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
UCF
Effect of R2
 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:

0.003 0.08 Pout

m (0.00145 )
P f
P : the number of poles
Pout : output power in Watt

Also
2 Bm Dl P m
m Bm
P 2 Dl
UCF Number of Turns per Coil on Stator

E1 2fN eff m 4.44 fN eff m

E1 0.97V ,rated (because R1 and X1 are small)

PqN c k w
N eff k w k p kd k s D 2r
1.1
where
The denominator 1.1 in Neff is to considering leakage flux.

1.07Vrated
Nc
2fPqk w m
UCF
Stator Volume and Size
D 2l 1
V0 (constant), V0 depends on cooling
T Js
Typically

V0 9 ~ 10 in 3 /(ft lb) for 10hp or less (air cooled)

V0 5 ~ 6 in 3 /(ft lb) for 10hp or more (water cooled)
The unit for D and l is inch.

If we design D=l, we have the stator bore (inner)

diameter estimated
1

Destimated (TV0 ) 3
UCF
Frame Diameter Estimation
Estimated Stator Core diameter (outer diameter):

1.03
D0,estimated (1.175 ) Destimated 0.647 inch
P
Estimated frame outside diameter:
D f ,estimated D0,estimated 2t f
tf is wall thickness, typically 0.5 inch

D f is picked up from NEMA frame

UCF
NEMA Standard Frame Size (inch)
UCF
Stator Bore Diameter and Length
Frame outside diameter:
D f is picked up from NEMA frame in last page.
Stator Core diameter (outer diameter):
D0 D f 2t f
tf is wall thickness, typically 0.5 inch
Stator Bore diameter (inner diameter):
D0 0.647 inch
D
1.03
1.175
P
Stator active region length:
TV0
l 2
D
UCF
Air Gap
Experienced formula
g 0.0016D 0.001l 0.0072 inch

Dr D 2 g

Effective airgap
g eff kcs kcr g

where the Carters coefficients

s (5 g bs )
kcs
s (5 g bs ) bs2

s (4.4 g 0.75br 2 )
kcr
s (4.4 g 0.75br 2 ) br22 NEMA Class B
UCF
Stator Slot Design
D
s
S
0.7in s 1.5in
2bs d s1 4bs
0.4s bs 0.6s
bs
rs , 0.4 rs 0.6
s
t s s bs
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
UCF
Stator Conductor Size
Stator current density
I1,rated
J sa
Aa
where Aa is stator (armature) conductor cross section
area and can be determined from the above formula
together with:
Air-cooled: 4A/mm 2 J sa 8 A/mm 2
Pout / Typical Efficiency :
I1,rated
3V ,rated pf 75% for Pout = 1-5 hp
85% for Pout = 5-40 hp
I1,rated
Aa 90% for Pout = 50-200 hp
J sa
UCF
Number of Slots (Bars) on Rotor
Certain number of slots (bars) must be avoided because they
can produce detrimental cusps in the speed-torque curve.

S r S (2k 1) P
S r S 3kP
(k 1,2,3...)
UCF
Rotor Effective Winding Factor
fix ( S r / P)
Rotor Coil pitch in electrical angle: r
Sr / P

P
Rotor Slot pitch in electrical angle: r
Sr
PS skew,r
Skewed angle in electrical radian: r
Sr
S skew,r is the number of slots skewed, typically1
k wr k pr kdr k sr
qr r
sin( )
r kdr 2 Sr r
k pr sin r
qr k sr sinc( )
2 qr sin( ) 3P
2
2
 Effective Number of Turns per
UCF Phase for Rotor
Effective number of rotor slots per phase (may not be integer)
Sr
3
Unlike the stator, the single cage rotor has only one conductor per slot
(or equivalent to single layer winding).

k wr S r
N effR
6
UCF Rotor Bar Size
Rated current in rotor bar

N eff
I b,rated I1,rated (transformer relationship)
N effr
I b,rated
Rotor bar current density J sb
Ab
where Ab is rotor bar cross section area and can be
determined from the above formula together with:
Air-cooled: 7A/mm 2 J sb 7.75 A/mm 2
Rotor bars can operate at higher temperatures than stator.
I b,rated
Ab
J sb
UCF
Rotor Slot Design
depth to width ratio :
d r1 d r 2
d 2w 4 ~ 6 (NEM A B)
br1
Sb
br1 d c1 d 2w br1
d 2w
br 2 0.01D 0.045 inch

d r 2 0.667br 2
d r1 d c 2 d r 2
Area is Sb Dr
t r1 br 2
Sb br1 (d r1 d r 2 ) Nr
( Dr 2d r1 )
bc 2 br1 dc 2 d r1 d r 2 tr 2
Nr
br1
UCF Rotor End Ring
UCF Rotor End Ring Size
Rated current in rotor end ring
Sr
I ring,rated I b,rated
P
I ring,rated
Rotor end ring current density J s ,ring
Aring
where Aring is rotor end ring cross section area and can
be determined from the above formula together with:
Air-cooled: 7.75A/mm 2 J s ,ring 9.3 A/mm 2
Rotor end rings can operate at higher temperatures than rotor bar.
I ring,rated
Aring
J s ,ring
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 MatLab code

imDesign.m by yourself.
Induction Machine Modeling
Relevance to Induction Machine

c bR b
aR aR axis
cR
qm
cR a axis
bR
aR
b
c
P
q me qm
a 2
 Arbitrary Reference Frame (1)

Stator quantities (Sabc) of current, voltage, or flux can be

converted to quantities (Sdq0) referenced to the rotor.
This conversion comes through the K matrix.
S dq0 KS abc
S abc K 1S dq0
where

cos q S cos q S 2 / 3 cos q S 2 / 3

K sin q S sin q S 2 / 3 sin q S 2 / 3
2
3
1 / 2 1/ 2 1/ 2
cos q S sin q S 1 (MITs notation)
K 1 cos q S 2 / 3 sin q S 2 / 3 1
cos q S 2 / 3 sin q S 2 / 3 1
 Arbitrary Reference Frame (2)

Rotor quantities (SaRbRcR) of current, voltage, or flux can

be converted to quantities (SdRqR0R) referenced to the
rotor. This conversion comes through the K matrix.
S d R qR 0 R K R S aR bR cR
1
where S aR bR cR K R S d R qR 0 R

cos q R cos q R 2 / 3 cos q R 2 / 3

K R sin q R sin q R 2 / 3 sin q R 2 / 3
2
3
1 / 2 1/ 2 1/ 2
cos q R sin q R 1 (MITs notation)
K R cos q R 2 / 3 sin q R 2 / 3 1
1

cos q R 2 / 3 sin q R 2 / 3 1

q R q S q me
 Voltage Equations (1)

Under motor reference convention for currents

(i.e. the positive reference direction for currents is into the machine):

For stator windings

d 1 0 0
v abc R S i abc abc R S Rs 0 1 0
dt
0 0 1
K 1

v dq0 R S K 1i dq0
d
dt

K 1 dq0

K K 1v dq0 KR S K 1i dq0 d

K K 1 dq0
dt


d d
v dq0 KR S K 1 i dq0 KK 1 dq0 K K 1 dq0
dt dt

d d
v dq0 R S i dq0 dq0 K K 1 dq0
dt dt
 Voltage Equations (2)

We derive the derivative of K-1:

sin q S cosq S 0
K S sin q S 2 / 3 cosq S 2 / 3 0
d 1
dq S
dt S
sin q S 2 / 3 cosq S 2 / 3 0 dt

Then, we get And for voltage, we get

d
0 S 0 R i
s d dt d
q S
d v d
K K 1 S 0 0 v R i d

dt q s q dt q
0 0
d S
0
v0 d
R i
s 0 0
dt
 Voltage Equations (3)

For rotor windings

d 1 0 0
v aRbRcR 0 R R i aRbRcR aRbRcR R R Rr 0 1 0
dt
0 0 1

d q R q S q me
R i
r d R dt d R qR R
0
0 R i d
r qR dt qR dR R

0 d
Rr i0 0
dt R

dq R
R S me
dt
 Dynamical Equations for Flux Linkage

d vd Rs id q S
v R i
q q s q d S

d 0 v0 Rs i0

dt d R R i
r dR qR R
q Rr iq d R
R R R

0 R


Rr i0 R

Let d vd Rs id q S
v R i
q q s q d S
0 v0 Rs i0
DQ
d R
V
R i R
q r dR qR

R Rr iq d R
0 R
R R

Rr i0 R
we have
d DQ
V
dt
The derivations so far are valid for both linear and nonlinear models.
 Flux Linkage vs. Current (1)

The next step is to relate current to flux linkage through

inductances. For round rotor, the inductances can be
approximately expressed as

L SS L SR
L ABC T
SR RR
L L

Laa Lab Lac Laa Lbb Lcc Lls LA

L SS Lba Lbb Lbc 1
Lab Lba Lbc Lcb Lac Lca LA
Lca Lcb Lcc 2

LaR aR LaRbR LaR cR LaR aR LbRbR LcRcR Llr LAR

L RR LbR aR LbRbR LbRcR 1
LaRbR LbR aR LbRcR LcRbR LaRcR LcR aR LAR
Lc a Lc b Lc c 2
RR R R R R
 Flux Linkage vs. Current (2)

LaaR LbbR LccR Lm 0 cos q me

LaaR LabR LacR
2
L SR LbaR LbbR LbcR LbaR LcbR LacR Lm 0 cosq me
3
Lca Lcb Lcc 2
R R R
LcaR LabR LbcR Lm 0 cosq me
3

Moreover:
2
Lm 0 N eff R LAR N eff R

LA N eff LA N eff

Ref: 1. A. E. Fitzgerald, C. Kingsley, Jr., and S. D. Umans, Electric Machinery,

6th Edition, pages 664-667.
2. P. C. Krause, O. Wasynczuk, and S. D. Sudhoff,
Analysis of Electric Machinery and Drive Systems, 2nd Edition,
pages 142-145.
 Flux Linkage vs. Current (3)

This matrix can be transformed into dq0 form and used to

find flux linkage.
abc L SS L SR i abc
From ABC L ABC i ABC with ABC L ABC T i ABC
aRbR cR L SR L RR i
aRbR cR
abc L SS i abc L SRi aRbRcR K 1

dq0 L SS K 1i dq0 L SR K R1i d R qR 0R

dq0 KL SS K 1 i dq0 KL SRK R1 i d R qR 0R

aRbRcR LTSRi abc L RR i aRbRcR K R

1

d R qR 0R LTSR K 1i dq0 L RR K R1i d R qR 0R

d R qR 0R K R LTSRK 1 i K L K i
dq0 R RR
1
R d R qR 0 R
DQ L DQ i DQ

dq0 KL SS K 1 KL SRK R1 i dq0

where DQ L DQ 1 1
i DQ

d R qR 0 R K L T
R SR K K L
R RR K R
i
d R qR 0 R
 Inductance Matrix in dq0 Frame
Through derivations, we have
LS 0 0 Lm 0 0
0 0
LS 0 0 Lm KL SS K 1 KL SRK R1
0 0 L0 0 0 0 L DQ T 1 1
L DQ R SR
K L K K L
R RR K R
Lm 0 0 LR 0 0
0 Lm 0 0 LR 0

0 0 0 0 0 L0 R

3
where LS Lls LA L0 Lls
2
3 L0 R Llr
and LR Llr LAR
2
3
Lm Lm 0
2 d LS id Lmid R d R Lmid LR id R

q LS iq LmiqR qR Lmiq LR iqR
From DQ L DQ i DQ L i
0 L0i0 0R 0R 0R
 Dynamical Equation in Terms of Current
For linear model
d DQ and DQ L DQ i DQ
from V
dt
di DQ dynamical equation
LDQ
1
V
dt in terms of current

where

vd Rs id q S
v R i d LS id Lmid R d R Lmid LR id R
q s q d S

v0 Rs i0 q LS iq LmiqR qR Lmiq LR iqR
V 0 L0i0 L i
R i
r dR qR R 0R 0R 0R

Rr iq d R
R R

Rr i0 R
 Power

Electrical instantaneous Input Power on Stator can also be

expressed through dq0 theory.

pin vaia vbib vcic vTabci abc vTdq0 (K 1 )T K 1i dq0

1 0 0
0 1 0
3
(K 1 )T K 1
2
0 0 2

pin vd id vqiq 2v0i0

3
2
 Torque
From d
R i
s d dt d
q r
pin vd id vqiq 2v0i0
3 v d
2 v R i d
q s q dt q d r

v0 d
R i
s 0 0
we have
dt

3 dd dq d 3 P
3
2
2 2 2

pin Rs id i q 2i0 id
2 dt
iq
dt
2i0 0
dt 2 2
m (d iq qid )

Copper Loss Magnetic Power in Mechanical Power

Windings pmech
Therefore, electromagnetic torque on rotor

pmech 3P
Te (d iq qid )
m 22
 Three Commonly Used Reference Frames

Stationary Reference Frame

S 0

Rotor Reference Frame

S me

Synchronously Rotating Reference Frame

S e