Geetha Shishu Shikshana Sangha (R)

GSSS INSTITUTE OF ENGINEERING & TECHNOLOGY FOR WOMEN

(Affiliated to VTU, Belagavi, Approved by AICTE, New Delhi & Govt of Karnataka)
KRS Road, Metagalli, Mysuru., 570016
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Electrical Machine Design(17EE64)

Module 4
Design of Induction Motor

Ashwini K R
Asst.Prof, Dept of EEE
GSSSIETW, Mysuru
 Introduction
• Induction motors are the AC motors which are
employed as prime movers in most of the
industries
Construction Details: Induction motor consists of
two parts
1) Stator : It is cylindrical in shape with circular
laminations. The inner periphery of stator is
having slots, three phase stator winding is hosed
in these stator slots.
2) Rotor: There are two types of rotor
a) Squirrel cage type of rotor
b) Slip ring type of rotor
Figure 4.1 stator and rotor Laminations Figure 4.2 Stator Laminations

Figure 4.2 Squirrel cage rotor Figure 4.2 Slip ring cage rotor
 Introduction to Design
The main purpose of the designing an Induction
motor is to obtain complete physical dimensions of
all the parts of the machine as mentioned below.
1) The Main dimension of the stator : Diameter of
the stator, No stator slots, Length of the stator
etc.
2) Stator winding details: No stator conductor per
slots, area of cross section of conductor.
3) Design details of rotor and rotor winding
4) Performance characteristics such as no load
current, no load losses, p.f, efficiency etc ..
 Design specifications/Requirements
• Rated power output , Rated voltage, Rated
current, current density.
• No of phases, Speed , Frequency.
• Type of stator winding, connection of stator
winding.
• Type of rotor, rotor winding.
• Limiting value of various performance parameters
such as iron and copper losses, no load current
losses, power factor, temperature raise etc.
Output Equation o 3 φ Induction Motor
Output of three phase Induction machine is given by
Out put Q in kW = Input x efficiency -------1
Input to motor = 3𝑉𝑝𝑕 𝐼𝑝𝑕 𝑋 𝐶𝑜𝑠 ∅ 𝑋 10−3 kW -------2
𝑇𝑝ℎ
Assuming 𝑉𝑝𝑕 = 𝐸𝑝𝑕 =4.44 𝑓 ϕ 𝑇𝑝𝑕 𝐾𝑤 = 2.22 𝑓 ϕ 𝑍𝑝𝑕 𝐾𝑤 (Since 𝑍𝑝𝑕 = )
2
𝑃𝑁𝑠 𝑃𝑛𝑠 𝑁2
W.k.t frequency f = = ( 𝑛𝑠 = )
120 2 60
Substituting these equation in output equation
𝑃𝑛𝑠
Output Q in k W = 3 X 2.22 X X ϕ 𝑍𝑝𝑕 𝐾𝑤 𝐼𝑝𝑕 X η Cos∅X 10−3 kW
2
Re arranging the terms in the above equation
Output Q in k W = 1.11 X Pϕ X 3 𝐼𝑝𝑕 𝑍𝑝𝑕 X 𝑛𝑠 𝐾𝑤 η Cos∅ X 10−3 kW ------3
𝑃ϕ
Specific Magnetic Loading 𝐵𝑎𝑣 = , Hence Pϕ = 𝐵𝑎𝑣 π D L and
𝜋𝐷𝐿
3𝐼𝑝ℎ 𝑍𝑝ℎ
Specific Electric Loading q = , therefore 3𝐼𝑝𝑕 𝑍𝑝𝑕 = q 𝜋𝐷
𝜋𝐷
Substituting these values in Equation 3
Output Q in kW = 1.11 x 𝐵𝑎𝑣 πDL x πD q x 𝑛𝑠 𝐾𝑤 η Cos ∅ x 10−3 kW ------ 4
Rearranging the terms in equation 4
Q = (1.11 𝜋 2 𝐵𝑎𝑣 q 𝐾𝑤 η 𝐶𝑜𝑠∅ X 10−3 )𝐷 2 𝐿 𝑛𝑠 kW

Therefore Output in kW Q = 𝑪𝒐 𝑫𝟐 𝑳 𝒏𝒔

Where Co = Output coefficient =(11 𝐵𝑎𝑣 𝑞 𝐾𝑤 η 𝐶𝑜𝑠∅ 𝑋 10−3 )

Vph = Phase voltage
Iph = Phase current
Zph =No of conductors per phase
Tph =No of turns per phase
120 𝑓
NS = Synchronous speed = 𝑝
,P=No of poles, f = frequency in Hz
nS = Synchronous speed in rps, Cos∅ = Power factor of the motor
q = Electric loading,ϕ= Electric flux in Webers
Bav = Average flux density Wb/𝑚2
K w =Winding factor, η =Efficiency of the motor
D=Diameter of the stator, L=Gross length of the stator.
Main Dimensions of stator
 Separation of D & L
Output equation gives relation ship between 𝐷 2 L product. To separate D and L
from product relation following are various assumption or design consideration
based on which suitable ratio between gross length and pole pitch can be
𝐿
assumed .
𝜏𝑝

𝐿
1) To obtain minimum over all cost , is assumed in the range 1.5 to 2.0
𝜏𝑝

𝐿
2) To obtain good Efficiency , is assumed in the range 1.4 to 1.6
𝜏𝑝

𝐿
3) To obtain over all good design , is assumed in the range 1.0 to 1.1
𝜏𝑝

𝐿
4) To obtain good power factor, is taken in the range 1.0 to 1.3
𝜏𝑝
As the power factor plays very important role it is advisable to design three
phase induction motor for best power factor
Hence to obtain the best power factor the following
relation will be usually assumed
Pole pitch 0.18
=
Core Length Pole pitch
Cirucumferance of stator πD
w.k.t Pole pitch τp = =
No of poles P
πD
P 0.18
= πD
L
P
Rearranging the terms of equation 1
2 0.18 L P2
D = Or D= 0.135 P 𝑳
π2
Where D and L are expressed in meters.

In general using above D and L relationship, D and L can

be separately obtained
 Choice of Specific Loadings
Choice of Specific magnetic Loading (Bav):
The average flux density is chosen with the limits mentioned below
Flux density in teeth < 1.8 Tesla
Flux density in the core between 1.3 -1.5 Tesla
In general for 50 Hz machine, 0.35 – 0.6 Tesla.
Choice of Specific Electric Loading (q): Normal range of specific electric loading
is 10000 ac/m – 450000 ac/m .
Advantages of Higher value of Advantages of higher Disadvantages of Higher value
Magnetic Loading(Bav) Electric Loading (q): of Electric Loading (q)

• Size of the machine reduced. • Reduced size. • Higher amount of copper

• Cost of the machine • Reduced cost • More copper losses
decreases. • Increased temperature rise
• Overload capacity increases • Lower overload capacity
Peripheral speed (𝒏𝒔 ): For normal design , Diameter
calculated should be such that it should not exceed the peripheral
speed 30 m/s. In special machines which involves higher cost
peripheral speed should not exceed 75 m/s. For standard
construction peripheral speed is upto 60 m/s
Efficiency and power factor :Choice of power factor and efficiency
under full load conditions will increase with increase in rating of
the machine. Percentage magnetizing current and losses will be
lower for a larger machine than that of a smaller machine. Further
the power factor and efficiency will be higher for a high speed
machine than the same rated low speed machine because of better
cooling conditions. Taking into considerations all these factors the
above parameters will vary in a range based on the output of the
machine. Similar to Bav and q, efficiency and power factor values
can be selected from Design data hand book.
Stator Winding details
1) Stator winding connection : Three phase winding connected in either star
or delta depending upon starting method employed. For Squirrel cage type
of rotor star delta starter is used hence stator is delta connected.
2) Turns per phase (𝑻𝒔 ): Stator turns per phase is calculated as below
𝜋𝐷𝐿
• Flux per pole 𝜙𝑚 = 𝐵𝑎𝑣 𝑋 𝜏𝑝 = 𝐵𝑎𝑣 𝑋
𝑃
• Stator induced emf 𝐸𝑠 =4.44 f 𝜙𝑚 𝑇𝑠 𝐾𝑤
• There fore stator turns per phase is given by
𝐸𝑠
𝑇𝑠 =
4.44 𝜙𝑚 𝑓𝐾𝑤
The winding factor is usually assumed as 𝐾𝑤 =0.955
3) Size of stator conductor (𝒂𝒔 ): Current density in the stator in the stator
winding is assumed between 3 to 5 A/𝑚𝑚2
Stator current per phase
𝑂𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑖𝑛𝑔 𝑄
𝐼𝑠 = =
3𝐸𝑠 3𝐸𝑠
𝑆𝑡𝑎𝑡𝑜𝑟 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝐼𝑠
Area of the conductor 𝑎𝑠 = = 𝑚𝑚2
𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 δ𝑠
Where 𝛿𝑠 = Current density.
For lower value of current round conductors are most convenient, for higher
value of current bar or strip conductor are better.
4) Shape or Type of stator Slots : Shape of the stator slot has an
important effect on operating performance of the motor and as well as
installation of the stator winding. and the different types of slots are as below
a)Open slots:
• Width of the slot = opening of the slot.
• better insulation for windings can be provided.
• Installation and servicing of the windings are easier.
• Excessive slot leakage can be avoided by using open slots
b) Semi closed slots:
• Width of the slot opening is much smaller than width of the slot.
• Air gap contraction is small ,small value of magnetizing current.
• Low tooth pulsation loss.
c)Tapered slots:
Width of the slot opening is smaller than width of The slot.
slot width will be varying from top of the slot to bottom of the
slot with minimum width at the bottom as shown in Fig. (iii).
These type of slots re used in small rating machine.
5)Selection of no of stator slots : There is no defined rule to select no of stator
slots , but while selecting stator slots following advantages and disadvantages
must be considered .
Advantages of higher no of stator slots Disadvantages of higher no of stator slots

• Reduced leakage reactance. • Increased cost.

• Reduced tooth pulsation losses.
• Higher over load capacity
• Increased weight.
• Increased magnetizing current
• Increased iron losses
• Poor cooling
• Increased temperature rise
• Reduction in efficiency

It is good practice to use as many slot as economically possible, no of slots per

pole phase should not be less than 2.In general no of slots selected to give an
integral no of slots per pole phase. The pole pitch at the air gap surface should
be between 15mm to 25mm.
 𝐺𝑎𝑝 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝜋𝐷
Total no of stator slots 𝑆𝑠 = =
𝑆𝑡𝑎𝑡𝑜𝑟 𝑠𝑙𝑜𝑡 𝑝𝑖𝑡𝑐𝑕 𝜏𝑠
Total no of stator conductor = 6 X Stator turns per phase =6X𝑇𝑠
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑠𝑡𝑎𝑡𝑜𝑟 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 6𝑇𝑠
Conductor per slot 𝑍𝑠 = =
𝑇𝑜𝑡𝑜𝑙 𝑛𝑜 𝑜𝑓 𝑠𝑡𝑎𝑡𝑜𝑟 𝑠𝑙𝑜𝑡𝑠 𝑆𝑠
Total no of conductors must be an even integer for double layer winding.

6) Area of the stator slots : When the no of conductors per slot has been
obtained, then the approximate area of slot can be calculated as below
𝑪𝒐𝒑𝒑𝒆𝒓 𝒂𝒓𝒆𝒂 𝒑𝒆𝒓 𝒔𝒍𝒐𝒕 𝒁𝒔 𝒂𝒔
Area of each slot = =
𝒔𝒑𝒂𝒄𝒆 𝒇𝒂𝒄𝒕𝒐𝒓 𝑺𝒑𝒂𝒄𝒆 𝒇𝒂𝒄𝒐𝒕𝒐𝒓
Space factor should be taken in the range 0.25 to 0.4.
Width of the slot should be taken such that mean flux density in
Tooth lies in the range 1.3 to 1.7 Wb/𝑚2
In general ratio of slot depth to slot width should between 3 to 6
7) Length of mean turn (𝑳𝒎𝒕𝒔 ): The approximate length of mean turn of the
motor upto 650V may be calculated from the relationship
Length of mean turn of stator winding
𝐿𝑚𝑡𝑠 =2 L+ 2.3 𝜏𝑠 +0.24, where L and 𝜏𝑠 are expressed in meter.

8) Dimension of Stator teeth: Maximum flux density in stator teeth should not
exceed 1.7Wb/𝑚2
ϕ
Minimum tooth area per pole = 𝑚 -------------------1
1.7
Tooth area per pole =No of slots/pole X Net iron length X Width of stator teeth
ϕ𝑚 𝑆𝑠
Tooth area per pole = = 𝑋𝐿𝑖 X𝑊𝑡𝑠 -------------------2
1.7 𝑃
Width of stator tooth from equation 2
ϕ𝑚 𝑋 𝑃
𝑊𝑡𝑠 =
1.7 𝑋 𝑆𝑠 𝐿𝑖
The above equation gives minimum with of stator tooth near gap surface
9.Stator core : Flux density in the core lies in the range 1.2 to 1.4
Wb/𝑚2 . From the figure 10.18. It is clear that flux through stator
core is half of the flux per pole.
ϕ𝑚
Flux in the stator core =
2
𝑓𝑙𝑢𝑥 𝑡𝑕𝑟𝑜𝑔𝑕 𝑐𝑜𝑟𝑒 ϕ𝑚
Area of the stator core = = ------1
𝐹𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑡𝑕𝑒 𝑠𝑡𝑎𝑡𝑜 𝑐𝑜𝑟𝑒 2𝐵𝑐𝑠
Area of the stator core =𝐿𝑖 𝑋𝑑𝑐𝑠 ----------2
Where 𝑑𝑐𝑠 = Depth of the stator core
From equation 1 and 2
ϕ𝑚 ϕ𝑚
𝐿𝑖 𝑋𝑑𝑐𝑠 = , 𝑑𝑐𝑠 = ----------3
2𝐵𝑐𝑠 2𝐵𝑐𝑠 𝐿𝑖
The outside diameter of stator Lamination
𝐷𝑜 = D + 2( depth of stator slots+ depth of stator core)
𝐷𝑜 = D+2(𝑑𝑠𝑠 + 𝑑𝑐𝑠 )
Rotor Design :
1) Length of the air gap : Following are the factors should be considered
while estimating the length of the air gap.
a) Power Factor : It is the length of the air gap
that primarily determines the magnetizing current
drawn by the machine. The figure (a) and (b) shows
the phasor diagram of two different cases.
The magnetizing current in case 2 is greater than in
case 1 and therefore the phase angle between stator
applied voltage and stator current in greater for case 2
ie angle ϕ2 is greater than ϕ1 , cos ϕ2 is smaller than cos ϕ1 . Hence, the lower
power factor of machine with a greater gap length is smaller .
b) Over load Capacity : The over load capacity of an induction motor is defined
as the ratio of the maximum output to the rated output. Over load capacity for
the is greater for the machine having smaller leakage reactances.
c) Pulsation losses : With larger of air gap, the variation of reluctance due to
slotting is small. The tooth pulsation loss, which is produced due to variation in
reluctance of the air gap is reduced accordingly. Therefore, the pulsation loss is less
with large air gap.
d) Unbalance magnetic pull : If the length of air gap is small, even a small
deflection or eccentricity of the shaft would produce a large irregularity in the
length of gap and is responsible for production of larger unbalanced magnetic pull
which has the tendency to bend the shaft still more at a place where it is already
bent resulting in fouling of rotor with stator. If the length of the air is large
unbalanced magnetic pull and noise is less.
e) Cooling : If the length of the air gap is large, the cylindrical surface of rotor and
stator are separated by large distance. This would afford better facilities for cooling
at the gap surfaces.
f) Noise : The noise is produced in induction motor is due to variation of reluctance
of path of the zigzag reluctance. By increasing the air gap length zigzag leakage is
made smaller which reduces the noise.

From the above discussion it can be conclude that the length of air gap in an
induction machine should be as small as mechanically possible in order to keep
down the magnetizing current and to improve the power factor. But for higher over
load capacity, better cooling , reduction in noise , reduction in unbalanced magnetic
pull large air gap should be used.
Relations for calculation of length of air gap
1)In order to estimate the length of air gap of small induction motors, the
following expression can be used 𝑙𝑔 =0.2+2 𝐷𝐿 mm, D and L are expressed in
meter.
2) For Small machine 𝑙𝑔 =0.125+0.35D+L+0.015𝑉𝑠 mm, 𝑉𝑠 is the peripheral
speed in meter per second.
3) The another alternate relation can also be used 𝑙𝑔 =0.2+D mm

Rotor Diameter 𝑫𝒓 = D-2𝒍𝒈 meter.

No of Rotor Slots: Proper numbers of rotor slots are to be selected in relation

to number of stator slots otherwise undesirable effects will be found at the
starting of the motor. Cogging and Crawling are the two phenomena which are
observed due to wrong combination of number of rotor and stator slots. In
addition, induction motor may develop unpredictable hooks and cusps in
torque speed characteristics or the motor may run with lot of noise
Rules for selecting rotor slots
1) No of rotor slots should never be equal to stator slots but must be 15 to 30
per cent larger or smaller than the no of stator slots.
2) The difference between stator slots and rotor slots should not be equal to to
P, 2P or 5P to avoid synchronous cusps.
3) The difference between no of stator slots and rotor slots should not be
equal to 3P in order to avoid magnetic locking.
4) The difference between no of stator slots and rotor slots should not be
equal to 1,2,(P±1) or (P±2) to avoid noise and vibrations.
Summarizing 𝑆𝑠 -𝑠𝑟 should not be equal to 0, ±𝑃, ±2𝑃, ±3𝑃, ±5𝑃, ±1, ±2,
± (P ± 1), ±(P ± 2)
𝑠𝑟 - No of rotor slots
NOTE : In general no of rotor slots calculated
𝑷
𝑺𝒓 =𝑺𝒔 -
𝟐
Design of Squirrel cage rotor
1)Rotor Bar Current 𝑰𝒃 : Rotor bar current is given by
6𝐼 𝑇 𝐾 𝐶𝑜𝑠∅ 𝟎.𝟖𝟓 𝑿𝟔 𝑰𝒔 𝑻𝒔
𝐼𝑏 = 𝑠 𝑠 𝑤𝑠 0r
𝑆𝑟 𝑺𝒓
2)Area of Rotor Bar(𝒂𝒃 ): Current density in rotor bars (𝛿𝑏 ) may be taken in the
range 4 to 7 A/𝑚𝑚2
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑡𝑕𝑟𝑜𝑢𝑔𝑕 𝑟𝑜𝑡𝑜𝑟 𝑏𝑎𝑟 𝐼𝑏
Area of each Rotor Bar 𝑎𝑏 = = 𝑚𝑚2
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑟𝑜𝑡𝑜𝑟 𝑏𝑎𝑟 𝛿𝑏

3)Shape and Size of Rotor slots: Closed slots are preferred for small size
machines because the reluctance of air gap is not large owing to absence of
slot openings. This gives a reduced value of magnetizing current. As the surface
of the rotor is smooth, the operation of the machine is quieter. High starting
current is limited in closed slots. Because of increased value of reactance
results in reduction in overload capacity. A semi closed slot gives better
overload capacity.
Rectangular shaped bars and slots are generally prefered to circular bars and
slots as the higher leakage reactance of the lower part of the rectangular bars,
during starting forces most of the current through the top of the bar. This
increases rotor resist ance at starting and improves the starting torque.
4)Copper losses in the rotor bars : By calculating length of the rotor bar and
resistance of the copper bar the copper losses in the rotor bar can be
determined.
Length of the rotor bar 𝑙𝑏 = L + Allowance for skewing
𝜌 𝑋 𝑙𝑏 0.021 𝑋 𝑙𝑏
Rotor bar résistance 𝑟𝑏 = =
𝑎𝑏 𝑎𝑏
Copper loss in the rotor bars = 𝐼𝑏 2 X𝑟𝑏 X No of
Rotor bars
5)End Ring Current( 𝑰𝒆 ): All the rotor bars are short
Circuited by connecting them to the end rings. The induced
Emf in the rotor bars will be sinusoidal over one pole pitch.
As the rotor is a short circuited body, There will be current
Flow because of this emf induced. The distribution of
current and End rings are as shown in the figure 10.28
Referring to the figure for one pole pitch. Half no of bars and Figure 10.28
End ring carry the current in one direction and other half in opposite direction .
Thus the maximum current through the end ring current may be taken as the
sum of the average current in half of the no of bars under one pole
 1 𝑁𝑜 𝑜𝑓 𝑟𝑜𝑡𝑜𝑟𝑠 𝑏𝑎𝑟𝑠
Maximum endring current 𝐼𝑒(𝑚𝑎𝑥) = 𝐼𝑏(𝑚𝑎𝑥) under one pole
2 𝑃𝑜𝑙𝑒
pitch, w.k.t 𝐼𝑏(𝑚𝑎𝑥) = 2 𝐼𝑏
𝐼𝑒(𝑚𝑎𝑥) 2 1 𝑆𝑟
RMS value of end ring current 𝐼𝑒 = = 𝑋 𝑋 𝑋 2𝐼𝑏
2 𝜋 2 2𝑃
𝑆𝑟 𝐼𝑏
There fore 𝐼𝑒 =
𝜋𝑃
6)Area of End ring (𝒂𝒆 ) : Area of end ring is determined by knowing
Current density 𝛿𝑒
𝐸𝑛𝑑 𝑟𝑖𝑛𝑔 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝐼𝑒
Area of end ring 𝑎𝑒 = =
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑦 𝑖𝑛 𝑡𝑕𝑒 𝑒𝑛𝑑 𝑟𝑖𝑛𝑔 𝛿𝑒
7)Copper loss in the end ring : In order to find the copper loss in the end ring
mean length of end is calculated, Mean diameter is considere to be 4 to 6cm less
than the stator diameter
Mean length of endring 𝑙𝑚𝑒 =𝜋𝐷𝑚𝑒 , Mean diameter of endring 𝐷𝑚𝑒 = D– 4to 6cm.
𝜌𝑒 𝑙𝑚𝑒
Resistance of the endring 𝑟𝑒 = , 𝜌𝑒 = resistivity of ending =0.021 Ω / m &𝑚𝑚2
𝑎𝑒
Total copper loss in the end ring = 2 𝐼𝑒 2 𝑟𝑒 in Watts
8) Equivalent Rotor Resistance : By knowing the total copper losses in the rotor and
equivalent current flowing in the rotor, equivalent rotor resistance can be
calculated.
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑝𝑝𝑒𝑟 𝑙𝑜𝑠𝑠 𝑖𝑛 𝑡𝑕𝑒 𝑟𝑜𝑡𝑜𝑟
Equivalent rotor resistance 𝑟𝑟 ′ = 2
3 𝑋 𝐼𝑟 ′
Total copper loss in the rotor = Copper loss in the rotor bar+ Copper loss in the end ring
= 𝐼𝑏 2X𝑟𝑏 X 𝑆𝑟 + 2 𝐼𝑒 2 𝑟𝑒

Design of phase wound Rotor/Design of slip ring rotor :

1) No of Rotor slots: The rotor winding for wound rotor motors are 3 phase
windings, and the no of rotor slots should be such that balanced winding is
obtained . It is preferable to se no of slots which are multiple of phases and pair
of poles in the case fractional slot winding.
2) No of rotor turns: No of rotor turns decided based on safety consideration.
To keep the rotor voltage to an acceptable level the ration of effective
stator to rotor turns must be properly adjusted.
𝐸𝑟 𝐾𝑤𝑟 𝑇𝑟
Voltage ratio =
𝐸𝑠 𝐾𝑤𝑠 𝑇𝑠
𝐸𝑟 𝐾𝑤𝑠
Hence rotor turns per phase 𝑇𝑟 = 𝑇𝑠
𝐸𝑠 𝐾𝑤𝑟
Where Er = open circuit rotor voltage/phase, Es = stator voltage /phase
Kws = winding factor for stator, Kwr = winding factor for rotor,
Ts = Number of stator turns/phase
3)Rotor current (𝑰𝒓 ): Rotor current can be calculated by comparing the amp-
conductors on stator and rotor
(𝐾𝑊𝑆 𝑋𝑆𝑠 𝑋𝑍𝑆 )𝐼𝑟 ′
Rotor current 𝐼𝑟 =
(𝐾𝑤𝑟 𝑋 𝑆𝑟 𝑋𝑍𝑟 )
Kws, Kwr – Stator and rotor winding factor
Ss, Sr – Stator and rotor number of slots.
Zs, Zr – no of stator and rotor conductors / stator slots,
I'r – equivalent rotor current in terms of stator current
I'r = 0.85 Is , where Is is stator current per phase.

4) Area of the Rotor conductor(𝒂𝒓 ) : Current density value for rotor conductors
may be assumed in the range 4 to 6 Ampere/𝑚𝑚2 .
𝐼𝑟
Area of rotor conductor 𝑎𝑟 = 𝑚𝑚2
𝛿𝑟
If area of conductor > 5 𝑚𝑚2 use circular condcotors , else rectangular
conductors width to thickness ratio = 2.5 to 4.
5) Size of Rotor slot: Mostly Semi closed rectangular slots employed for the rotors.
Based on conductor size, number conductors per slot and arrangement of conductors
similar to that of stator, dimension of rotor slots can be estimated. Size of the slot must
be such that the ratio of depth to width of slot must be between 3 and 4.
6) Total Copper loss : Length of mean turn of rotor conductor is calculated
𝑙𝑚𝑡 = 2L+2.3𝜏𝑝 +0.08m
𝜌 𝑙𝑚𝑡 𝑇𝑟
Rotor resistance 𝑅𝑟 = Ω
𝑎𝑟
Total copper loss = 3𝐼𝑟 2 𝑅𝑟 Watts

Flux density in the rotor teeth : In order to calculate dimensions of the rotor slot flux
density has to be determined from 1/3rd height to root of the teeth. Flux density has
to be limited to 1.8Tesla. Following stepwise procedure has to be followed.

2 𝑕𝑡𝑟
Diameter at 1/3rd height 𝐷𝑟 ′ = D-
3
′ 𝜋𝐷𝑟 ′
Slot pitch at 1/3 height = 𝜏𝑟 =
rd
𝑆𝑟
Tooth Width at this section is =𝑏𝑡𝑟 ′ = 𝜏𝑠𝑟 ′ -𝑏𝑠𝑟
Area of one rotor tooth =𝑎𝑡𝑟 ′ = 𝑏𝑡𝑟 ′ X 𝑙𝑖
Iron length of the rotor 𝑙𝑖 = (L- 𝑤𝑑 X𝑛𝑑 ) X 𝑘𝑖 𝑘𝑖 = iron space factor
𝑏𝑡 ′ 𝑙𝑖 𝑆𝑟
′
Area of all the rotor tooth /pole = 𝐴𝑡𝑟 =
𝑃
Φ
Mean flux density in rotor teeth 𝐵𝑡𝑟 ′ = ′
𝐴𝑡𝑟
Maximum flux density in the rotor teeth < 1.5 𝐵𝑡𝑟 ′

Depth of the stator core below the slots: Below rotor slots there is certain solid
portion which is called depth of the core below slots. This depth is calculated based
on the flux density in the rotor core. Flux density in the rotor core must be between
1.2 to 1.4 Tesla. Then depth of the core can be found as follows
ϕ
Flux in the rotor core Φ𝑐 = 2
ϕ𝐵𝑐𝑟
Area of the rotor core 𝐴𝑐𝑟 = 2
Area of the rotor core 𝐴𝑐𝑟 = 𝐿𝑖 X𝑑𝑐𝑟
𝐴
Hence, depth of the core 𝑑𝑐𝑟 = 𝐿𝑐𝑟
𝑖

Inner diameter of the rotor core = D-2𝑙𝑔 -2ℎ𝑡𝑟 -2𝑑𝑐𝑟

Performance Evaluation: Based on the design data of the stator and rotor of
an induction motor, performance evaluation of the machine has to be
evaluated. The parameter for performance of the evaluation are no load
current, no load power factor, leakage reactance etc. Based on the values of
these parameters design values of the stator and rotor can be justified.

Iron losses : Iron losses are occurring in all the iron

parts due to the varying magnetic field of the
machine. Iron loss has two components ,Hysteresis
loss and eddy current losses , which depend on the
frequency of the supply voltage. The frequency
of the induced voltage in rotor is equal to slip frequency
which is very low and hence the iron losses in the
induction motor is mainly due to the losses in the stator alone.
Losses in the stator core :
No Load current : The no load current of induction motor has two components
magnetizing components, Im and Iron loss component Ic.

Thus the no load Current 𝐼𝑜 = 𝐼𝑚 2 + 𝐼𝑐 2

Magnetizing current (𝑰𝒎 ): Magnetizing current is responsible for producing
the required amount of the flux in the different parts of the machine. The
Ampere turns for all the magnetic circuit such as stator core, stator teeth, air
gap, rotor core and rotor teeth gives the total ampere turns required for the
magnetic circuit. The magnetizing current is given by
𝑃 𝐴𝑇30
𝐼𝑚 =
1.17 𝐾𝑤 𝑇𝑝ℎ

𝐴𝑇30 = Total Ampere turns of the magnetic circuit at 30𝑜 from the center of the
pole. Tph – Total no stator turns per phase.
Iron loss component of current (𝑰𝑪 ) :This component of the current is
responsible for supplying the iron losses in the magnetic circuit.
𝑇𝑜𝑡𝑎𝑙 𝑁𝑜 𝑙𝑜𝑎𝑑 𝑙𝑜𝑠𝑠𝑒𝑠
Iron loss component of current 𝐼𝑐 =
3 𝑋 𝑝𝑕𝑎𝑠𝑒 𝑣𝑜𝑙𝑡𝑎𝑔𝑒

No Load Power factor : Induction motor is having very poor power factor.
𝐶𝑜𝑟𝑒 𝑙𝑜𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝐼
No load power factor Cosϕ𝑜 = =𝑐
𝑁𝑜 𝑙𝑜𝑎𝑑 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝐼𝑜
Question Bank
1) Obtain the Output equation of 3 phase induction motor by first principles?
2) Explain the factors which influences the length of the air gap in three
phase induction motor ? Write empherical formulae used to calculate
length of the air gap
3) Derive the expression for rotor bar and endring current in squirrel cage
induction motor
4) Discuss the steps to be followed to design the stator of three phase
induction motor
5) Discuss the steps to obtain No load current in three phase induction motor
6) Discuss the steps design slip ring (wound) rotor for three phase induction
motor .
 References:
Electrical machine Design – A K Sawhney
Design of electrical machines – V N Mittle

Thank you