EEE 3114: Electrical Machine Design

Construction of Electrical Machinery

Nazmul Hasan
Lecturer, Dept. of EEE
Jashore University of Science and Technology

Thanks: University of Minnesota

Active magnetic materials used in electrical machines
All electric machine types require soft pure iron materials to
carry magnetic flux around the circuit.
Impurities like carbon contribute to hysteresis losses
Hi-flux densities & frequencies contribute to eddy
current losses

Permanent magnets are considered hard materials

Best grades exhibit high hysteresis residual flux

All electric machines require conductors of electricity

Copper has lowest electrical resistance
Aluminum is a good choice for cast cage rotors
 Two magnetic material classes
Soft materials: Small hysteresis
Electrical steels 2.1 Tesla

Pure iron bar stock

Sintered pure iron
1.4 Tesla
Hard materials: Large hysteresis
Permanent Magnets
 Electrical steels (soft iron)
Rotor & stator cores from sintered electrical steel grades
Can be used for complicated core shapes

Rotor & stator core laminations punched from electrical steel

lamination grades with low cope loss & surface insulation.
Non-Oriented Silicon M-19 grades # 24, # 26 & # 29 gages
Oriented M-3 grades (0.003” thick)

Stator core components from Amorphous materials (MetGlas)

Lowest core losses with fabrication difficulties
Medium to low flux densities (1.56 T max)
Both Fe & Co based alloys available
 Stator lamination design guidelines
Progressive dies
Used for punching
of Stator & Rotor
Laminations

Laser cutting for

prototypes
Wasted material
~20% in corners.

Punch rotor core from stator hole whenever possible

 Stator Core Manufacturing

Nippon Steel
Lamination cross section proportions

AC Induction:
Assume air gap circumference flux = 1.0 Tesla
All stator teeth carry total air-gap flux
Low pole numbers, max O.C. tooth flux = 1.7 T
High pole numbers, max O.C. tooth flux density = 1.4 T
Yoke flux based upon 0.5 pole flux, Max = 1.4 T

SPM or IPM Brushless:

Determine air gap flux/pole from magnet design
Stator teeth over rotor pole span carry rotor pole flux
Low pole numbers, max O.C. tooth flux = 1.7 T
High pole numbers, max O.C. tooth flux density = 1.4 T
Yoke flux based upon 0.5 pole flux, Max = 1.4 T
Lamination set from AC Induction machine

(36) semi-open stator slots

with round slot bottoms

(40) semi-open rotor slots

with round slot bottoms

Probably for a 4 or 6
pole 10 KW machine

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 Core assembly examples
Neat small TIG welds Grooves for OD end clamps (not used)

Welding OD clamps Inter-locking

on large stator core dimples
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(4) Pole Traction motor stator core & winding

Hand stacked core and bonded

Machine wound coils & hand inserted

35% to 45% slot fill of bare copper to
slot cross section area

Machine insertion 25% to 35% slot fill

Use of rectangular
Mod 11 Copyright: JR Hendershot 2012 wire like REMY motor,
1060
to 75% slot fills are possible
High slot fill stator core designs

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 Mechanical considerations for stator cores
Finger plates required
for vibration control, noise
& coil insulation wear.

Stator ducts Rotor ducts

Cooling passages for

excessive thermal
diffusion distances.
End turn
brace

Bracing of end turns to

withstand vibration and
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magnetic forces
 Another example of end turn bracing

End turn bracing

allows thermal
expansion

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 Toyota stators

Parallel wound Taper

wound
Mod
Special layer wound coils for11high
Copyright: JR Hendershot 2012
slot fill 14
10 Pole stator by REMY

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 Advanced stator design
for super conducting machine

Coil end turn supports Stator teeth end fingers

Patent # 6,787,967 Mod 11 Copyright: JR Hendershot 2012 16

 Punched core laminations
Rotor cores punched from
stator ID in progressive die
reduces material cost.

Mod 12 Copyright: JR Hendershot 2012 17

Yoke thickness of stator or rotor
B = average air-gap flux density
By = peak yoke flux density
D = rotor OD

Yoke thickness varies as the number of poles vs stator

OD & rotor ID for fixed stator slot depth & rotor OD
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 Flux density guidelines by two experts
Position Typical flux density Maximum flux
range (Say) density (Lipo)
Airgap Bg 0.65 – 0.82 T (ave.)

Stator yoke 1.1 – 1.45 T (peak) 1.7 T

Stator teeth 1.4 – 1.7 T 2.1 T
Rotor yoke 1.2 T 1.7 T
Rotor teeth 1.5 – 1.8 T 2.2 T

Max flux density in stator yoke & teeth for ACM & RSM
For open circuit PMSM machines, 1.2T/1.4T in yoke &
1.4T/1.6T in teeth for max flux density. (JRH)
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Air-Gap correction
Magnetic factor
Air Gap (Carter
Correction Coefficient)
Factor

The magnetic air gap

must be corrected in
accordance with the
stator slot width vs the
air gap.

(Known as the Carter

Coefficient)

Correct Bg in previous
slide by adjusting the
air gap and Permeance
Coefficient

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 Rotor & Stator Laminations
Magnetic circuit
dimensions of
magnetic circuit
optimized for
Stator Lamination Details
flux densities

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Toyota Camry & Lexus stator lams

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Stacked & insulated stator cores

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 Laminated stator cores
Laminated stator cores
Die Interlocked Cores

Cleated Cores
Welded Cores

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Stator cores stacked from thin laminations

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Segmented stator design using either laminated stacked
teeth or Sintered teeth.

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 Skewed rotor cores for AC motors

Die interlocking principle

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Mitsui High-tec
 Large Turbo Generator Stators
Large Turbo Generator Cores

Notice- Finger Plates on core end to prevent lamination vibration

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Stator cores for rail traction motors
End turn supports

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 Finger –Vent Plates
Fabricated by stamping and spot-welding

Finger Plates on
core ends prevent
lamination vibration

Vent plates in between axial groups of laminations

Mod 12 Copyright: JR Hendershot 2012 30
This work is licensed under a Creative Commons
Attribution-ShareAlike 3.0 Unported License.
It makes use of the works of Nazmul Hasan.