating a few micrometers thick.

The individual sheets are stacked on top of each other and baked or screwed
together to form a sheet stack. A stack of laminations represents a magnetic
core and thus a rotor or stator.

Material for magnetic cores – electrical

steel strip
Electrical steel strip is used to manufacture the individual laminations of
rotors and stators. Electrical steel strip or electrical sheet is an iron-silicon
alloy with special magnetic properties that are particularly suitable for use in
electric motors and generators.

Due to these special properties, the use of laminations made of electrical

steel in the manufacture of rotors and stators contributes to significantly
improved energy efficiency (efficiency) of electrical systems and thus to
sustainable and optimal use of the required energy.

The electrical steel used for laminated core consists of an iron-silicon alloy
and is basically classified into two types: isotropic or non-grain-
oriented and anisotropic or grain-oriented electrical steel.

The magnetic properties of isotropic electrical steel are largely uniform and
therefore almost independent of the direction of magnetization. This isotropy
arises due to a non-ordered distribution of the location of iron elementary
cells in the electrical steel.

Homogeneity of magnetic properties is important for all rotating machines,

such as electric motors or generators. Minor inhomogeneities (anisotropies),
which are unavoidable in the manufacturing process of electrical steel, can
be compensated by using special technologies in the construction of
electrical machines.

Manufacturing rotor and stator

Sheet packages for motors in the form of stator (also called stator) and rotor
are made of layered individual laminations of electrical steel insulated from
each other. The laminations usually have a material thickness of between
0.10 and 1.00 mm, with the most common thicknesses of 0.35 mm and 0.50
mm establishing themselves as the standard.

Insulation between the sheets is achieved by a specific coating that prevents

electrical contact between the individual sheets. These coatings often have a
thickness of only a few micrometers.

Electric sheet lamination for stator sheet laser cutting TEPROSA

Laser cutting of rotor and stator

The individual laminations are stamped or laser cut, with the stamping
process being suitable for high-volume production and laser cutting offering
flexibility for prototyping and small- and medium-scale production.

Laser cutting also has several other specific advantages over punching, for
example, virtually no structural changes occur at the edges of the individual
layers during laser cutting compared with punching. The individual sheets
are then firmly joined together. With punching, this step already takes place
in the punching tool.

This is also referred to as punch packaging. Laser-cut lamellae are

precisely aligned with a corresponding device, stacked on top of each other
and glued (adhesive packaging) or baked (baked enamel process).

Both the baked varnish process and adhesive stacking result in complete
insulation of the individual sheets and prevent possible short circuits
between the laminations, which can cause an increase in eddy current
losses. The full-surface bonding of the layers also suppresses unwanted
vibrations.

TEPROSA relies on laser cutting of the sheet and packaging of the packages
using the baked enamel process. The magnetic cores we manufacture in this
way are free of short circuits and have ideal magnetic properties due to the
gentle manufacturing process.

Isolation coating of the laminations in the rotor / stator

To prevent the short circuits between the laminations in electrical
laminations and thereby reduce the eddy currents, various coatings are
applied to the strip.

The coating thicknesses vary from 1 to 4 µm. Depending on the processing

technology and subsequent application, coatings exist for better corrosion
protection, improved insulation of the individual layers, heat resistance,
improved punching properties or weldability.

 Coating C3 – Coating for improving the lubricating effect. Relevant, for

example, for the stamping process.
 Coating C4 – Coating to improve corrosion protection and insulation
resistance.
 Coating C5 – Coating to optimize the temperature resistance. Relevant,
for example, for stress-relief annealing after the stamping process.
 Coating C6 – Coating for a particularly high insulation resistance.
 Baking varnish – baking varnish process; coating as a bonding
technology for sheet packs and core sheets.
The benefits of stator laminations

The purpose of stator laminations is to minimize power loss and

reduce vibration and noise. The laminated construction of the
stator core helps to reduce eddy currents, which reduces power
loss and increases efficiency. The laminated construction also
helps reduce vibration and noise by reducing magnetic flux and
magnetic iron loss.

What are Motor Rotor Laminations?

Like stator lamination stacks, rotor laminations are also made
from laminated sheets of metallic alloy. But they are much more
complex in design. While the stator’s main job is to create a
magnetic field. The rotor’s job is to respond to that magnetic field
in a way that generates rotational motion.

Rotor lamination stacks are typically made from thicker sheets of

metal alloys that can be easily magnetized and demagnetized.
The stacks consist of several stacks of steel laminates that are cut
into the precise shapes necessary to create the rotor’s
electromagnetic field when paired with the stator.

The rotor is typically the moving component of the motor, with its
central shaft running through the center of the stator. Without the
rotor, the motor would not be able to generate power, as the
interaction between the stator’s magnetic field and the rotors
current create rotational motion.

Key Differences Between Motor Stator and Rotor Lamination

Although rotor and stator lamination stacks are made from

laminated sheets of metallic alloy, they differ in several ways.

Application in the motor

One of the most significant differences is their application within

the motor. Simply put, the stator core is a stationary component
that creates a magnetic field, whereas the rotor is the rotating
component that responds to that magnetic field.

Thickness
Another difference is in their respective designs. Stator lamination
stacks are made from thin metal sheets, typically only a few
hundredths of an inch thick.

In contrast, rotor lamination stacks are made from thicker metal

sheets, often several times thicker than those used for stator
lamination stacks.

Materials

The materials used for stator stacks are typically low-carbon steel
alloys. These alloys are inexpensive, easy to work with, and offer
high magnetic permeability, making them ideal for creating a
magnetic field.

On the other hand, rotor stacks require thicker laminates, such as

nickel or cobalt, which have a higher magnetic saturation point
than low-carbon steel.

Function

Functionally, stator stacks minimize power loss and reduce

vibration and noise. This is accomplished through their stacked,
laminated design, which helps to reduce eddy currents and
improve magnetic flux.

Conversely, rotor stacks respond to the magnetic field created by

the stator, generating the mechanical rotation required to
generate power.
This is accomplished through the rotor’s complex shape and the
precise arrangement of its laminated sheets.

Shape

The design differences between stator and rotor lamination stacks

extend beyond their shapes, extending even to the general shape
of the motor itself.

The stator typically has an annular shape surrounding the rotor,

while the rotor is a simple cylinder with or without fins on the
outside.

The Role of Motor Stator and Rotor Lamination Stacks in Electric

Motors

The role of stator and rotor stacks in electric motors is critical to

their overall functionality. The primary role of the stator stack is
to create a magnetic field. Because of their laminated design,
stator stacks minimize power loss and reduce vibration and noise,
helping to make the motor efficient and functional.

On the other hand, the rotor stack responds to the magnetic field
created by the stator, generating the necessary mechanical
rotation to generate power. Without a properly functioning rotor,
the motor will not generate any power, making it useless.

The stator and rotor laminations work at the most basic level to
produce rotational motion. When electrical energy is applied to
the motor, it creates a magnetic field in the stator stack, which
then causes the rotor to rotate. This action creates a mechanical
force that generates energy in the form of motion or rotation.

Common Applications of Stator and Rotor Lamination Stacks

Electric motors are suitable for various applications, and

laminated cores are essential. Some common applications
include:

Industrial equipment and machinery

HVAC systems

Electric vehicles

Power tools

Kitchen Appliances

Electric motors also play a key role in renewable energy systems,

such as wind turbines, where the rotor laminations are essential
in converting wind energy into electrical energy.

Our Capability For Stator And Rotor Lamination Stacks

We can design and manufacture a range of high-quality stator

and rotor lamination stacks for electric motors, including
stamping, mold designing and manufacturing, and stacking. We
ensure that every component we produce is made to the highest
standard, meeting the precise requirements of our clients.

With our expertise in motor components, we can provide

customized solutions that meet the unique needs of our
customers, ensuring that their motors run efficiently and
effectively. Whether you require a high-volume production run or
a custom-made component, we have the experience and
capabilities to handle all your needs.

From stamping to insulation, bonding, assembly, and quality

testing, we offer a simplified supply chain and short lead times for
motor laminations prototypes and mass production.

For a 10kW, 24-slot, 4-pole, 3-phase induction motor, you'll need

to consider various parameters and formulas related to motor
design and performance. Key aspects include calculating winding
configurations, determining synchronous speed, and
understanding torque and slip characteristics. The number of
slots, poles, and phases dictates the winding arrangement and
the motor's speed and torque capabilities.

Here's a breakdown of relevant calculations and formulas:

1. Winding Arrangement:

Coil Groups:

A 3-phase motor with 24 slots and 4 poles will have (24 slots / 4
poles) = 6 slots per pole. Since it's a 3-phase motor, each phase
will have (6 slots/pole * 4 poles) / 3 phases = 8 slots per phase.
With a single-layer winding, this translates to 4 coils per phase.

Pole Pitch:
The pole pitch is the number of slots per pole, which is 6 in this
case, according to a document from Scribd.

Coil Pitch:

For a full-pitched winding, the coil pitch is equal to the pole pitch
(6 slots). For a fractional-pitched winding, it will be less than the
pole pitch, says a document from Scribd.

Electrical Degrees:

The electrical degrees are (number of pole pairs * 360°), so for 2

pole pairs (4 poles), it's 720 electrical degrees.

2. Synchronous Speed:

The synchronous speed (Ns) is calculated using the formula: Ns =

(120 * f) / p, where 'f' is the supply frequency (e.g., 50Hz or 60Hz)
and 'p' is the number of poles.

For a 50Hz supply and 4 poles, the synchronous speed is (120 *

50) / 4 = 1500 RPM (Revolutions Per Minute).

The actual rotor speed (Nr) will be slightly less than the
synchronous speed due to slip.

3. Slip and Rotor Frequency:

Slip (s) is the difference between synchronous speed and rotor

speed, expressed as a fraction of synchronous speed: s = (Ns -
Nr) / Ns.

The rotor frequency (fr) is related to slip and supply frequency (f):
fr = s * f.

4. Torque and Power:

The output power (P) is related to the torque (T) and speed (ω)
by: P = T * ω.
Torque can be further related to slip, rotor resistance, and rotor
reactance.

5. Key Parameters for Design:

Specific Magnetic Loading (Bav): Bav = (P * Φ) / (π * D * L), where

Φ is the flux per pole, D is the stator bore, and L is the core
length.

Specific Electric Loading (ac): ac = (Z * I) / (π * D), where Z is the

number of conductors and I is the current per conductor.

Output Coefficient (Co): Co = 1.11 * π² * Bav * ac * Kw * 10^-3,

where Kw is the winding factor.

Output Equation: Q = Co * D² * L * ns.

6. Other Important Considerations:

Winding Factor (Kw):

This factor accounts for the distribution and pitch of the winding,
affecting the induced voltage.

Efficiency (η) and Power Factor (cosφ):

These are important performance indicators that are influenced

by various design choices and operating conditions.