UNIVERSITY INSTITUTE OF

ENGINEERING
Bachelor of Engineering
Electrical Engineering
Subject Name: Electrical Machine-II

Design Factors DISCOVER . LEARN . EMPOWER

• TEXT BOOKS:
• Electric Machines: I.J. Nagrath and D.P. Kothari, TMH, New
Delhi.
• Electric Machinery, Fitzgerald & Kingsley, MGH.

• REFERENCE BOOKS:
• Theory of alternating current machinery, A.S. Langsdorf,
TMH.
• Electrical Machinery, P. S. Bimbhra, Khanna Publishers
Delhi.
• Generalized theory of Electrical Machine, P. S.Bimbhra,
Khanna Publishers Delhi.
 Weightage of Electrical Machines in Competitive Exams

• Gate 2020- 14 Marks (Average Last Ten Years)

• SSC Exams- 25-30 Marks (Average Last Ten Years)

• EES Exam- 20-25 Marks (Average Last Ten Years)

• Other State Level Competitive Exams -30-35) (Average Last Ten Years)
MAJOR CONSIDERATION IN DESIGN
DESIGN FACTORS
LIMITATIONS
Symbols
• D= Armature Diameter or Stator Bore (m)
• L= Stator core length (m)
• n= Speed (rps)
• ns = Synchronous Speed (rps)
• P= No. of Poles
• a= no. of parallel paths
• Ʈ = Pole Pitch (m)
• Z = Total no. of armature or stator conductors
• Tph = Turns per phase
• Iz = current in each conductor (A)
• Kw = Winding Factor
• Ia = Armature current (A)
• Iph = Current per phase (A)
• E= Back emf (V)
• Eph = Induced emf per phase (V)
• P= Rating of a machine (KW)
• Pa = Power developed by armature (KW)
• Q= KVA rating of machine. 26
Limitation in Design
 Saturation
 Temperature Rise
 Insulation
 Efficiency
 Mechanical Parts
 Commutation
 Power Factor
 Consumer Specifications
 Standard Specifications

9
Saturation
Electrical M/c use Ferro Magnetic materials -Bmax –
Increased
Excitation resulting in higher cost for the field system.
Temperature Rise
 Cooling and ventilation –required to keep the temperature rise
in safe limits.
 Coolant become excessive.
Insulation
 Able to withstand the electrical, mechanical and
thermal stresses.
 Type of insulation – decided by maximum temperature.
 size of insulation - decided by maximum voltage stress
and mechanical stress.

10
Efficiency
The capital cost of a M/C designed for high efficiency is high while
its running cost is low.
Mechanical Parts
 Mechanical stresses at the bottom of rotor teeth do not exceed the

maximum allowable limit – Turbo Alternator.

 Air gap length as small as possible to maintain high power factor- IM

 Bearings of rotating M/Cs are subjected to the action of rotor weight,

external loads, Inertia forces.

Commutation
Commutation conditions limit the maximum output.
Power Factor
Poor PF results in larger values of current for the same power – larger
conductor sizes have to be used.
Size and cost of IM reduced by using Bmax which leads to saturation
of iron parts and poor PF.

11
Consumer’s Specification
Specification laid down in the consumer’s order have to be met and
the design evolved should be satisfies all the specifications and also
the economic constraints imposed on the manufacture.
Standard Specification
These specifications are the biggest strain on the design because the
manufacture as well as the consumer cannot get away from them
without satisfying them.
Modern Machine Manufacturing Techniques
**Wide range of power output
Small size Machines – M/cs having power o/p of 750watts.
Medium size Machines - power o/p of few KW to 250KW.
Large size Machines - power o/p of 250KW to 5000KW.
Larger size Machines - power o/p as high as hundreds of
megawatt.

12
🞂​ Trend to build machines which are smaller in size.
Using lesser materials without sacrificing their
efficiency and capacity.
** Modern M/c – Magnetic materials having high
permeability, low iron loss and high mechanical strength.
**improvement in the insulating materials
** Marked with the use of higher electro magnetic loadings
for active parts and increased mechanical loadings
**Different and refined manufacturing techniques are used
for individual machine parts.
**M/cs are operates satisfactorily under the desired
environmental conditions.
13
🞂 ​ According to Size:
◦ Small Size : up to 750 Watts
◦ Medium Size : up to 250 KW
◦ Larger Size : 250 KW to 5000KW
🞂 ​ According to speed:
◦ Low speed : < 500 r.p.m.
◦ Medium speed: 500 to 1000 r.p.m.
◦ High speed / Turbo: > 1000 r.p.m.
🞂 ​ SIEMENS
🞂 ​ ABB
🞂 ​ KIRLOSKAR
🞂 ​ GEC
🞂 ​ BHEL
🞂 ​ INDO TECH
🞂 ​ GD Electricals
Total Magnetic loading
Total flux around the armature periphery at the air gap.
= PØ

Total Electric loading

Total No.of conductors around the armature
armature periphery.
= IzZ
🞂​ Every section of armature is capable of carrying
certain amount of current. Hence ampere- turn per unit
section of armature periphery is an important parameter to
estimate the intensity of electric loading

ac =(Total Armature ampere conductors) / Armature

periphery at air gap
= (Iz Z)/πD
🞂​Copper loss: Higher the value of
ac- larger will be the number of armature
of conductors which results in higher copper
loss.
- This will result in higher temperature rise and reduction
in

efficiency.

Voltage: A higher value of ac

- can be used for low voltage machines

- since the space required for the insulation will be smaller.

🞂​ Synchronous reactance: High value of ac leads to
-higher value of leakage reactance and armature reaction
and hence higher value of synchronous reactance.
- Such machines will have
poor voltage
regulation,
lower value of current under short circuit condition
low value of steady state stability limit and
small value of synchronizing power.
🞂​ Stray load losses: With increase of q =>stray load losses will
increase.

Values of specific magnetic and specific electric loading can be

🞂​ Each unit area of armature surface is capable of receiving
a certain magnetic flux. Hence Ф/A is an important parameter
to estimate the intensity of magnetic loading.

Bav = Total flux around the air gap/Area of flux path at the air
gap
= PØ/πDL
🞂​ Iron loss: A high value of flux density in the air gap leads to higher value
of
flux in the iron parts of the machine which results in
- increased iron losses and
- reduced efficiency.

🞂​ Voltage: When the machine is designed for higher voltage

- space occupied by the insulation becomes more
- making the teeth smaller and hence
- higher flux density in teeth and core.
🞂​ Transient short circuit current: A high value of gap density results in
- decrease in leakage reactance and hence
🞂​ Stability: The maximum power output of a
machine under steady state condition is indirectly proportional
to synchronous reactance.
- If higher value of flux density is used it leads to smaller number of
turns per phase in armature winding.
- This results in reduced value of leakage reactance and hence
increased value of power and hence increased steady state stability.
🞂​Parallel operation: The parallel operation of synchronous generators
depends
on the synchronizing power.
- Higher the synchronizing power higher will be the ability of
the
machine to operate in synchronism.
-The synchronizing power is inversely proportional to the
synchronous reactance and hence the machines designed with higher
 Introduction
The aim in the design of dc machine is to obtain the
complete dimensions of various parts like
 Main dimension of armature structure
 Design detail of armature wingding
 Main dimension of field structure
 Design detail of field wingding
 Design detail of commutator and brushes
 Design detail of the interpoles & its windings
 Performance characteristics
For design of dc machine required
 Detail specification of dc machine
 Thelimiting value of performance characteristics
like ion losses ,cu losses and efficiency
 Design equation based on which design procedure is to
be initiated
 Information for proper choice of various deign

parameters regarding availability of material for

 Information
various

Specifications of dc machines
Output : kW (for generators), kW or Hp (for motors)
 Voltage : V volt
 Speed : N rpm
 Rating : Continuous or Short time
 Temperature rise: θ0C for an ambient temperature of 400C
 Cooling : Natural or forced cooling
 Type : Generator or motor
 Voltage regulation
 Speed control
 Efficiency: must be as for as possible high
 Type of enclosure: based on the field of application – totally
enclosed, screen protected, drip proof, flame proof, etc.,
 Size of the machine etc.,
 Output Equation of DC Machines
Output Equation gives a relation between the machine rating
and its armature dimensions in terms of armature diameter,
core length, speed, specific electric and specific magnetic
loadings.
E : emf induced or back
emf Ia : armature current
Φ : Average value of flux /
pole
Z : Total number of armature
conductors N : Speed in rpm
P : Number of poles
A : number of armature paths or
circuits D : Diameter of the armature
L : Length of the armature core
Let
Pa = power developed by armature in kW
Pa = generated emf × armature current × 10-3
Pa =E × Ia × 10-3 ---------------(1)

Generated emf in a dc machine,

Let current in each conductor

=
Main dimension
⚫ For square pole length must be approximately equal
to pole arc L = b = ψτ
The value of ψ is usually between 0.64 to o.72
Assume value of ψ = 0.67
there fore L/τ = ψ= 0.64 to 0.72
In practice L/τ is usually between 0.7 to 0.9 for
square pole
Τ= pole pitch, ψ= pole arc/pole pitch
The limiting values of

B gm = 1.2 wb/m2

Va = 30

m/sec E cm =30

v
Design of Induction
Motors
 Design of
Stator
The Design consideration of Stator Involves in estimation of
• Stator Winding
• Stator Turns per Phase
• Length of Mean Turn
• Stator Conductors
• Shape & No of Stator Slots
• Area of Stator Slot
• Stator Teeth
• Depth of Stator Core
 DESIGN OF STATOR
• Stator of an induction motor consists of
stator core & stator slots.
• Stator slots: in general two types of stator slots are
open slots & semi closed slots.
• Open slots: In this type , the slot opening will be equal to that
of the width of the slots.
• In thisslots 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
Semi closed slots: In such type, slot opening is much smaller
than the width of the slot. 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.

Tapered slots: In this type of slots also, opening will be much

smaller than the slot width. However the slot width will at the
bottom. be varying from top of the slot to bottom of the slot with
minimum width
 Stator Winding
• For Small Motors up to 5 HP Single layer Winding are used.

• For large capacity machines Double layer Winding ( Lap or

Wave ) with diamond shaped coils is used.
• The three phases of winding can be connected in either star
or Delta depending on the Starting Methods Employed.
• Squirrel cage – Star Delta Starter – Stators designed - Delta
• Slip ring – Rotor resistance – Either star or Delta
 Turns per phase
EMF equation of an induction motor is given by
Eph = 4.44fΦTphkw
Hence turns per phase 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,
Total number of stator conductors Z = 6Tph
conductors /slot Zs = Z/Ss or 6
Tph/Ss ,
where Zs is an integer for single layer
 Length of the mean Turn
• Length of the mean turn is calculated using an
empirical formula Lmt = 2L + 2.3 Ƭ + 0.24 m
where L = the gross length of the stator & Ƭ = pole
pitch in meter.
• Resistance of stator winding: Resistance of the
stator winding per phase r s = (0.021 x Lmt x Tph ) /
as where Lmt =length of mean turn of meter and
as
=area in mm2.
 Stator Conductors
kVA rating Q = 3 Es Is 10-3
Stator Current / Phase , Is = Q / 3 Es x 10-3
Area of Cross Section , as = Is / ðs
Where, ðs – Current Density – 3 to 5 A/mm2
Area of Cross Section , as = Πds / 4
2
Where, ds – Diameter of Stator
Conductor
Round conductors are
generally used for small diameter.
 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
 Choice of Stator
Slots
• number of slots/pole/phase may be selected as three
or more for integral slot winding
• fractional slot windings number of slots/pole/
phase may be selected as 3.5
• Slot Pitch for open type of Slots should be 15 to
25 mm.
• Slot Pitch for Semi enclosed type of Slots should be <
15 mm.
• Stator slot pitch, Yss = Gap Surface / Total No of Slots
= π . D / Ss
So, Ss = π . D / Yss
• Stator Slots Ss = Number of phases x poles x slots/pole/phase
Guide lines to select a suitable number of
slots
• 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 between 15 to 25
mm.
• Stator slot pitch at the air gap surface =Yss= πD/Ss
• Total number of stator winding conductors = 3X2XTs
for
3Ø
• No. of conductors per slot = Zss = (3X2X Ts ) / Ss
• copper area /slot
area of each slot as =
------------------------
-
• Copper area per slot = (Zssspace
xas) / sfactor
f
(sf)

• Space factor varies from 0.25 to 0.4

• The flux density in the teeth lies between 1.3 to 1.7 wb/m2
ratio of slot depth to width should be 3 to 6
 Following are the advantages and disadvantages of selecting Highe
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
(iv) magnetizing
(v) current
(vi) Increased iron losses
(vii) Poor cooling
Increased
 Conductors per Slot
Total No of Stator Conductors Zs = Phase x conductors/Phase
= 3 x 2 Ts = 6 Ts
Conductors per Slot, Zss = Total No of Zs / Total No of Ss
=
6 Ts / Ss
Where, Ts – Stator Turns per Phase
Ss – Total Stator Slots
Zss – Must be Even for double
layer winding
 Area of Stator Slot

Area of each slot = Copper Area per slot / Space

Factor

= Zss x as / S f

Where, Zss – No of Conductors per

slot as – Area of each

Conductor

S f = Space

factor Space Factor – 0.25

 Stator Teeth
• The Dimensions of slot determine the flux density in the teeth.

• Higher Flux Density – iron loss – Greater Magnetizing mmf.

• Mean Flux density in tooth < 1.7 Wb/m2

Minimum teeth Area per pole = flux per pole / flux density in the
teeth
=

Øm / 1.7
Teeth area per pole = (Ss / p) x Li x Wts (Width of stator

Tooth) So, Øm / 1.7 = (Ss / p) x Li x Wts min

Wts min = Øm / 1.7 (Ss / p ) x Li
 Conductor cross section
Area of cross section of stator conductors
Ac = the stator current per phase and assumed value of current
density for the stator windings.

Sectional area of the stator conductor as = Is / δs

where δs is the current density in stator windings
Stator current per phase Is = Q / (3Vph cosΦ)

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
 Depth of stator
• corein the stator core may
theflux density
be
assumed varying between 1.2 to 1.4 Tesla.
• The flux in the stator core is half the flux per dcs
pole. dss

Flux in the stator core section Φc = ½ Φ

D
Do
Area of stator core Ac = Φ/2Bcs
Area
Hence, depth of the of stator
stator core Ac = Li x=dcs
core
d cs
Ac / Li
• outer diameter of the stator core
D = D + 2d + 2d
o ss cs

Where dss = is the depth of the stator slot.

D = stator
diameter
 Length of Air
Gap
Advantages larger air gap length :
• Increased overload capacity
• Increased cooling
• Reduced unbalanced magnetic pull
• Reduced in tooth pulsation
• Reduced noise
Disadvantages of larger air gap length
• Increased Magnetising current
• Reduced power factor
For Small Induction Motor – lg = 0.2 + 2 Sqrt(DL) mm
Lg = 0.125 +0.35D+ L + 0.015 Va
For General Use - mm
lg =0.2 + D mm
For journal bearings - lg = 1.6 sqrt (D) –
0.25 mm
 DESIGN OF SQUIRREL CAGE AND SLIP RING
ROTOR
• There are two types of rotor construction.

squirrel cage rotor & 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 aluminum

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.
 Cond..
• This type of rotor consists of star connected distributed
three phase windings.
• 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.
• Hence length of the air gap is selected considering the
advantages and disadvantages of larger air gap length.
 Cond..
Advantages:
• Increased overload capacity
• Increased cooling
• Reduced unbalanced magnetic pull
• Reduced in tooth pulsation
• Reduced noise

Disadvantages
• Increased Magnetizing current
• Reduced power factor
 Shape and Size of the Rotor slots
• Generally semi-closed slots or closed slots with very
small or narrow openings are employed for the
rotor slots.
• In case of fully closed slots the rotor bars are force fit
into the slots from the sides of the rotor.
• The rotors with closed slots are giving
better performance to the motor in the following way.
 Cond..
• As the rotor is closed the rotor surface is smooth at the
air gap and hence the motor draws lower
magnetizing current.
• reduced noise as the air gap characteristics are better
• increased leakage reactance and
• reduced starting current.
• Over load capacity is reduced
• Undesirable and complex air gap characteristics. From
the above it can be concluded that semi-closed slots
are more suitable and hence are employed in rotors.
 Cross sectional area of Rotor bar
• Sectional area of the rotor conductor can be calculated
by rotor bar current and assumed value of
current density for rotor bars.
• As cooling conditions are better for the rotor than the
stator higher current density can be assumed.
• Higher current density will lead to reduced sectional area
and hence increased resistance, rotor cu losses
and reduced efficiency.
• With increased rotor resistance starting torque will
increase.
• As a guideline the rotor bar current density can be
assumed between 4 to 7 Amp/mm2
• Hence sectional area of the rotor bars , Ab = Ib/δb mm2.
 Equivalent Rotor Resistance
• Knowing the total copper losses in the rotor circuit and
the equivalent rotor current equivalent rotor
resistance can be calculated as follows.
• Equivalent rotor resistance

r'r= Total rotor copper loss / 3 x (Ir' )2

 Design of wound Rotor
• This is another type of induction motor 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 and rotor
Turns
• Numbers of rotor turns are decided based on the safety
consideration of the personal working with the
induction motors.
• 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 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.
 Cond..
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 =
 Rotor Current
• Rotor current can be calculated by comparing the amp-cond
on stator and rotor
Ir = (Kws xSs x Z's) x I'r / ( Kwrx Sr x Z'r)

Kws - winding factor for the stator, Ss - number of stator slots,

Z's - number of conductors / stator slots,
Kwr - winding factor for the rotor,
Sr - number of rotor slots,
Z'r - number of conductors / rotor slots and
I'r- equivalent rotor current in terms of stator current
I'r= 0.85 Is where Is is stator current per phase
 Area of Rotor Conductor
• 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
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 similar to that

of stator conductor.
 Size of Rotor slot
• Mostly Semi closed rectangular slots employed
for
the rotors.
• Based on conductor size, number conductors per

slot and arrangement of conductors similar to that

of stator, dimension of rotor slots can be estimated.
• Size of the slot must be such that the ratio of depth

to width of slot must be between 3 and 4.

• Rotor bar current I b = 0.85 (6I sTs) / Sr
• Length of rotor bar lb= L + allowance for skewing Rotor

bar resistance = 0.021 x lb/ Ab

• Copper loss in rotor bars = Ib2x rb x number of rotor bars

• area of the rotor bars Ab = Ib/δb mm2

• End Ring Current:
• All the rotor bars are short circuited by connecting them
to the end rings at both the end rings.
• Area of each end ring Ae= Ie/ δe mm2

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

• Ar = Ir / δr mm2
• Total copper loss:
Length of the mean be calculated from the
Turn can empirical formula
lmt = 2L + 2.3 τp + 0.08 m

• Resistance of rotor winding is given by

Rr = (0.021 x lmt x Tr ) / Ar
Total copper loss = 3 I 2R Watts
 Depth of stator core below the slots

• Below rotor slots there is certain solid portion which is

called depth of the core below slots.
• This depth is calculated based on the flux density and flux in th
rotor core.
• Flux density in the rotor core can be assumed to be
• between 1.2 to 1.4 Tesla.
• Then depth of the core can be found as follows.
 Cond..
• Area of stator core Acr = Φ/2Bcr

• Area of stator core Acr = Li x dcr

• Hence, depth of the core dcr = Acr / Li

• Inner diameter of the rotor can be calculated as follows

• Inner diameter of rotor = D - 2lg - 2htr - 2 dcr

• Flux in the rotor core section Φc = ½ Φ

 PERFORMANCE CALCULATION FROM
DESIGNED DATA
Based on the design data of the stator and rotor of an
induction motor, performance of the machine has to be
evaluated.
The parameters for performance evaluation are iron
losses, no load current, no load power factor, leakage reactance
etc.
Based on the values of these parameters design
values
of stator and rotor can be justified.
Iron losses
• Iron losses are occurring in all the iron parts due to the
 Cond..
• Iron loss has two components, hysteresis and eddy
current losses occurring in the iron parts depend
upon the frequency of the applied voltage.
• The frequency of the induced voltage in rotor is equal to
the slip frequency which is very low and hence the
iron losses occurring in the rotor is negligibly small.
• Hence the iron losses occurring in the induction motor is
mainly due to the losses in the stator alone.
 Cond..
• Total iron losses in induction motor = Iron loss in stator core +
iron losses in stator teeth.
• In addition friction and windage loss can be taken into account
by assuming it as 1- 2 % of the output of the motor.
• Hence total no load losses = Total iron losses + Friction and
windage loss.
• No load current: the no load current of an induction motor
has two components magnetizing component, Im and iron loss
component, Iw.
Thus the no load current I0= √(Im)2 + (Iw)2 amps
 Magnetizing current
• Magnetizing current of an induction motor is
responsible for producing the required amount of flux
in the different parts of the machine.
• Hence this current can be calculated from all the
magnetic circuit of the machine.
• The ampere turns for all the magnetic circuit such as
stator core, stator teeth, air gap, rotor core and
rotor teeth gives the total ampere turns required
for the magnetic circuit.
 Cond..
• Based on the total ampere turns the magnetic circuit the
of
magnetizing current can be calculated as
Magnetizing current Im= p AT30 / (1.17 kwTph)
where p - no of pairs of poles, Tph - Number of stator turns per
phase
AT30 - Total ampere turns of the magnetic circuit at 300 from the
centre of the pole,
. Iron loss component of current:
this component can be calculated from no load losses and applied
voltage.
• Iron loss component of current
Iw= Total no load losses / ( 3 x phase voltage)
 No load Power Factor
• No load power factor of an induction motor is very poor.
As the load on the machine increases the power factor
improves.
• No load power factor can be calculated knowing the
components of no load current.
No load power factor cosΦ0 =
Iw / I0
 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.

1. The main dimensions of the stator.

2. Details of stator windings.
3. Design details of rotor and its windings
4.Performance characteristics. Like iron& cu
loss, magnetizing current ,no load current, power factor,
short circuit current, efficiency etc
In order to get the above design details the designer needs
the following
• Detailed specification of IM

• Limiting value of performance parameter iron & cu loss,

magnetizing current ,no load current, power factor,
short circuit current, efficiency etc
• Design equations based on which design procedure is to
be initiated
• Information for proper choice of various design parameters

• Information regarding availability of materials for various

parts
 Specification of 3 phase IM
• rated output power
• rated voltage
• number of phases
• speed
• frequency
• connection of stator winding
• type of rotor winding
• Power factor
• efficiency
• Class of insulation
• shaft extension details etc.
 Output Equation
• output equation is the mathematical expression
which gives the relation between the various
physical and electrical parameters of the
electrical machine.
In an induction motor the output equation can be
obtained as follows

Consider an ‘m’ phase machine,

with usual notations
 = phase voltage ; Iph = phase current
Vph
Zph = no of conductors/phase

Tph = no of turns/phase

Ns = Synchronous speed in rpm

ns = synchronous speed in rps

Φ = air gap
p = no of poles, q = Specific
flux/pole; Bav = Average flux density
electric loading kw = winding factor

η = efficiency cosΦ= power factor

D = Diameter of the stator, L = Gross core length
Co = Output coefficient
 Out put Q in kW = Input x efficiency kW -------------(1)
Input to motor Q= mVph Iph cos Φ x 10-3 kW

For a 3 Φ machine m = 3
Input to motor = 3Vph Iph cos Φ x 10-3 -----------(2)
Assuming Vph = Eph
Vph = Eph = 4.44 f Φ Tph Kw
= 2.22 f ΦZph Kw -------------------(3)

ie, Tph = Zph /2

f = PNS/120 = Pns/2, -------------(4)

 PΦ = BavπDL , Φ = Bav πDL / P
---------(5)
Subsitute eu (4) & (5) in euq (3)
Vph = 2.22 x (Pns/2) x (BavπDL / P)--------------(6)
Zph Kw
Vph = 1.11 x ns x BavπDL Zph
Kw Subequ (6) in (2)
Input = 3 x(1.11π ) Iph cosΦ x 10-3
For IM DB Lns Zph Kloading
theavspecific w is
3Iph Zph/ πD = ac
Input = 3 Zph Iph x(1.11π ) cosΦ x 10-3
DB avLn
Input Kw πDac D B Ln K cosΦ x 10-3
=s1.11π av s w
 Input = 11 Bav ac D2 Lns Kw cosΦ x 10-3 kW–(7)

Sub (7) in (1)

Output to motor Q = 11 Bav ac Kw η cosΦ D2 L ns x 10-3 kW

Output Q = Co D2L ns kW
where Co = (11 Bav ac Kw η cosΦ x 10-3)
Main dimensions D and L
 Separation of D and L
• The output equation gives the relation between D2L product
and output of the machine.
• To separate D and L for this product a relation has to be
assumed or established.
• Following are the various design considerations based on
which a suitable ratio between gross length and pole pitch (L/)
can be assumed.

i. To obtain minimum over all cost 1.5 to 2.0

ii. To obtain good efficiency 1.4 to 1.6

iii. To obtain good over all design 1.0 to 1.1

iv. To obtain good power factor 1.0 to 1.3

• As power factor plays a very important role the performance
of induction motors it is advisable to design an induction
motor for best power factor unless specified.

• Hence to obtain the best power factor the following relation

will be usually assumed for separation of D and L.
Pole pitch/ Core length = 0.18/pole pitch or
(πD/p) / L= 0.18/ (πD/p)

i.e Ƭ = √0.18L where D and L are in meter.

Peripheral Speed
For the normal design of induction motors the calculated
diameter of the motor should be such that the peripheral
speed must be below 30 m/s.

In case of specially designed rotor the peripheral speed

can be 60 m/s.

Ventilating Ducts : Provided when core length exceeds 100 –

125 mm. The width of Duct – 8 to 10 mm
 Choice of Specific
loadings
•Specific Magnetic loading or Air gap flux density
Iron losses largely depend upon air gap 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, 0.35 – 0.6 Tesla. The suitable values
of Bav can be selected from design data hand book.
Specific Electric loading (q or ac)
-Total armature ampere conductor over the
periphery. Advantages of Higher value of q
• Reduced size
•Reduced cost
Disadvantages of Higher value of q
• Higher amount of copper
• More copper losses
• Increased temperature rise
• Lower overload capacity
Normal range 10000 ac/m – 45000 ac/m. The
suitable values of q can be selected from design data
hand book.
 Choice of power factor and
efficiency
• power
25
factor and efficiency under full load conditions
will
increase with increase in rating of the machine
• Percentage magnetizing current and losses will be lower for a
larger machine than that of a smaller machine
• the power factor and efficiency will be higher for a high speed
machine than the same rated low speed machine because of
better cooling conditions
• Squirrel cage – Efficiency – 0.72 to 0.91 & P.F – 0.66 to 0.9

• Slip ring - Efficiency – 0.84 to 0.91 & P.F – 0.7 to 0.92

REFERENCES

[1]
http://eeeinterviewtips.blogspot.in/2011/09/discuss-different-type
s-of-motors-their.html
[2] http://www.nptel.ac.in/courses/IIT-MADRAS/Electrical_Machines_II/pdf/1_4.pdf
[3] Electrical Machines by P.S Bhimbra
[4] Electrical Machines by Ashfaq Hussain
[5] http://www.nptel.ac.in/courses/IIT-MADRAS/Electrical_Machines_II/pdf/1_8.pdf
THANK YOU

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