6 November 2023

Motor-CAD Software Tutorial:

Motor-CAD Induction Motor – Combined electromagnetic

and thermal model

Contents
1. Description ..................................................................................................................... 2
2. Model Definition ............................................................................................................. 2
3. Machine Geometry......................................................................................................... 3
4. Winding .......................................................................................................................... 4
5. Materials ........................................................................................................................ 8
6. Calculation ..................................................................................................................... 9
7. Solving ......................................................................................................................... 16
8. Numerical Results ........................................................................................................ 17
9. Graphs Results ............................................................................................................ 22
10. Finite Element Performance Tests............................................................................ 26
11. Coupled Electromagnetic / Thermal model ............................................................... 36
12. Solving the coupled electromagnetic thermal model ................................................. 38
13. Conclusion ............................................................................................................... 44
1. Description
The Motor-CAD allows the machine performance, losses and temperatures to be calculated
for an Induction Machine. This tutorial will describe how to model the electromagnetic
performance of an induction machine and then how to combine this electromagnetic model
with a thermal model to calculate the full machine performance.

2. Model Definition
Motor-CAD has four modules: electromagnetic, thermal, LAB, and mechanical. These
models can be used separately or as a combined electromagnetic + thermal model. In this
case we will start by using the electromagnetic model by selecting the option shown below.

Make sure that the Motor Type -> IM

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3. Machine Geometry
The standard default machine geometry for an induction machine is used in this tutorial as
shown below. This is a 4-pole, 50Hz, 18 slots, 26 bars induction machine.

Note that only the machine components relevant for the electromagnetic analysis are
displayed.

Radial View:

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Axial view:

4. Winding

Click on the Winding tab as shown below:

Note that here the user can specify the winding definition, type and the wedge model.

For this model will use the default settings:

Parameter Value
Divider Type Overlapping
Wdg Definition Copper Slot Fill
Copper Slot Fill 0.4

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The winding pattern can now be defined in the Pattern tab as shown below.

There is the option to define the winding pattern in Motor-CAD in 2 ways:

1. Lap/Concentric – Automatically creates a winding pattern based on the user input

parameters. Winding feasibility rules are applied to ensure that the winding is valid.
The user can change:
• the number of Phases (limited to a choice of 3 or 6 for induction machines)
• the turns/coil (Turns)
• the coil pitch (Throw)
• the number of Parallel Paths
• the coil placement in the slot (Path Type)
• the number of Winding Layers in the slot

2. Custom allows the user to specify the winding pattern coil by coil. Winding feasibility
is not checked.

In this example we will use the Lap winding pattern option with the following settings:

Parameter Value
Turns 100
Winding Layers 2
Path Type Central

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The goodness of the winding pattern can be studied in various ways. The phasor diagram
shows the MMF values for each winding coil:

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5. Materials
Motor-CAD has a materials database populated with commonly used materials. Other
materials can be added as required. (Yellow highlighting indicate materials being used in the
current model.)

Note: if you have an old materials database then this can be updated to include the new
magnetic materials by selecting Create Database and then selecting the existing database
name (usually 'solids.mdb').

You will then get the prompt below:

After selecting Yes, the database will then be updated with the magnetic materials.

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In this model will use the default materials provided from the materials database as shown
below:

Note the properties of the materials and the weights on which it is further possible to have
cost estimations if the price/unit are known.

6. Calculation

The calculation page shown below allows the calculation of the machine performance
(speed, frequency, slip, voltage and connection) to be defined. It also allows any skew angle
to be defined on the rotor or stator.

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This section of the tutorial will describe some of the options available.

Operating Mode (is used in conjunction with Performance Tests -> Torque-speed
characteristic)

• Motor: The induction machine operates between zero speed (slip = 1) and
synchronous speed (slip = 0). The corresponding performance curves are plotted
when selecting Torque/speed
• Generator: The induction machine operates between synchronous speed (slip = 0)
and double value of the synchronous speed (slip = -1)
• Motor/Generator: The induction machine operates between zero speed (slip = 1)
and double value of the synchronous speed (slip = -1)
• Brake: The induction machine operates between negative synchronous speed (slip =
2) and zero speed (slip = 1)

For this tutorial we select motor mode.

Operating Point Definition

Used to define one singular operation point that is of interest. By using sensitivity analysis it
is possible to calculate the performance for a given range of speed, frequency or slip values

• Speed - the rotational speed of the machine

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 • Slip - The relative difference between the synchronous speed of the revolving
magnetic field, and the shaft speed
• Frequency - the fundamental supply frequency
• Torque/Frequency or Power/Frequency – specifies a torque/power value for a
given frequency; Motor-CAD will search along the torque/speed characteristic and if
the required torque/power value is found, the results will reflect the machine
performance at the imposed operating point.

NOTE: The relation between the shaft speed, slip and frequency is given below, where poles
is the machine’s number of magnetic poles:

𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
𝑆𝑝𝑒𝑒𝑑 = 120 × × (1 − 𝑠𝑙𝑖𝑝)
𝑝𝑜𝑙𝑒𝑠

For this tutorial we will keep the defaults of slip/frequency at a slip of 0.03 and a frequency of
50:

Supply Definition

Two methods are available to control the supply voltage of the induction machine

• AC Mains (voltage driven) – the machine is connected directly on the AC mains

voltage line
• Inverter Fed (current driven) – the machine is supplied and controlled via an
inverter

For this tutorial we will use AC Mains.

For the Inverter fed machine different PWM control strategies for the inverter are available in
the Input Data -> Settings -> E-Magnetics page as shown below:

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The ratio between the output line-line RMS voltage of the inverter and the DC bus voltage is
given in the table below:

PWM Modulation Strategy Ratio VII(RMS)/DC Bus Voltage

SixStep 180 0.780
Hexagon tracking: piecewise linear 0.7446
Hexagon tracking: secant 0.7418
Circle tracking 0.707
SixStep 120 0.675
Maximum linear range of sine/triangle 0.612

Voltage Drive

• for AC Mains, assumes sinusoidal voltage for which the peak or the rms value of the
line-line voltage is given
• for Inverter Fed, the DC bus voltage is available in conjunction with the PWM
modulation strategy.

For this tutorial set the supply voltage for this machine to 430V RMS.

The settings at this point should be as follows:

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Temperatures and Thermal Coupling

As this model is an electromagnetic model without the coupled thermal model then the
temperatures for the electromagnetic performance will be given by the user. In this case we
will use the default temperature values.

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Saturation Model

Before running any calculations, lookup tables must first be calculated for saturation factor,
magnetizing reactance, core loss resistance and iron losses. Two methods are available,
Analytic and FEA. The FEA method will take longer but will be more accurate and is
necessary for complex machine geometries. The max voltage (or current if using inverter
fed) must be greater than or equal to the supply. More details can be found in the manual.

For this tutorial, select the analytic method and set the max RMS voltage as 430V. The click
Calculate Saturation Model.

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Performance Tests

The performance test options section allows the user to select which calculations to run.
Most Analytic performance tests are selected by default. Note that at this stage no Finite
Element calculations are selected. The calculation time can be sped up by removing
calculations that are not required.

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7. Solving

Save the file as testIM.mot.

The Motor-CAD electromagnetic module uses both analytical algorithms and 2D finite
element analysis to calculate the electromagnetic performance.

The model can now be solved by clicking on the Solve E-Magnetic Model [Ctrl + R] button
as shown below. Note that if you have not yet calculated the saturation model you will be
prompted to do so now.

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8. Numerical Results
Once the calculation is completed then the numerical output data can be viewed. This
example model is for a small 3-phase fractional horse power induction motor, that will deliver
a maximum efficiency of 69%.

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The equivalent circuit for this machine is shown below:

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All the numerical results can be copied directly from the results screens or can be saved in a
*.csv file format via File - > Export Results.. -> E-Magnetic Solution

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9. Graphs Results
Various graphs can be viewed as shown below with analytical estimation of the airgap flux-
density (Bgap with both saturated and unsaturated values), torque, current, power, efficiency
and power factor variation vs speed.

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10. Finite Element Performance Tests
The induction motors module in Motor-CAD has several finite element performance tests
implemented.

Single Load Point (non-rotating)

Using 2D Transient FEA solver calculations, fixed rotor position, and input stator current as
estimated by the analytic model, the torque and power levels are estimated by multiplying the
bars electrical conductivity with slip and thus forcing the induced eddy-currents in rotor bars
to vary with a frequency equal to slip * frequency.

Single Load Point (rotating)

Using 2D Transient FEA solver calculations, rotating rotor position, and input stator current
as estimated by the analytic model, the torque and power levels are estimated by allowing
the rotor to rotate with a speed proportional to (1-slip) * frequency. By default, this calculation
starts with initialisation cycles using a fixed rotor position to stabilise the induced eddy-
currents in the rotor bars, before the full motion calculation starts. The number of initialisation
cycles can be set under Input Data -> Settings -> Calculation -> FEA.

Locked rotor

Using 2D Transient FEA solver calculations, and fixed rotor position, and input stator current
as estimated by the analytic model, the torque and power levels are estimated using various
FEA methods: virtual work, Maxwell stress, DA or power balance. The induced eddy-
currents in rotor bars will vary with a frequency proportional to supply fundamental
frequency. The number of frequencies and proportionality constants can be set under Input
Data -> Settings -> Calculation -> FEA.

Electromagnetic Forces

This requires a Single Load Point (rotating) calculation to also be run. Electromagnetic
forces are calculated from flux densities using the Maxwell Stress Tensor and allows for
force analysis.

Synchronous Speed -> Core Losses

Using 2D Transient FEA solver calculations and a rotating rotor, the core losses at
synchronous speed (slip = 0, no-load) and estimated at various input current levels imposed
by the user. The rotor bars region can be treated as air or solid conducting material. The
latter case will allow the inclusion of the induced rotor bars eddy-currents by the space MMF
harmonics.

Synchronous Speed -> Self and Mutual Inductances

Using a fixed rotor position with 2D Magneto-static FEA solver calculation and various input
current levels imposed by user, the self and mutual inductances are estimated.

For illustration, we will demonstrate how to calculate the single load point (non-rotating)
using the finite-element method. It is recommended to use an FEA saturation model for

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single load point calculations, so first we will update this by selecting FEA and clicking
Calculate Saturation Model.

The single load point (non-rotating) case benefits from an automatic convergence detection,
that is enabled through Input Data -> Settings -> Calculation -> FEA. This compares the
torque values from the latest cycle to the previous to produce an RMS error value for

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determining convergence. Select Until converged under Convergence (non-rotating).

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Returning to the Calculation tab, select the Single Load Point (non-rotating) option and click
solve. Depending on machine performance this should take around 20 seconds.

The minimum solution based on symmetry is automatically selected for the finite element
calculations. The finite element model and results can be viewed while solving by selecting

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the E-magnetics tab as shown below:

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Clicking on any region with the mouse will display the field and flux density values.

Single load point torque is shown below:

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Single load point back EMF:

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The output sheets provide information on the parameters calculated using the finite-element
method:

Convergence provides information about the error in various parameters from cycle to cycle
(Note only torque is computed using RMS error. Other parameters use cycle averages):

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11. Coupled Electromagnetic / Thermal model

In the first section we have produced an electromagnetic model for an induction motor, but
this has assumed that the winding, lamination and rotor have fixed temperatures. The Motor-
CAD model has calculated the winding, magnet and iron losses, so these can now be used
in a thermal model to calculate the motor temperatures.

To couple the electromagnetic and thermal models select the Thermal option shown below.
This option will use the same model but will give the thermal interface view of the model.

The thermal view of the model also shows components of the machine important for the
machine cooling for example housing, cooling systems etc.

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The thermal model can now be set up with housing type, ducts, materials and cooling
options etc. For this example, will use the default machine values, with a finned housing and
natural convection cooling only. Hence, we will make no changes to the thermal model.

Once the thermal model has been set up we then can return to the magnetic interface view
of the model as shown below:

12. Solving the coupled electromagnetic thermal model

In the E-Magnetic context, navigate to the tab Calculation, and select “Iterate to Converged
Solution” in the E-Magnetics – Thermal Coupling section.

In this model we will only calculate the minimum set of Analytic performance tests as
highlighted below:

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To solve the model now select the Solve E-Magnetic Model:

The dialog box below should then be displayed.

Clicking on the OK button should then run an iterative solution between the electromagnetic
and thermal models. This will pass the losses to the thermal model that will calculate the
machine temperatures. The machine temperatures will then be returned to the
electromagnetic model that will then recalculate the performance and losses.

This process will repeat until the temperature and loss values converge.

After pressing the OK button, the iterative calculation will then run. This is normally quite a
fast calculation.

In this case the convergence took 3 iterations as shown below. In this model the final
winding and rotor temperatures are quite low, so the performance of the machine has
improved slightly from the initial predictions.

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The machine temperature calculated in the thermal model that are used in the
electromagnetic model are now shown in the calculation sheet:

The losses are calculated based on the machine temperatures:

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The thermal model can be viewed by selecting to view the thermal interface using the option
Model -> Thermal:

Can now see the losses that have been calculated in the electromagnetic model being used
for the thermal model, Input Data -> Losses -> Loss Models:

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Under the Temperatures tab, the schematic, radial and axial views show the main points in
the thermal model including the winding, stator, rotor iron and rotor cage temperatures.

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Now that the electromagnetic and thermal models have been combined, they can be studied
separately and then coupled to transfer results between them when required.

13. Conclusion
This example shows how to create a combined electromagnetic and thermal model in Motor-
CAD. This model takes into account the machine temperatures and losses when calculating
the machine performance and allows different electromagnetic and thermal design concepts
to be fully evaluated.

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