Design a Squirrel-cage Induction Motor.

Design a 2-hp 3-phase 440-volt

60-cycle. 1,800-srpm motor, the rotor to be of the squirrel-cage type.
In this problem it is not proposed to aim at any specified performance; but, by
following usual practice and adopting reasonable values for current and flux densities,
a normal design should be produced. An investigation of the performance of the
machine, as designed, and the determination of power factor, starting torque, and
other characteristics of the design will form the subject of another problem at the
conclusion g the following chapter.
CALCULATIONS
Items 1 and 2: Number of Poles.
2 X 60 X 60
p= =4
1,800

Volts per phase (star):

440
E= =254 V
3
Items 3 and 4. These are estimated with the aid of the curves of Fig. 127 and
128 (Art. 99).
= 0.81
=0.83
cos

Items 5, 6, and 7. The current in stator windings is obtained from the

equation.
Hp X 746=3 EI c cos

HPx 746 2 x 746

I c= =
3 E cos 3(254)(0.81)(0.83)

Whence I c =2.91 amp.

''
For B g we shall select 24,000 lines per sq in. (refer to Art. 100).
2
For f= 60 Hz, Bg lies between 23,000 and 38,000 lines/ ,
2
common value being around 26,000 lines/ . The higher values of
air-gap density occur in machines of large output, large diameter of
rotor, low voltage and small number of poles.

For the specific loading q=360 from Fig. 129 (Art. 100); but this is subject
to correction when the winding details have been worked out.
Item 8. The winding factor depends upon the number of slots per pole per
phase and on the pitch of the coils, that is to say, whether or not we have a short pitch
of chorded winding. This factor was discussed in Art. 69. The probable number of
slots per pole per phase is obtained by referring to the table in Art. 101, although this
assumes the pole pitch to be known. In a 2-hp motor running at 1,800 rpm the pole
pitch is not likely to be less than 3 or more than 4 in., so that the proper number of
slots per pole for a three-phase winding is almost certain to be six. With a pitch factor
 '
k =1 , which is likely to be used in a small motor such as this one, the value of
d is 0.9659.

Ns ( B ) 2 ( 30 )
sin ( ) sin ( )
2 2
kd= = =0.9659
B 30
Ns sin ( ) 2 sin( )
2 2

6 slots 180 180

Ns= 3 phase = =
pole slot per pole 3

Ns = 4 = 30

d= kp x kd= 1x0.9659= 0.9659

Item 9. Inserting numerical values in Eq. (100) of Art. 102, we have

g q Ns d cos}
4.07 X 1011 X HP
D2 la =

2 4.07 X 10 11 X 2
D la = =81
24000 x 360 x 1800 x 0.81 x 0.83 x 0.9659

Items 10 to 13. Refer to Art. 102. The output per pole is 2/4 = 0.5 hp, and
from the table on page 275 it appears that a suitable pole pitch will be about 3 in. This
would require a stator diameter (internal) of (4 X 3) / = 3.82 in. Since the table on
page 275 is to be used merely from the suggested values are permissible, we shall try
a stator diameter of 4 in., which makes the pole pitch () 3.14 in. (item 12).
DS (4)
= = =3.14
4 4

The peripheral velocity of the rotor (the diameter of which is only very little
smaller than 4 in.) is approximately, by formula (101),
v =10 f

v =10 X 60 X 3.14=1,884 fpm

which is not excessive.

The gross length of the stator core (or the length of the air gap measured
parallel with shaft) is
D 2 la 81
l a= 2
= 2 =5.065 5.25.
( Ds) (4 )

the figure 258 being item 9.

Items 14 and 15. Refer to Art. 102. With a gross length of stator of only 5.25
3
in., two 8 -in. vent duct should be sufficient. Then, if the stacking factor is taken

as 0.9, the net length of iron is

As stated in Article 16. the ventilating spaces in self-cooling
machines consist of radial ducts provided by inserting special
ventilating plates at intervals of 2 to 4 inches and so dividing the
stator core into sections around which the air can circulate. In this
case to determine the number of radial vent ducts needed, I prefer
to use 2-inch interval, which makes:
l a 5.25
= =1.3125 1radial vent ducts
2 2

Also, it stated in Article 16, the width of the ventilating spaces (measured in a
direction parallel to the axis of rotation) is rarely less than 3/8 or more than inch in
machines without forced ventilation. In this case, I choose a width of inch.

l n=0.9 ( l anumber radial vent ductsx air duct )

3
(
l n=0.9 5.251 x
8)=4.39

Items 16 to 20. When discussing the item 8 was assumed 6 slots per pole. This
may be checked and compared with other possible numbers of slots by constructing a
table as follows:

Number of Number of Slot pitch Number of inductors Specific

slots per pole slots per pole loading ( q )
per slots ( C s )
()
per phase
(n s) corrected

Calculate Selecte
d d for
trial

2 6 0.5233 64.738 65 361

3 9 0.3488 43.15 44 367
4 12 0.2616 32.36 33 367

The figures in the third column are the slot pitch , which results from
dividing the pole pitch of 2.35 in. by the number of slots per pole; the calculated
number of conductors per slot, by formula (69), in the fourth column, is

=
slot per pole

With slot per pole = 3,

3.14
= = 0.5233 inch
3
 With slot per pole = 6,

3.14
= =0.3488 inch
6

With slot per pole = 9,

3.14
= =0.2616 inch
9

q 457
C s= = X
I c 2.91

With =0.5233 inch,

360
C s= x 0.5233 = 64.738 65
2.91

With = 0.3488 inch,

360
C s= x 0.3488=43.15 44
2.91

With =0 .2616 inch,

360
C s= x 0.2616=32.36=33
2.91

The obtained values of Cs are rounded off since it must be a whole

number. Also, these values are used to calculate the correct specific
loading
Cs Ic
qfinal=

With Cs=165,
65 x 2.91
qfinal= 0.5233 = 361

With Cs=83,
44 x 2.91
qfinal= 0.3488 = 367

With Cs=55,
 33 x 2.91
qfinal= 0.2616 = 367

With only 4 slot per pole per phase, the slot pitch is rather small for so a small a
diameter of stator. With n s=3 and a total number of 9 slots per pole, there is
possible advantage in that the stator can be wound for two-phase operation if desired,
and also that three-phase windings could be put on in the form of two parallel circuits
which might be connected in series for operation on 440 volts. However, 6 slots per
pole seems best if we have merely to consider the machine as specified, and we shall
decide upon a stator with 24 slots. Then the number of conductors in series per phase
(item 20) is
Z =C s X n s X p

65 cond 2 slots cond .

Z= X X 4 poles=520
slot pole phase
phase

Items 21 to 24. Having decided upon the number of conductors, the necessary
flux per pole should be calculated so as to check the air-gap and the tooth densities.
By formula (64 a) on page 173 we have

E
=
2.22 X kp x kd f Z

254 X 108
= =379,660 maxwells
2.22 x 1 x 0.9659 x 60 x 520

The corrected value for air-gap density (average value) is

379,660
B ''g = = =23,031lines per sq .
l a 3.14 X 5.25

The maximum value (sine-wave assumption) is

X 23,031=36,177 lines per sq .
2

In order to calculate the minimum permissible tooth width, a tooth density must be
assumed
As stated in Art. 100, for f=60 Hz,
B ''t lies between 75,000105,000 a commob value of being B't ' =85,000 lines/2 . Let
'' lines
us try B t =85,000 2 ,then :

t=Bgmax x x la} over {Bt x ln=0.583.

36,177 X 0.5233 X 5.25

t= =0.27 .
85000 X 4.39
which would make = t = 0.2533 in. Usually the slot width is about the same as
''
the tooth width t and, since B t =85,000 is the apparent density in the narrowest
part of the tooth, the actual density at the center of the tooth will be appreciably less
and a somewhat narrower tooth permissible. Let us try t = 0.21 in. at the narrow end;
then = 0.5233 0.21 = 0.3133 in., which is the slot width as measured in the
punching; but, owning to slight inequalities, the finished slot, when ready for the
insulation, will not be quite so wide as this. Allowing 0.004 in. for slot tolerance,
the actual width of slot space available for conductors and insulation of 0.3133-0.004
= 0.3093 inch
The corrected maximum apparent tooth density (item 22) is
0.27
B 't' =85,000 X =109,286 lines /2
0.21

Before deciding upon the depth of slot, it is necessary to consider the dimensions of
the conductors and space taken up by insulation.
Items 25 to 28. For current density (see Art. 105) we shall try = 1800 amp
per sq in.; where area of conductor cross section = 2.91/1800 = 0.001612 sq in. A
single wire of this cross section would be enough so small a motor and we shall try
2.91
one wire No. 17 wires. The area is = 0.00161; whence = 00.161 =1808A, which

is probably not too high. The thickness of slot insulation by formula (16) on page 34,
E
is 27+ 30 = 41.67 mils, or about 0.042 in., so that the width of slot available to

accommodate 0.3093 (2 X 0.042) = 0.2253 in., and, since a No. 17 B & S wire
measures about 0.056 in. over the cotton (see Table I, p. 431), there will be ample
room for 4 wires side by side, but not for 5. Since C s=65 , we have 65x1=65 of
single No. 17 wires to accommodate in one slot and, therefore, =17 wires in depth. If
we adopt the full-overlap type of mush winding as illustrated in Fig. 130, there
will be only one coil side per slot, and the total depth of slot may be computed as
follows:
Slot lining 0.042
17 wires... 0.952
Slot lining and wedge.. 0.072
Tooth thickness... 0.09
Allowance for spaces between wires.. 0.05
Total slot depth 1.206
Ratio d/s = 3.85, which is somewhat on the high side, but not objectionable.
This ratio is commonly between 3 and 4 . The tooth and slot dimensions are
shown in Fig. 131. The connections between stator coils must be made in any
convenient manner which will cause all the emfs due to rotation of the flux to be
additive. A greatly simplified sketch of one of the phase windings is shown in Fig.
132, and a complete diagram of the double-layer three-phase star connected lap
windings is given in Fig. 133.
Items 29 to 32. By formula (102) on page 277, the means length per turn of the
stator winding is, approximately
Mlt= 2la +2.3 + 6
 ( 2 X 5.25 )+ ( 2.3 X 3.14 ) +6=21.94 22.

The number of turns in series per phase is 260 and the length per phase winding (of
the one wires) is 477 ft.
Number of turns in series phase is:

1 turn 65 cond 2 slot

4 polex x x =260 turns / phase
2 cond slot pole
phase

And the length per phase winding of single wire is:

22 inches 260 turn 1 ft
x x =477 ft / phase
turn phase 12inches

The resistance per phase winding is:

477 ft 5.887 ohms
X =2.8 ohms
phase 1000 ft

where the figure 5.887 is obtained from Table I (p. 431) for an assumed temperature
of 60 .

The IR drop per phase (item 31) is 2.91 X 2.81= 8.2 volts. The total copper
2
loss in the stator (item 32) is 3 X 2.91 X 2.81 = 72 watts.

Items 33 to 35. Referring to Art. 100, we shall try a density of 60,000. The
amount of leakage flux is small and, assuming the flux in stator core to be one-half
the flux of air gap, the radial depth of core below the slots should be
379,660
Radial dimension= =0.72.
2 X Bg X ln = 2 X 60,000 X 4.39

This makes the outside diameter of stator stampings =Ds+2(d+radial dimension) =

7.852 in. Let us make this exactly 8 in., which makes the corrected value of the
2
maximum flux density in the core approximately 53,117 53200lines /

379,660 2
co= = =54,460lines /
2 x Rdepth x ln 2 x 0.794 x 4.39

The weight of iron in stator core, not including teeth (item 35), is

Mcore = Pfe x ( DssRdepth ) Rdepth x ln

0.28 X ( 80.794 ) X 0.794 X 4.39=22.11 lbs

 Items 36 to 39. The width of the stator teeth at the narrow end (near the air
Ds 3
gap) on a circle of about 2 = 2 -in. radius is 0.21 in. The slot is 0.3133 in. wide,

which makes the tooth width 1.55 in. near the bottom of the slot, the average width
being 1.075 in. The weight of iron in the teeth is, therefore,
Ds+ ( 2 xD ) (Sxs)

Tw(bottom)=

S=T=12 teeth
Tw ( bottom )+ tw( narrowend) 0.54+0.21
Tw(ave)= = =0.375inch
2 2

Mteeth= pfe x tw(ave) x slot depth x ln x T

0.28 X 0.375 X 1.2606 X 4.39 X 24=13.95lbs

In order to calculate the losses in the teeth, we first calculate the flux density at s
section one-third up from the narrow end (see Art. 52). The width here is:

1
(( 4)+ (2 x 1.2606))(24 x 0.3133)
3
Tw= = 0.32 inch

and the density is, therefore:

0.21
t= 109,286 x =71,719 lines /2
0.32

This is not the true maximum density, because the figure 158,667 (item 22) is the
apparent density at the narrow end. The true density may be calculated as explained
in Art. 36 by means of formula (40), but since density is fairly low, this would be a
refinement which need not be introduced here.
Using the curve in Fig. 67 we have
2
Watts lost in stator core: (54,460 lines/ );

0.048 watts
= lbs/cycle x 60 cycles x 22.11 lbs = 64 W

2
Watts lost in stator core: (71,718 lines/ );

0.081watts
= lbs/cycle x 60 cycles x 13.95 lbs = 68W

Total = 132 Watts

Items 40 and 41. Referring to Art. 106, the number of squirrel-cage bars will
be made 7 . With a difference of (24 - 19) = 5 between stator and rotor slots, this will
fulfill conditions (1) and (2) indicated in that article concerning cogging and
synchronous cusps, although not (p+1), for noisy operations; latter is not particularly
objectionable if the rotor is provided with a stiff shaft and skewed slots. This makes
slot pitch r = 0.66 in.

Items 42 to 48. Since the total ampere-conductors on the rotor are about the
same as the stator, the current in each of the 7 rotor bars is easily calculated. The total
primary (stator) current is 2.91 amp (item 5), but part of this is required for excitation
and to supply stator losses. About 85 per cent of the full-load primary current would
be required to balance the secondary (rotor) current, or, equating the primary and
secondary ampere-conductors, we have
I r X 20=( 0.85 X I c ) X (3 Z )

whence the current in each rotor conductor is

0.80 X 2.91 X 3 X 520
Ir = =191.14 amp
19

The current density in the rotor bars and ring connections may be calculated so
as to give a definite slip (see Art. 108), but the adjustment of rotor resistance is best
done in the end rings. For the bars in the slots, the current density may be somewhat
higher than in the stator windings, and shall try = 1900 amp per sq in. This gives a
bar cross section of 191.14/1900 = 0.1006 sq in. (approx). We shall try a section 0.2x
0.5 and see if the tooth density is not too high. Since the frequency of the flux reversal
in the iron of the rotor is very low (it is the slip frequency), the rotor iron losses are
practically negligible and densities as high as 115,00 lines per sq in. in the teeth are
permissible.
Allowing 0.05 in. for thickness of tooth over the conductor (see Fig. 131) and
neglecting the air-gap clearance, the width of the rotor tooth at the root is
Dr
2 x( tooth depth)
Trw= 2
width
number of rotor bars

4
2 x ( 0.55)
2
0.2=0.279
19

whence, if the net core length is the same as in the stator, max tooth densityis:
P x
rt= x
2 Nr x ln x trw

4 X 379,660
X =102,507 lines per sq in.
2 7 X 4.39 X 0.279

which is considerably higher than the permissible maximum tooth density. The hole in
the rotor core stampings may be 2.25 in. in diameter without forcing the flux density
2
in the iron above about 110,000 lines per sq in. The I R loss in the rotor bars
(item 48) may now be calculated for an operating temperature of 60.
Allowing 1 in. for skewing the rotor bars one slot pitch (0.66 in) and for the
distance between the ends of the rotor core and the short-circuiting rings, the length of
each rotor bar is Ia+1.5= 6.75 in. and the resistance per rotor bar is

length 6.75
= =5.3014 X 105 ohm

thickness x 4 x 106
x width
4
0.5 X 0.20 x x 10
6

2
whence the I R loss in the slot conductors is

19 X (191.14)2 X 5.3014 X 105 37 watts

Items 49 to 55. Referring to Art. 107 and formula (103), the current in the end
rings
19 X 191.14
I e= =289 amp
4X

The current density in the end rings, and the material used, will depend upon the
resistance required. This, together with the rotor-bar resistance, will determine the
starting torque (to be discussed in the next chapter) and the slip under running
collections (see Art. 108). From the table on page 284 we see that a slip of 4.6 per
cent is usual value for a 2-hp squirrel-cage rotor; but in order to obtain a good starting
torque, we shall aim at about 5 per cent slip, although this necessarily involves some
loss of efficiency. In order to produce this slip, the rotor copper losses must have a
2
definite value to satisfy Eq. (104) of Art. 108. Let x be the total rotor I R loss;
then
X
0.05=
746
2 HP x +X
HP

whence x = 78.52, or (say) 80 watts; which leaves 80 37 = 43 watts to be dissipated

from the end rings. The resistance of each of the two short-circuiting rings should,
4
therefore, [43/ (289)2] = 2.574x 10 ohm. The mean length of the current path
of ring is about x 6, or (say) 19 in. Assume that the alloy of which the end rings are
cast has four times the resistivity of the copper. The resistance of the two end rings
will, therefore, be
2 x 19 x 4 152
Re = =
(m) ( m)

2
Since the total end-ring copper loss is 24 watts, I e R e = 43= [(289)2 x 152)/ (m)],
whence
2899


2 x 152

( m )=

The cross section of each ring (at 60) thus becomes 0.2319 sq in.

2
d2 ( 0.5434) 2
Aring = == =0.2319
4 4
 Mils
d= 295,238CMx = 0.5434 mils
1000 CM

The current density in the end rings (item 50) will be 289/0.2319 = 1247 amp
per sq in., which is not excessive. By using an alloy of high specific resistance for the
cast rings, a larger cross section may be used without reducing the amount of the rotor
losses.
The slip at full load, by Eq. (104), is
80
s= =0.051
1492+80

The slip revolutions are 1,800 X 0.051 = 92 which makes the full-load speed
(item 55) equal to 1,800 92 = 1,708 rpm.
Item 56: Efficiency. The efficiency of motor is
output output
= =1
output +losses output +losses

The losses must be include an estimate for friction and windage loss (refer to table on
p. 284). The iron loss in rotor is almost negligible under running condition (when the
speed is near synchronous speed) but may be estimated at about 5 per cent of the
stator iron loss.
SUMMARY OF LOSSES
Stator copper = 72W (item 32)
Rotor copper = 80W (item 53)
Stator iron = 132W (item 39)
Rotor iron = 6.6W (5 per cent of the stator iron loss)
Friction and windage = 64.2W (assumed 4.3 per cent of ouput)
Total = 354.8 watts
whence efficiency = 1 [ 354.8 /(1492 + 354.8 )] = 0.81
Figure 143 shows the general arrangement and gives the over-all dimensions
of the motor as designed.
Ite 2 HP 3phase motor with squirrel
m cage rotor,440Volts ,1800 rpm,60 Numerical
No. cycles, (synchronous) Symbol values
1 Number of Poles P 4
2 Volts per phase ( use star connection) E 440
3 Estimated full-load power factor cos 0.81
4 Estimated full-load efficiency 0.83
Full-load current in stator winding
5 (Amp) Ic 2.91
Average flux density in air gap (lines
6 per sq. in) Bg' 24,000
7 Specific loading of stator q 360
 Distribution factor ( pitch factor =
8 0.9659) d 0.9659
9 The quantity D^2la (in. units) .... 81
10 Internal Diameter of stator D 4
Peripheral velocity of rotor (approx)
11 (fpm) v 1884

12 Pole pitch (on stator) 3.14

13 Gross length of stator core la 5.25
Number and size of vent ducts (1/2 in.
14 wide) 0.375
15 Net length of iron in stator core ln 4.39
16 Number of slots per pole per phase Ns 2
17 Number of slots per pole 6
18 Slot pitch 0.5233
19 Number of stator conductor per slot Cs 65
Number of stator conductor in series
20 per phase Z 520
21 Air-gap flux per pole 379,660
Maximum "apparent" tooth density
22 (lines per sq.in) Bt" 36,177
23 Tooth width (narrow end) t 0.21
24 slot width s 0.3133
25 Current density in windings 1800
26 Thickness of slot insulation . 0.042
One No. 18
27 Size of wire B&S
28 Depth of stator slots d 1.206
29 Length per turn of stator winding . 22
30 Ohms per phase ( hot) .. 2.8
31 IR drop per phase (volts) .. 8.2
32 Total stator copper loss (watts) W 72
Flux density in iron of stator core (lines
33 per sq. in) 54,460
34 Outside diameter of stator stampings .. 8
35 Weight of iron in stator core (lb) .. 22.11
36 Weight of iron in stator teeth (lb) .. 13.95
37 Losses in stator core( watts) 64
38 Losses in stator teeth (watts) 68
39 Total stator iron loss (watts) 132
40 Number of slots sr 19

41 slot pitch r 0.66

42 Current per rotor bar (amp) .. 191.14
Current density in rotor bars (amp per
43 sq in.) . 1900
44 Dimensions of rotor bar 0.2x 0.5
45 Width of rotor slot wr 0.2
46 Depth of rotor slot dr 0.55
47 Maximum flux density in rotor teeth 102,507
48 I^2R loss in rotor bars (watts) . 37
49 Current in end rings (amp) . 289
Current density in end rings (amp per
50 sq in.) .. 1247
51 Dimensions of end rings (sq. in) . 0.2319
52 I^2R loss in end rings (watts) 43
53 Total I^2R loss in rotor (watts) Wr 80
54 Slip at full load (percent) .. 5.1
55 Full-load speed (rpm) 1708
Calculated efficiency ( compare with
56 item 4) 0.81
 UNIVERSITY OF THE EAST
COLLEGE OF ENGINEERING
DEPARTMENT OF ELECTRICAL
ENGINEERING

POLYPHASE INDUCTION MOTOR-

DESIGN OF THREE-PHASE MOTOR

Submitted by;

Musca, Lester L.

Submitted to;

Engr. Darwin Alpis

Complete Diagram Of Single Laye