Design of Stator – Induction Motors

Stator of an induction motor consists of stator core and stator slots.

Stator slots: in general two types of stator slots are employed in induction
motors viz, open clots and semi-closed slots. Operating performance of the
induction motors depends upon the shape of the slots and hence it is important
to select suitable slot for the stator slots.

(i) Open slots: In this type of slots the slot opening will be equal
to that of the width of the slots as shown in Fig 10. In such type
of slots assembly and repair of winding are easy. However such
slots will lead to higher air gap

contraction factor and hence poor power factor. Hence these

types of slots are rarely used in 3Φ induction motors.

(ii) Semiclosed slots: In such type of slots, slot opening is much

smaller than the width of the slot as shown in Fig 10 and Fig 11.
Hence in this type of slots assembly of windings is more
difficult and takes more time compared to open slots and hence
it is costlier. However the air gap characteristics are better
compared to open type slots.

(iii) Tapered slots: In this type of slots also, opening will be much
smaller than the slot width. However the slot width will be
varying from top of the slot to bottom of the slot with minimum
width at the bottom as shown in Fig. 10.
Selection of number of stator slots: Number of stator slots must be
properly selected at the design stage as such this number affects the weight, cost
and operating characteristics of the motor. Though there are no rules for
selecting the number of stator slots considering the advantages and
disadvantages of selecting higher number slots comprise has to be set for
selecting the number of slots. Following are the advantages and disadvantages
of selecting higher number of slots.

Advantages :
(i) Reduced leakage reactance.
(ii) Reduced tooth pulsation losses.
(iii) Higher over load capacity.
Disadvantages:
(i) Increased cost
(ii) Increased weight
(iii) Increased magnetizing current
(iv) Increased iron losses
(v) Poor cooling
(vi) Increased temperature rise
(vii) Reduction in efficiency

Based on the above comprise is made and the number of slots/pole/phase may
be selected as three or more for integral slot winding. However for fractional
slot windings number of slots/pole/phase may be selected as 3.5. So selected
number of slots should satisfy the consideration of stator slot pitch at the air gap
surface, which should be between1.5 to 2.5 cm.

Stator slot pitch at the air gap surface = τss= πD/Sss where Sss is the number
of stator slots

Turns per phase

EMF equation of an induction motor is given by Eph = 4.44fΦTphkw

Hence turns per phase can be obtained from emf equation Tph = Eph/
4.44fΦkw

Generally the induced emf can be assumed to be equal to the applied voltage per
phase

Flux/pole, = Bav x πDL/P,

winding factor kw may be assumed as 0.955 for full pitch distributed winding
unless otherwise specified.
Number conductors /phase, Zph = 2 x Tph, and hence Total number of stator
conductors Z = 6 Tph and conductors /slot Zs = Z/Ss or 6 Tph/Ss , where Zsis an
integer for single layer winding and even number for double layer winding.

Conductor cross section: Area of cross section of stator conductors can be

estimated from the stator current per phase and suitably assumed value of
current density for the stator windings.

Sectional area of the stator conductor a s = Is / δs where δs is the current

density in stator windings

Stator current per phase Is = Q / (3Vph cos ϕ )

A suitable value of current density has to be assumed considering the

advantages and disadvantages.

Advantages of higher value of current density:

(i) reduction in cross section

(ii) reduction in weight
(iii) reduction in cost

Disadvantages of higher value of current density

(i) increase in resistance

(ii) increase in cu loss
(iii) increase in temperature rise
(iv) reduction in efficiency

Hence higher value is assumed for low voltage machines and small machines.
Usual value of current density for stator windings is 3 to 5 amps.
Based on the sectional area shape and size of the conductor can be decided. If
the sectional area of the conductors is below 5 mm 2 then usually circular
conductors are employed. If it is above 5 mm 2 then rectangular conductors will
be employed. Standard bare size of round and rectangular conductors can be
selected by referring the tables of conductors given in Design data Hand book.
In case of rectangular conductors width to thickness ratio must be between 2.5
to 3.5.

Area of stator slot: Slot area is occupied by the conductors and the
insulation. Out of which almost more than 25 % is the insulation. Once the
number of conductors per slot is decided approximate area of the slot can be
estimated.

Slot space factor = Copper area in the slot /Area of each slot

This slot space factor so obtained will be between 0.25 and 0.4. The detailed
dimension of the slot can be estimated as follows.

Size of the slot: Normally different types of slots are employed for carrying
stator windings of induction motors. Generally full pitched double layer
windings are employed for stator windings. For double layer windings the
conductor per slot will be even. These conductors are suitably arranged along
the depth and width of the winding. Stator slots should not be too wide, leading
to thin tooth width, which makes the tooth mechanically weak and maximum
flux density may exceed the permissible limit. Hence slot width should be so
selected such that the flux density in tooth is between 1.6 to 1.8 Tesla. Further
the slots should not be too deep also other wise the leakage reactance increases.
As a guideline the ratio of slot depth to slot width may assumed as 3 to 5. Slot
insulation details along the conductors are shown in Fig. 12.
Proper slot insulation as per the voltage rating of the machine has to be provided
before inserting the insulated coil in the slots. This slot insulation is called the
slot liner, thickness of which may be taken as 0.5 mm to 0.7 mm. Suitable
thickness of insulation called coil separator separates the two layers of coils.
Thickness of coil separator is 0.5 mm to 0.7 mm for low voltage machines and
0.8 mm to 1.2 mm for high voltage machines. Wedge of suitable thickness (3.5
mm to 5 mm) is placed at the top of the slot to hold the coils in position. Lip of
the slot is taken 1.0 to 2.0 mm. Figure 13 shows the coils placed in slots.
Length of the mean Turn:

Length of the mean turn is calculated using an empirical formula lmt = 2L +

2.3 τp + 0.24 where L is the gross length of the stator and τp is pole pitch in
meter.

Resistance of stator winding: Resistance of the stator winding per phase is

calculated using the formula = (0.021 x lmt x Tph ) / as where lmt is in meter and
as is in mm2. Using so calculated resistance of stator winding copper losses in
stator winding can be calculated as

Total copper losses in stator winding = 3 (Is)2 rs

Flux density in stator tooth: Knowing the dimensions of stator slot pitch,
width of the slot and width of the stator tooth flux density in the stator tooth can
be calculated. The flux density in the stator tooth is limited to 1.8 Tesla. As the
stator tooth is tapering towards the bottom, the flux density is calculated at
1/3rd height from the narrow end of the tooth. The flux density at the
1/3rd height from the narrow end of the tooth can be calculated as follows.

Diameter at 1/3rd height from narrow end D' = D + 1/3 x hts x 2

Slot pitch at 1/3rd height = τ's = π x D' /Ss

Tooth width at this section = b't = τ's – bs

Area of one stator tooth = a't = b't x li

Area of all the stator tooth per pole A't = b't x li x number of teeth per
pole

Mean flux density in stator teeth B't = Φ / A't

 Maximum flux density in the stator teeth may be taken to be less than 1.5
times the above value.

Depth of stator core below the slots: There will be certain solid portion
below the slots in the stator which is called the depth of the stator core. This
depth of the stator core can be calculated by assuming suitable value for the flux
density Bc in the stator core. Generally the flux density in the stator core may be
assumed varying between 1.2 to 1.4 Tesla. Depth of the stator core can be
calculated as follows.

Flux in the stator core section Φc = ½ Φ

Area of stator core Ac = Φ/2Bc

Area of stator core Ac = Li x dcs

Hence, depth of the core = Ac / Li

Using the design data obtained so far outer diameter of the stator core can be
calculated as

Do = D + 2hss = 2 dcs where hss is the height of the stator slot.