Design of Induction Motor

NEMA Class B,
Squirrel-cage Type
UCF
NEMA Design Class
National Electrical Manufactures Association (NEMA)
breakdown torque: pullout torque
locked-rotor torque: starting torque
UCF
NEMA Rotor Shape
Class B, A
Class C
Class D
double cage
Rotor Peripheral Speed
The maximum allowable peripheral speed of the rotor is a central consideration in
machine design. With present-day steel alloys, rotor peripheral speeds of 50,000
ft/min (or about 250 m/s) represent the design limit.
1 ft/min =0.0051 m/s
This is typically not a problem for low speed motor.
UCF
Maximum Flux
Experienced formula is:
in Watt power output :
poles of number the :
08 . 0
)
003 . 0
00145 . 0 (
out
out
m
P
P
f
P
P
+ = u
Dl
P
B
P
Dl B
m
m
m
m
2
2 u
= = u
Also
UCF
Number of Turns per Coil on Stator
m eff m eff
fN fN E u ~ u = 44 . 4 2
1
t
r D 2 =
1 . 1
w c
eff
k PqN
N =
s d p w
k k k k =
where
The denominator 1.1 in N
eff
is to considering leakage flux.
m w
rated
c
fPqk
V
N
u
=
t
|
2
07 . 1
small) are and (because 97 . 0
1 1 , 1
X R V E
rated |
~
UCF
Stator Volume and Size
The unit for D and l is inch.
cooled) (water more or 10hp for lb) ft /( in 6 ~ 5
3
0
= V
Typically
cooled) (air less or 10hp for lb) ft /( in 10 ~ 9
3
0
= V
If we design D=l, we have the stator bore (inner)
diameter estimated
3
1
0
) (TV D
estimated
~
cooling on depends
1
, (constant)
0 0
2
s
J
V V
T
l D
=
UCF
Estimated Stator Core diameter (outer diameter):
inch 647 . 0 )
03 . 1
175 . 1 (
, 0
+ + =
estimated estimated
D
P
D
Estimated frame outside diameter:
f estimated estimated f
t D D 2
, 0 ,
+ =
t
f
is wall thickness, typically 0.5 inch
frame NEMA from up picked is
f
D
Frame Diameter Estimation
UCF
NEMA Standard Frame Size (inch)
UCF
Stator Core diameter (outer diameter):

03 . 1
175 . 1
inch 647 . 0
0
P
D
D
+

=
Frame outside diameter:
f f
t D D 2
0
=
t
f
is wall thickness, typically 0.5 inch
page. last in frame NEMA from up picked is
f
D
Stator Bore diameter (inner diameter):
Stator Bore Diameter and Length
Stator active region length:
2
0
D
TV
l =
UCF
Air Gap
Experienced formula
g k k g
cr cs eff
=
where the Carters coefficients
2
) 5 (
) 5 (
s s s
s s
cs
b b g
b g
k
+
+
=

2
2 2
2
) 75 . 0 4 . 4 (
) 75 . 0 4 . 4 (
r r s
r s
cr
b b g
b g
k
+
+
=

NEMA Class B
inch 0072 . 0 001 . 0 0016 . 0 + + = l D g
Effective airgap
g D D
r
2 =
UCF
Stator Slot Design
S
D
s
t
=
s s s
b d b 4 2
1
s s
in 5 . 1 in 7 . 0 s s
s

s s s
b 6 . 0 4 . 0 s s
s s s
b t =
Use 0.015-in coil separator and slot liner for 230V motor
Use 0.030-in coil separator and slot liner for 460V motor
NEMA 284T or smaller frames: use 0.06 in slot wedge
Larger than NEMA 284T frames: use 0.125 in slot wedge
6 . 0 0.4 , s s =
s
s
s
s
r
b
r

UCF
Stator Conductor Size
Stator current density
a
rated
sa
A
I
J
, 1
=
where A
a
is stator (armature) conductor cross section
area and can be determined from the above formula
together with:
2 2
A/cm 800 400A/cm : cooled - Air s s
sa
J
pf V
P
I
rated
out
rated
,
, 1
3
/
|
q
=
sa
rated
a
J
I
A
, 1
=
Typical Efficiency q:
75% for P
out
= 1-5 hp
85% for P
out
= 5-40 hp
90% for P
out
= 50-200 hp
UCF
Number of Slots (Bars) on Rotor
...) 3 , 2 , 1 (
3
) 1 2 (
=
=
=
k
kP S S
P k S S
r
r
Certain number of slots (bars) must be avoided because they
can produce detrimental cusps in the speed-torque curve.
UCF
Rotor Effective Winding Factor
Rotor Coil pitch in electrical angle: t
P S
P S fix
r
r
r
/
) / (
=
Rotor Slot pitch in electrical angle:
r
r
S
P t
=
sr dr pr wr
k k k k =
)
2
sin(
)
2
sin(
r
r
r r
d
q
q
k

=
)
2
( sinc
r
sr
k
,
=
P
S
q
r
r
3
=
|
.
|

\
|
=
2
sin
r
pr
k

Skewed angle in electrical radian:
r
r skew
r
S
PS
,
t
, =
1 typically skewed, slots of number the is
,r skew
S
UCF
Effective Number of Turns per
Phase for Rotor
Effective number of rotor slots per phase (may not be integer)
3
r
S
Unlike the stator, the single cage rotor has only one conductor per slot
(or equivalent to single layer winding).
6
r wr
effr
S k
N =
UCF
Rotor Bar Size
Rated current in rotor bar
ip) relationsh er (transform
, 1 , rated
effr
eff
rated b
I
N
N
I =
Rotor bar current density
, b rated
sb
b
I
J
S
=
where S
b
is rotor bar cross section area and can be
determined from the above formula together with:
2 2
A/cm 775 700A/cm : cooled - Air s s
sb
J
Rotor bars can operate at higher temperatures than stator.
sb
rated b
b
J
I
S
,
=
UCF
Rotor Slot Design
2 2
667 . 0
r r
b d ~
B) (NEMA 6 ~ 4 2
: ratio width depth to
1
2 1
=

=
r
r r
b
d d
w d
inch 045 . 0 01 . 0
2
+ ~ D b
r
Area is S
b
2 1 2 1 2

r r c r c
d d d b b ~ ~
) (
2 1 1 r r r b
d d b S ~
1 1 1
2
2
r c
b
r
b w d d
w d
S
b = =
2 2 1 r c r
d d d + =
1
1
2
2 1
) 2 (
r
r
r r
r
r
r
r
r
b
N
d D
t
b
N
D
t

=
=
t
t
UCF
Rotor End Ring
UCF
Rotor End Ring Size
Rated current in rotor end ring
rated b
r
rated ring
I
P
S
I
, ,
t
=
Rotor end ring current density
ring
rated ring
ring s
A
I
J
,
,
=
where A
ring
is rotor end ring cross section area and can
be determined from the above formula together with:
2
,
2
A/cm 930 775A/cm : cooled - Air s s
ring s
J
Rotor end rings can operate at higher temperatures than rotor bar.
ring s
rated ring
ring
J
I
A
,
,
=
UCF
Example
Design a 50 hp, 460 V, 60 Hz, 6 pole, Y-connected, 1175 rpm,
NEMA Class B squirrel cage induction motor, pf 0.85 lagging.
Pick up: 54 stator slots, 8/9 pitch, no skew on stator
51 rotor slots (bars), 1 slot skewed
Following the notes discussed, please study the MatLabcode
imDesign.mby yourself.