Inductionmotor Design
Inductionmotor Design
INDUCTION
MOTOR
Construction of Induction
Motor
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Rotor
Rotor is the rotating part of the induction motor. The rotor also
consists of a set of slotted silicon steel laminations pressed
together to form of a cylindrical magnetic circuit and the
electrical circuit. The electrical circuit of the rotor is of the
following nature
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Wound rotor consists of three sets of insulated windings
with connections brought out to three slip rings mounted
on one end of the shaft. The external connections to the
rotor are made through brushes onto the slip rings. Due to
the presence of slip rings such type of motors are called
slip ring motors.
Some more parts to complete the constructional details of an
induction motor, are:
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Introduction to Design
The main purpose of designing an induction motor
is to obtain the complete physical dimensions of all
the parts of the machine as mentioned below to
satisfy the customer specifications. The following
design details are required.
Total Loadings:
Total Magnetic Loading : the total flux around the
armature ( or stator) periphery at the air gap is called
the total magnetic loading.
total magnetic loading = pφ
Output Equation
Let
Vph = phase voltage ; Iph = phase current
Zph = no of conductors/phase; Tph = no of turns/phase
Ns = Synchronous speed in rpm; ns = synchronous speed
p = no of poles ; ac = Specific electric lo
Ф= air gap flux/pole; Bav = Average flux dens
Kw = winding factor ; η = efficiency
D = Diameter of the stator; L = Gross core length
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Co = Output coefficient; cos υ = power factor
Consider ‘m’ phase machine, with usual notations
Out put Q in kW = Input x efficiency
Input to motor = mVph Iph cosφ * 10-3 kW
For a 3 –υ machine ‘m’ = 3
Input to 3- υ motor = 3Vph Iph cosφ * 10-3 kW
Assuming Vph = Eph, Vph = Eph = 4.44 f Ф TphKw
= 2.22 f Ф ZphKw
f = PNS/120 = P* ns/2
Therefore Output Q = Co D2 L ns kW
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where Co = (11 Bav ac Kw η cosφ * 10-3) = Output
coefficient
Choice of Specific Loadings
Specific Magnetic loading or Air gap flux density
i. Power factor: poor power factor for high flux density
in air gap ii. Iron loss: iron losses increase with
increase in flux density iii. Overload capacity: overload
capacity increase with increase in flux density
Limitations :
Flux density in teeth < 1.8 Tesla
Flux density in core 1.3 – 1.5 Tesla
Advantages of Higher value of Bav
• Size of the machine reduced
• Cost of the machine decreases
• Overload capacity increases
For 50 Hz machine the value of Bav lies between 0.35 – 0.6
Tesla.
Specific electric loading or ampere conductors per meter
i. Copper loss and temperature rise: a large value of ac
gives higher copper losses and large temp. rise
ii. Voltage: for high voltage machine value of ac should
be small iii. Overload capacity: overload capacity
decreased with high value of ac.
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The value of ac depends upon the size of the motor,
voltage of stator winding, type of ventilation and overload
capacity desired.
It varies between 5000 – 45000 ampere conductors per
meter.
Separation of D and L
The output equation gives the relation between D 2L and
output of the machine. To separate D and L for this
product a relation has to be assumed. Following are the
various design considerations based on which a suitable
ratio between gross length and pole pitch (L/τ)
assumed.
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Rotor Design
There are two types of rotor construction. One is the squirrel
cage rotor and the other is the slip ring rotor. Most of the
induction motor are squirrel cage type. These are having the
advantage of rugged and simple in construction and
comparatively cheaper. However they have the disadvantage of
lower starting torque. In this type, the rotor consists of bars of
copper or aluminium accommodated in rotor slots. In case slip
ring induction motors the rotor complex in construction and
costlier with the advantage that they have the better starting
torque. This type of rotor consists of star connected distributed
three phase windings.
Length of Air-gap
Between stator and rotor is the air gap which is a very
critical part. The performance parameters of the motor like
magnetizing current, power factor, over load capacity,
cooling and noise are affected by length of the air gap.
Power Factor:- the mmf required to send the flux through
air gap is proportional to the product of flux density and
length of air gap.
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fig shows phasor diagrams of an induction motor with two
different air gap lengths.
With increase in air gap
length, magnetizing mmf
increases and hence greater
the magnetizing current.
Therefore, the phase angle
between applied voltage and
stator current will increase
which gives low power factor.
Overload Capacity:- overload capacity of induction motor is
the ratio of maximum output to rated output and the maximum
output is obtained from circle diagram. The diameter of circle
diagram is Vs/Xs where Xs is reactance of motor. The length of
air gap affects the leakage reactance. If the length of air gap is
large, the leakage flux is reduced, hence reduced value of
leakage reactance. With decrease in the value of leakage
reactance the diameter of circle diagram increases and hence
the overload capacity increases.
Pulsation loss:- the tooth pulsation losses, which is produced
due to variation in reactance of the air gap, is reduced with
large air gap.
Cooling:- the large air gap provide better facilities for cooling
at the gap surfaces due to the cylindrical surfaces of stator and
rotor are separated by large distance.
Noise:- noise in induction motor reduced with increase in air
gap length due to reduction in leakage flux which is the cause
of noise.
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Hence length of the air gap is selected considering the
advantages and disadvantages of larger air gap length.
Advantages:
(i) Increased overload capacity
(ii) Increased cooling
(iii) Reduced unbalanced magnetic pull
(iv) Reduced in tooth pulsation
(v) Reduced noise
Disadvantages
(i) Increased Magnetising current
(ii) Reduced power factor
Magnetising current and power factor being very important
parameters in deciding the performance of induction motors,
the induction motors are designed for optimum value of air gap
or minimum air gap possible. Hence in designing the length of
the air gap following empirical formula is employed.
Air gap length lg = 0.2 + 2√DL mm
Design of Squirrel Cage Rotor
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Crawling: The rotating magnetic field produced in the air gap
will be usually nonsinusoidal and generally contains odd
harmonics of the order 3rd, 5th and 7th. The third harmonic
flux will produce the three times the magnetic poles compared
to that of the fundamental. Similarly the 5th and 7th harmonics
will produce the poles five and seven times the fundamental
respectively. The presence of harmonics in the flux wave
affects the torque speed characteristics. The motor with
presence of 7th harmonics is to have a tendency to run the
motor at one seventh of its normal speed.
Cogging: In some cases where in the number of rotor
slots are not proper in relation to number of stator 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.
Hence in order to avoid such bad effects a proper number
of rotor slots are to be selected in relation to number of
stator slots. In addition 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 will slightly
increase the rotor resistance and increases the starting
torque. However this will increase the leakage reactance
and hence reduces the starting current and power factor.
Selection of number of rotor slots: The number of rotor slots may be
selected using the following guide lines.
(i) To avoid cogging and crawling: (a)Ss ≠ Sr (b) Ss - Sr ≠ 3P
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(ii) To avoid synchronous hooks and cusps in torque speed
characteristics Ss - Sr ≠ P, 2P, 5P.
(iii) To noisy operation Ss - Sr ≠ 1, 2, (P ±1), (P ±2)
End Ring Current: All the rotor bars are short circuited by
connecting them to the end rings at both the end rings. As the
rotor is a short circuited, there will be current flow because of
induced emf in the rotor bars. The distribution of current and
end rings are as shown in Fig. 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 the maximum end ring current may be taken
as the sum of the average current in half of the number of bars
under one pole.
Maximum end ring current Ie( max )
= (Number of bars over half a pole pitch) Ib(av)
= Sr/2P*[2/π * Ib(max) ]
= (Sr*Ib(max))/πP
rms value of bar current Ib = Ib(max)/√2 Ie(max) = (Sr*Ib * √2)/πP
rms value of end ring current Ie = Ie(max)/√2 Ie = (Sr*Ib)/πP
Area of end ring: Knowing the end ring current and assuming
suitable value for the
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current density in the end rings cross
section
for the end ring can be calculated. Current
density in the end ring may be
assume as 4.5 to 7.5 amp/mm2.
Area of each end ring Ae = Ie /δe mm2
Ae = te*de whre te = thickness of end ring
and de = depth of end ring
Design of wound Rotor
These are the types of induction motors where in rotor also
carries distributed star connected 3 phase winding. At one
end of the rotor there are three slip rings mounted on the
shaft. Three ends of the winding are connected to the slip
rings. External resistances can be connected to these slip
rings at starting, which will be inserted in series with the
windings which will help in increasing the torque at
starting. Such type of induction motors are employed where
high starting torque is required.
Number of rotor slots: The number of rotor slots should
never be equal to number of stator slots. Generally for
wound rotor motors a suitable value is assumed for number
of rotor slots per pole per phase, and then total number of
rotor slots are calculated. So selected number of slots
should be such that tooth width must satisfy the flux density
limitation.
Semi-closed slots are used for rotor slots.
Number of rotor Turns: The voltage between the slip rings
on open circuit must be limited to safety values. In general
the voltage between the slip rings for low and medium
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voltage machines must be limited to 400 volts. For motors
with higher voltage ratings and large size motors this
voltage must be limited to 1000 volts. Based on the
assumed voltage between the slip rings comparing the
induced voltage ratio in stator and rotor, the number of
turns on rotor winding can be calculated.
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 Current and conductor section
Assuming rotor mmf = 0.85* stator mmf
2x3xIr.Tr = (0.85) 2x3xIs.Ts
Rotor current per phase Ir = (0.85) Is.Ts/T
Rotor conductor area Ar = Ir/δr
The current density could be taken as 3 to 5 A/mm2
Rotor Teeth The flux density in the rotor teeth does not
exceed about 1.7 wb/m2. The maximum flux density for
rotor teeth occurs at their root as their section is minimum
there.
Minimum width of rotor teeth Wir(min) = Φm/(1.7*(Sr/p)*L i
Minimum width actually provided should be larger than the
value given by above equation.
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Wir = rotor slot pitch at the root – rotor slot width = ((D r-
2dsr)/Sr)- Wsr dsr = depth of rotor slot and Wsr = width of
rotor slot
Rotor Core
The flux density in the rotor core is generaly equal to ststor cire
density.
Depth of rotor core dcr = Φm/(2*Bcr *L i)
Bcr = flux density in the rotor core
Inside diameter of rotor lamination
Di = Dr – 2(dsr + dcr)
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Operating Characteristics
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Magnetising current Im= P*AT60 / (2.34 kw Tph ) where p – no of
pairs of poles, AT30 – Total ampere turns of the magnetic
circuit at 600 from the centre of the pole, Tph – Number of
stator turns per phase.
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Dispersion coefficient defined as the ratio of magnetizing
current to ideal short circuit current.
Thus dispersion coefficient, σ = Im/Isci
=Im/(Es/Xs)Isci = Es/Xs
=Im.Xs/Es
For small values of Im and Xs dispersion coefficient is
small and power factor is good. Thus for a small value of
dispersion coefficient power factor is good, where as for
large value of dispersion coefficient power factor is poor.
Magnetizing current Im = P*AT60 / (2.34 kw Tph )
Where AT60 is the total mmf consumed by flux path, out of
which a large part is consumed by air gap length.
AT air gap = 800000* 1.36* Bav l’g
Im α P * Bav l’g
/ Kws. Ts
Isci =
Es/Xs
∟ODC =90o
For σ = 0.05, maximum
p.f. = 0.905 For σ = 0.10,
maximum p.f. = 0.818
Hence there is a large decrease in maximum p.f. when the
dispersion coefficient increases.
2. Effect on overload capacity:
Assuming, an induction motor is designed to have maximum
pf at full load , its corresponding output will be DE. The
maximum output will be corresponding to FC
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