Effect of the Induction Motor Stator Outer/Inner

Diameter Ratio on the Motor Performance

Asım Gökhan Yetgin*, Ali İhsan Çanakoğlu+, Ayhan Gün+, Mustafa Turan#, Barış Cevher#
*
Mehmet Akif Ersoy University, Department of Electrical and Electronics Engineering, Burdur, Turkey
agyetgin@mehmetakif.edu.tr
+
Dumlupınar University, Department of Electrical and Electronics Engineering, Kutahya, Turkey
{aihsan.canakoglu, ayhan.gun}@dpu.edu.tr
#
Sakarya University, Department of Electrical and Electronics Engineering, Sakarya, Turkey
{turan, bcevher}@sakarya.edu.tr

Abstract— Induction motors are frequently used in industrial and
domestic applications. For this reason, an improvement in
performance values has a great saving in terms of energy savings.
In order to be able to improve the performance values, it is
necessary to be done with care from the beginning to the end of
the design period of the motor. In recent years, a noticeable
improvement in motor performance has been achieved, especially
with the improvement of materials used in motors. In addition,
performance enhancements are provided by using optimization
methods for the parameters of stator and rotor slot dimensions.
Also, stator winding structures have been changed to reduce the
losses and increase the efficiency value.
In this paper, the variation of the stator outer diameter value and
the stator inner diameter value ratio (KD) obtained at the
beginning of the induction motor design process was investigated.
Although this ratio is not considered much during design, but it
has a great influence on the motor volume. Other parameters of
the motor were taken constant during analysis. The analyses were
carried out on a 5.5 kW and 10 kW squirrel cage induction motor.
According to the results obtained, decrease in the outer diameter
of the stator was accompanied by increase of the KD ratio. The
decrease in outer diameter resulted in a reduction in stator back
iron height, resulting in an increase in the magnetic flux density
values in the stator back iron parts. There was also a certain
increase in the weight of the back iron with the increase of the
outer diameter. In the case of stator back iron and iron losses,
there is no visible change due to the increased value of the
magnetic flux density and the decreased weight. The efficiency
value also remains constant.
Keywords— Induction motor, Stator outer diameter, Stator inner
diameter, KD ratio, Performance analyses.
I. INTRODUCTION
Induction motors are widely used in domestic, commercial
and various industrial applications. Mostly, the squirrel cage
induction motor is used because of its simplicity, robustness
and low cost, which has always made it very attractive, and it
has therefore captured the leading place in industrial sectors.
High efficiency motors lead to significant reductions in energy
consumptions and also reduces the environmental impact.
Sustainable use and investments also demands increased motor
reliability. An important measure for wide market acceptance
of high efficiency motors is availability of harmonized
standards, dealing with motor performance testing, efficiency
classification, and display of ratings [1].
The design of electrical machines involves several fields of
physics, electromagnetism, thermic, mechanics, and acoustics.
For a multiphysics model machines there are three approaches:
the first is the analytical approaches: based on the analytical
solution or equivalent circuit, quick and easy but the lowest in
terms of accuracy. The second one is semi-analytical approach
based on the nodal modeling or permeances network, the
principle of nodal modeling method is to simplify the study of
a system equivalent circuit. The most common formulation is
one in which Kirchhoff’s current law is used to establish a
system of nodal equations, the second method based on a
decomposition of the magnetic field of the machine into
elements. Permeances network less accurate and needs offline
FEM results to evaluate the unknown air-gap permeances. The
last one represents the state-of-the-art in the numerical
magnetic field computation relating to electrical machines,
FEM 2D or 3D is a numerical method to solve the partial
differential equations (PDE) that expresses the physical
quantities of interest. Give a more accurate result co analytical
modeling, which can be regarded as a simplification of the PDE
[2].
The selection of the frame size normally dictates the outer
diameter of the stator laminations. Each manufacturer has
standard lamination dimensions by frame size and poles. For a
typical 4-pole motor, the stator inner diameter is approximately
2/3 that of the stator lamination outer diameter. The inner
diameter of the rotor lamination may be affected by mechanical
considerations, such as the need for a specific shaft diameter.
After the initial lamination diameters are determined, the
number of stator slots, the stator-rotor slot combination, and
grade of electrical steel must be determined. These choices are
influenced by the kW/HP rating, rpm, winding type, rotor
construction, and performance criteria [3].
In this study, the ratio between stator inner diameter and
stator outer diameter have been changed and it has been
investigated that effect of this ratio on motor performance. By
changing this ratio, the stator outer diameter values were
changed and all the other parameters belonging to the motors
were kept constant. Thus, only the effect of stator outer
diameter on the motor performance has been investigated.
 II. DESIGN PROCEDURE OF INDUCTION MOTOR 1 60 K E  Pn
Dis2 L    (3)
The design of an induction motor aims to determine the C0 n1   cos 
induction motor geometry and all data required for where n1 is the synchronous speed, Pn is rated power, η is
manufacturing to satisfy a vector of performance variables efficiency, cosφ is power factor, KE is design constant. The flux
together with a set of constraints. Because induction motors are per pole Ø is calculated by Equation (4) [4].
now a well-developed technology, there is a wealth of practical
  L  Bav
knowledge, validated in industry, on the relationship between  (4)
their performance constraints and their physical aspects. 106
Moreover, mathematical modeling of induction motors using where τ is the pole pitch and it is given by Equation (5) [4].
circuit, field or hybrid models provides formulas of   Dis
performance and constraint variables as functions of design  (5)
p
variables [4].
From past experience (or from optimal lamination concept),
The design process may start with design specifications and
the ratio of the inner to outer stator diameter Dis/Dout, bellow
assigned values of: rated power, nominal voltage, frequency,
100 kW for standard motors is given in Table I and the ratio is
power factor, type (squirrel cage or slip-ring), connection (star
given by Equation (6) [6].
or delta), ventilation, ducts, iron factor, insulation, curves like
BH, losses, carter coefficient, tables like specific magnetic TABLE I
loading, specific electric loading, density etc. Then, design INNER/OUTER STATOR DIAMETER RATIO
constraints for flux densities, current densities are specified [4]. 2p 2 4 6 8
The basic steps of the design process summarized below [3]: Dis/Dout 0.54-0.58 0.61-0.63 0.68-0.71 0.72-0.74
1) Review customer specs and standards Dis
2) Chose frame size & enclosure KD  (6)
Dout
3) Dis2  L estimate
4) Lamination diameter selection Despite the use of Equation (6) in many design books,
5) Choose stator/rotor slot combination Boldea and Nasar [6] stated that this ratio can also be found by
6) Electrical steel selection Equation (7). In Equation (7), Kaspect is defined as the slot height
7) Winding configuration hs to slot width bs ratio and it has been stated that the value of
8) Rotor construction Kaspect changes between 3 and 6. In Equation (7), Ns is number
9) Flux density calculations of stator slot, Bg is air-gap flux density, Bts is stator teeth flux
10) Performance analysis density αi is flux density shape factor.
Dout 2  K aspect    B g  i  B g
A. Design Formulas  1  1     (7)
Dis Ns  Bts  2 p Bts
The design process of induction motors begins with
obtaining the Dis2  L expression. Main dimensions of an III. USED MOTORS
induction motor are shown in Fig. 1 [5]. Output coefficient C0
Two motors with different powers were used for the analyses.
is obtained by following Equation (1).
The parameters of the motors are given in Table II. The KD
ratio of the 5.5 kW motor was 0.62 while the KD ratio of the 10
kW motor was 0.562. These values are seen to be consistent
with the KD values given in Table I. In the analysis, the stator
inner diameter value for the first motor was fixed at 111.6 mm
and the stator inner diameter value for the second motor was
fixed at 135 mm. However, all of the other parameters of the
motor is kept constant. KD values were changed to change the
stator outer diameter values of both motors.
Fig. 1 Main dimension of induction motor TABLE II
PARAMETERS OF USED MOTORS
C0  11  Bav  ac  k ws / 1000 (1)
Here, Bav is average flux density in air gap (or specific Motor Parameters Motor 1 Motor 2
magnetic loading), ac is ampere conductor per meter of stator Rated power Pn [kW] 5.5 10
periphery (or specific electrical loading), and kws is stator Synchronous speed [rpm] 1800 3000
Number of pole 2p 4 2
winding factor. The length is calculated by Equation (2) [6].
Line supply voltage V1 [V] 460 400
    Dis Supply frequency f1 [Hz] 60 50
L (2)
2 p Number of phases m 3 3
where Dis is stator inner diameter, λ is the stack length to pole Phase connections Star Delta
pitch ratio, p is number of pole. The Dis2  L is computed using Targeted power factor 0.83 0.95
Equation (3): Targeted efficiency [%] 89.5 90
Number of stator slot Ns 36 48
 Number of rotor slot Nr 28 44 This caused the stator outer diameter to decrease from 250 mm
Stator inner diameter Dis [mm] 111.6 135 to 232.758 mm.
Stator outer diameter Dout [mm] 180 240.2
TABLE III
Stack length L [mm] 131.5 300 STATOR OUTER DIAMETER VALUES FOR MOTOR 1 AND MOTOR 2
KD 0.62 0.562
Motor 1 Motor 2
The stator outer diameter values obtained according to KD KD Dout (mm) KD Dout (mm)
values are given in Table III for motor 1 and motor 2. A cross- 0.61 182.950 0.54 250
sectional view of the 10 kW motor is shown in Fig. 2. In this 0.62 180 0.55 245.450
model, the ratio between the outer diameter of the stator and the 0.63 177.142 0.56 241.071
0.57 236.842
inner diameter of the stator is increased up from 0.54 to 0.58.
0.58 232.758

Fig. 2 Cross-section of 10 kW induction motor

When Fig. 3 is examined, a decrease in stator outer diameter

IV. RESULTS AND DISCUSSION values occurs due to the increase of KD values. A decrease of
In these analyses, all the design parameters are fixed values 6.89% for the 10 kW motors and a decrease of 3.17% for the
except for the motor outer diameter in order to monitor only the
impact of the stator outside diameter. The stator outer diameter 5.5 kW motors. The variation of KD-stator back iron height is
values obtained according to the variation of the KD coefficient given in Fig. 4.
are given in Fig. 3 for 5.5 kW and 10 kW motors.
36 10 kW
255 5.5 kW
10 kW
245 31
5.5 kW
235 26
hcs (mm)

225
Dout (mm)

21
215
205 16

195 11
185 6
175 0,54 0,55 0,56 0,57 0,58 0,61 0,62 0,63
0,54 0,55 0,56 0,57 0,58 0,61 0,62 0,63 KD
KD
Fig. 4 KD versus hcs graphs
Fig. 3 KD versus Dout graphs
 When Fig. 4 is examined, there is a decrease in the hcs values 118
for both motors. This has occurred due to reduced outer 10 kW
113
diameter of the stator. The 10 kW motors had a decrease of 5.5 kW
108
23.62% while the 5.5 kW motors were 24.57%. The variation

St. Iron loss (W)

103
between KD ratio and stator back iron flux density is given in
Fig. 5. 98
93
88
1,6 10 kW
5.5 kW 83
1,4 78
0,54 0,55 0,56 0,57 0,58 0,61 0,62 0,63
1,2 KD
Bcs (T)

Fig. 7 KD versus stator iron loss graphs

1,0
Stator iron losses in induction motors are obtained by
0,8
multiplying both the stator core weight value and stator
0,6
magnetic flux density value. Fig. 7 shows that the stator iron
0,54 0,55 0,56 0,57 0,58 0,61 0,62 0,63 losses increase by about 10 W for a 10 kW motor and only by
KD 1 W for a 5.5 kW motor. This can be explained by the decrease
of the back iron weight value due to the decrease of the stator
Fig. 5 KD versus Bcs graphs
back iron height value (hcs) for both motors and the increase of
When the Fig. 5 is examined, the stator back iron flux density the flux density values of the stator back iron parts due to the
value shows an increase for both motor types. This has occurred decrease of the hcs value. The stator outer diameter impact on
due to reduced height of the stator back core. For a 10 kW motor efficiency is shown in Fig. 8.
motor, while the hcs value was 36.5 mm, the flux density value
was obtained 0.6867 T. If the hcs value was 27.879 mm, the flux 92,0
10 kW
density value increased by 29.88% to 0.892 T. 91,8
5.5 kW
91,6
70 91,4
Efficiency (%)

10 kW 91,2
60
St. Back Iron Weight (Kg)

5.5 kW 91,0
50 90,8
90,6
40
90,4
30 90,2
20 90,0
0,54 0,55 0,56 0,57 0,58 0,61 0,62 0,63
10 KD
0 Fig. 8 KD versus efficiency graphs
0,54 0,55 0,56 0,57 0,58 0,61 0,62 0,63
KD When Fig. 8 is examined, almost no change in efficiency
values occurs. This is because only the stator outer diameter
Fig. 6 KD versus stator back iron weight graphs
value changes and many parameters remain constant in the
When Fig. 6 is examined, the decrease in the stator back iron analysis. In particular, stator and rotor copper losses remain
height decreases the material used in the stator back iron. This constant and changes in iron losses of 10 W and 1 W cause the
has resulted in a reduction in weight. The weight for the 10 kW motor efficiency to remain constant.
motor has decreased from approximately 65 Kg to 50.6 Kg. A
decrease of 25.82% has occurred for 5.5 kW motor. The change V. CONCLUSION
between KD and total iron loss is given in Fig. 7. In this study, the effect of the ratio of induction motor stator
inner diameter to stator outer diameter on the motor
performance was investigated. According to obtained results,
the value of stator outer diameter decreased with increasing KD
value. Because of this reason, the stator back iron height value
is decreased and the magnetic flux density value in these parts
is increased. A decrease has occurred in the motor weight with
the decrease of the outer diameter sizes. The efficiency values
for both motors have not changed because of the other
parameters of the motors are kept constant except the stator
outer diameter and due to the small change in iron losses.
In view of the obtained information, it is obvious that the
most important factor in selecting the outer diameter of the
motor will be the motor cost.
Large outer diameter motors have higher moment of inertia.
But the amount of extra core is increasing the motor cost. In
small diameter motors, the obtained torque may not have the
force and the moment to move the load. For this reason cost-
performance analysis needs to be done well for the motors.

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