UNIT 4

Three phase Induction Motor Design – Part 1

4.1 Specification and Constructional features

4.2 Design of ac windings
4.3 Output equation with usual notations
4.4 Specific electrical and magnetic loadings
4.5 Ranges of specific loadings
4.6 Turns per phase
4.7 Number of stator slots

4.1 Specification and Constructional features:

 Simple and rugged construction
 Low cost and reliable
 High efficiency and good power factor
 Requires minimum maintenance
 It is self-starting hence no special arrangement is required.
Three phase induction motor consists of stator and rotor. There are two types 3
phase induction motors:
 Squirrel cage induction motor.
 Phase wound induction motor.

Squirrel cage Induction motor:

Figure 1. Stator
The stator is wound with 3 phase windings fed from a 3 phase supply. It is wound
for defined number of poles, the number of poles determine from the required
speed. For greater speed less no of poles are required.

When stator windings are supplied with 3 phase ac supply it produces alternating
flux which revolves with synchronous speed.

The synchronous speed is inversely proportional to the number of poles (Ns =

120f/P) . This revolving or rotating magnetic field induces current in rotor
winding according to Faradays law of mutual induction.

The rotor of 3 phase induction motor can be squirrel cage rotor and phase wound
rotor.
 Squirrel cage rotor:

Squirrel cage type rotor is simple in its construction. This type of rotor
consists of cylindrical laminated core, having parallel slots on it. These
parallel slots carry rotor conductors.
In this type of rotor, heavy bars of copper, aluminium or alloys are used as
rotor conductors instead of wires.
Rotor slots are slightly skewed to achieve following advantages –
 It reduces locking tendency of rotor that is the tendency of rotor teeth to
remain under stator teeth due to magnetic attraction.
 It increases effective transformation ratio between stator and rotor
 It increases rotor resistance due to increased length of the rotor
conductor.

Figure 2. Squirrel Cage rotor.

The rotor bars are brazed or electrically welded to short circuit the end rings
at both ends. Thus, the rotor construction looks like squirrel cage. The rotor
bars are permanently short circuited therefore it is not possible to add any
external resistance to the armature circuit.

Phase wound rotor:

Figure 3. Phase wound rotor

Phase wound rotor
o It is wound with 3 phase, double layer, distributed winding. The number of
poles of rotor are kept same as the number of poles of the stator. The
rotor is always wound 3- phase even if the stator is wound two phases.
The three- phase rotor winding is internally star connected. The other
three terminals of the winding are taken out through three insulated sleep
rings mounted on the shaft with the brushes resting on them.
o These three brushes are connected to an external star connected
rheostat. This arrangement is done to introduce an external resistance in
rotor circuit for starting purposes and for changing the speed / torque
characteristics.
When motor is running at its rated speed, slip rings are automatically
short circuited by means of a metal collar and brushes are lifted above the
slip rings to minimize the frictional losses.

4.2 Design of AC windings:

The ac windings for induction motors is built in one or two layers. The basic
structural element is represented by lap and wave coils.

Figure 4. Bar coils: a.) continuous bar, b.) semi bar

The single turn bar coils are made of continuous bars for open bars as shown in
figure for open slots or from semi-bars bent and welded together after insertion
in semi-closed slots as shown in figure. These are preformed coils generally
suitable for large machines.

Continuous bar coils can be made from few elementary conductors in parallel
to reduce the skin effect to acceptable levels.
On the other hand, round-wire, mechanically flexible coils forced into semi-
closed slots are typical for low power induction machines. Such coils have
various shapes shown in figure 5.

Figure 5. Full pitch coil groups/phase/pole−for q = 2−for single layer

a.c. windings:

The coils for single layer windings are always full pitch as an average. These
coils may be concentrated or identical. The main criteria should be to
produce equal resistance and leakage inductance per phase.

The rounded concentrated or chain-shape identical coils are preferred for

single layer windings. For double layer windings for low power induction
machines are of trapezoidal shape and round shape wire type.
Figure 6. Typical coils for two-layer a.c. windings:

a. trapezoidal flexible coil (round wire);

b. rounded flexible coil (rounded wire);

c. preformed wound coil (of rectangular wire) for open slots.

For large power motors multi bar or uni-bar coils are used. For a.c. windings
design may be integer q or fractional q (q = a+b/c) windings with total
number of slots

N = 2p1qm.

The number of slots per pole is integer. For fractional q the latter is different
and integer for phase under different poles. Only average q is fractional.

Single-layer windings are built only with an integer q. As one coil sides
occupy 2 slots, it means that Ns/2m = integer (m– number of phases; m = 3 )
for single-layer windings. The number of inward current coil sides is equal to
the number of outward current coil sides.

For two-layer windings the allocation of slots per phase is performed in one
upper layer. The second layer is occupied “automatically” by observing the
coil pitch whose first side is in one layer and the second one in second layer.

In this case Ns/m = an integer.

Full pitch coil groups/phase/pole−for q = 2−for single layer a.c. windings:

a.) with concentrated rectangular shape coils and 2 (3) store end
connections.

b.) with concentrated rounded coils

c.) with chain shape coils.

A pure traveling stator mmf with an open rotor winding and a constant
airgap when the stator and iron core permeability is infinite, will produce no-
load ideal flux density in the airgap as

Bg10(x,t)= µ0 1gF m cosπτ x − ω1t ----------(1) according to Biot – Savart law.

This flux density will self-induce sinusoidal emfs in the stator windings.

The emf induced in coil sides placed in neighboring slots are thus phase
shifted by αes
αes = 2Nπps ----------------------- (2)

The number of slots with emfs in phase, t, is

t = greatest common divisor (Ns,p1) = g.c.d. (Ns,p1) ≤ p1  --------------(3)

Thus, the number of slots with emfs of distinct phase is N s/t. Finally, the
phase shift between neighboring distinct slot emfs αet is
αet =2Nπst ----------------------------------(4)

If αes = αet, that is t = p1, the counting of slots in the emf phasor star diagram
is the real one in the machine.
Now consider the case of a single winding with Ns = 24, 2p1 = 4.
In this case αes = 2Nπps 1 = 2π⋅242 = π6 -----------------------(5)
t = g.c.d. (Nsp1) = g.c.d.(24,2) = 2 = p1 --------------------------------(6)

So, the number of distinct emfs in slots is Ns/t = 24/2 = 12 and their phase
shift αet = αes = π/6.
So, their counting (order) is the natural one as shown in figure 7.
Figure 7. The star of slot emf phasors for a single-layer winding
q=2,2p1=3,m=3, N1 = 24 slots

 The allocation of slots of phases to produce symmetric winding is done

as follows for
 Single-layer windings
o Built up the slot emf phasor star based on calculating αet, αes, Ns/t
distinct arrows counting them in natural order after αes.
o Choose randomly Ns/2m successive arrows to make up the
inward current slots of phase A Figure 7.
o The outward current arrows of phase A are phase shifted by π
radians with respect to the inward current ones.
o By skipping Ns/2m slots from phase A, we find the slots of phase
B.
o Skipping further Ns/2m slots from phase B we find the slots of
phase C.
 Double-layer windings
o Build up the slot emf phasor star as for single-layer windings.
o Choose Ns/m arrows for each phase and divide them into two
groups (one for inward current sides and one for outward current
sides) such that they are opposite as possible.
o The same routine is repeated for the other phases providing a
phase shift of 2π/3 radians between phases.
 The above rules are valid for the case of fractional q. Fractional q
windings are built in two-layers only and small q to reduce the order of
first slot harmonic.
 Placing the coils in slots For single-layer, full pitch windings, the inward
and outward side coil occupy entirely the allocated slots from left to
right for each phase. There will be Ns/2m coils/phase.
 The chorded coils of double-layer windings, with a pitch y (2τ/3 ≤ y <τ
for integer q and single pole count windings) are placed from left to
right for each phase, with one side in one layer and the other side in
the second layer. They are connected observing the inward (A, B, C)
and outward (A’, B’, C’) directions of currents in their sides.
 Connecting the coils per phase Ns/2m coils per phase for single-layer
windings and the Ns/m coils per phase for double-layer windings are
connected in series (or series/parallel) such that for the first layer the
inward/outward directions are observed.
 With all coils/phase in series, we obtain a single current path (a = 1).
We may obtain “a” current paths if the coils from 2p1/a poles are
connected in series and, then, “a ” chains in parallel.

 Example

Let us design a single-layer winding with 2p 1 = 2 poles, q = 4, m = 3

phases.

Solution
Figure 8. The star of slot emf phasors for single-layer winding q=1,
2p1=2,m=3,N1=24.

The angle αes and αst are

αes = 2πps / N ; N=24
αet =2πst /N
α es = 2πP3 / N
= 2π .1 /24 = π/12
αet =2πst /N
t = g.c.d.(Ns, P1) = g.c.d. (24,1) = 1
Also, the count of distinct arrows of slot emf star Ns/t = 24/1 = 24.
Consequently, the number of arrows in the slot emf star is 24 and their order
is the real (geometrical) one (1, 2, … 24) as shown in figure 8.

Making use of figure 8 we may allocate the slots to phases in Figure 9.

Figure 9. Single layer winding layout.

a)slot/phase allocation b.) rounded coils of phase A c.) coils per
phase

2p1 = 4, m = 3, (Ns = 2p1qm = 36 slots), chorded coils y/τ = 7/9 with a = 2

current paths.

Solution
To calculate αes, t, αet:

Figure 10. The star of slot emf phasors for a double-layer winding

αes = 2 π Ps /Ns = 2 π . 2 / 36 = π / 9.

t = gcd(36,2) = 2

with 2p1 = 4 poles , q=3 slots/pole/phase m=3 , Ns =36

= αes N / ts = 36/ 2 =18

There are 18 distinct arrows in the slot emf star as shown in Figure 10. The
winding layout is shown in Figure 11.

We should notice the second layer slot allocation lagging by τ – y = 9 – 7 = 2

slots, the first layer allocation. Phase A produces 4 fully symmetric poles.
Also, the current paths are fully symmetric. Equipotential points of two
current paths U – U’, V – V’, W – W’ could be connected to each other to
handle circulating currents due to, say, rotor eccentricity.

Figure 11. Double layer winding 2p1 = 4 poles , q=3, y/τ = 7/9 , Ns =
36 slots , a=2 current paths.

4.3 Output equation with usual notation

The output equation is the mathematical expression which gives the relation
between various physical and electrical parameters of the electrical machine.

 In induction motor the output equation is obtained as :

 Consider an ‘m’ phase machine, with usual notations

 Output Q in kW = Input x efficiency

 Input to motor = 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 kW

Assuming
 Vph = Eph, Vph =

Eph = 4.44 f Φ TphKw

 = 2.22 f ΦZphKw

 f = PNS/120 = Pns/2,

 Output = 3 x 2.22 x Pns/2 x ΦZphKw Iph η cos Φ x 10-3 kW

Output = 1.11 x PΦ x 3Iph Zph x ns Kw η cos Φ x 10-3kW

PΦ = BavπDL, and 3Iph Zph/ πD = q

Output to motor = 1.11 x BavπDL x πDq x ns Kw η cos Φ x 10-3 kW

 Q = (1.11 π2 Bav q Kw η cos Φ x 10-3) D2L ns kW

Q = (11 Bav q Kw η cos Φ x 10-3) D2L ns kW

Therefore, Output Q = Co D2L ns kW

where

Co = (11 Bav q Kw η cos Φ x 10-3)

Vph = phase voltage ;

Iph = phase current

Zph = no of conductors/phase

Tph = no of turns/phase

Ns = Synchronous speed in rpm

ns = synchronous speed in rps

p = no of poles,

q = Specific electric loading

Φ = air gap flux/pole;

Bav = Average flux density

kw = winding factor

η = efficiency cosΦ= power factor

D = Diameter of the stator,

L = Gross core length

Co = Output coefficient
Figure 12. Dimensions of D and L

KVA input (Q) = KW/ ¿ cos Ø)

The KVA input (Q) in terms of horse power is given by :
Q = h.p x 0.746/ η cos Ø

4.4 Specific electrical and magnetic loading:

Specific electrical loading can be defined as the number of armature conductors
per meter of armature periphery at air gap.

Specific magnetic loading :-The average flux density that is, the total magnetic
loading divided by the peripheral area in the armature of a machine.

Specific magnetic loading:

The specific magnetic loading is determined by
 Maximum flux density in iron parts of the machine.
 Magnetizing current
 Core losses
Maximum flux density in iron:
The maximum flux density in any iron part of the magnetic circuit of the machine
must be below a certain limiting value depending on the material used.
The flux density in air gap that is specific magnetic loading as shown by equation
by
Flux density in teeth B4 = flux in each tooth / area of each tooth
Bav = ys L/Wt L = ys/Wt.-------------------(1)
In a salient pole machine, the flux is concentrated over pole arc therefore the
teeth under the pole arc carry whole of the flux carried by the teeth lying outside
the pole arc.

Hence, flux density in the teeth of salient pole machine is Bt = Bg/ φ . ys/Wt
------------(2)
where
Bg = maximum flux density in the air gap

φ=¿ ratio of pole to pole pitch.

From equations (1) and (2) it is clear that flux density in the teeth is directly
proportional to specific magnetic loading.
We have

Bt/Bav = ys/φ . Bg’…………………………..(3)

Relation between the flux density in teeth and average flux density in
air gap.
Let us consider non-salient pole machine having S armature slots .
Flux over one slot pitch = pØ/S = p. Bav π DL/p . 1/S = Bav . π D/S L = Bav ys L
Where ye = slot pitch = π D/S
If we neglect saturation the entire flux over a slot pitch is carried by the tooth

Figure 13. Flux over slot pitch

Figure 14. Armature with tapered teeth

If we neglect saturation the entire flux over a slot pitch is carried by the tooth. In
a salient machine the flux is concentrated over the pole arc and therefore the
teeth which are under the pole arc carry whole of the flux and hardly any flux is
carried by the teeth lying outside the pole arc
Hence, flux density in the teeth of salient pole machine is Bt = Bav/Ø .ys / Wt.
But Bg = Bav/ Ø
Where Bg = maximum flux density in the air gap
Ø = ratio of pole arc to pole pitch.

Magnetising current:
The magnetising current is directly proportional to the mmf required to force the
flux through air gap and iron parts of the machine.
The mmf required for air gap is directly proportional to the gap flux density that
is specific magnetic loading.

Figure 15. Relation between B-H curve.

The value of flux density depends on the value of specific magnetic loading. If a
small value of specific magnetic loading is chosen, the flux density in iron parts
is low therefore these parts are worked on the linear or knee portion of B-H
curve.

This requires small or even negligible value of mmf for iron parts as H, mmf per
metre length is very small for flux densities on the linear and knee portions of
the curve.

If large value of specific magnetic loading is assumed the flux density in iron
parts work in the saturation region of B-H curve.

Core Loss:
The area of cross-section of iron parts of the magnetic circuit of a machine is

= flux carried by the part / flux density in the part α 1/B

If this part is subjected to alternating magnetization there will be core loss in it.
Total core loss = loss per unit volume x volume

= loss per unit volume x area x length α B2 x (1/B) α B

Thus core loss in any part of the magnetic circuit is directly proportional to the
flux density to be designed.

Specific electrical loading:

Figure 16. Slot and teeth armature of rotating machine

Permissible temperature rise:
An armature of a rotating machine is shown in figure 16. For this machine , let
Z = total number of armature conductors
S = number of armature slots
As = area of each conductor

ρ=¿ resisitivity of conductor material

δ =¿ current density.
Therefore, if we consider a slot pitch ampere conductors per metre for this
portion are :

---------------------(1)
Where Zs = Z/S = number of conductors per slot.

Resistance of slot portion of each conductor = ρ L/¿ az-----------------(2)

I 2
R loss in slot portion of each conductor = Iz 2
ρ L/¿ Z ----------------------(3)
Therefore, I2 R loss in each slot = Zs Is 2 ρ L/¿ az -------------------------(4)
Heat produced in a slot is dissipated over the surface over one slot pitch.
Considering only the cylindrical surface
Heat dissipating surface S = ys L -------------------------(5)

Loss dissipated per unit area of armature surface q = loss / surface = Zs Lz2 ρ L/
az ys L = Iz Zs /ys . Iz/az . ρ ----------------------(6)

ac = Iz Zs/ys and δ =¿ Iz/az

= ac δ ρ .--------------------------------------(7)

Therefore heat dissipated per unit area of armature surface is proportionl to

specific electric loading.

Temperature rise θ = Qc /S where Q is the loss dissipated and S is the dissipation

surface and c is the cooling co-efficient.
Loss dissipated per unit area q = Q/S---------------------(8)

Temperature rise θ = qc = ac ρ δ c ----------------------------------------(9)

Therefore, specific electric loading ac = θ / ρ δ c -------------------------------------(10)

The effects of different factors are :

 Temperature rise:
The spein a machine high maxicific electric loading is used when high maximum
temperature is allowed. The maximum allowable temperature is determined by
the type of insulating materials used.

For example organic materials like cotton, paper and varnishes may be worked
upto maximum temperature. Hence, better quality insulating materials can
withstand high temperature rises are used in machines.

 Cooling co-efficient
From equation(10) we find that if the cooling coeffecient of the machine is small
high specific electric loading may be used in the machine.
The value of cooling coeffecient c depends upon the ventilation conditions of the
machine. A machine with better ventilation has lower value for cooling co-
efficient and therefore high value of specific electric loading may be used due to
high speed ventilation conditions.
Voltage
Area of each slot = height of slot x width of slot = ds Ws

D
Total area of all slots = SdsWs = π dsWs = π D ds (Ws/ys)
ys
Therefore, total area of conductors in slts = π D ds (Ws/ys) St ------------(1)

where
Sf = space factors for slots.

Also total area of conductors (bare) = Zaz = Z Iz ¿ δ = π D ac/ δ ------------------(2)

As az = Iz/δ and Iz Z = = π D ac

π D ac/ δ = π D ds(Ws/ys) St --------------------(3)

a c = ds ds(Ws/ys) St --------------------(4)

From eq(4) for a fixed ratio of slot width to slot pitch and fixed values of depth of
slot and current density the specific electric loading is directly dependent upon
the space factor Sf that is the ratio of bare conductor area to total slot area.

In high voltage machines greater insulation thickness is required and space

factor for these machines are lower.

Problems:
A 125W , 230V 5000rpm universal motor has a full load effeciency of 50 per cent.
Calculate the power developed by a motor if the sum of the friction and winding
losses is approximately 1/3 of total losses.
Solution:
Efficiency = output/ output + losses
0.5 = 125/125 + losses
Total losses = 125W and constant losses = 125/3 =42 W
Therefore, power developed by armature Pa = 125 + 42 = 167 W

4.5 Ranges of specific loadings

The ranges of specific loadings are :
Specific magnetic loading = 0.3 to 0.6 Wb / m2
Specific electric loading = 5000 to 45000 amp.cond/m
4.6 Turns per phase
On armature:
Each slot has two positions: top and bottom (double layer winding)
Each coil needs to occupy 2 positions: top position of one slot and bottom
position of another slot.
Number of armature coils = number of armature slots (S)
M phase machine:
Number of coils per phase Sph = S/m
Number of turns per phase Nph = Sph Nc = S x Nc/m
Number of conductors per phase Cph = 2 Nph = S x Nc Xx 2 / m

Figure 17. 2-pole , 4-pole Phase A full pitch

Slot pitch is defined by

where is the mechanical angle between two adjacent slots:

The slot pitch is defined as the arc length between two slots on stator inner
circle(with diameter D)

Figure 18. Three phase 2-pole Phase A full pitch.

Full-Pitch coil: If the armature coil stretches across the same angle as pole pitch
it is called full-pitch coil. The coil spans across Sp slots, if Sp is an integer.

Fractional Pitch coils: If the armature coil stretches across an angle smaller than
a pole pitch it is called fractional-pitch coil. The coil spans less than Sp slots.

Let Sc be the number of slots that the coil spans.

Let ρm = Se γm.

Coil pitch in electrical angle us defined by ρ=¿P/2 ρm .

ρ/ π = ρm / ρp = Sc/Sp.

The emf equation of induction motor is given by

Eph = 4.44 fØ Tph Kw-------------------(1)

Hence, the turns per phase can be obtained from emf equation Tph = Eph / 4.44
fØ Kw.

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

Flux/pole = Bav x π D L / P

winding factor kw may be assumed to be 0.955 for full pitch distributed winding
unless otherwise specified.

Number conductors/phase = Zph = 2 x Tph

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.

4.7 Number of stator slots

In general, two types of stator slots are used in induction motors open type and
semi-closed slots. Operating performance on induction motor depends on the
shape of the slots and hence to select suitable slot for stator slots

Open slots: In this type the slot opening is equal to the width of the slots as
shown in figure. In such type of slots assembly and repair of winding are easy.
But such slots lead to higher air gap contraction factor hence there is poor power
factor. These are rarely used.
Semi-closed slots: The slot opening is smaller than the width of the slot. Hence
in this type of slots in assembly of windings is more difficult and takes more time
compared to open slots hence it is costlier.

Tapered slots: In this type of slots opening will be much smaller than the slot
width. The slot width will be varying from top of the slot to bottom of the slot
with minimum width at bottom.

Figure 19. Stator slots.

Selection of number of stator slots:

Number of stator slots must be properly selected at design stage such that this
number affects the weight, cost and operating characteristics of motor. Though
there are no rules for selecting the number of stator slots the higher number
slots has to be set for selecting the number of slots.
Problem:
Obtain the following design information for the stator of a 30kW , 440 V
, 3∅ , 6 pole , 50 Hz delta connected squirrel cage induction motor.

 Main dimension of the stator

 No of turns/phase
 No of stator slots
 No of conductors per slot
Assume suitable values for the missing design data.
Specific magnetic loading Bav = 0.48 Tesla
Specific electrical loading q = 26000 ac/m
Full load efficiency η = 0.88
Full load power factor cos ∅ = 0.86

Winding factor Kv = 0.955

 Main dimension from output equation is given by :

2 3
D L = Q(Co no) m

Co = 11 Bav q Kv η cos ∅ x 10 -3

-3
= 11 x 0.48 x 26000 x 0.955 x 0.88 x 0.86 x 10

= 99.2

Ns = 16.67 rpm

2 3
D L = 30(99.2 x 16.67) = 0.0182 m
Designing the machine for better power factor
D = 0.135 P√L
= 0.135 x 6 √ L
D = 0.33 m and L = 0.17 m
No of stator turns
Ø = ( π D L /P) Bav
= π x 0.33 x 0.17 /6) x0.48 = 0.141 wb

Assuming Eph = Vph = 440 volts

Tph = Eph / 4.44 f ∅ Kv

= 440 / 4.44 x 50 x 0.141 x 0.955 = 148

 No of stator slots

Assuming the no of slot/pole/phase = 3

Total no of slots = 3 x 3 x 6 = 54

 No of conductors per slot

Total no of conductors = 148 x 2 = 296

No of conductors/slot = 296/54 = 5.5
Assuming 76 conductors/slot
Total no of conductors = 54 x 6 = 324.
Revised no of turns/phase = 162.

Problems:
A 15 kW 440m volts 4 pole, 50 Hz, 3 phase induction motor is built with a stator
bore of 0.25 m and a core length of 0.16 m. The specific electric loading is 23000
ac/m. Using data of this machine determine the core dimensions, number of slots
and number of stator conductors for a 11kW, 460 volts,6 pole, 50 Hz motor.
Assume full load efficiency of 84 % and power factor of 0.82. The winding factor
is 0.955.
Soln: For 15 kW motor:
Motor Input = 15 /0.84 = 17.857 kW ;
Synchronous speed ns= 120 x 50 /(4 x 60) = 25 rps;
we have output coefficient Co = out put / D2 Lns = 15 /( 0.252 x 0.16 x 25) = 60
we have Co = 11 Bav q Kw η cosΦ x 10-3 = 11 x Bav x 23000 x 0.955x 0.84 x
0.82 x 10-3 = 166.42 Bav Hence Bav = 60/166.42 = 0.36 Tesla
Pole pitch τp= π D/p = π x 0.25/4 = 0.196 m;
L/ τp = 0.815 For 11kW motor:
The design data from 15 kW machine has to be taken
So Bav = 0.36 Tesla;
q = 23000 ac/m ; L/ τp = 0.815; and C0 = 60
Synchronous speed = 120 x 50 / (6 x 60) = 16.667 rps;
2
D L = Q/ (Co ns ) m3 = 11 / (60 x 16.667) = 0.01099 m3 L/ (π D /p) = 0.815 ,
So L/D = 0.815 x π /6 = 0.427 or L = 0.427 D
Substituting this value in D2 L product and solving for D and L 0.427 D3 =
0.01099
hence D = 0.30 m and L = 0.125 m
Number of slots:
Considering the slot pitch at the air gap between 1.5 cm and 2.5 cm
Number of slots = π x D/ τs for slot pitch 1.5 cm,
Ss = π x 30 / 1.5 = 63
For slot pitch 2.5 cm
Ss = π x 30 / 2.5 = 37
Hence number of slots must be between 37 & 63
Assuming no. of stator slots /pole/phase = 3,
Ss = 6 x 3 x 3 = 54
Flux per pole = Bav x D x L / p = 0.36 x π x 0.3 x 0.125/6 = 7.07 x 10-3 wb
Assuming star delta connection for the machine, under running condition using
Delta connection Stator turns per phase Tph= Eph/ (4.44 f Kw) = 460 /(4.44 x 50
x 7.07 x 10-3 x 0.955) =307
Number conductors/phase = 307 x 2,
Total number of stator conductors = 307 x 2 x 3 =1872
Number of conductors per slot = 1872/54 = 34.1 ≈ 34
Hence, total number of conductors = 34 x 54 =1836.
During the preliminary design of a 270 kW, 3600 volts, 3 phase, 8 pole 50 Hz slip
ring induction motor the following design data have been obtained. Gross length
of the stator core = 0.38 m, Internal diameter of the stator = 0.67 m, outer
diameter of the stator = 0.86 m, No. of stator slots = 96, No. of conductors /slot
= 12, Based on the above information determine the following design data for
the motor.
(i) Flux per pole
(ii) Gap density
(iii) Conductor size
(iv) size of the slot
(v) copper losses
(vi) flux density in stator teeth
(vii) flux density in stator core.
Soln.

(i) Flux per pole Number of slots per phase 96/3 = 32 Number of turns per
phase Tph = 32 x 12/2 = 192,
Assuming full pitched coils, kw = 0.955, Eph = Vph and star connected
stator winding, Eph = 3600/√3 = 2078 volts,
We have Eph = 4.44fΦTphkw, ie Φ= Eph /( 4.44fTphkw) = 2078 /( 4.44 x
50 x 192 x 0.955) = 0.051wb.

(ii) Gap flux density

Ag = πDL/p = π x 0.67 x 0.38 / 8 = 0.1 m2 Bg = Φ/ Ag = 0.051/ 0.1 =0.51
Tesla

(iii) Conductor size Assuming an efficiency of 91% and a full load power factor
of 0.89 Input power to the motor = 270 x 103 / 0.91 = 296703 w Full load
current per phase = 296703 / ( 3 x 2078 x 0.89) = 53.47 amps Assuming
a current density of 4.1 amp/mm2 , area of cross section of the conductor
= 53.47 /4.1 = 13.04 mm2 as the conductor section is > 5 mm2
rectangular conductor is selected. Standard size of the conductor selected
satisfying the requirements is 2.5 mm x 5.5 mm. Thus, sectional area of
the conductor 13.2 mm2 Size of the conductor with insulation thickness of
0.2 mm is 2.9 mm x 5.9 mm
(iv) size of the slot 12 conductors per slot are arranged in two layers with 6
conductors in each layer. Six conductors in each layer are arranged as 2
conductors depth wise and 3 conductors width wise.

With this arrangement the width and depth of the slot can be estimated as
follows.

(a) Width of the slot Space occupied by insulated conductor, 3 x 2.9 8.7 mm Coil
insulation, 2 x 1.0 2.0 mm Slot liner, 2 x 0.2 0.4 mm Clearance 0.9 mm Total
width of the slot 12.0 mm

(b) Depth of the slot Thus the dimension of the slot 12.0 mm x 35.0 mm

(v) Copper losses in stator winding Length of the mean turn, lmt = 2L + 2.3 τp +
0.24 = 2 x 0.38 + 2.3 x π x 0.67/8 + 0.24 = 1.6 m

Resistance per phase = (0.021 x lmt x Tph ) / as = 0.021 x 1.6 x 192 / 13.2 =
0.49 ohm.

Total copper losses = 3Is 2 rs = 3 x 53.472 x 0.49 =4203 watts

(vi)Flux density in stator tooth

Diameter at 1/3rd height, D' = D + 1/3 x hts x 2 = 0.67 + 1/3 x 0.035 x 2

= 0.693 m
Slot pitch at 1/3rd height = τ ' s = π x D' /Ss = π x 0.693 /96 = 0.02268 m
Tooth width at this section = b' t = τ ' s – bs = 0.02268 – 0.012 = 0.0168
m assuming 3 ventilating ducts with 1cm width and iron space factor of
0.95 Iron length l i = ( 0.38 -3 x 0.01) 0.95 = 0.3325 m
Area of the stator tooth per pole A' t = b' t x l i x number of teeth per pole
= b ' t x l i x Ss /p = 0.01068 x 0.3325 x 96/8 = 0.04261 m2
Space occupied by insulated conductor, 4 x 5.9 23.6 mm Coil insulation, 4
x 1.0 4.0 mm Slot liner, 3 x 0.2 0.6 mm
Coil separator, 1 x 1.0 0.5 mm Top liner, 1 x 1.0 0.5 mm Wedge 3.0 mm
Lip 1.5 mm Clearance 1.3 mm Total height of the slot 35.0 mm Mean flux
density in stator teeth B't = Φ / A' t = 0.051/ 0.04261 = 1.10 Tesla
Maximum flux density in stator tooth =1.5 x 1.10 = 1.65 Tesla

(vii)Flux density in stator core

Depth of the stator core dcs = ½ ( Do- D – 2 hss) = ½ ( 0.86 - 0.67 – 2
x 0.035) = 0.06 m Area of stator core Ac = Li x dcs = 0.3325 x 0.06 =
0.01995 m2
Flux in stator core = ½ x Φ = ½ x 0.051 = 0.0255 wb
Flux density in stator core, Bc = Φc / Ac = 0.0255/ 0.01995 = 1.28
Tesla

While designing the stator of a 3 phase 10 kW, 400 volts, 50 Hz, 4 pole, wound
rotor induction motor, following data are obtained. Internal diameter of stator =
0.19 m Gross length = 0.125 m Number of stator slots = 36 Number of
conductors/slot = 38 Dimension of stator slot = 1.1 cm x 3.5 cm Depth of the
stator core = 3 cm Number of rotor slots = 30 Dimension of the rotor slot = 0.7
cm x 3.0 cm Depth of rotor core = 3.0 cm Carter’s coefficient for the air gap =
1.33 Based on the above data.

Calculate the following performance data for this motor. (

i) Flux per pole

ii) Iron losses
iii) Active component of no load current
iv) No load current
v) No load power factor

Soln.

(i) Flux per pole Total number of stator conductors = 36 x 38 = 1368 Stator
turns per phase Tph = 1368 /6 = 228 Assuming star delta connection for
the motor Vph = 400 volts Assuming Eph = Vph = 400 volts, winding
factor = 0.955 Air gap flux per pole Φ = Eph/(4.44fTph kw) = 400/( 4.44 x
50 x 228 x 0.955) = 0.00827 wb
(ii) Iron losses Total Iron losses = Iron losses in stator teeth + Iron losses in
stator core Iron losses in stator teeth: For the given stator length
assuming one ventilating duct of width 1cm and iron space factor of 0.95,
Li = (L – nd x wd)ki = (0.125 -1 x 0.01)0.95 = 0.109 m Diameter at 1/3rd
height, D' = D + 1/3 x hts x 2 = 0.19 + 1/3 x 0.035 x 2 = 0.213 m Slot
pitch at 1/3rd height = τ ' s = π x D' /Ss = π x 0.213 /36 = 0.0186 m Tooth
width at this section = b' t = τ ' s – bs = 0.0186 – 0.011 = 0.0076 m Area
of the stator tooth per pole A' t = b' t x l i x number of teeth per pole = b'
t x l i x Ss /p = 0.0076 x 0.109 x 36/4= 0.00746 m2 Mean flux density in
stator teeth B't = Φ / A' t = 0.00827/ 0.00746 = 1.10 9 Tesla Maximum
flux density in stator tooth =1.5 x 1.109 = 1.66 Tesla Volume of all the
stator teeth = b' t x l i x height of teeth x number of teeth = 0.0076 x
0.109 x 0.035 x 36 = 0.001044 m3 Weight of all the teeth = volume x
density Assuming a density of 7.8 x 103 kg/ m3 Weight of all the teeth =
0.001044 x 7.8 x 103 = 8.14 kg Total iron losses in the stator teeth =
Total weight x loss/kg Iron loss in the material at a flux density of 1.66
Tesla from graph PP-22 of DDH loss/kg = 23 w/kg Total iron losses in the
stator teeth = 23 x 8.14 = 187.22 watts Iron losses in stator core :
Sectional area of the stator core = l i x dc = 0.109 x 0.03 = 0.00327 m2
Mean diameter of the stator core below the slots = 0.19 + 2 x 0.035 +
0.03 = 0.29 m Volume of the stator core = π x D x Acs = π x 0.29 x
0.00327 = 0.002979 m3 Weight of the stator core = 0.002979 x 7.8 x 103
= 23.23 kg Flux density in stator core = Φc / Acs = 0.00827/(2 x 0.00327)
= 1.264 Tesla At this flux density iron loss/kg = 17 watts/kg Iron losses in
the stator core = 17 x 23.23 = 394.91watts Total iron losses in the stator
= 187.22 + 394.91= 582.13 watts
(iii) Active component of no load current Assuming the friction and windage
losses as 1% of output Friction and windage loss = 100 w Total no load
losses = 582.13 + 100 = 682.13 watts Active component of no load
current = Iron loss component of current Iw= Total no load losses / ( 3 x
phase voltage) = 682.13/( 3 x 400) = 0.568 amps
(iv) Magnetising current: In order to calculate the magnetizing current ampere
turns required for the various parts of the magnetic circuits are to be
calculated.
(a) Ampere turns for the stator core: Pole pitch at he mean diameter of
the stator core = π x D/ P = π x 0.29/ 4 = 0.23 m Length of the flux path
in stator core = 1/3 x 0.23 = 0.077 m Ampere turns per meter at a flux
density of 1.264 Tesla from graph (PP-22 of DDH) 400 AT Hence total
ampere turns required for the stator core = 400 x 0.077 = 31
(b) Ampere turns for the stator teeth: Length of the flux path in stator
teeth = 0. 5 = 1.36 x 1.10 9 =1.508 Tesla Ampere turns per meter at a
flux density of 1.508 Tesla (from graph PP-22 of DDH) is 1000 AT Hence
total ampere turns for the stator teeth = 1000 x 0.035 = 35
(c) Ampere turns for the air gap: Length of the air gap = 0.2 + 2√DL = 0.2
+ 2√0.19 x 0.125 = 0.51 mm Average flux density in the air gap = Φ/ (π x
DL/ P) = 0.4696 Tesla Carter’s coefficient for the air gap = 1.33
Air gap flux density at 300 from the centre of the pole Bg = 1.36 x Bav =
1.36 x 0.4696 = 0.6387 Tesla Hence Ampere turns for the air gap =
796000Bgkglg ATg = 796000 x 0.687 x 1.33 x 0.51 x 10-3 = 371 AT
(d) Ampere turns for the rotor Teeth : Diameter of the rotor = D -2lg
=0.19 – 2 x 0.00051= 0.189 m Diameter at 1/3rd height form the narrow
end of the teeth Dr ’ = D – 2 x 2/3hrs = 0.189 – 4/3 x 0.03 = 0.149 m
Slot pitch at 1/3rd height = τ ' r = π x Dr ' /Sr = π x 0.149 /30 = 0.0156 m
Tooth width at this section = b' tr = τ ' r – br = 0.0156 – 0.007 = 0.0086 m
Area of the stator tooth per pole A' tr = b' tr x l i x number of teeth per
pole = 0.0086 x 0.107 x 30/4 = 0.0069 m2
Flux density in rotor teeth at 300 from pole centre = 1.36 x
0.00827/0.0069 = 1.63 Tesla Ampere turns/m at this flux density, from
graph (PP-22 of DDH) = 2800
Length of flux path in rotor teeth = 0.03 m Ampere turns for the rotor
teeth 2800 x 0.03 = 84
(e) Ampere turns for the rotor core Depth of the rotor core dcr = 3 cm
Area of the rotor core Acr = 0.03 x 0.107 = 0.00321 m2 Flux in the rotor
= ½ x 0.00827 = 0.004135 wb Flux density in the rotor core =
0.004135/0.00321= 1.29 Tesla Ampere turns/m at this flux density, from
graph (PP-22 of DDH) = 380
Mean diameter of the rotor core = Dr – 2 x hrs – dcr = 0.189 – 2 x 0.03 –
0.03 = 0.099 m Pole pitch at this section = π x 0.099 /4 = 0.078 m
Length of the flux path in rotor core = 1/3 x 0.078 = 0.026 m
Total ampere turns for the rotor core = 380 x 0.026 =10
Total Ampere turns for the magnetic circuit = 31 + 35 + 371 + 84 +10 =
531 AT
Magnetising current Im = p(AT30) / (1.17 x Kw x Tph) = 2 x 531 /( 1.17 x
0.955 x 228) = 4.2 amps
(v) No load current No load current per phase Io = √( Iw 2 + Im 2 ) = √( 0.562
+ 4.22 ) = 4.24 amps
(vi) No load power factor cos 0 = Iw/I0 = 0.56 /4.24 = 0.132
References:
1. A.K Sawhney – A course in Electrical Machine Design 10 th Edition –
Dhanpat Rai and sons.
2. Design of Electrical Machines, New age publication KG Upadhyay
3. Principles of Electrical Machine Design R.K Agarwal.
4. Electrical Machine Design Book by V. Rajini and V. S. Nagarajan
5. Design Of Electrical Machines by Mittle V.N
.