XIX International Conference on Electrical Machines - ICEM 2010, Rome

Field and circuit calculation of the core losses in

the energy-saving small-size induction motor
Krzysztof Komeza, Maria Dems

Φ
Abstract -- This paper presents no-load core loss analysis of 3-
phase energy-saving small size induction motor supplied by
sinusoidal voltage. In field-circuit part the distribution and
changes of magnetic flux densities of the motor are computed
by using time-stepping FEM. Discrete Fourier Transform is
used to analyze the magnetic flux density waveforms in each
element of the motor model. Rotational aspect of the field is
included by introducing correction to first harmonic of
alternating losses. Core losses in each element are evaluated
using core loss curve measured on toroidal core at different
frequencies. In addition, rapid circuit method is presented. The
results are compared with the measurements.
Index Terms — induction motors; magnetic losses; finite
element method; rotating machine transient analysis; rotating
machine measurements; circuit modelling.
I. INTRODUCTION
measurements were performed on toroidal core [5],[6]. The
toroidal core was chosen because it better reflects the
phenomena of the machine core, also the cutting stress
effect, than an Epstein test frame. The samples of the non-
oriented silicon steel M600-50A thickness 0.5 mm for tests
were cut in form of rings with width 10 mm and assembled
in toroidal form of height 10 mm, to approximate changes of
their parameters to these obtained as results of cutting sheets
at manufacture a magnetic core of an electrical motor. The
measured specific core losses as a function of frequency for
different values of peak magnetic flux density are presented
in Fig. 1 and as function of frequency and flux density in
Fig. 2. This approach is an extension of ideas presented in
[7] where a possible way to characterize the core losses is
the use of the ring-test data collected on the machine under
study.

T he core losses generated in the small size induction

motors constitute a significant part of total losses in the
motor. Precise determination of these losses is important
especially in the energy-saving motors. Core losses of the
electrical machine are determined by the core losses density
of the electrical sheets, which depends strongly on
frequency, magnitude and form of applied magnetic field.
Usually specific losses are only given for 50 Hz alternating
flux. Therefore, different forms of estimation are taken for
higher frequencies. To avoid errors connected with this
approach the direct use of specific losses measured at ring
samples have been proposed. The core no-load losses are
calculated with field-circuit and circuit method and results
are compared with the measurements. Fig.1. Measured specific core losses as a function of peak magnetic flux
density for different values of frequency.
II. CORE LOSSES MODELING
Core losses in induction motors are usually modelled
using the two: hysteresis and eddy-current
components[1],[2] or developed by Bertotti three-component
methods [3] composed of summation of classical eddy-
current, hysteresis and excess losses. Specific iron losses
caused by sinusoidal magnetic flux are described by three-
component method in the form:

w = k f 2 B2 + k f Bα + k f 1,5 B1,5 (1)

Fe e h a
where coefficients ke, kh, ka and α are calculated from the
measured data and are assumed to be constant. However,
results obtained from measurements [4] demonstrate the fact
that the loss coefficients need to be dependent of both: flux
density and frequency. In practice the specific iron-loss for
the same grade of material varies within acceptable
manufacturing tolerances. Therefore, to correctly specify the Fig.2. Measured specific core losses as a function of peak magnetic flux
behaviour of specific losses at investigated motor the density and frequency.

Φ
The curves of the specific core loss versus peak flux
This work was supported by the Ministry of Science and Higher
Education (Project N N510 388235).
density for different frequencies were approximated by third
K. Komeza and M. Dems are with Institute of Mechatronics and order polynomials.
Information Systems, Technical University of Lodz, Stefanowskiego 18/22, Sample of that polynomial for 50 Hz have the form:
90-924 Lodz, Poland (e-mails: komeza@p.lodz.pl, mdems@p.lodz).

978-1-4244-4175-4/10/$25.00 ©2010 IEEE

 wFe,50 = 0.0403*B3+2.0452*B2+0.2474*B+0.0306 (2) III. OBJECT OF INVESTIGATION
For the measured sample specific core losses for higher The four-pole energy-saving small induction motor with
frequencies up to 250 Hz can be calculate with limited core made from the non-oriented silicon steel M600-50A
accuracy using relation was examined. The supply voltage was 230 V for the
1, 4 frequency 50 Hz. Stator windings were delta connected. The
⎛ f ⎞ number of series turns of stator windings was 368. The
w =w ⎜ ⎟ (3)
Fe, f Fe,50 ⎝ 50 ⎠ external diameter of the stator core was 120 mm, the internal
diameter is 70.5 mm, and stator core lengths is 102 mm.
where: wFe,50 – specific core loss for frequency equal 50Hz.
The measured and calculated specific core losses curves IV. THE FIELD CIRCUIT CALCULATIONS
vs. flux density of the examined steel for different values of
Different models of varying degrees of complexity and
frequency are presented in Fig. 3.
accuracy can be used to calculate the core losses in induction
motors. More sophisticated methods allow for the inclusion
of magnetodynamic vector hysteresis behaviour observed in
the cores of electrical machines directly inside the solution
process [8],[9]. Overview of that area of research was
conducted in [10],[11]. The main drawback of these methods
is still a long time of calculations. The general aim of this
work was to search for methods that are sufficiently accurate
and gave results in reasonable time. Therefore, the popular
approach employing a post-processor formula of magnetic
field solution was chosen. This approach is usually based
upon an empirical procedure exploiting two or three
components methods of estimation of specific core losses.
Fig.3. Measured (black line) and calculated using (3) (red line) specific To avoid problems associated with errors of these methods
core losses as a function of peak magnetic flux density for different
frequencies. experimental results are used directly. The flux density
distribution in machine core is calculated using the time-
Approximation of losses using (3) was only used in circuit stepping FEM coupled with the circuit equations of the
method for losses calculation. Field-circuit method uses supply circuit and the end windings. The Opera-2d/RM, a
polynomial approximation for all harmonic frequencies. transient eddy current solver, extended to include the effects
For circuit method the Bm/Hm characteristic was of rigid body (rotating) motion and also provides for the use
approximated in the two section, ie. for flux density of external circuits was chosen. The mesh was refined to
Bm<1.5 T and flux density Bm>=1.5 T. minimize the solution errors. The mesh density is a
For the non-oriented silicon steel M600-50A these compromise between accuracy and calculation time. Finally
approximation are in the form: mesh consists of 10734 elements. The mesh is shown in
For the flux density Bm < 1.5 T Fig.5.
6 5 4
H = 4615.1B − 16772 B + 22647 B +
m m m m
(4)
3 2
− 13391B + 3053 B + 55.066 B + 6.1089
m m
and for the flux density Bm >= 1,5 T
Fig. 5. The finite element mesh consists of 10734 elements
13 11
H = 0.0280098 B − 0.17054 B +
m m m The application of the field-circuit method to the
(5)
9 modelling of the magnetic field distribution in an induction
+ 0.345908 B − 1.373247 B motor, taking into account the movement of the rotor,
m
required the introduction of a special element to the model,
which properly joins the unmoving and moving parts. In the
applied module RM of the software packet Opera 2D, this
element took the form of a gap-element. The gap region
(Fig. 6) is divided quite uniformly on 264 elements along the
circumference of the gap. It gives time of displacement of
one element equal to about 3 10-5 s at synchronous speed,
comparable with the average time step of computation.
The gap region division is fundamental for avoiding
erroneous oscillation generations of the field due to meshing.
The machine was running at synchronous speed and feed
with sinusoidal voltage. The time-stepping analysis was run
over 10 periods of the supply voltage up the steady state was
Fig.4. Measured and approximated B/H characteristic for non-oriented
silicon steel M600-50A reached. After this time several snapshots are taken for next
voltage period.
Fig. 6. The gap region division

Fig. 7 show the magnetic field of the motor at time 0.2 s.

1.0 1.08 1.16 1.24 1.32 1.4 1.48 1.56 1.64 1.72 1.8

Fig. 8. Magnitude of the first harmonic of magnetic flux density.

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

Fig. 7. The equipotential lines of the vector potential correspond to time 0.2
s. One flux tube contains a flux per unit length of 0.001 Wb/m. (left)
Magnitude of magnetic flux density at time 0.2 s (right)

The number of samples was chosen according to

following discrete Fourier transform (DFT) analysis. 80
samples were used. It is important that the values of air gap
division angle and angle between samples are not the same
or were an integer multiple of. 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Using the calculated at samples values of x and y
Fig. 9. Magnitude of the third harmonic of magnetic flux density.
components of magnetic flux density in each element the
DFT analysis was performed on the flux density components
waveform in order to consider the contributions of the higher
harmonics.

N −1
− i 2πkn / N
B pk = ∑ B (n )e p = x and y k = 0,.., N - 1 (6)
p
n=0

where k is harmonic order, N is number of samples.

Necessary transformation taking into consideration
rotor position was also included. The number of calculated 0.0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
harmonics was chosen according to Nyquist–Shannon
sampling theorem as half of the samples number.
Fig. 10. Magnitude of the fifth (left) and tenth (right) harmonic of magnetic
This method is very popular since many years [2],[12]- flux density.
[16] considering the dependence of losses on the magnetic
flux derivative. This method is very helpful, when the
machine is running supplied from PWM inverter, but the
separation loss is necessary, which is difficult. However,
additional advantage of the previous method is to separate
the harmonic and place of their impact. Designers can easily
determine the source of the various harmonics using years of
experience, their contribution to the overall losses and
localization of losses caused by. To highlight the impact of
motion of the rotor, the calculations were done with and
without of rotor movement. At next Fig. 8-13 the
distribution of calculated flux density harmonics magnitude
were shown.
Another problem with which we meet calculating core losses
is rotational losses. At low and medium flux density values 0.0 0.04 0.08 0.12 0.16 0.2 0.24 0.28 0.32 0.36 0.4
the rotational losses may be several times higher than the
Fig. 11. Magnitude of the eighth harmonic of magnetic flux density.
alternating flux density losses.
 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Fig. 14. Axis ratio distribution for the first harmonic.

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Fig. 12. Magnitude of the twelfth harmonic of magnetic flux density.

0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Fig. 15. Magnitude of the first harmonic of magnetic flux density.

Rotor cage, even rotating at synchronous speed, is

0.0 0.1213 0.2426
Fig. 13. Magnitude of the twenty-fourth harmonic of magnetic flux density
They are two possible solution of this problem. The first
one presented in [17]-[19] use correction coefficients for
hysteresis and excess losses, the second use correction for
the total losses computed for pure alternating flux [20]-[22].
The second approach, more convenient in our case, was use
to correct calculated losses. The correction was made only
subjected to the magnetic flux density change due to slotting.
Therefore, additional losses occurrence can be notice. These
losses are comparably high up to several percent of total
losses. This part of losses is calculated as an average value
taken from all time snapshots [24].
To underline the necessity to take into account the motion
of the rotor in calculation of losses Fig. 16 and 17 present a
comparison between losses calculated for those two cases.
24,00
22,00
20,00

for first harmonic. The ground for such procedure was that 18,00 with rotor movement
Stator core losses ( W )

the higher harmonics do not cause circulation of the resultant 16,00

without rotor movement
14,00
flux density vector. Additionally, correction is mainly made
12,00
on hysteresis losses they contribution to total losses decrees 10,00
significantly with frequency growth. For examined machine 8,00
this problem is not crucial because only small area of the 6,00
core is subjected to rotational flux (less than 12% for first 4,00

harmonic). Level of rotation is expressed on axis ratio which 2,00

is defined as the ratio between minor and major axis of the 0,00
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
flux density loop. Harmonic order
Fig. 16. Core losses spectrum calculated with and without rotor movement.
λ=B /B (7) 2,20
min maj 2,00
1,80
where Bmaj and Bmin are the peak flux density values
Stator core losses ( W )

1,60
along major and minor axis of the field loop.
1,40
The rotational losses are calculated as [20]-[22] 1,20
with rotor movement

⎡ ( )⎤
1,00

P = P ⎛⎜ B ⎞⎟ + P B γ ⎛⎜ λ , B ⎞⎟ without rotor movement

(8) 0,80
rot ⎣⎢ alt ⎝ maj ⎠ alt min ⎥⎦ ⎝ maj ⎠ 0,60
0,40

where Palt are alternating measured iron losses. 0,20

0,00
For the high power machines, about 60-70% of stator 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
core volume is subjected to alternating flux and about 30% is Harmonic order
Fig. 17. Stator core losses spectrum calculated with and without rotor
subjected to rotational flux [23]. movement. First harmonic omitted.
Furthermore, the average aspect ratio was about 0.2 and
in regions where the ratio was higher the amplitude of flux Next Fig. 18-20 present the iron loss components from
density was near 1.5 for that the correction is rather small. the fundamental component to the 40th harmonic component
The next two Fig. 14 and 15 show the flux density according to the harmonic order.
magnitude and aspect ratio for first harmonic.
 24,00
22,00 ρ D2 l k B2
20,00 Fe si( re) Fe ts( r ) r ( s )ν
P = p (9)
18,00
s0ν scν
16,00 4k ν
14,00
Fe r ( s )
Core losses ( W )

12,00
10,00 where ρ is mass density of the core material, Dsi is
8,00 Fe
6,00 internal diameter of the stator core, Dre is external diameter
4,00
of the rotor core, lFe is length of stator core, kFe is packing
2,00
0,00
factor of the core, kts(r) defines the ratio of tooth width to
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 stator or rotor slot pitch, pscν is eddy current loss density in
Harmonic order
Fig. 18. Total core losses spectrum calculated with rotor movement.
the sheets for flux density Br(s)ν and frequency fν.
Total additional surface loss in the stator and rotor teeth we
6,00 can calculate from formula:
5,50
5,00
P = ∑P (10)
4,50 s0 s 0ν
4,00 ν
3,50
Additional pulsation losses in the stator teeth, caused by the
Core losses ( W )

3,00
2,50 flux of the harmonic rotor fields, were calculated from
2,00 formula in the form [25]:
1,50
1,00
2
0,50 P =m B p (11)
0,00 p0ν ds rν pcν
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic order
Fig. 19. Total core losses spectrum calculated with rotor movement. First and P = ∑P (12)
harmonic omitted. p0 p0ν
ν
4,50
where mds is weight of teeth, ppcν is specific pulsation core
4,00
loss for flux density Brν and frequency fν.
3,50
Additional pulsation losses in the rotor cage, caused by the
Rotor core losses ( W )

3,00
flux of the harmonic stator fields, were calculated from
2,50
formula in the form [25]:
2,00

1,50 πD
2 1.5 re (13)
P = 0.85e − 6( B k k ) f b l Q k
1,00
Alν sν cr s r1 Fe r cr 2 ν
0,50 sν s
0,00
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 where kcr is rotor Carter factor, Bsν and fni. are amplitude of
Harmonic order
Fig. 20. Rotor core losses spectrum. the flux density and frequency of the νs harmonic of the
stator field, br1 is a width of opening of the rotor slot, Qr is
From these results it is clear that including motion of the number of the rotor slots. Total no-load core losses
rotor is crucial for proper losses calculation. One can notice calculated are presented in the Table 1.
the significant contribution of slotting harmonics to the total
losses. Fundamental losses amount only about a half of total TABLE I
losses. The losses in the rotor are dominated by the losses in BASIC AND ADDITIONAL NO LOAD CORE LOSS CALCULATED WITH USE
FIELD CIRCUIT AND CIRCUIT METHOD AND MEASURED
the tooth-tips. The no-load core losses calculated by use of
the field-circuit method are presented in the Table 1. The no-load core loss [W]
Calculated by use Calculated by Measured
field circuit use circuit
V. THE CIRCUIT CALCULATIONS method method
In the circuit calculation of the basic core loss only first Total basic stator 22.5 23.9
harmonic of the field was taken into account. The calculation core loss for first
harmonic
of the basic core loss in the stator teeth was made including Stator core loss for 8.59 2.00
the division of the tooth into 6 parts, for value of the flux higher harmonics
density in each of these parts. For frequency 50 Hz the basic Rotor core loss for 5.14 9.52
no-load core losses of the motor were respectively: in the higher harmonic
stator teeth – 7.54 W, and in the stator yoke – 16.36 W Additional loss of 3.41 2.78
In the calculations of the additional no-load core loss the pulse in the rotor
higher harmonics of the magnetic fields in the air-gap were Total core loss 39.64 38.20 39.3
taken into account.
Additional surface loss Ps0ν in the stator and rotor teeth, The measured total no-load core loss was obtained from the
caused by the flux of the νr(s) order harmonic rotor and stator tests made with rotor movement. Mechanical no-load losses
fields, were calculated from formula proposed by F. Taegen were measured for the entire range of rotor speed [5], using
[26], in the form: accurate torque transducer placed between the measured
unsupplied driven motor and additional driving motor.
 An error of total no-load core loss calculation in relation to
the measurement results is:
• for the field –circuit method – 0.9 %
• for the circuit method – 2.8%
All circuit calculations were made with including 40 field
harmonics.
VI. CONCLUSIONS
This paper presents no-load core loss analysis of 3-phase
energy-saving small size induction motor fed by sinusoidal
voltage. In field-circuit part the distribution and changes in
magnetic flux densities of the motor are computed by using a
using time-stepping FEM. Discrete Fourier Transform has
been used to analyze the magnetic flux density waveforms in
each element of the analyzed model. Rotational aspect of the
field was included by introducing correction to first
harmonic of alternating losses. Core losses in each element
are evaluated using core loss curve measured on toroidal
core at different frequencies. In addition, rapid circuit
method is presented. The results are compared with the
measurements and good agreement was obtained for both
methods. However, the field-circuit time-stepping method is
quite time consuming, so the choice for optimization
methods is rather the rapid circuit method.
VII. ACKNOWLEDGMENT
The authors gratefully acknowledge the contributions of
J. Szulakowski from TU Lodz for his work on core losses
measurements and of A. Michaelides from Vector Fields
Software Cobham Technical Services for valuable help.
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IX. BIOGRAPHIES
Krzysztof Komeza is vice director of Institute of Mechatronics and
Information Systems at Technical University of Lodz, Poland. He obtained
his Ph.D. in 1983 and D.Sc. in 1995 at the Technical University of Lodz.
From 1998 he works as a professor at the Technical University of Lodz.
His research interests include computational electromagnetics, efficient
finite element computations and coupled field computations and design and
optimisation of electrical machines. He has done a number of consultancy
works for electrical machines industry. He has published over 160 papers.
Maria Dems Ph.D, D.Sc. obtained her Dipl.Ing. and M.Sc. in Electrical
Engineering at the Technical University of Lodz in 1970 and her Ph.D. in
1978. The title D.Sc. she obtains in 1996. From 1998 she works as a
professor at the Technical University of Lodz, Poland. She specializes in
electrical engineering, especially in modelling, design and optimization of
electrical machines, applications of modern tools, databases and expert
systems. She has done a number of consultancy works for electrical
machines industry. Author or joint author of over 150 publications.