UNIT – V

Three phase Induction Motor Design

5.1 Suitable combination of rotor and stator slots

5.2 Calculations for main dimensions and stator design
parameters
5.3 Selection of length of air gap
5.4 Factors affecting length of air gap
5.5 Unbalanced magnetic pull
5.6 Design of rotor slots
5.7 Size of bars
5.8 End rings for cage rotor and rotor slots
5.9 Turns and area of cross-section of conductor for
wound rotor

5.1 Suitable combination of stator and rotor slots

The stator/rotor slot combinations and armature winding configurations with
different pole pairs for DC-biased VRMs is thoroughly investigated. Firstly, the
relationships among stator/rotor slots and armature winding pole pairs are based
on the working principles. Then, several feasible stator/rotor slot combinations
are obtained, and the electromagnetic performances are compared by the finite
element analysis (FEA).

The results show that the 8-rotor-slot, 5 armature pole pair machine exhibits
highest torque in rated load, but with highest torque density, the 10-rotor-slot, 4-
armature pole pair machine shows highest torque in over load condition, and the
12/11 and 12/13 machine presents the minimum pulsation torque

Slot/Pole Combinations and Armature Winding Factors of 12-Stator-Slot

Machine

5.2 Calculations for main dimensions and stator design parameters:

Figure 1. Main dimensions of D and L

The armature diameter D (or stator bore) and stator core length L are known as
main dimensions. The quantity D 2 L is in m3 called as volume of the machine.
The size or volume of the active parts of machine is given by D 2 L which depends
on two factors

o Output co-efficient Co
 o Speed

Thus, obtain smallest dimensions of machine, the output co-efficient Co must be

selected as high as possible. The separation of D and L from product D2L
depends on ratio L/τ where τ =π D/p.

In induction motors most of the operating characteristics are decided by L/ τ

ratio of motor. The ratio of core length to pole pitch L/τ for various design
features are listed in table.

Generally, L/τ lies between 0.6 to 2. It is shown that for best power factor the

pole pitch τ is given the equation .

The diameter of the stator bore therefore the diameter of rotor is limited by
peripheral speed. Standard constructions are employed for peripheral speeds
upto 60 m/s. For normal design, the diameter should be chosen that the
peripheral speed does not exceed about 30m/sec.

Stator Design:
 Number of turns in main winding:
Stator induced voltage E = 4.44 f∅ mTm Kwm.
Where Tm = number of turns in the running winding
Kwm = winding factor for the running winding
Number of turns in the running winding
∅ m = flux per pole
∅=¿flux density x slots per pole x Wb
The number of turns per series pole for the main(running) winding= Tmp.

 Running winding conductors current carried by each running winding

conductor
I rated = hp x 0.746 / V η cos Ø
Efficiency and power factor for single phase motors.

Area of running winding conductor Am = Im δ ;where δ is the current

density in Amps/mm2

Conductor size for the running winding can be calculated as follows-

 Therefore, area of running winding conductor = IRatedδ
Diameter size of running winding conductor d=

 Starting winding
The stating winding is designed for maximum torque per ampere of
starting current. To calculate starting torque and current, the rotor
resistance is increased by 17.5% to consider the skin effect. Therefore,
total resistance in terms of main winding Rm=rsm+1.175 r’rm at 20 .
 Total impedance at 20 Zm=
 Auxiliary winding reactance Xla=Xlm/((Is/Ism)^2- 1)
 Resistance of auxiliary winding Ra=(Rm+Zm(Is/Ism))/((Is/Ism)^2-1)
 Auxiliary winding conductor section aa=

 Diameter of bare conductor =

 In capacitor start method reactance of the capacitor
Xc=Xla+((Ra*Rm)/(Zm+Xlm))

5.3 Selection of the length of air gap:

Figure 2. Stator and Rotor slot

 The induction motor has stator and rotor as its major parts. The stator is
stationary part while the rotor is a rotating part. The stator of the motor
consists of overlapping coils that are placed 120-degree electrically apart.
 When the stator is connected to three phase supply sources, the rotational
magnetic field of constant magnitude and varying direction is produced.
The flux produced in stator travels through the air gap and gets linked to
rotor conductors.
 The rotor winding is short-circuited through end rings or connected to the
external resistance. The linking flux of stator induces EMF in rotor circuit,
and current starts to flow in the short-circuited rotor winding because of
induced EMF in rotor. Due to interaction of rotor current and main flux,
torque is produced, and motor starts rotating.
  In the stator the electric energy gets converted to magnetic energy. The
magnetic energy travels through the air gap of the motor. The air gap
increases the reluctance of the magnetic circuit.

Figure 3. Equivalent Electrical circuit of the magnetic Circuit

Where,

Rc and Rg is the reluctance of the magnetic and the sir gap circuit.

The air gap plays a significant role in the performance of the motor. 

5.4 Factors affecting Length of Airgap:

The length of the air-gap affects the following performance parameters of the
induction motor.

 Magnetizing current
 Power factor
 Overload Capacity
 Cooling
 Noise
 Magnetizing Current and Power Factor:

The magnetizing current of the motor depends on specific magnetic loading and
the length air gap of the machine. A large air-gap length leads to higher
magnetizing current and poor power factor.

A large air-gap length increases the reluctance of the path of the

magnetic flux. The reluctance of the magnetic circuit is like the resistance of
the electric circuit. The reluctance of a magnetic circuit is;

R=MMF/Φ   -----(1) 
Also,
R= L/μA      -------(2)

MMF=RΦ  

Φ =MMF/R

Φ =MMF*(μA /L)   -----(3)

Where,

R = Reluctance of the magnetic circuit

MMF =Magnetomotive force(MMF=NI)
L    =length of the air gap 
Φ  =Flux in the air gap
μ       = Permeability of the magnetic material

The MMF required for producing and sending the flux through the air gap
depends on the flux density and the air-gap length.

If air gap length increases, the reluctance of the magnetic circuit increases. This
increase in reluctance will demand more magneto-motive force in order to
produce the required flux in the motor.

In order to meet the additional requirement of MMF, the stator magnetizing

current is increased. The power factor of the motor gets worsened with an
increase in magnetizing stator current. The phasor diagram of the motor having
small and large air gap length is shown below. The relationship between
the air gap length and the power factor can be understood with the help of
phasor diagram. 

Figure 4. Small and Large air-gap length

The air gap length in fig (b) is more than the air gap in fig (a). The angle between
the applied voltage and stator current is more in fig(b) than in fig(a).With
increase in air gap length, more magnetizing current is required to produce the
rated flux in the magnetic core, and the phase angle between the applied
voltage and the magnetizing current increases. As a result, power factor
becomes low.

Overload Capacity:

The leakage flux is reduced for an increase in air gap length. The flux produced
in the stator winding gets almost completely coupled with the rotor winding if
air gap length is more. Hence, overload capacity of large air gap length motor is
more than overload capacity of the motor that has a small air-gap length. With
an increase in the air-gap length, the leakage reactance decreases and overload
capacity increases.

Cooling:

With an increase in air gap length, the stator and rotor are separated by large
distance , hence cooling is better. The copper loss (I^2*R Loss) takes place in the
stator and rotor winding and iron loss takes place in the core. The heat gets
transferred easily if the motor has large air- gap. The insulation of the winding
can be used of H class or F class with temperature rise limit to B class if
the air gap length is more. 
Noise:

The leakage flux gets reduced if air- gap length is more. Less noise is generated
in motor with more air- gap length. 

Tooth pulsation loss:

The tooth pulsation loss reduces in a large air- gap length motor because of

small difference in the reactance of air gap.

The optimum air gap of an induction motor can be expressed by the following

empirical formula.
lg = 0.2 + 2√ LD    mm
Where,
lg = Air gap Length (mm)
L = Stator core Length(Meter)
D = Internal diameter of the Stator core(Meter)
Example:
If the stator  core length and diameter is 0.18 meter and 0.34 meter
respectively, the air gap length between the stator and the rotor

lg = 0.2 + 2√ LD    mm

     = 0.2 +2√0.18*0.34
       = 0.2 +0.494
     = 0.694 mm

5.5 Unbalanced Magnetic Pull.

Unbalanced magnetic pull is caused by an unequal air gap. It acts in the direction

of shortest air gap.
The pull can be minimized by tight tolerances or by making air gap large within
all the design constraints.

The motor with small air gap length draws less magnetizing current, and the
power factor of the motor is better than the motor having large air gap length.
 Figure 5. Cross selection of electrical machine with eccentric
rotor

5.6 Design of rotor slots:

Proper numbers of rotor slots must be selected in regard to number of stator

slots otherwise undesirable effects will be found while the starting of the motor.
Cogging and Crawling are the two phenomena observed due to wrong
combination of number of rotor and stator slots. Also, the induction motor may
develop unpredictable hooks and cusps in torque- speed characteristics or the
motor may run with lot of noise.

 Crawling: The rotating magnetic field produced in the air gap is non-sinusoidal

and contains odd harmonics of 3rd, 5th and 7th order. The third harmonic flux will
produce three times the magnetic poles compared to the fundamental. Similarly,
the 5th and 7thharmonics produces the poles five and seven times the
fundamental respectively.

The presence of harmonics in the flux wave affects the torque speed
characteristics. The Figure below shows the effect of 7th harmonics on the
torque speed characteristics of three phase induction motor. The motor with
presence of 7th harmonics tends to tend to run the motor at one seventh of its
normal speed. The 7th harmonics will produce a dip in torque speed
characteristics at one seventh of its normal speed as shown in torque speed
characteristics.

Cogging: In some cases where the number of rotor slots are not proper in
relation to number of stators slots the machine refuses to run and remains
stationary. Under such conditions there will be a locking tendency between the
rotor and stator. Such a phenomenon is called cogging.

 In order to avoid such bad effects, proper number of rotor slots must be selected
in relation to number of stator slots.

Also, the rotor slots will be skewed by one slot pitch to minimize the tendency of
cogging, torque defects like synchronous hooks and cusps and noisy operation
while running.

Effect of skewing slightly increases the rotor resistance and increases the
starting torque. However, this increases the leakage reactance thereby reduces
the starting current and power factor.

Figure 6. Torque – Speed characteristics

Selection of number of rotor slots: The number of rotor slots may be

selected using the following guidelines.

 (i)        To avoid cogging and crawling: (a)Ss ≠ Sr  (b) Ss - Sr  ≠ ±3P

(ii)       To avoid synchronous hooks and cusps in torque speed

characteristics ≠ ±P, ±2P, ±5P.
(iii)     To noisy operation Ss - Sr  ≠ ±1, ±2, (±P ±1), (±P ±2)

 
5.7 Size of bars

Generally semi-closed slots or closed slots have an exceedingly small or narrow

opening used for the rotor slots. In fully closed slots the rotor bars are forced to
fit into the slots from the sides of the rotor.

The rotors with closed slots give better performance to the motor in the following
way.

(i) As the rotor is closed the rotor surface is smooth at air gap and hence
motor draws lower magnetizing current.
(ii) Reduces noise because air- gap characteristics are better
(iii) Increases leakage reactance and reduces starting current.
(iv) Over- load capacity is reduced.

From the above we see that semi-closed slots are more suitable and employed in
rotors.

5.8 End rings for cage rotor and rotor slots

All the rotor bars are short circuited by connecting them to the end rings at both
the end rings. The rotating magnetic field produced induces emf in the rotor bars
which is sinusoidal over one pole pitch. As the rotor is short -circuited body,
there is current flow because of this induced emf. The distribution of current and
end rings is shown in Figure. Referring to figure considering the bars under one
pole pitch, half of the number of bars and the end ring carry the current in one
direction and the other half in the opposite direction. Thus, maximum end ring
current may be taken as the sum of the average current in half of the number of
bars under one pole.
 Figure 7. Currents in cage rotor bars and end rings

Maximum end ring current  Ie(max) = ½ ( Number rotor bars / pole) Ib(av)

= ½ x Sr/P x Ib/1.11

 Hence rms value of   Ie = 1/2√2 x Sr/P x Ib/1.11

  = 1/π x Sr/P x Ib/1.11

5.9 Turns and area of cross-section for wound rotor.

The Area of rotor conductor can be calculated based on the assumed value for
the current density in rotor conductor and calculated rotor current. Current
density rotor conductor can be assumed between 4 to 6 Amp/mm2

  Ar =  Ir / δr          mm2

 If Ar <  5mm2  use circular conductor, else rectangular conductor, for
rectangular conductor width to thickness ratio = 2.5 to 4. Then the standard
conductor size can be selected like that of stator conductor.

Number of rotor Turns: 

The Number of rotor turns are decided based on the safety consideration of the
personal working with the induction motors. The volatge between the slip rings
on open circuit must be limited to safety values.

Generally, the voltage between the slip rings for low and medium voltage
machines must be limited to 400 volts. For motors with higher voltage ratings
and large size motors this voltage is limited to 1000 volts.

Depending on the assumed voltage between the slip rings and comparing the
induced voltage ratio in stator and rotor the number of turns on rotor winding
can be calculated as

 Voltage ratio       Er/ Es = (Kwr x Tr) / (Kws x Ts )

 Hence  rotor turns per phase Tr = (Er/Es) (Kws/Kwr) Ts

  Er = open circuit rotor voltage/phase

Es = stator voltage /phase

Kws = winding factor for stator

Kwr = winding factor for rotor

Ts  = Number of stator turns/phase

Rotor ampere turn = 0.85 x stator ampere turn

IrTr = 0.85 x Is Ts

Rotor current Ir = 0.85 Is Ts / Tr. 

References:

1. A.K Sawhney – A course in Electrical Machine Design 10 th Edition –

Dhanpat Rai and sons.
2. Design of Electrical Machines, New age publication KG Upadhyay
3. Principles of Electrical Machine Design R.K Agarwal.
4. Electrical Machine Design Book by V. Rajini and V. S. Nagarajan
5. Design Of Electrical Machines by Mittle V.N