Technical Report General Design Data of a Three Phase Induction Machine 90kW Squirrel Cage Rotor Tasos Lazaridis Electrical Engineer CAD/CAE Engineer tasoslazaridis13@gmail.com
Three-Phase Induction Machine Design GENERAL DATA Given Output Power (kw): 90 Rated Voltage (V): 380 Winding Connection: Wye Number of Poles: 4 Given Speed (rpm): 1463 Frequency (Hz): 50 Stray Loss (W): 1620 Frictional Loss (W): 1000 Windage Loss (W): 2500 Operation Mode: Motor Type of Load: Constant Power Operating Temperature (C): 75 STATOR DATA Number of Stator Slots: 48 Outer Diameter of Stator (mm): 349 Inner Diameter of Stator (mm): 235 Type of Stator Slot: 1 Stator Slot hs0 (mm): 0.5 hs2 (mm): 21 bs0 (mm): 3 bs1 (mm): 9.3 bs2 (mm): 11.4 Top Tooth Width (mm): 6.72953 Bottom Tooth Width (mm): 7.38096 Length of Stator Core (mm): 300 Stacking Factor of Stator Core: 0.95 Type of Steel: D23_50 Number of lamination sectors 0 Press board thickness (mm): 2 Magnetic press board Yes Number of Parallel Branches: 1 Type of Coils: 21 Coil Pitch: 4 Number of Conductors per Slot: 8 Number of Wires per Conductor: 1 Wire Diameter (mm): 4.62 Wire Wrap Thickness (mm): 0 Wedge Thickness (mm): 0 Slot Liner Thickness (mm): 0.3 Layer Insulation (mm): 0.3 Slot Area (mm^2): 303.35 Net Slot Area (mm^2): 251.069
Slot Fill Factor (%): 68.0113 Limited Slot Fill Factor (%): 75 Wire Resistivity (ohm.mm^2/m): 0.0217 Conductor Length Adjustment (mm): 0 End Length Correction Factor 1 End Leakage Reactance Correction Factor 1 ROTOR DATA Number of Rotor Slots: 38 Air Gap (mm): 0.7 Inner Diameter of Rotor (mm): 70 Type of Rotor Slot: 1 Rotor Slot hs0 (mm): 0.5 hs2 (mm): 22.5 bs0 (mm): 1.5 bs1 (mm): 7 bs2 (mm): 7 Cast Rotor: Yes Half Slot: Yes Length of Rotor (mm): 300 Stacking Factor of Rotor Core: 0.95 Type of Steel: D23_50 Skew Width: 0 End Length of Bar (mm): 0 Height of End Ring (mm): 32 Width of End Ring (mm): 23 Resistivity of Rotor Bar at 75 Centigrade (ohm.mm^2/m): 0.0263158 Resistivity of Rotor Ring at 75 Centigrade (ohm.mm^2/m): 0.0263158 Magnetic Shaft: Yes MATERIAL CONSUMPTION Armature Copper Density (kg/m^3): 8900 Rotor Bar Material Density (kg/m^3): 2689 Rotor Ring Material Density (kg/m^3): 2689 Armature Core Steel Density (kg/m^3): 7820 Rotor Core Steel Density (kg/m^3): 7820 Armature Copper Weight (kg): 23.3299 Rotor Bar Material Weight (kg): 3.01416 Rotor Ring Material Weight (kg): 2.49448 Armature Core Steel Weight (kg): 85.2642 Rotor Core Steel Weight (kg): 78.6141 Total Net Weight (kg): 192.717 Armature Core Steel Consumption (kg): 181.997 Rotor Core Steel Consumption (kg): 96.6668
RATED-LOAD OPERATION Stator Resistance (ohm): 0.0674703 Stator Resistance at 20C (ohm): 0.0554998 Stator Leakage Reactance (ohm): 0.126467 Rotor Resistance (ohm): 0.0270918 Rotor Leakage Reactance (ohm): 0.282897 Resistance Corresponding to Iron-Core Loss (ohm): 86.3582 Magnetizing Reactance (ohm): 3.12506 Stator Phase Current (A): 196.241 Current Corresponding to Iron-Core Loss (A): 2.253 Magnetizing Current (A): 62.2595 Rotor Phase Current (A): 169.394 Copper Loss of Stator Winding (W): 7794.93 Copper Loss of Rotor Winding (W): 2332.14 Iron-Core Loss (W): 1315.06 Frictional and Windage Loss (W): 3502.88 Stray Loss (W): 1620 Total Loss (W): 16565 Input Power (kw): 106.558 Output Power (kw): 89.9932 Mechanical Shaft Torque (N.m): 587.205 Efficiency (%): 84.4545 Power Factor: 0.812457 Rated Slip: 0.0243366 Rated Shaft Speed (rpm): 1463.5 NO-LOAD OPERATION No-Load Stator Resistance (ohm): 0.0674703 No-Load Stator Leakage Reactance (ohm): 0.126973 No-Load Rotor Resistance (ohm): 0.0270573 No-Load Rotor Leakage Reactance (ohm): 0.288555 No-Load Stator Phase Current (A): 67.8374 No-Load Iron-Core Loss (W): 1535.74 No-Load Input Power (W): 7785.61 No-Load Power Factor: 0.13809 No-Load Slip: 0.000754578 No-Load Shaft Speed (rpm): 1498.87 BREAK-DOWN OPERATION Break-Down Slip: 0.08 Break-Down Torque (N.m): 941.169 Break-Down Torque Ratio: 1.60279 Break-Down Phase Current (A): 418.008 LOCKED-ROTOR OPERATION Locked-Rotor Torque (N.m): 474.54
Locked-Rotor Phase Current (A): 679.546 Locked-Rotor Torque Ratio: 0.808134 Locked-Rotor Current Ratio: 3.46282 Locked-Rotor Stator Resistance (ohm): 0.0674703 Locked-Rotor Stator Leakage Reactance (ohm): 0.115617 Locked-Rotor Rotor Resistance (ohm): 0.0616147 Locked-Rotor Rotor Leakage Reactance (ohm): 0.193633 DETAILED DATA AT RATED OPERATION Stator Slot Leakage Reactance (ohm): 0.0881042 Stator End-Winding Leakage Reactance (ohm): 0.0201604 Stator Differential Leakage Reactance (ohm): 0.018202 Rotor Slot Leakage Reactance (ohm): 0.152883 Rotor End-Winding Leakage Reactance (ohm): 0.00686664 Rotor Differential Leakage Reactance (ohm): 0.123145 Skewing Leakage Reactance (ohm): 0 Stator Winding Factor: 0.478831 Stator-Teeth Flux Density (Tesla): 1.70722 Rotor-Teeth Flux Density (Tesla): 1.16603 Stator-Yoke Flux Density (Tesla): 1.87124 Rotor-Yoke Flux Density (Tesla): 0.588304 Air-Gap Flux Density (Tesla): 0.753862 Stator-Teeth Ampere Turns (A.T): 190.167 Rotor-Teeth Ampere Turns (A.T): 16.1044 Stator-Yoke Ampere Turns (A.T): 521.959 Rotor-Yoke Ampere Turns (A.T): 4.31289 Air-Gap Ampere Turns (A.T): 478.047 Correction Factor for Magnetic Circuit Length of Stator Yoke: 0.246496 Correction Factor for Magnetic Circuit Length of Rotor Yoke: 0.7 Saturation Factor for Teeth: 1.43149 Saturation Factor for Teeth & Yoke: 2.53236 Induced-Voltage Factor: 0.886832 Stator Current Density (A/mm^2): 11.7062 Specific Electric Loading (A/mm): 102.071 Stator Thermal Load (A^2/mm^3): 1194.86 Rotor Bar Current Density (A/mm^2): 8.33598 Rotor Ring Current Density (A/mm^2): 3.38302 Half-Turn Length of Stator Winding (mm): 407.209
WINDING ARRANGEMENT The 3-phase, 2-layer winding can be arranged in 12 slots as: AAAAZZZZBBBB Angle per slot (elec. degrees): 15 Phase-A axis (elec. degrees): 52.5 First slot center (elec. degrees): 0 TRANSIENT FEA INPUT DATA For one phase of the Stator Winding: Number of Turns: 64 Parallel Branches: 1 Terminal Resistance (ohm): 0.0674703 End Leakage Inductance (H): 6.04158e-005 For Rotor End Ring Between Two Bars of One Side: Equivalent Ring Resistance (ohm): 5.92974e-007 Equivalent Ring Inductance (H): 3.99331e-009 2D Equivalent Value: Equivalent Model Depth (mm): 300 Equivalent Stator Stacking Factor: 0.963333 Estimated Rotor Inertial Moment (kg m^2): 0.68408
Διάγραμμα 1. Χαρακτηριςτική καμπφλη φαςικοφ ρεφματοσ ταχφτητασ. Διάγραμμα 2.Χαρακτηριςτική καμπφλη απόδοςησ ταχήτητασ. Διάγραμμα 3. Χαρακτηριςτική καμπφλη ςυντελεςτή ιςχφοσ ταχφτητασ.
Διάγραμμα 4. Χαρακτηριςτική καμπφλη ιςχφοσ ταχφτητασ. Διάγραμμα 5. Χαρακτηριςτική καμπφλη ροπήσ ταχφτητασ. Διάγραμμα 6. Χαρακτηριςτική καμπφλη φαςικοφ ρεφματοσ ιςχφοσ εξόδου.
Διάγραμμα 7. Χαρακτηριςτική καμπφλη απόδοςησ - ιςχφοσ εξόδου. Διάγραμμα 8. Χαρακτηριςτική καμπφλη ςυντελεςτή ιςχφοσ - ιςχφοσ εξόδου. Διάγραμμα 9. Χαρακτηριςτική καμπφλη ολίςθηςησ - ιςχφοσ εξόδου.
Διάγραμμα 10.Χαρακτηριςτική καμπφλη ροπήσ - ιςχφοσ εξόδου. Διάγραμμα 11.Χαρακτηριςτική καμπφλη ροπήσ - ολίςθηςησ
Διάγραμμα 12. Το ςτιγμιότυπο ςτο οποίο λαμβάνονται οι μετρήςεισ τησ Ηλεκτρομαγνητικήσ προςομοίωςησ. Διάγραμμα 13. Διάγραμμα του διανυςματικοφ δυναμικοφ ςτον κινητήρα.
Διάγραμμα 14.Διάγραμμα των δυναμικών γραμμών του διανυςματικοφ δυναμικοφ ςτον κινητήρα. Διάγραμμα 15.Διάγραμμα του μαγνητικοφ πεδίου ςτον κινητήρα.
Διάγραμμα 16. Διάγραμμα του μζτρου του μαγνητικοφ πεδίου ςτον κινητήρα. Διάγραμμα 17.Διαγράμματα ρευμάτων εκκίνηςησ χρόνου.
Διάγραμμα 18.Διάγραμμα ροπήσ εκκίνηςησ χρόνου. Διάγραμμα 19. Διάγραμμα επαγώμενων τάςεων χρόνου.
Διάγραμμα 20. Διάγραμμα ροών διαροήσ χρόνου. Διάγραμμα 21. Διαγράμματα ηλεκτρικήσ και μηχανικήσ ιςχφοσ χρόνου.