Performance analysis of diecast multicage induction

motors: a comparative study of two approaches

M. Ramakrishna Rao, M.Tech., Mem.I.E.E.E., V. Subba Rao, M.Tech., Ph.D., Mem.I.E.E.E., and
B.G. Desai, M.E., Ph.D., Sen. Mem.I.E.E.E.

Indexing terms: Machine theory, Skin effect, Squirrel-cage motors

Abstract

The paper presents a comparative study of the analysis of diecast double-cage induction motors by
single-cage/deep-bar approach^nd.multicage-approach methods. In both the methods, saturation of
leakage flux paths and main flux paths have been considered. The performance of individual cages and
saturation effects have been clearly brought out. The skin-effect ratios for the rotor, obtained by both
the methods, are compared. The validity of the equations is ascertained by comparison with the
experimental results.
List of symbols

B = flux density, T
/ = frequency, Hz
G = current density, A/m2
H field intensity, A/m
/ = inductance, H
r = resistance, S7
H = permeability
p = resistivity, 2m
OJ = angular frequency = 2irf

Introduction

During the diecasting process of double-cage induction motors, the portion separating the top and bottom
cages is also filled up with aluminium and this provides an
electrical contact between top and bottom cages all along
their length. The filling up of the neck of the rotor slots
enables one to view it either as a multicage or a single-cage
rotor.
Although solutions for a.c. impedance of straight and
tapered bars have been developed to some extent, there is
no published literature dealing exclusively with conductor
sections encountered in the present analysis. Babb and
Williams1 have approached the impedance of single-cage
conductors of complicated shape by analogy with transmission lines in which the accuracy depends on the number
of T or IT sections used. But in the present case, the singlecage/deep-bar approach has been extended to multicage
rotors.
Many authors, e.g. Alger and Wray,2 Lee,3 Goodman4
and Jacobs,s have suggested methods for double-cage rotors.
Alger2 has extended his method of analysis to triple-cage
rotors, but his method of analysis pertains to unskewed
rotors with rectangular sections. In the discussion of his
paper, Lee has suggested a better way of representing the
triple cage, and in the present paper, this suggested method
has been adopted.
Results of analysis obtained by both the methods have
been compared with each other under saturated and
Paper 7237 P, first received 8 th May 1973 and in revised form
12th June 1974
Mr. Ramakrishna Rao and Dr. Desai are with the Research <$ Development Centre, Rotating Electrical Machines Section, Jyoti Ltd.,
Baroda, India, and Dr. Subba Rao is with the Department of
Electrical Engineering, Indian Institute of Technology, Bombay,
India

1122

unsaturated conditions. Tests have been carried out on

machines ranging from about 11 kW to 90 kW (15 HP to
120 HP) and the test results compared with the computed
results of both methods.
2

Method of approach

2.1

Single-cage/deep-bar approach

In this approach, no distinction is made between

the individual cages, and the triple-cage slot is viewed as one
cage. Skin-effect ratios have been rigorously accounted for
by evaluating analytically the skin-effect phenomenon within
the conductor at various slips. Here, the method suggested
by Liwschitz6 for evaluating the skin-effect ratios has been
extended. These ratios are assumed to be independent of
the magnitude of the bar currents.
2.1.1

Derivation of a.c. impedance of the rotor bar

The derivation is based on the following assumptions:

(a) the vertical component of flux is zero
(b) the current density along any line parallel to the bottom
of the slot is constant
(c) the permeability of iron is infinite
(d) the resistivity of the conductor is constant over the depth
of the slot
(e) the width of the bar at any section is the same as the
width of the slot.
The impedance of the bar, at any slip, for the slot with
tapered top and bottom cages is given by

The derivation of the above expression is given in Appendix

7.
2.1.2

Calculation of other machine parameters

The calculations for stator-slot leakage, and zig-zag

leakage for the stator and rotor can be found in Reference 7.
Overhang-leakage reactance was calculated using Barnes's8
PROC. IEE, Vol. 121, No. 10, OCTOBER 1974

formula. Trickey's9 correction factor has been applied to

rotor-ring resistance. Rotor-ring leakage reactance was
calculated by the Lee3 formula. Skew-leakage reactance and
flux were calculated as suggested by Chalmers.11
2.1.3

Saturation of leakage-flux paths

The saturation of leakage-flux paths has been

accounted for in a way similar to that suggested by Chalmers.11
The core length was divided into 20 equal parts, and the
saturation factors for the flux components in the sections
were computed and summed up appropriately to obtain the
total saturated leakage reactance. The limiting flux density
was taken as 2-0 T.
2.2

Multicage approach

In this approach, for the purpose of simplicity of

analysis, the rotor conductors can be considered to constitute a triple cage, the third cage arising from the filling
of the neck. Such a view facilitates an extension of the
double-cage equivalent circuit to suit the present requirement. The equivalent circuit suggested by Lee in Alger's2
paper has been adopted. The skin-effect phenomenon
which takes place in individual cages has not been considered.
Stator slot leakage, zig-zag leakage, overhang leakage, ring
leakage, skew leakage and resistance were calculated in a
similar way to that given in Section 2.1.2. Chalmers's11
method has been extended to take saturation of leakage
flux paths into account.
2.3

Saturation of main flux paths

Saturation of main flux paths has been considered

as suggested by Lee.10 The demagnetising effect of rotor
currents produced by saturation harmonics was not considered.

Comparison of results

Machines ranging from about 90 kW to 11 kW were

selected for comparison of the theoretical values from both
the methods with experimental values. These are 415 V, 50
Hz, 4-pole motors, and are skewed by one stator-slot pitch.
The top and bottom cages of the rotor slots are trapezoidal,
as shown in Fig. 1.

The performance data of the machines were obtained

from an analysis program on a CDC 3600 computer. The
various performances were as follows:
(a) the no load performance at the rated voltage, i.e. when
there is no saturation of leakage flux paths and full
saturation of main flux paths
(b) short-circuit performance at reduced voltage, i.e. when
there is no saturation of main flux paths and some
saturation of leakage flux paths
(c) starting performance, i.e'. when there is full saturation of
main and leakage flux paths
(d) full-load performance at the rated voltage.
The two methods of approach (triple-cage and single-cage/
deep-bar) were applied to each of the above conditions, and
the performances were compared with the test values. The
tests conducted were
(a) no-load test
(b) locked-rotor test at reduced voltage
(c) starting-current oscillograms
(d) full-load test.
The calculated fundamental core losses were multiplied by
an empirical factor. The complete performances obtained
from both the methods are compared and shown in Table 1.
It can be seen that the no-load currents closely agree with
the experimental values in all machines, and that there is
considerable discrepancy in core losses in one machine even
after multiplying by an empirical factor.
From the locked-rotor tests, the reactances and rotor
resistances were calculated taking the effect of magnetising
reactance into account. To ensure compatability of the
measurements with calculated resistance values, the temperature effect has been accounted for as suggested in Reference
12. The resistances obtained from the deep-bar approach are
consistently 2530% less than the test values, whereas the
use of the multicage approach resulted in a much smaller
discrepancy. Also, it can be noted that the saturated current
values show good agreement with the test values, which
indicates that, even at a reduced voltage of 150 V, there is
considerable saturation under locked-rotor conditions. Noload starting-current oscillograms were taken, and the starting currents were compared with the computed values. The
single-cage approach gave higher values than those obtained
experimentally.
Full-load tests at the rated voltage were carried out on
these motors. Slip and stator I2R losses were corrected to

x=O

10

30
40
frequency. Hz

Fig. 2

Variation of skin-effect ratio for rotor resistance with

frequency
Fig. 1

Shape of rotor slot

PROC. IEE, Vol. 121, No. 10, OCTOBER 1974

o = multicage approach
A = experimental results
X = single-cage approach

1123

Table 1

COMPARISON OF PERFORMANCE
37kW(50hp)motor

56 kW (75 hp) motor

90 kW (120 hp) motor

llk\V(15hp)motor

MultiSinglecage
cage
approach approach

Test
value

47-25

48-2

360

36-0

37-2

16-3

16-3

19-5

168-5

168-5

168-5

158-5

158-5

158-5

MultiSinglecage
cage
approach approach

Test
value

SingleMulticage
cage
approach approach

Test
value

SingleMulticage
cage
approach approach

Test
value

No-load current,
47-25

8-67

8-67

10-4

Locked-rotor test
(reduced voltage)
Applied voltage,
V

Current, A
unsaturated
saturated
r'2 SI

Xx + X'2 a

153-0

153-0

1530

163-3
199-8
0-25
0-86

181-3
229-0
0-21
0-58

112-2
i an A
19/-U 152-4
0-29
0-36
0-66
0-96

121-8
176-1
0-30
0-81

lil-5
0-41
1-12

376-0

3760

376-0

336-2

336-2

336-2

354-0

354-0

3540

394-2

394-2

394-2

985-0

11900

1090-0

610-0

6800

4840

352-0

415-0

379-0

188-0

232-0

177-0

10

1 C

65-0
78-6
0-62
1-76

75-6
90-6
0-52
1-50

nn r\
1 h\J

0-68
1-77

98-4

98-4

98-4

14-5
16-8
1-62
5-44

15-5
18-3
1-26
5-00

lo-4
1-55

\ r A

5-4

Starting current
(oscillograms)
Applied voltage,
V

Starting current,
A

Full load test

Current, A
Efficiency, %
Power factor
Slip, %
Losses, kW
Stator I2R losses
Rotor I2R losses
Core losses
Friction and
windage losses
Stray-load losses
Total losses

152-0
91-9
0-89
1-83

150-5
921
00-89
1-66

1560
91-2
0-87

2-65
1-73
1-67

2-60
1-52
1-67

306

2-02
1-86

2-24
0-95
1-08

1-35
0-48
7-88

1-35
0-48
7-62

1-35
0-48
8-77

112

0-30
5-68

215

97-5
90-7
0-87
1-63

89-6
0-89
2-78

19-7
88-5
0-85
2-00

19-6
88-6
0-85
1-58

21-6
87-1
0-82
1-71

1-64
0-84
0-67

1-74
1-08
0-79

0-49
0-23
0-47

0-49
0-18
0-47

019

0-40
0-20
3-75

0-40
0-20
4-21

0-20

0-20
0-06
1-43

006

0-86
1-81

62-5
90-1
0-91
2-68

61-2
90-8
0-92

21

2-23

1-74

0-82
1-08

103

105

1-87

0-67

1-12
0-30
5-41

1-12
0-30
6-57

0-40
0-20

96-7
91-4
0-87
1-45

990
891

406

2-2

640

006

1-48

0-56
0-59
0-20
1-61

=! 4
Q.

o0

0-1

0-2

03

O4

0-5 0-6 0 7
slip, p.u.

06

0-9

10

Fig. 3
Current distribution in cages at various slips
a
b
c
d
e
/
g
h

= saturated phase current

= unsaturated phase current
= bottom-cage current (saturated)
= bottom-cage current (unsaturated)
= top-cage current (saturated)
= top-cage current (unsaturated)
= middle-cage current (saturated)
middle-cage current (unsaturated)

75C. The efficiency was calculated by the separation-oflosses method. The stray load losses were taken as 0-5% of
motor input power. The comparison of tested full-load
performance with predicted values is shown in Table 1, from
which it can be seen that there is a good agreement with
the full-load test values.
To study the skin-effect phenomena in rotor conductors,
variable frequency-locked-rotor tests were carried out at
1124

0-1 0-2 03 04 0-5 0-6 07 06 09

slip.pu.

10

Fig. 4
Torque contribution of cages at various slips
a
b
c
d
e
/
g
h

total torque (saturated)

total torque (unsaturated)
= top cage (saturated)
= top cage (unsaturated)
= bottom cage (saturated)
= bottom cage (unsaturated)
= middle cage (saturated)
= middle cage (unsaturated)

rated current. The frequency was varied from 60 Hz to as

low as 12 Hz. Fig. 2 shows the variation of skin-effect ratio
(r'2 atf/r2 at 120 Hz) with frequency, obtained directly by
experiment, and computed by both the methods. It can be
seen that, near and above the rated frequency, the resistance
ratio is greater for the single-cage/deep-bar approach than
for the multicage approach. This was observed in all
PROC. IEE, Vol. 121, No. 10, OCTOBER 1974

machines. However, there is a good~agreement between

tested values and multicage approach results.
Figs. 3 and 4 illustrate the distribution of current and
torque in the rotor cages of a 37 kW motor at various slips
before and after taking saturation into account. It is interesting to note that, under starting conditions, the currents
carried and torques produced by the middle and bottom
cages are not negligible. The currents carried by top, middle
and bottom cages are 45%, 18% and 61%, respectively, and
their torque contributions are 55%, 13% and 20%, respectively.
4

Conclusions

The performance of diecast multicage squirrel cage

motors has been studied by single-cage and multicage
approaches. The results calculated from the multicage
approach have been found to be in close agreement with
experimental results. Results calculated from the
single-cage approach do not agree well with experimental
results, especially during starting conditions. Although,
only a few numerical results have been presented in the
paper, the above conclusions have been found to be true
for a wide range of motor designs.
5

Acknowledgments

The authors wish to thank Jyoti Limited, Baroda,

India, for permission to publish this paper.

6
1

2
3
4
5
6
7
8
9
10
11
12
13

bBx
If we assume G\, G2, and G3 are the current densities in
the three regions, respectively, then it can be shown that
the differential equations for current densities in the three
regions are as follows:
dX2

\w6 dXj dX

d2Gx
dX2

= 0

d2G3
dX

1 dwb\dG3
I
\wb dXJdX

Where wb is the width of the bar at a distance X from the

origin. The solutions for current densities in the three
regions are given by13
G, = AtJ0 {(x + C1)atj3l2} + BtK0 {(x + Cx)ottjxl2}
G2 = KA cosh Kx + KB sinh Kx
G3 = CtJQ {(x + C2)atj*l*}+.DtK0
where At,Bt,A,B,
and

{(x + C2)atjx'2}

Ct andZ>( are constants to be evaluated

at =

References
BABB, D.S., and WILLIAMS, J.E.: 'Network analysis of a.c.

machine conductors', Trans. Amer. Inst. Elect. Engrs., 1951,

70, Pt. II, pp. 2001-2005
ALGER, P.L., and WRAY, J.H.: 'Double and triple squirrel
cages for polyphase induction motors', ibid., 1953, 72, Pt. Ill,
pp. 637-645
LEE, C.H.: 'A design method for double squirrel-cage induction motors', ibid., 1953, 72, Pt. Ill, pp. 630-636
GOODMAN, J.: 'A design method for double squirrel-cage
induction motors', ibid., 1953, 72, Pt. Ill, pp. 645-650
JACOBS, P.: 'Defining the equivalent circuit of the double
cage motor', ibid., 1953, 72, Pt. Ill, pp. 651-657
LIWSCHITZ, M.: 'Skin effect bars of squirrel cage rotors',
ibid., 1954, 73, Pt. Ill, pp. 255-258
ALGER, P.L.: 'The nature of polyphase induction machines'
(Wiley, 1951)
BARNES, E.C.: 'An experimental study of induction machine
end-turn-leakage reactance', Trans. Amer. Inst. Elect. Engrs.,
1951, 70, Pt. I, pp. 671-679
VEINOTT, C.G.: 'Theory and design of small induction
motors' (McGraw-Hill, 1959)
LEE, C.H.: 'Saturation harmonics of polyphase induction
motors', AIEE Trans., 1961, Pt. Ill, pp. 579-603
CHALMERS, B.J., and DODGSON, R.: 'Saturated leakage
reactances of cage induction motors', Proc. IEE, 1969, 116,
(8), pp. 1395-1404
'Test procedure for polyphase induction motors and generators', IEEE 112A,Sept. 1964
McLACHLAN, N.W.: 'Bessel functions for engineers' (Oxford
University Press, 1955)

K = (1+7)0*
C, = h^mlimAm 7

1)

h2-h3

m = b5lb6
rri - b3/b2
The boundary conditions are
(i) H = 0 at the bottom of the slot

dx

=0

(ii) at the top of the slot, H is independent of current distribution in the bar and depends only on the total current /
in the bar
atx = (h3 + h2), Hb2 = I
iGj
dx
(iii) at x = 0, the current density is same for both parts of
the composed bar, that is (G2)x=0 = (Gi)x=0
(iv) at x = h3 the current density is same for both parts

Appendix

Derivation of equation for bar composed of

trapezoidal top and bottom connected by parallel neck:
In order to determine the impedance for a bar carrying
current / amperes, let
Gx = current density
Bx = flux density

(v) at x = 0, H changes in the ratio

(dGA
\dx)

=
x=0

lbj\(di_
\bs)\dx
/x=0

(vi) at x = h3,H changes in the ratio of b3/b^, and so

f

at a distance X, so that, at a distance X + Ax, the current

and flux densities become, respectively (see Fig. 1),
/""I

+ Ax -

dG

PROC. IEE, Vol. 121, No. 10, OCTOBER 1974

i, and so

dGj\
x

)x=h3

(bA(dG3\
\b*)\dx)x=h3

Applying the boundary conditions and simplifying, we

obtain
1125

 cosh Kh3 + sinh Kh3

C3 - ? * ,
- A: sinh Kh3 + K cosh Kh3l

C2)atj3'2 + K0(h3 + h2 + C2)atj1'2

C 2 )a,/ 3/2 + K'0(h3 + h2 + C2)at}1'2

where

1126

Si =
A

and

Bt " / ^ + co/ 3 / 2

. /, Koi 121, No. 10, OCTOBER 1974