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

E1 2 fN eff m 4 .44 fN eff m

E1 0.97V , rated (because R1 and X 1 are small)

PqNc kw
Neff kw k p kd ks D 2r
1.1
where
The denominator 1.1 in Neff is to considering leakage flux.

1 .07 Vrated
Nc
2 fPqk 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 .0016 D 0 .001 l 0 .0072 inch

Dr D 2g

Effective airgap
g eff k cs k cr g

where the Carters coefficients

s (5 g bs )
k cs
s ( 5 g b s ) b s2

s ( 4 . 4 g 0 . 75 br 2 )
k cr
s ( 4 . 4 g 0 . 75 br 2 ) br22 NEMA Class B
UCF
Stator Slot Design
D
s
S
0.7in s 1.5in
2bs d s1 4bs
0 .4 s b s 0 .6 s
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 : 400A/cm 2 J sa 800 A/cm 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, typically 1
k wr k pr k dr k sr
qr r
sin( )
r kd 2 Sr r
k pr sin r
qr k sr sinc ( )
2 q r 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

Neff
I b,rated I1,rated (transformer relationship)
Neffr
I b,rated
Rotor bar current density J sb
Sb
where Sb is rotor bar cross section area and can be
determined from the above formula together with:
Air - cooled : 700A/cm 2 J sb 775 A/cm 2
Rotor bars can operate at higher temperatures than stator.
I b ,rated
Sb
J sb
UCF
Rotor Slot Design
depth to width ratio :
d r1 d r 2
d 2w 4 ~ 6 (NEMA B)
br1
Sb
br 1 d c1 d 2 w br 1
d 2w
b r 2 0 . 01 D 0 . 045 inch

d r 2 0 .667 br 2
d r1 d c 2 d r 2
Area is Sb Dr
t r1 br 2
S b br1 ( d r1 d r 2 ) Nr
( Dr 2d r1 )
bc 2 br1 d c 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 : 775A/cm 2 J s ,ring 930 A/cm 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.