1

CHAPTER 1
INTRODUCTION

1.1 GENERAL

Computer Aided Design (CAD) is the technology concerned with the use of computer
systems to assist in the creation, modification, analysis and optimization of a design.

Main objectives of computer-aided design are to design a machine to meet the design
specifications, improve the performance and power density of the machine, and the reduction of
materials & cost used in the product design. Computer Aided Design is valuable in two particular
ways: Calculating and evaluating a large number of options often characterized by small changes
in a large number of parameters, Performing very detailed electromagnetic and mechanical
analysis to permit the design to be stretched to its limit with confidence, while avoiding the
need for a large prototyping and test program, which would be expensive, and time consuming.

1.2 PERMANENT MAGNET MACHINES

The use of permanent magnets (PMs) in construction of electrical machines brings the
following benefits: No electrical energy is absorbed by the field excitation system and thus there
are no excitation losses which means substantial increase in efficiency, higher power density
and/or torque density than when using electromagnetic excitation, better dynamic performance
than motors with electromagnetic excitation (higher magnetic flux density in the air gap).

Some PM synchronous motors are designed for constant speed applications to improve
efficiency and power factor in comparison to induction and wound rotor synchronous motors.
Such motors have a squirrel cage winding to provide the torque from standstill to near
synchronous speed. The same cage windings also serve to damp rotor oscillations. Once the
motor pulls into synchronism, the cage windings do not contribute to electrical torque as there
are no induced voltages and hence no currents flow in them at zero slip.
2

The machine will start as an induction motor and then pull into synchronism running at
synchronous speed. Note that then the speed of the machine is determined by the stator
frequency (utility frequency in this case) and will operate at a fixed speed only. This is desirable
in some applications than a complete shutdown of the motor in case of inverter failure. A case
in point is critical pumping applications such as in nuclear power plants or in ships. Such line
start PMSMs with cage windings (LSPM) have been advocated for fan and pump applications
to improve the operational efficiency of the system with a single speed. The efficiency
improvement due to the synchronous operation as compared to the induction motor operation
with slip losses justified an investment in the PM rotor construction.

The design is based on an asynchronous AC motor with squirrel-cage rotor, which
additionally contains permanent magnets in the rotor. This double technology brings about a
reduction of losses that usually occur in asynchronous AC motors as a result of slip. Line start
permanent magnet motors in this way combine the advantages of the robust asynchronous
motors with those of the low-loss synchronous motors.

1.2.1 FEATURES OF LSPM
Slip-free speed control without encoder feedback, which means lower installation and
purchase costs
Can be used as individual or group drive on the grid and with a frequency inverter
Small frequency inverters can be used due to the reduced power consumption
Constant torque in the speed setting range without forced cooling fan
Low maintenance

1.2.2 ADVANTAGES OF LSPM
For Applications involving frequent starts and stops because the PM motor has a low
inertia
Come in the same frame size as conventional induction motors for the same motor rating
and in the same current and power factor as Premium Efficiency induction motors
Do not require a controller or feedback device
Compatible with adjustable speed drive operation
3

LSPM motors can save up to 20% on energy consumption compared to conventional
induction motors and reduce all current-related costs, such as for cables and power
supplies.

1.2.3 APPLICATIONS OF LSPM
Submersible Pumps
Fans, Compressors, Mixers
Electrical Car Motor Drives
High Efficiency Motors for Household Equipments

The stator of a LSPM motor consists of stacked steel lamination with windings placed in
the slots that are axially cut along the inner periphery, and it resembles that of an induction
motor. Rotor is made of permanent magnet and can vary from two to eight pole pairs with
alternate north and south poles. Rotor is chosen depending upon the application requirements.
Based on the required magnetic field density in the rotor, the proper magnetic material is chosen
to make the rotor. Neodymium Iron boron is used as (permanent) magnet.

1.3 CAD PACKAGE OVERVIEW

In computer aided approach the design goes hand in hand with the motor Design
engineering environment. In our CAD package Finite Element analysis (FEA) is the basic
numeric-analyzing tool. In electromagnetic field analysis FEA is particularly valuable in
optimizing the design of electromagnetic devices such as motors, generators, solenoids and so
on. It is used to study the field configurations in integrated circuits and electronic beam devices.
In this thesis work MAGNET Software version 7.1.1 is used.

1.4 LITERATURE REVIEW

Qin Fen Lu and Yun Yue Ye have discussed in this paper Design and Analysis of Large
Capacity Line-Start Permanent Magnet Motor (IEEE) the optimal design of the LSPM motor.
4

Andrew Fraser has discussed in this paper Design of a High efficiency Line-Start Permanent
Magnet Motor the basic idea about Infolyticas Magnet software and Induction motor design.

Qinfen LU, Xiaoyan HUANG, Yunyue YEand Youtong FANG have discussed in this paper
Experiment and analysis of high power line-start PM motor the Load performance and Power
factor and Efficiency of LSPM.

Steluta Nedelcu, Tiberiu Tudorache, Constantin Ghita have discussed in this paper Influence of
design parameters on a line start permanent magnet machine characteristics (IEEE) the design
procedure for structure and mesh analysis.

C. Mutize and R-J.Wang have discussed in this paper Performance comparison of induction
motor and line-start pm motor for cooling fan applications the steady state performance of IM
and LSPM.

R. Krishnan has discussed in this book Permanent Magnet Synchronous and Brushless DC
Motor Drives: CRC Press, the introductory concept of LSPM

E.S. Hamdi has discussed in this book Design of Small Electrical Machines: John Wiley &
Sons, the Recommended Stator & Rotor Diameter values and its formulas

Ion Boldea and Syed A. Nasar have discussed in this book The Induction Machines Design
Hand Book: Second Edition, CRC Press, the Output power, Stator and Rotor Slot calculations
in detail

Jacek F. Gieras has discussed in this book Permanent Magnet Motor Technology Design and
Applications: Third Edition, CRC Press, the different types of rotor configurations, permanent
magnet materials and circuits, comparison between synchronous and IM

VTU e-Learning has discussed Winding Diagram and its calculations

5

1.5 OBJECTIVE OF THE THESIS

The objective of this project is to design and analyze the performance of LSPM from the
modification of IM and comparison between IM and LSPM. The simulation of induction motor
& LSPM have been carried out.

1.6 ORGANIZATION OF THE THESIS
This thesis comprises of five chapters with introduction as the first chapter. The
generalized design procedure for Induction motor & LSPM is explained in the second chapter.
The third chapter deals with the Finite Element Analysis and Magnet Software. The fourth
chapter shows the static and dynamic results and explains the performance of both motors. The
fifth chapter shows the future work and conclusion of the thesis.

1.7 SUMMARY
In this chapter we dealt about the introduction of LSPM Machine, and CAD package
software. Literature review and organization of the thesis are also discussed.












6

CHAPTER 2
DESIGN OF INDUCTION MOTOR AND LSPM

2.1 INTRODUCTION
Induction motors are the ac motors which are employed as the prime movers in most of
the industries. Such motors are widely used in industrial applications from small workshops to
large industries. These motors are employed in applications such as centrifugal pumps,
conveyers, compressors crushers, and drilling machines etc.

2.2 CONSTRUCTIONAL DETAILS
Similar to DC machines an induction motor consists of a stationary member called stator
and a rotating member called rotor. However the induction motor differs from a dc machine in
the following aspects. Laminated stator, Absence of commutator, Uniform and small air gap,
Practically almost constant speed

The AC induction motor comprises two electromagnetic parts:
Stationary part called the stator
Rotating part called the rotor
The stator and the rotor are each made up of An electric circuit, usually made of insulated
copper or aluminum winding, to carry current
A magnetic circuit, usually made from laminated silicon steel, to carry magnetic flux

2.2.1 STATOR
The stator is the outer stationary part of the motor, which consists of
The outer cylindrical frame of the motor or yoke, which is made either of welded sheet
steel, cast iron or cast aluminum alloy.
The magnetic path, which comprises a set of slotted steel laminations called stator core
pressed into the cylindrical space inside the outer frame. The magnetic path is laminated
to reduce eddy currents, reducing losses and heating.
A set of insulated electrical windings, which are placed inside the slots of the laminated
7

stator. The cross-sectional area of these windings must be large enough for the power
rating of the motor. For a 3-phase motor, 3 sets of windings are required, one for each
phase connected in either star or delta. Details of construction of stator are shown in
Fig.2.1
Fig. 2.1 Stator and Rotor Laminations

2.2.2 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 Squirrel cage rotor
consists of a set of copper or aluminum bars installed into the slots, which are connected to an
end-ring at each end of the rotor. The construction of this type of rotor along with windings
resembles a squirrel cage. Aluminum rotor bars are usually die-cast into the rotor slots, which
results in a very rugged construction. Even though the aluminum rotor bars are in direct contact
8

with the steel laminations, practically all the rotor current flows through the aluminum bars and
not in the lamination.

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, which are required to complete the constructional details of an induction
motor, are:
Two end-flanges to support the two bearings, one at the driving-end and the other at the
non driving-end, where the driving end will have the shaft extension.
Two sets of bearings to support the rotating shaft
Steel shaft for transmitting the mechanical power to the load
Cooling fan located at the non driving end to provide forced cooling for the stator and
rotor
Terminal box on top of the yoke or on side to receive the external electrical connections
2.3 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. The main dimensions of the stator,
Details of stator windings, Design details of rotor and its windings, Performance characteristics.

In order to get the above design details the designer needs the customer specifications
Rated output power, rated voltage, number of phases, speed, frequency, connection of stator
winding, type of rotor winding, working conditions, shaft extension details etc.

In addition to the above the designer must have the details regarding design equations
based on which the design procedure is initiated, information regarding the various choice of
9

various parameters, information regarding the availability of different materials and the limiting
values of various performance parameters such as iron and copper losses, no load current, power
factor, temperature rise and efficiency.
2.4 OUTPUT POWER CALCULATIONS
Q =


--------------------------- (2.1)
Po = Outpu Power in KW
Q = Motor KVA Input

Q = Co D
2
L n
s
---------------------------- (2.2)
Co = 1.11
2
Bav ac kw x 10
-3
Co = Output Co-efficient
Bav = Average Flux Density Tesla
Ac = Specific Electric Loading Amp. Conductor/m
D & L = Stator ID & Core Length m
kw = Winding Factor kd x kc; Initially kd = 0.955, kc = 1
n
s
= Synchronous Speed rev./sec

2.4.1 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
10

Specific Electric loading
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

2.5 TURNS PER PHASE

EMF equation of an induction motor is given by Eph = 4.44 f Tph k
w
-------------------------- (2.3)

Hence turns per phase can be obtained from emf equation Tph = Eph / 4.44 f k
w


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

Flux/pole, = B
av
x (DL/P) -------------------------- (2.4)

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 Zs is an integer for single layer winding
and even number for double layer winding.


11

2.6 STACK LENGTH CALCULATIONS
L =

(0.6 to 2.0) -------------------------- (2.5)

L = Stack length
p = pole pair
D = Stator inside diameter
Airgap Length l
g
= 3.06

-------------------------- (2.6)
2.7 STATOR SLOT CALCULATIONS
Fig.2.2 shows the individual stator slot diagram with various parameters, these parameters
derived from the following expressions.

Fig. 2.2 Stator Slot with Parameters
B
s1
=

- b
ts
-------------------------- (2.7)
D
in
= Stator ID
H
os
= 0.5 to 1.0 mm
12

H
w
= 1 to 4 mm = Wedge Height
B
ts
= 5.51 x 10
-3
(Calc.) = Tooth Width
H
s12
=

-------------------------- (2.8)
A
su
= 140.22 mm
2
(Calc.) = Useful Slot Area
The calculated values are listed as,
B
01
= 4 mm
H
s0
= 0.5 mm
Z
s1
= 30 degree
B
s1
= 6.35 mm = Lower Slot Width
B
s2
= 9.89 mm = Upper Slot Width
H
s12
= 14 mm = Slot Height

D
in
=

----------------------------- (2.9)
b
ts
=

---------------------------- (2.10)

where, B
g
= 0.65 to 0.78 T for P=4

s
=

; q = No. of phases
=

B
ts
= 1.5 to 1.65 T, K
fe
= 0.96 for 0.5 mm lamination thickness
13

B
s2
=

---------------------------- (2.11)

N
s
= No of Stator Slots
B
s1
= Slot Lower Width
B
s2
= Slot Upper Width
A
su
=

---------------------------- (2.12)

d
co
= 1.15 mm wire diameter
ap = No. of conductors in parallel (1 for single layer winding)
n
s
= No. of turns per slot
K
fill
= 0.35 to 0.4 for <10 KW machines
Note: Slot Width should not be below 3.5 mm
2.8 ROTOR SLOT CALCULATIONS










Fig. 2.3 Rotor Slot with Parameters
14

Fig.2.3 shows the individual rotor slot diagram with various parameters, these parameters
derived from the following expressions.
D
r
= D
in
2 l
g
---------------------------- (2.13)

D
in
= Stator ID
D
r
= Rotor Diameter
D
in
=

---------------------------- (2.14)

= L/ = Stack Aspect Ratio
The calculated values are listed as
B
02
= 0.15 mm
H
r0
= 0.5 mm
H
r1
= 1.6 mm
B
r1
= 3.2 mm = Upper Slot Width
B
s2
= 2.4 mm = Lower Slot Width
H
r2
= 5.2 mm = Slot Height

Table 2.1 Aspect Ratio Limits
Poles 2 4 6 8
0.6 1.0 1.2 1.8 1.6 2.2 2.0 3.0
(Din / Dout) 0.54 0.58 0.61 0.63 0.68 0.71 0.72 0.74

Note: Rotor teeth, Rotor core should not exceeded to 7.9mm, 7.0 mm respectively

15

2.9 WINDING DIAGRAM CALCULATIONS
No. of poles = 4; No. of conductors = 24;
Pole pitch = 24/4 = 6; No. of slots/pole/phase =24/ (4x3) = 2
No. of coils = 24/2 = 12
Slot angle = 180/pole pitch = 180/6 = 30
Winding pitch = 180 (slot angle) = 180 30= 150
Hence coil span = 180 / 30 = 6 slots
Y
b
= 6 and Y
f
= 6, Connections: Rs = 1, Ys = 1 + 120/30 = 5; Bs = 1 + 240/30 = 9

2.9.1 Winding Table
Table 2.2 Winding Diagram Calculations
Phase R Phase B Phase Y
1 + 6 = 7 7 + 6 = 13 9 + 6 = 15 15 + 6 = 21 5 + 6 = 11 11 + 6 = 17
13 + 6 = 19 19 + 6 = 25 (1) 21 + 6 = 27(3) 3 + 6 = 9 17 + 6 = 23 23 + 6 = 29 (5)
(1 + 1) + 6 = 8 8 + 6 = 14 10 + 6 = 16 16 + 6 = 22 6 + 6 = 12 12 + 6 = 18
14 + 6 = 20 22 + 6 = 28 (4) 18 + 6 = 24

2.9.2 Winding Diagram
Fig. 2.4 24 Slots, 3 Phase, Single Layer Wave Winding
16

2.10 Line-Start PMSM
Some PM synchronous motors are designed for constant speed applications to improve
efficiency and power factor in comparison to induction and wound rotor synchronous motors.
Such motors have a squirrel cage winding to provide the torque from standstill to near
synchronous speed. The same cage windings also serve to damp rotor oscillations. Once the
motor pulls into synchronism, the cage windings do not contribute to electrical torque as there
are no induced voltages and hence no currents flow in them at zero slip.

Variable speed PM synchronous motor drives have no need for the damper windings to
offset hunting and oscillation. The damping is provided by properly controlling the input currents
from the inverter. This results in a compact and smaller rotor than that of the machine with
damper windings. The way damping is produced in the PM synchronous motor with and without
damper windings deserves a comment. The machine with the damper windings operates to
suppress the oscillations with no external feedback. The feedback comes internally through the
induced emf due to the slip speed in the cage windings. Whereas in the inverter-controlled PM
drives, the control has to be initiated by an external signal or feedback variable to counter the
oscillation. Hence its dependence on an external feedback loop compromises reliability.
Wherever reliable operation regardless of the accuracy in torque or position control is a major
concern or requirement, the synchronous motor with damper windings may prove to be an
intelligent choice. For example, if the load can tolerate a constant speed, then during moments of
inverter failure, it is possible to bypass the inverter and connect the PMSM with damper
windings to the fixed frequency utility supply. Then the machine will start as an induction motor
and then pull into synchronism running at synchronous speed. Note that then the speed of the
machine is determined by the stator frequency (utility frequency in this case) and will operate at
a fixed speed only. This is desirable in some applications than a complete shutdown of the motor
in case of inverter failure.

A case in point is critical pumping applications such as in nuclear power plants or in
ships. Such line start PMSMs with cage windings have been advocated for fan and pump
applications to improve the operational efficiency of the system with a single speed. The
efficiency improvement due to the synchronous operation as compared to the induction motor
17

operation with slip losses justified an investment in the PM rotor construction but it was felt that
many low-cost applications could not justify the capital investment in the inverter.

2.11 PERMET MGETS ITS CHRCTERISTICS
Materials to retain magnetism were introduced in electrical machine research in 1950s.
Materials that retain magnetism are known as hard magnet materials. Various materials such as
Alnico-5, ferrites, samarium-cobalt and neodymium-boron iron are available as permanent
magnets for use in machines. The B-H demagnetization characteristics of these materials as
shown in figure 2.5.1, for second quadrant only, because the magnets have a negative magnetic
field strength. In this design neodymium boron iron used as a permanent magnet.


Fig. 2.5 Second quadrant BH characteristics of PMs
18


Fig. 2.6 Operating point of magnets
SUMMARY
In this chapter, A 4 Pole, 3 phase, 1 kW Induction motor and LSPM motor design
calculations including Output power calculations, Stator and Rotor slot design calculations and
winding diagram calculations, permanent magnet material and its characteristics were discussed.








19

CHAPTER 3
FINITE ELEMENT ANALYSIS & MAGNET SOFTWARE

3.1 INTRODUCTION
The finite element method is a numerical method for solving electromagnetic field
problems, which are too complex to be solved using analytical techniques, especially those
involving non-linear material characteristics. FEA is a computer based numerical technique for
calculating the parameters of electromagnetic devices. It can be used to calculate the flux
density, flux linkages, inductance, torque emf etc., In finite element method, the large
electromagnetic device is broken down into many small elements. The behavior of an individual
element can be described with a relatively simple set of equations. Just as the set of elements
would be joined together to build a whole device, the equations describing the behaviors of the
individual elements are joined into an extremely large set of equations that describe the behavior
of the whole device. The computer can solve this large set of simultaneous equations. From the
solution, the computer extracts the behavior of the individual elements. The spatial variation of
magnetic potential throughout the motor is described by a nonlinear partial differential equation
derived from Maxwells equations. Application of the finite element method to machine design
involves three stages,
Pre-Processing
Field Solution
Post - Processing

3.2 PRE-PROCESSING
This is the most user- intensive part of finite-element analysis. Three tasks must be performed.

3.2.1 Mesh generation
It involves in the division of the rotor cross - section into a set of triangular elements (2-D
solutions) or the division of the motor volume into bricks. Modern mesh generation is carried out
using the internal specialist drafting facilities of the finite element software. Specialist mesh
generation software calculates the coordinates required to define the motor geometry. The cross
section is usually split up into regions represent ing different materials such as current carrying
20

conductors, air, steel, and magnets. Each region may define a different component used in the
construction of the motor for example, the shaft, rotor core, magnets, stator lamination, airgap,
etc. In most cases it is beneficial to split the components further into smaller polygons along the
lines of symmetry.

3.1.1 2D mesh diagram
Stator lamination can be created by reflection followed by multiple rotational copies of
half a slot pitch. This procedure reduces the amount of data needed to specify the geometry, and
reduces the chance of errors. When rotation of the motor rotor is to be modeled, it is essential to
define the airgap using a sliding surface is to be defined and is splitted at least two layers. One of
these layers is fixed to the rotor and one to the stator. The node spacing on the central sliding
surface is set to a constant such that it is possible to rotate the rotor by any multiple of this
constant. Figure 3.1 shows a mesh in which the airgap region is divided into two layers and the
sliding surface is central to the air gap.

3.2.2 Material definition
It involves curve fitting of the nonlinear B-H characteristics of the steel and magnet
materials used in the construction of the motor. Many finite element programs include databases
of material data for the convenience of the user.

3.2.3 Problem definition
It involves the application of the correct boundary condition, imposing the correct current
densities in the appropriate winding elements and definitions of the direction of magnetization of
magnets. Periodic boundary conditions should be used if possible, model need only a fraction of
the cross section. For example in the case of a 4-pole motor, if the number of slots per pole is an
integer, it is only necessary to model the motor over one pole pitch.

3.3 FIELD SOLUTION
Once the model has been completed the field solution package is invoked and the
program automatically assembles the stiffness matrix, modifies it to include the boundary
condition and solves the system of N-equation in the N unknown potential values. The solution
21

of the discretized partial differential equation uses a specialized mathematical algorithm. The
algorithm is often based on the minimization of energy functional. The discretisation transforms
the partial differential equation into a large number of simultaneous non- linear algebraic
equations containing the unknown node potentials. Iterative methods like Newton raphson and
conjugate-gradient procedures are widely used. With linear elements the potential is assumed to
vary linearly between the nodes and the flux density is constant within each element. Current
density is also assumed to be constant within each element associated with a winding.

3.4 POST PROCESSING
The field solution is expressed in terms of magnetic vector or scalar potential, but the
design engineer needs quantities such as flux densities, force and torque. The extraction of these
quantities from the potential solution is called post-processing. A good interactive graphics
facility is important for that the essential information and parameters can be extracted from the
large number of node potentials effectively and quickly.

Finite-element analysis can be used to generate the following output,
Flux plots - These are especially useful for forming a picture of the flux. They can also be used
for estimating the leakage flux and calculating leakage permeances.

Flux calculation - The flux between two points of interest is calculated from the difference in
vector potential at the two points multiplied by the axial length. This calculation can be extended
to obtain flux-linkage and hence the inductance of windings.

Flux density contour - Colored filled zones can be used to indicate areas of high local
saturation. Flux density values at any point can be readily obtained by using a cursor.

Graphs of flux density variation - The required component of flux density (radial, X-
component, Y-component etc.) can be plotted along a pre-determined path. The variation in
radial component of airgap flux density can be plotted around the rotor.

22

Flux density vector plot - A field of arrows is plotted over the cross-section, representing the
local flux density vector.

Back EMF & core loss calculation - Finite element analysis can be performed for incremental
rotor positions from which variation of flux and flux- linkage against rotor position can be
obtained. This can be used to calculate back-emf (by differentiation with respect to time) and
core losses.
Force and Torque - Force and torque are commonly calculated using Maxwell stress and virtual
work.

Inductance - Self and mutual inductances can be calculated from the stored energy or flux-
linkage. However, the calculation is made more complex due to the presence of magnet flux. To
overcome this problem, the field solution analysis at a particular value of load current has to be
carried out.
A modern CAD system incorporates in the pre and posts processors both interactive and
batch operation. The solver may be regarded as the principle part of the system but its operation
usually doesnt require the user interaction. On the other hand, modeling of the problem
normally involves the number of issues related to the geometry of the device under consideration
and the expected characteristics of its fields. The plan view may be regarded as a relevant step
for the choice of the appropriate solver, its sequence of solutions and corresponding convergence
criteria.
With FEA, the weight of materials used in the design can be minimized and there can be
a reduction in the number of prototypes built. Field-testing will be used to establish the
performance validation, which can be used to do future design improvements via Finite Element
Analysis. The background of a Finite element analysis includes an understanding of
electromagnetic principles & the theory underlying the finite element method.
Prior to designing the motors, the accuracy and suitability of Magnet Software were
verified from various literature surveys. It was observed that Magnet Software accurately
predicted the operating characteristics of the physical machine within a set of certain limitations.
Firstly, the Magnet software used in this study only modeled designs in two dimensions. This
introduced errors in the results by neglecting the motor end components (rotor end rings and
23

stator end windings). Secondly, the Magnet Software transient solver did not accurately account
for iron core losses (hysteresis and eddy current losses). Finally, Magnet modeled components
and materials as ideal and did not account for impurities and other uncertainties present in
physical motors. Despite these deficiencies, it was found that Magnet Software was a powerful
tool for use in the design and simulation of motors and acceptable for future motor design.

3.5 SUMMARY
In this chapter, computer design procedure using Finite Element Method & Magnet
Software has been discussed. In this procedure pre processing, field solution and post processing
are also discussed.

















24

CHAPTER 4
ANALYSIS OF INDUCTION MOTOR AND LSPM

4.1 MODELING THE PHYSICAL MOTOR
4.1.1 Creating the Geometric Model
In order to simulate a machine in Magnet Software, a geometric model must first be
created. Magnet Software does have drawing capabilities however, for more complex models,
these drawing tools become tedious to use. An easier alternative is to import a previously drawn
model from a cad package such as AutoCAD directly into the program. Before importing into
Magnet, the user must first set the desired units for the simulation. For this example, length was
set to millimeters, time was set to milliseconds, frequency was set to Hertz and temperature was
set to Celsius. After setting the units, the stator and rotor lamination drawings were imported into
Magnet and arranged so that the rotor was housed within the stator.







(a) (b)
Fig. 4.1 (a) Two dimensional wireframe view of IM motor, (b) Two dimensional wireframe view
of LSPM motor

4.1.2 Making the Components
Once the drawing has been imported and assembled correctly, the individual components
must be made. The user selects a surface and uses the make component in a line command to
25

create a particular component. In this step the material types and the sweep, or depth (using
translational geometry), are specified. Table lists the components used for the simulation.

Table 4.1 Specifications of proposed IM & LSPM
Attributes IM Value LSPM Value
Rated Power 1 kW 1 kW
Rated Speed 1500 rpm 1500 rpm
Poles 4 4
Frequency 50 Hz 50 Hz
Voltage & Phase 415 V & 3 415 V & 3
No. of Stator Slots 24 24
No. of Rotor Slots 40 28
Stator OD 139 mm 139 mm
Stator ID 86 mm 86 mm
Rotor OD 85 mm 84 mm
Rotor ID 30 mm 30 mm
Air gap 0.5 mm 1 mm
Coils in Slot 1 1
No. of Turns per Phase 432 432
Stack Length 100 mm 100 mm
Magnet Width --- 21.2 mm
Magnet Thickness --- 4 mm

Table 4.2 Material details
Component Material Sweep
Stator Housing Cold Rolled Steel 100 mm
Stator Lamination Cold Rolled Steel 100 mm
Stator Slots Copper 100 mm
26

Rotor Lamination Cold Rolled Steel 100 mm
Rotor Bars Copper 100 mm
Shaft 304 Stainless Steel 100 mm
Magnets Neodymium Iron Boron 100 mm
Airgap Air 100 mm

The final step in creating the components is to specify an air-box or boundary
surrounding the entire model. Boundary conditions define the behaviour of the magnetic field at
the boundaries of the model. Since the motor was designed to have negligible flux leakage
outside the stator housin g, an air box component was created in the form of a circle that is just
larger than the motor components.

Fig. 4.2. shows the complete model. Two views are shown, one observing the XY axis
and one of a rotated view illustrating the sweep distance.
4.2 COMPLETED MODEL
4.2.1 Two dimensional front view of motors








(a) (b)
Fig. 4.2 (a) Dynamic model of IM, (b) Dynamic model of LSPM

The two dimensional front view of IM & LSPM is shown in fig. 4.2. This is completed
model after assigning the materials in the stator, rotor and shaft, it has 24 stator slots, and 40
27

rotor slots. The Airgap is 0.5 mm for IM. For LSPM, 24 stator slots, and 40 rotor slots, airgap is
1 mm. The different colors defining the various materials used in the model.

4.2.2 Three - dimensional view of motors








(a) (b)
Fig. 4.3 (a) Three dimensional view of IM, (b) Three dimensional view of LSPM

The Three dimensional view of IM & LSPM from Magnet Software is shown in fig. 4.3.
This illustrates the motor how looks in the XYZ axis. This is useful to find any discontinuities in
the model.
4.2.3 2-D Mesh diagram of motors








(a) (b)
Fig. 4.4 (a) 2D Mesh Diagram of IM, (b) 2D Mesh Diagram of LSPM
28

2D Mesh Diagrams of IM & LSPM from Magnet Software are shown in fig. 4.4. This
illustrates how the triangles are formed to calculate the output parameters using the finite element
analysis. We can change the no. of triangles to get more accuracy results, when increase the
triangles. In this maximum element size is defined as 4mm for stator air box and rotor air box,
0.5mm for stator air gap and rotor air gap, 2mm for overall components of the design.
4.3 Creating the Electrical Components
Once the components have been made, the electrical properties must be specified. The
individual rotor bars were defined as solid coils using the make simple coil command in
Magnet. The stator coils were created using the winding data from the physical motor shown in
Table. The new circuit window command was used to connect the stator windings and the
supply source. The individual rotor bar coils were connected in parallel to simulate the copper
end rings in the physical motors rotor.

Fig. 4.5 Stator coupling circuit
4.3.1 Creating the Motion Component

In order to use the motion solver, the user must first specify a motion component. This is
done by selecting all the sections of the model where motion is of interest and using the make
29

motion component command. For this simulation the motion component included all the parts
of the rotor. Once the motion component has been made, two motion solution options are
available. The velocity driven solution simulates the machine operating at a user defined
rotational speed. The load driven solution simulates the machine driving a user defined load
(Here applied load is 6.7 Nm). The former is suitable for simulating generators, as specifying the
rotational speed of the motion component simulates a prime mover driving the generator. The
load driven solution is suitable for simulating motors running from start-up to steady state
driving a user specified load.
For this simulation load driven solutions were used. A number of simulations were run,
each defining a different design parameter for comparison analysis.

Fig. 4.6 Motion components input data

4.3.2 Solving the Model
Before solving the model, the solution options must be set. Magnet help files state that
the sampling rate for the motion solver should ideally be between 10-20 samples per cycle. For a
50Hz supply, the period of one cycle is 20ms. Therefore the sampling rate was set to 1ms (20
samples per cycle). The simulation run-time was set to 700ms so as to ensure the motor had
reached a steady state. For a 700ms simulation, solutions took around 60 minutes to compile
using a 2GHz processor with 1GB of RAM.
30

4.4 IM & LSPM SIMULATION RESULTS

4.4.1 OPEN CIRCUIT FLUX DISTRIBUTION

The Open Circuit Flux Distribution from Magnet Software is shown in fig. 4.5. This shows the
magnetic flux lines initially form the four poles in the motor model. The dynamic FEM model is
also suitable to analyze the induction motor. Initial static 2-D analysis is done under no excitation
to stator windings and it shows the result of 4-pole creation and stator magnetic flux lines linking
with rotor.


Fig. 4.7 Flux Distribution of IM & LSPM

4.4.2 PERFORMANCE ANALYSIS OF IM AND LSPM

Based on the dynamic model, the transient performance of the proposed LSPM is obtained by
no load test and blocked rotor test. The air gap flux density has a third-order harmonic component
although the permanent magnets are shaped to get a sinusoidal wave. It produces the third-order
harmonic current in this delta-connected LSPM. The back-EMF is lower than the line voltage due
to high starting ability at heavy load.
Rotor speed of the motors are shown in fig.4.6, from this we can conclude that the LSPM have
less oscillations to reach steady state and also it maintains the synchronous speed i.e., 1500 rpm.
31


Fig. 4.8 Rotor speed during on-load start-up (T
L
= 6.7 Nm) of IM & LSPM

Fig. 4.9 Time variation of stator currents during on-load start-up (T
L
= 6.7 Nm)
Three phase stator currents under excitation are shown in fig.4.7, from this we can conclude
that the starting ripples are in few milliseconds after that the sinusoidal current drawn is takes
place.

-1000
-500
0
500
1000
1500
2000
2500
0 50 100 150 200 250 300
S
p
e
e
d

(
R
P
M
)

Time (ms)
Rotor Speed
LSPM IM
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
0 50 100 150 200 250 300
C
u
r
r
e
n
y

[
A
]

Time [ms]
Stator Current
R Y B
32


Fig. 4.10 Net Torque during on-load start-up (TL = 6.7 Nm) of the IM & LSPM
The time variation of Net Torque is shown in fig.4.8, from this the torque developed in the
LSPM is higher than the IM, also it shows two different waveforms for different configuration of
LSPM. At synchronous speed the net torque is approximately zero.

Fig. 4.11 Speed variation during on-load start-up of the LSPM for different PMs thicknesses
.The different values of magnet thicknesses were used and simulated to find changes in
the rotor speed, shown in fig.4.9. From this comparing to high thickness values, less thickness
values are adaptable to reach steady state and synchronous speed in quick manner.
-100
-50
0
50
100
150
0 50 100 150 200 250 300
N
e
t

T
o
r
q
u
e

[
N
m
]

Time [ms]
Net Torque
IM LSPM (28 Bars) LSPM (40 Bars)
-1000
-500
0
500
1000
1500
2000
2500
0 50 100 150 200 250 300
S
p
e
e
d

[
R
P
M
]

Time [ms]
Magnet Thickness
5 mm 4.5 mm 4 mm
33


Fig. 4.12 Speed variation during on-load start-up of the LSPM for different PMs thicknesses
The different values of magnet widths were used and simulated to find changes in the
rotor speed, shown in fig.4.10. From this a specific range of values are adaptable to reach steady
state and synchronous speed.

Fig. 4.13 Speed variation during on-load start-up of the LSPM for different rotor slot opening heights
The height of rotor slot openings with and without conditions were used and simulated to
find changes in the rotor speed, shown in fig.4.11. From this without slot opening height gives
the better steady state and synchronous speed in quick manner.

-1000
-500
0
500
1000
1500
2000
2500
0 50 100 150 200 250 300
S
p
e
e
d

[
R
P
M
]

Time [ms]
Magnet Width
21.2 mm 14.8 mm 27.5 mm
-1000
-500
0
500
1000
1500
2000
2500
0 50 100 150 200 250 300
S
p
e
e
d

[
R
P
M
]

Time [ms]
Rotor Slot Opening Height
0.5 mm 0 mm
34


Fig. 4.14 Speed variation during on-load start-up of the LSPM for different number of rotor bars
The different number of rotor bars used in the LSPM which were simulated to find
changes in the rotor speed, shown in fig.4.12. From this more number of rotor bars gives less
ripple on speed, and reaches its synchronous speed in quick.
4.5 COMPARISON STUDY BETWEEN IM & LSPM
Compared with the induction motor, the LSPM have lower steady-state current, and
much higher power factor. Therefore, the predicted efficiency is almost much higher than that of
induction motor. The proposed LSPM have 28 rotor slots but it is conflict with better design
analysis, the main purpose to chosen the copper quantity and moment of inertia (J = 0.004 kg m
2
)
is lesser than in the 40 rotor slots model. The better design parameter values were highlighted.
The comparison study is made between the IM and LSPM, with various performance
parameters, Total power loss, slip, efficiency, power factor, flux density and better design
influence parameters.





-500
0
500
1000
1500
2000
0 50 100 150 200 250 300
S
p
e
e
d

[
R
P
M
]

Time [ms]
Number of Rotor Bars
28 Bars 40 Bars
35

Table 4.3 Output Data from Magnet Software
COMPARISON STUDY
Parameter LSPM IM
Total Power Loss 129 W 356 W (67+289)
Speed 1500 rpm 1465 rpm
Slip 0% 2.3%
Efficiency 89% 73%
Power Factor 0.82 0.75
FLUX DENSITY
Airgap 0.34 T 0.42 T
Teeth (Stator, Rotor) 1.56, 1.11 T 1.56, 1.22 T
Backiron 1.48 T 1.45 T
ANALYSIS FOR BETTER DESIGN
Rotor Slot Opening Height 0.5 mm 0 mm
Number of Rotor Bars 28 40
Magnet Thickness 5 mm 4.5 mm 4 mm
Magnet Width 21.2 mm 14.8 mm 27.5 mm

4.5 SUMMARY
The IM & LSPM were successfully simulated in Magnet Software. The design and
analysis (Flux Distribution, Speed, Torque, Power Losses), Comparison of both motors (Slip,
Efficiency, Power Factor), and better design analysis (Rotor Slot Opening Height, Number of
Rotor Bars, Magnet Thickness, Magnet Width) have been completed.





36

CHAPTER 5
CONCLUSION AND FUTURE WORK

CONCLUSION

The aim of this thesis was to design a three phase electric motor suitable for use in
submersible pumping applications. Before producing a fully working submersible motor, it was
initially decided to design a simulation model to ensure the ideas developed in this study would
be feasible and that the design would be viable. A conventional 1kW induction motor and a high
efficiency permanent magnet synchronous motor were designed and simulated using the Magnet
software.
A conventional 6 inch 1kW induction motor was designed to provide a reference for
efficiency levels before designing the LSPM. The induction motor was a wye connected four
pole machine rated to 1kW with an operating voltage of 220V line-to-line at a frequency of
50Hz. The stator consisted of 24 stator slots wound in a full coil arrangement with 54 turns per
slot. The rotor consisted of 40 solid copper rotor bars connected in parallel at either end of the
rotor by copper end-rings. Magnet simulations indicated a full load efficiency of 75% (neglecting
iron losses and other losses arising from a 2 dimensional analysis), power factor of 0.58
(lagging) and a motor slip of approximately 2.3%. Based on the induction motor, a LSPM was
designed with an identical stator assembly and a modified rotor. Four neodymium iron boron
permanent magnets, arranged in a circumferentially magnetized layout, were installed in the
rotor.
Damper windings were also fitted to allow for line starting and line operation. These
windings negated the requirement for costly control hardware and added a degree of machine
stability when operating under a variable load. It was found, through simulations, that the
LSPM was approximately 14% more efficient than the conventional induction motor when
operating at full load. Full load power factor was 0.82 and speed remained at synchronous speed.
Simulations indicated that the motor would successfully line start and synchronize from all initial
rotor positions down to a reduced line voltage of 68% of normal line voltage. Based on the
positive results obtained through simulations, it was decided that it would be economically viable
to produce a working prototype of the LSPM for further, practical, testing.
37

FUTURE WORK

The three phase line start permanent magnet motor using magnet software can be
fabricated in future, practical as per given motor specifications.

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