Design Problem : Design a 50 Hp, 415 V, 3-phase, 50 Hz, 1000 synchronous r.p.m.

squirrel cage induction motor. The machine is to be started by a star delta starter. The efficiency
is 0.85 and power factor is 0.85 at full load.

Main Dimension : Synchronous speed (ns) = 1000/60 = 16.67 r.p.s.

Number of poles (p) = 2 f/ns = 6.
[The machine is meant to be sold in a highly competitive market and therefore its price is
the major consideration and its performance characteristics like efficiency and power factor can
be sacrificed. In order to design a cheap machine we must use higher values for specific electric
and magnetic loadings ]

Assuming Bav = 0.48 Wb/m2 ; ac = 28000 A/m and Kw = 0.955

Output coefficient Co = 11.1 Kw Bav ac 10- 3
= 11.1 x 0.955 x 0.48 x 28000 x 10 -3 = 142.471
kVA input Q = (50 x 0.7457)/(0.85 x 0.85) = 51.605 kVA

D2 L = Q / ( C o n s )
= 51.605 /( 142.471 x 16.67)
= 0.0216 m 3
For a cheap design, ratio L/T should be between 1.5 to 2 where T is pole pitch.
Assuming L/T = 1.25

L/(ℼD /4) =1.25 or, L= 0.654 D

0.654 D3 = 0.0216
or,D = 0.320 m, L= 0.209 m and T= 0.167 m.
As the length of core is 0.209m , therefore there is necessity of providing one radial
ventilating duct of 10mm width.
Net iron length ( L i )= 0.9 x ( 0.209 - 0.01) = 0.1791 m.
Lohys 0.5 mm thick laminations are used for the machine.

Stator Design:

Winding:

The machine is to be designed for delta connection as it is started by a star delta starter.
Stator voltage per phase E = 415 V.
Flux per pole (Øm) = Bav T L = 0.48 x 0.167 x 0.209 = 16.7 x 10 -3 Wb.
Stator turns per phase (Ts) = E/(4.44 x f x BavTL x Kw) = 415/(4.44 x 50 x 16.7 x 10 -3 x 0.955)

= 118.

[ The slot pitch should be between 15 to 25 mm but can be less than 15 mm for small
machines using semi-enclosed slots ]
Taking slots per pole per phase (qs) = 3
Total stator slots (Ss) = 3 x 6 x 3 = 54.
Stator slot pitch (yss) = ℼD/Ss=(22/7) x 0.320 x 103/54 = 18.60 mm.
 Total stator conductors =6 x Ts= 6 x 118 = 708
Conductors per slot(Zss) = 708/54 = 14
in
[ Mush winding in tapered semi-enclosed slots is used for the stator. Mush winding is a
single layer winding and the total number of stator coils is equal to half the number of
stator slots i.e. 27 ]

Coil Span (Cs)= slots/poles = 54/6 = 9.

[ The coil span should not be an even integer in case of mush windings ]

Thus the coils are chorded by one slot pitch.

Angle of chording (α) = (1/6) x 180° = 30°.
Pitch factor (Kp) = cos(α/2) = 0.966.
Distribution factor (Kd) for 3 slots per pole per phase,
= sin (60/2)/ sin 60 / (2 x 3)
Stator winding factor (Kws) = Kd x Kp = 0.966 x 0.966 = 0.933.

Conductor Size:

Stator current per phase =(51.605x10 3 )/(3x415x0.85x0.85)

= 57.369 A.
Stator line current (I) =√3 x 57.369 =99.367 A.

[Choosing a current density of 5 A/mm2]

Area of stator conductor required (as) = 57.369/5 = 11.473 mm2.

Diameter of conductor (bare) required =√(4as/ ℼ) = 3.823 mm.
From Table 17.7, the nearest standard conductor has a bare diameter
d = 4mm.
Area of stator conductor used (as) = ℼd2/4 = 12.571 mm2.
Current density for stator conductors (J)= 57.369/12.571= 4.563 A/mm2.
Diameter of enamelled conductor(d 1 ) = 4.155 mm. (Using medium covering
according to Table 23.7)

Slot Dimensions:
Space required for bare conductors in a slot
= Zss x as = 14 x 12.571 = 176 mm2.
Taking a space factor of 0.4 for the slots
Area of each slot = 176/0.4 = 440 mm2.
[Before deciding the slot dimensions to give
the above area the minimum tooth width
that
would keep the flux density within limits must be found. The maximum allowable flux density is
1.7 Wb/m2]

Minimum stator tooth width (Wts min) =0.0167/(1.7 x(54/6)x 0.1791)=6.094mm.

A tooth of constant width 12.0 mm is taken.
 The dimensions of the slot are worked as under :
Take lip = 1 mm and wedge = 3 mm.

Inner width of stator slot =ℼ(D+(2x4)) - 6 = 13.089 mm.

54
Outer width of the slot = ℼ(D+ 2 x 4 + 2h) =
54
Area of conductor portion of slot= (1/2)x h x (13.089+13.089+h)=
Solving, h=
Width at the bottom of the slot =
and depth of the slot (dss) = 17 + 4 = 21 mm.
Length of mean turn (L mts ) = 2L + 2.3T + 24 = 0.68 mm.

Stator Teeth:

Flux density in stator teeth =Ø m / (Ss/p) x Wtsmin x Li =

[This is a good figure as there is no saturation and also the teeth are not being worked
at a low flux density]

Stator Core:

Flux in stator core = Ø m /2=4.54 x 10-3/2 = 2.27 10 -3

Wb/m2.

[Assume a flux density of 1.2 Wb/m 2]

Area of Stator Core (A cs)= (Ø m /2)/1.2=

Depth of stator core (dcs) = Acs/Li =

Taking the core depth (dcs) = 17 mm.

Flux density in stator core (Bss)= (16.8/17) x 1.2 = 1.185 Wb/m2
.
Outside diameter of stator lamination( Do ) = D + 2dss + 2dcs
= 105 + 2(21 + 17) = 181 mm.

Rotor Design:

Air Gap:

Length of air gap (L g) = 0.2 + 2√(D L) = 0.43 mm.

[But this would result in a large magnetizing current and therefore a shorter gap should be
used. A gap of 0.3 mm length may be . suitable]
 Referring to Table 10.2.
Length of air gap (Lg) = 0.3 mm.
Diameter of rotor (Dr) = 105 - 2 x 0.3 = 104.4 mm.

Rotor slots:

[The number of rotor slots is taken as one pole pair (i.e. 2 in this case) smaller than the
number of stator slots]

The number of stator slots (Ss )= 24 and the number of rotor slots (S r) = 22.
Rotor slot pitch at the air gap (Ysr) =(ℼ x Dr)/Sr = 0.0149 m = 149 m = 14.9 mm.

Rotor Bars:

Rotor bar current (I b)= (2msKwsTs/Sr) x Is cosθ=

[In order to obtain a good starting torque, a high value of current density should be used for in
rotor bars]
Taking the rotor bar current density (J r) = 6 A/mm2.

Area of each rotor bar (ab) = (Ib/Jr) = 40.7 mm2.

Referring to Table 23.1, the dimensions of conductor used are 7.0 x 6.5 mm 2 with an area of
(ab)= 44.6 mm2.
So, Area of bar used (ab) = 44.6 mm 2 .
The slot used is shown in Fig. 10.45.
Width of rotor slot (W sr) = 6.8 mm.
Depth of rotor slot (D sr ) = 9.3 mm.

[Before finally deciding the dimensions of the rotor slots, the flux density in the rotor teeth at
the root should be checked]
Slot pitch at the bottom of slots = ℼ {Dr - (2 x D sr )}/Sr =
Tooth width at the root (W t ) = 12.2 - 6.8 = 5.4 mm.
Flux density at the root of rotor teeth= Øm/{(Sr/p) x L i x W sr} =
[The flux density in teeth is within limits]

[The bars are skewed by one slot pitch. Extending the bars by about 15 mm beyond the core on
each side and taking 10 mm as increase in length because of skewing]
 —01 1.5 I-0—
Fig. 10.45. Rotor slot. All dimensions in mm. Fig. 10.46. Rotor details. All Dimensions in mm.
Length of each bar (L b) = L + 2 x 15 + 10 = 165 mm
015 12,
5 ' Bar
7. i 9.
3
_4
0 (rb) = 0.021 x Lb x 10-3 =
Resistance of each bar
A 1,0
I
ab 757F
0.8
Total copper loss in bars = = Sr x (Ib) 2 x r8,58
b = 101 W.

E 6 .5 i i
= 6, =
End Rings:8
I 6,58 End
ring

End ring current (Ier) = (Sr Ib)/ℼp =

Taking the current density in end ring (J er) = 6 A/mm2.
Area of end ring (a e) = 428/6 = 71.3 mm2.

Using a ring of 10 x 8 mm section.

Where, depth of ring (de) = 10 mm, thickness of ring (te) = 8 mm

and area of each end ring (ae) = 80 mm2.
The ring is brazed to the bars as shown in Fig. 10.46.
[In practice, however, the rotor of this machine may be die cast using aluminium]

Outer diameter of end ring = 104.4 - (2 x 9.3) = 85.8 mm.

Inner diameter of end ring = 85.8 - (2 x 10) = 65.8 mm.

Mean diameter of end ring (De) = 75.8 mm.

Resistance of each ring (re ) = (0.021 ℼ De/ ae) =

Copper loss in two end rings = 2 x (428)2 x 62.5 x 10 -6 = 23 W.

Total rotor copper loss = 101 + 23 = 124 W.

Now, (Rotor copper loss/Rotor output) = s/(1-s)

Or, full load slip (s) = 5.6 %

[This is a reasonable figure for a 2.2 kW machine]

Rotor Core:

The value of depth of rotor core is taken equal to that of stator core.
So, depth of rotor core (dcr) = dcs = 17 mm.

Flux density in rotor core (Bcr)= 1.185 Wb/m2.

Inner diameter of rotor laminations (Di)= Dr - 2dsr - 2dcr
= 104.4 - (2 x 9.3) - (2 x 17) = 51.8 mm.

No Load Current:

Magnetizing Current:

The mmfs required for various parts of magnetic circuit are calculated below,
(i)Air Gap :

For stator slots,

(slot opening/gap length) = 2/0.3 = 6.67.

From Fig. 3.9, Carter's co-efficient corresponding to 6.66 for semi-enclosed slots, (K c s ) =
0.68.

Gap contraction factor for stator slots (Kgss) = yss/(yss -KcsWo)=

For rotor slots,

(slot opening/gap length) = 15/3 = 5.

Corresponding to a ratio 5, K cs = 0.6.

Gap contraction factor for rotor slots (Kgsr) = ysr/(ysr -KcsWo)=

So, gap contraction factor for slots (Kg) =Kgs x Kgr =

[As there are no ducts, the gap contraction factor for ducts K gd is unity]
Gap contraction factor Kg = Kgs x Kgd = 1.18 x 1 = 1.18.
Area of air gap (Ag) = (ℼ D L)/4 =
Bg60 = 1.36 Bav = 1.36 x 0.44 = 0.6 Wb/m2.
Effective length of air gap(l ge) = 1.18 x 0.3 = 0.354 mm.
Mmf required for air gap ATg = 800,000 x 0.6 x 1.18 x 0.3 x 10-3 = 170 A.

(ii) Stator Teeth :

Area of teeth per pole = (Sg/p) x Wts x Li

= (24/4) x 6 x 10 -3 X 0.1125 = 4.05 x 10 -3
M2.

Flux density in stator teeth (B ts) = 1.12 Wb/m2.

 Bts60 = 1.36 x 1.12 = 1.52 Wb/m2.
Corresponding to this flux density (see Fig. 3.2 for Lohys steel)
atcs = 1200 A/m
Mmf required for stator teeth = 1200 x 21 x 10 3 = 25 A.

(iii)Stator Core :

Area of stator core (Acs) = Li d cs = 0.1125 x 0.017 = 1.915 x 10 3 M2.

Flux density in stator core (B cs) = 1.185 Wb/m2.

Length of magnetic path through stator core (l cs) = ℼ( D+2dss+dcss)/3p=

[Corresponding to a flux density of 1.85 Wb/m2, atcs = 280 A/m] Mmf

required for stator core AT cs= 289 x 43 x 10 -3 = 12 A.

(iv)Rotor Teeth :
Width of rotor teeth at 1/3 height from narrow end,

Wts1/3 ={ℼ(Dr - 4dsr1/3)/Sr}- Wsr =

Area of teeth per pole at 3 height from narrow end

Atr = (Sr/p) x Wts1/3 x 10 —3 x 0.1125 = 3.9 x 10 -3 m2.

Flux density in rotor teeth at 1/3 height (Btr1/3) = 1.16 Wb/m2.

Btr60 = 1.36 x 1.16 = 1.575 Wb/m2.

Corresponding to this flux density (a tr) = 2000 A/m.
Mmf required for rotor teeth (A tr) = 2000 x 9.3 x 10 3 = 19 A.

(v)Rotor Core :

Rotor core area Act. = Li d„ = 0.1125 x 17 x 10 -3 = 1.915,x 10 -3 m2.

Flux density in rotor core = 1.185 Wb/m2. Corresponding
to this flux density ate,. = 280 A/m. Length of flux path in
rotor core
lcr= n(Dr 2dSr — 2dcr ) 18 x 10 - 3
m.
3xp
Mmf for rotor core = AT„ = 280 x 18 x 10 -3 = 5 A.

The magnetization data is tabulated below :

 Part
Area Length 7-13 B60
Wb /m2
at
(m2)

Air Gap 0.354 0.44 0.6

[ 10.3x10-3 48000
Stator Teeth 21 1.12 1.52 1200
4,05x 10-3
Stator Core 1.915 x 10-3 .
43 1.185 280
Rotor Teeth 3.9 x 10-3 9.3 1.16 1.575 2000
Rotor Core 1.915 x.10-3 1.8 1.185 280

Magnetizing current per phase /In = K.7;

0.427x 4 x 231
0.934 x 416 - 1.0 A.
Loss Component
Iron loss in stator teeth
Volume of stator teeth = 0.34 x 10 -3 m3.
Weight of stator teeth = 0.34 x 10 -3 x 7.6 x 103 = 2.6 kg.
Maximum flux density in teeth = it12 x 1.12 = 1.76 Wb/m2.
Using 0.5 mm thick (Lohys steel) laminations.
Corresponding to this flux density, loss per kg from Fig. 3.28 is 11.5 W.
Iron loss in stator teeth = 11.5 x 2.6 = 30 W.
Iron loss in stator core
Volume of stator core = 0.985 x 10 -3 m3.
Weight of stator core
= 0.985 x 10 -3 x 7.6 x 103 = 7 5 k .
Flux density in stator core = 1.185 Wb/m2.
Corresponding to this flux 'density, iron loss per kg is 4.9 W.
Iron loss in core = 7.5 x 4.9 = 37 W.
Total iron loss
= 30 + 37 = 67 W.
The actual iron loss will be about 2 times this loss.
Total iron loss = 2 x 67 = 134 W.

Friction and windage losses. Frog 10.6, the friction and windage losses are
2.5 percent of output.
about 4 per cent of output. But with the use of ball and roller bearings, the loss would be around
F and W loss = (1.5/100) x 2200 = W.

33
Total no load losses = 134 + 33 = 167 W.

Loss component of no load current per phase // = No load current Ic = 1.02 + 0.1392 = 1.0 A.

No load current expressed as a percentage of full load current

= (1.0/2.77) x 100 = 36%.
This figure is within normal limit (see Table 10.7).
 No load power factor cos 40 = 0,139/1.0 = 0.139.
Phase angle of no load current 40 = cos - 10.139 = 82°6'.
Short Circuit Current
Leakage reactance
Stator slot leakage :
From Eqn. 3.73, for a tapered slot, specific slot permeance
[ 2 h 1 2 h 2 2 h 3 h 4 3 (Ws + W2) 4- +W2++WoWo [ 2 x 1 7 2 x 3 1 1
Ass = thr x 10 -7 = 19.7 x r

-7
10 .
3(13.2 + 8.8) 8.8 + 2 2
(Considering the height h2 also to be occupied by conductors).
Rotor Slot Leakage :
From Eqn. 3.72 for a parallel sided slot,
Specific slot permeance
hl h2 2h3 /14
Xsr= ilokriTs+ Ws+ Ws +VV0 Wo

7 2 x 1 .0 -7
3 x
= 4TC X 10-7 6.8 6.8 + 1.5+ 1.5 1 = 15.7 x 10 .
[

K W, 2
This referred to stator side is k` si. = Asr x 2 SS
K,
0.9342 x 24
= 15.7 x 10-7 X = 14.95 x 10 -7.
• 1 x 22
Total specific slot permeance As = ass+ = 34.65 x 10 -7.
2
Slot leakage reactance xs = 87c f Tph L(klpq)

-
= 87c x 50 x 4162 x 0.125 x 34.65 x 10 = 11.8 a.
Overhang leakage (4 x 2)
From Eqn. 3.94, L0X0 =Ego Kst2hy55.
coil span = - 5 = 0.833.
Nov ratio
pole pitch 6
Corresponding to this, the value of K, from Fig. 3.58 is 0.875.
Loo X = 47( x 10-7 x 0.875 x 0.08252,, = 1.73 x 10-7i
x 1 3 . 7 5 x 1 0 '
Overhang leakage reactance x0 = 87T /752 (Loit.dpq s)
= 8rc x 50 x 4162 x 1.73 x 0 -7/(4 x 2) = 4.7 1 Q.
Zigzag leakage :
:. Magnetizing reactance X„, = 400/1.0 = 400 O.
From Eqn. 10.46, zigzag leakage reactance per phase
5 X,„ (11
xz = 6 In2 q32 + 2
qr )

5 x 400 [ 1 1
= 20.3 W
 = -6- 3 2 2 2 + 1.835 2 '
as qs = 24/(3 x 4) = 2 and qr = 22/(3 x 4) = 1.885.
The differential leakage reactance can be ignored in the case of squirrel cage
induction motors.
:. Total leakage reactance per phase referred to stator
Xs . 11.8 + 4.7 +
20.3 = 36.8 O. Resistance. Resistance of
stator winding per phase
0.021 x 416 x 0.68
r- = 3.37 S2
0.709
Total stator copper loss = 3 x 2.77 2 x 8.37
= 193 W. Total rotor copper loss = 124 W.
(calculated earlier) Rotor copper loss per
phase = 124/3 = 41.3 W.
Rotor resistance referred to stator
r ' = ______
41.3 x 1
„
= 7.83 g.
2.77' 0.825'
Total resistance referred to stator Rs = 8.37 +
7.83 = 16.2 a Impedance
Total impedance of rotor at standstill

Zs = 1136.82 + 16.22 = 40.2 a

Short circuit (blocked rotor) current per phase 'Sc = 400/40.2 = 9.95 A.
Short circuit power factor cos 11)s, =
16.2/40.2 = 0.403. Phase angle of short
circuit (blocked rotor) current
Esc . 66° 12'.
Losses and Efficiency
Stator copper loss = 193.0 W.
Rotor copper loss = 124.0 W.
Total iron loss = 134.0 W.
Friction and windage loss = 33.0 W.
Total loss at full load = 484 W.
Output at full load = 2200 W. :. Input at full load = 2684 W.

Efficiency at full load T1 = 2200/(2684) x 100 = 81.8 per cent less 2 per cent

= 81.3 percent

Stator Temperature Rise

Iron losses in stator = 134 W. Stator copper losses Pc = 193 W.
Copper loss in slot portion = 2L . P c = 71 W.
Lints
Total loss to be dissipated by stator surface = 71 + 134 = 205 W.
-32
Outside cylindrical surface of stator = n x 0.181 x 0.125 = 71.2 x 10 M.
Cooling co-efficient = 0.03 (See Table 4.6).
Loss dissipated from back of core = 71.2 x 10 -3/0.03 = 2.38 W/°C.
Inside cylindrical surface of stator = 41.2 x 10 -3 m2. .
Peripheral speed Va = TC x 0.105 x 25 = 8.25 m/s.
From Table 4.6, cooling co-efficient
0.04 0.04
_ __________ _ __________
1+ 0.1 V a 1+0.1x8.25-0.022.
Loss dissipated from inside surface of stator = 41.2 x 10 -3/0.022 = 1.87 W/C°.
-

Cooling surface of two ends =2x (0.1812 - 0.105)2 = 44 x 10-3 rn2.

Velocity of air at end surface
Cooling co-efficient
Loss dissipated from end surfaces
Total loss dissipated
Temperature rise
This is within limits.
4
= 0.1 x 8.25 = 0.825 m/s.
= 0.15/V = 0.182.
44 x 10 -3/0.182 = 0.242 W/°C.
= 2.38 + 1.87 + 0.242 = 4.5 W/°C.
= 205/4.5 = 45.6°C.