Induction Motor Analysis

Master Thesis
Time-stepping FE-analysis of a 22kW Variable

Impedance Induction Motor (VZIM) and thermal
analysis

Mehdi Hajinoroozi

Advisors:
Prof. Dr.-Ing. habil. h.c. Andreas Binder
Dipl.-Ing. Hooshang Gholizad

Novemebr 2011

ii

Summary
Variable Impedance Induction Motor consists of a sectionalized rotor, with 3 different
sections and each section has its own bars and end-rings which have different geometry and
materials, in order to achieve high starting torque and high efficiency at the rated operating
point together with high breakdown torque. In order to investigate the electromagnetic and
thermal characteristics of this motor (22 kW VZIM), three different motors VZIM1, VZIM2
and VZIM3 with the same stator but different rotors have been considered and analyzed.

Electromagnetic and thermal analyses of a 22kW Variable Impedance (Z) Induction Motor
(VZIM) are the aim of this master thesis. Finite element method is a precise and useful
approach to analyze electrical machines, therefore the electromagnetic analysis of the VZIM
motor is done using Flux2D software and the thermal analysis is done by ANSYS software.
Furthermore all the calculation results obtained by finite element method and relevant tools
are compared with analytical calculations, carried out by KLASYS program. In order to do
steady state AC and time stepping electromagnetic analysis of the 22kW VZIM motor, first
the geometries of three assumed independent motors VZIM1, VZIM2 and VZIM3 are
generated in Flux2D and with assigning the materials and meshing the geometries, the models
are solved and relevant torque-slip, fundamental stator phase current-slip, input power-slip,
efficiency-slip and power factor-slip characteristics are calculated by Flux2D and compared
with the results of the KLASYS software.

In addition, for thermal calculations due to the existence of the measured values of the 5.5kW
VZIM motor, first the 5.5kW motor is analyzed with the ANSYS tool and the results are
compared with measured values, afterwards the 22kW VZIM motor is analyzed with ANSYS
tool and the results are compared with a simplified thermal equivalent circuit model results.
To carry out the simulation with ANSYS, first the geometries of three assumed independent
motors VZIM1, VZIM2 and VZIM3 are generated and after assigning the materials and
meshing the geometries, the models are solved with assigning the loss densities of different
parts of the motors as heat sources. At the end the values of analytical calculations and finite
element method are compared to make sure that the temperature rise in the stator winding
does not exceed the thermal limit of the insulations.

iii

Contents
Table of Contents
List of Symbols
List of Figures
List of Tables

1 Introduction
1.1 Preface 1
1.2 Electromagnetic and thermal analysis of the 22kW VZIM 3
1.3 Introduction to finite element method 3
1.4 Electrical and mechanical parameters and dimensions of the 22kW VZIM 6
1.5 Procedure of the project 10

2 Geometry and mesh generation with Flux2D
2.1 Introduction 11
2.2 Geometry creation 11
2.3 Meshing the geometry 12
2.4 Material assignment 14
2.5 Electrical circuit for the motor 15
2.6 Calculation of values of circuits elements 16
2.6.1 Stator resistance 16
2.6.2 Inductance of stator winding overhang 16
2.6.3 Rotor end-ring leakage inductance 17
2.6.4 Resistance of the end-Ring Segment VZIM1 17

3 Steady state electromagnetic analysis
3.1 Introduction 20
3.2 Steady state AC analysis of the 22kW VZIM 21
3.2.1 Steady state AC analysis of the VZIM1 21

4 Time stepping analysis of VZIM
4.1 Introduction 32
4.2 Stator and rotor field spatial harmonics 32
4.3 Asynchronous harmonic torques 32
4.4 Synchronous harmonic torques 33
4.5 Derived slips used for time stepping analysis 34
4.6 Time-stepping analysis of induction motors 35
4.6.1 Time-stepping analysis of VZIM1 35

iv

4.7 Instantaneous Torque wave forms at different rotor speeds 50
4.8 Synchronous harmonic torque assessment in VZIM 54
4.9 Power losses in different parts of the motor 61
4.9.1 Losses of VZIM at different speeds 63

5 Thermal analysis
5.1 Preface 65
5.2 Temperature rise calculation by thermal equivalent circuits 65
5.2-1 Calculation of
and
for VZIM2 (22kW) 69

and
for VZIM3 (22kW) 70

5.3 Numerical calculation of temperature rise 71
5.3.1 Thermal analysis of 5.5kW VZIM2 72
5.3.2 Thermal analysis of 5.5kW VZIM3 75
5.3.3 Thermal analysis of 22kW VZIM2 79
5.3.4 Thermal analysis of 22kW VZIM3 82

6 Conclusion 87

7 Bibliography 88

8 Appendix
8.1 Appendix I 89
8.2 Appendix II 91
8.3 Appendix III 109
8.4 Appendix IV 111

v

List of Symbols
- number of parallel baranches of winding
- parallel wires per turn

B T magnetic flux density
H A/m magnetic field strength
A Vs/m Magnetic vector potential
m inner stator diameter

f Hz electric frequency
h m height of stator slot opening
- distribution factor
- slot fill factor, frequency coefficient
- pitching factor
- winding factor
m Pole pitch
l m axial length
L m self-inductance
L m overall length
- permeance /unit length
m length of the winding overhang

m - number of phases
m mean diameter of the end-ring
m length of the end-ring segment
m cross section area of end-ring
m end-ring thickness
m end-ring height
M N.m. torque
n 1/s rotational speed
- number of turns per phase
- number of turns per coil

p - number of pole pairs
P W power
q - number of slots per pole and phase
Q - number of slots
R Ohm electric resistance and thermal resistance
s - slip
m slot opening
t s time
u,U V electric voltage
- current/voltage transformation ratio

V A magnetic voltage (m.m.f.)
m circumference co-ordinate
m air gap width
S/m electric conductivity

density
Ohm.m electric resistivity
- ordinal number of rotor space harmonics
Vs/(Am ) magnetic permeability
- ordinal number of stator space harmonics

vi

1/s electric angular frequency
K/W Heat resistance

temperature
K temperature rise
W Copper losses
W iron losses
W/(
) heat transfer coefficient

j A/
current density
i A current
W volume density of instantaneous power loss
Ws/(
) hysteresis coefficient
1/(Ohm.m)) coefficient of losses in excess
T peak value of the magnetic flux density

m/s wind speed over stator outer surface and winding overhang
d m thickness of slot insulation and stator and rotor lamination
W/(m.) Thermal conductivity

vii

List of Figures
1.1-1 Cross-section of variable impedance induction motor, rotor position at stand still
[6]
2
1.1-2 Cross-section of variable impedance induction motor rotor position at nominal
speed [6]
2
1.4-1 Cross-section of Variable Impedance Induction motor (VZIM1), Prepared by
ANSYS
8
ANSYS
9
ANSYS
9
2.2-1 Created geometry of VZIM1, by Flux2D 11
2.3-1 Generated mesh of VZIM1 in the air-gap using Flux2D 12
2.3-2 Generated mesh of VZIM1 using Flux2D 13
2.4-1 B-H characteristic of M270-50A iron sheets, which are used in stator and rotor
lamination [7]
14
2.5-1 Star connected stator electrical circuit of the motor, by Flux2D 15
3.1-1 Nonlinearity relation of B and H [5] 20
3.1-2 Static and equivalent B-H curves for different cases [5] 21
3.2.1-1 Torque-slip characteristics of VZIM1, comparison of the steady state calculation
results of Flux2D and the analytical calculations by KLASYS
22
3.2.1-2 Torque-slip characteristics of VZIM1, comparison of skewed and unskewed rotor,
obtained by KLASYS
23
3.2.1-3 Phase current-slip characteristic of VZIM1, comparison of the steady state
calculation results of Flux2D and the analytical results of KLASYS
23
3.2.1-4 Normal component of air-gap flux density for one pole pair of VZIM1 at a
slip of 0.0253, calculated by Flux2D
24
3.2.1-5 Numerically calculated flux lines in VZIM1 at a slip of 0.0253, obtained
by Flux2D
25
26
27
27
3.2.2-4 Numerically calculated flux lines in VZIM2 at a slip of 0.0253, obtained by
Flux2D
28
29
30
30
3.2.3-4 Numerically calculated flux lines in VZIM3 at a slip of 0.0253, obtained by
Flux2D
31
4.3-1 Asynchronous harmonic torques of the 5
th
and 7
th
stator field harmonics,
which are superimposed on fundamental asynchronous torque [2]
33
4.4-1 Typical effects of synchronous and asynchronous harmonic torques in induction
machines [2]

34

viii

4.6.1-1 Torque-slip characteristic of unskewed VZIM1, calculated with Flux2D time-
stepping, the effects of the synchronous harmonic torques at slips
, and of the the motor are observable
36
4.6.1-2 Torque-slip characteristic of unskewed VZIM1, calculated with KLASYS, the
effects of the synchronous harmonic torques at slips , and
of the the motor are observable
36
4.6.1-3 Torque-slip characteristic of unskewed VZIM1, time-stepping and AC analysis
results obtained by Flux2D, the harmonic torque effects at lower speeds of the
motor are obvious
38
4.6.1-4 Stator phase current of unskewed VZIM1, time stepping analysis results
calculated by Flux2D and KLASYS
38
4.6.1-5 Input power-slip of VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS
38
4.6.1-6 Output power-slip of VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS
39
4.6.1-7 Efficiency-slip of VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS
39
4.6.1-8 Power factor-slip of VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS
40
4.6.2-1 Torque-slip characteristic of unskewed VZIM2, obtained by KLASYS and Flux2D
time-stepping calculations, the harmonic torque effects at lower speeds of the
motor are observable
41
41
motor are obvious
42
4.6.2-4 Stator phase current of unskewed VZIM2, comparison of the time stepping
analysis results calculated by Flux2D and KLASYS
43
Flux2D and KLASYS
43
Flux2D and KLASYS
44
Flux2D and KLASYS
44
4.6.2-8 Power factor-slip of VZIM2, comparison of the analysis results calculated by
Flux2D and KLASYS
45
4.6.3-1 Torque-slip characteristic of unskewed VZIM3, calculated with Flux2D time-
stepping, the effects of the synchronous harmonic torques at slips
, and of the the motor are observable
46
46
motor are obvious
47
4.6.3-4 Stator phase current of unskewed VZIM2, comparison of the analysis results
calculated by Flux2D and KLASYS
47
Flux2D and KLASYS
48
Flux2D and KLASYS
48

ix

Flux2D and KLASYS
49
4.6.3-8 Power factor of VZIM3, comparison of the analysis results calculated by Flux2D
and KLASYS
49
4.7-1 Torque-time characteristic of VZIM2 at 1462rpm, calculated by Flux2D, torque
oscillates around a constant mean value after reaching the steady state
50
4.7-2 Torque-time characteristic of VZIM2 at 1462rpm, calculated by Flux2D, zoomed
view after steady state is reached
51
51
view after a steady state is reached
52
oscillates around a constant mean value
52
53
4.7-7 Torque-time of VZIM2 at 205.5rpm, calculated by Flux2D, where break down slip
of the 7
th
asynchronous torque harmonic happens at slip 0.863 or 205.5rpm
53
4.8-1 First and second positions of the rotor bars with fixed stator position to
calculate the synchronous harmonic torques, prepared by Flux2D
54
4.8-2
Torque-time of unskewed VZIM2 at , calculated by Flux2D, rotor
position step 1
54
4.8-3
position step 5
55
4.8-4
position step 7
55
4.8-5
Variation of synchronous torque at as a function of rotor position 56
4.8-6
Variation of synchronous torque at a function of rotor position 56
4.8-7
Variation of synchronous torque at as a function of rotor position 56
4.8-8 Torque-time of unskewed VZIM2 at speed 224.28 rpm, calculated by Flux2D 58
4.8-9 Torque-time of unskewed VZIM2 at speed 10 rpm, calculated by Flux2D 59
4.8-10 Torque-time of unskewed VZIM2 at speed -97.14 rpm, calculated by Flux2D 59
4.9.1-1 Comparison between losses of VZIM1 at speed equal to 1390.9 calculated
with Flux2D and KLASYS
63
64
64
5.2-1 The simplified thermal equivalent network for an induction motor 66
5.2-2 Output power-slip characteristics of 22kW VZIM2 and VZIM3 and the average of
the powers
67
5.2-3 Calculated output power of the VZIM motor with the supper-position and
equivalent circuit methods
68
5.3.1-1 2D model of the 5.5kW VZIM2 and meshing, by ANSYS 72
5.3.1-2 3D model of the 5.5kW VZIM2, by ANSYS 72
5.3.1-3 3D model meshing of the 5.5kW VZIM2, by ANSYS 73
5.3.1-4 The thermal solution of the 5.5kW VZIM2 under nominal operation, by ANSYS 74
5.3.1-5 The calculated temperature in the winding overhang of VZIM2, by ANSYS 75
5.3.2-1 2D model of the 5.5kW VZIM3 and meshing, by ANSYS 75
5.3.2-2 3D model of the 5.5kW VZIM3, by ANSYS 76
5.3.2-3 3D model meshing of the 5.5kW VZIM3, by ANSYS 76
5.3.2-4 The thermal solution of the 5.5kW VZIM3 under nominal operation, by ANSYS 78
5.3.2-5 The calculated temperature in winding overhang of 5.5kW VZIM3, by ANSYS 78

x

5.3.3-1 2D model of the 22kW VZIM2 and meshing, by ANSYS 79
5.3.3-2 3D model of the 22kW VZIM2, by ANSYS 79
5.3.3-3 3D model meshing of the 22kW VZIM2, by ANSYS 80
5.3.3-4 The thermal solution of the 22kW VZIM2 under nominal operation, by ANSYS 81
5.3.3-5 The calculated temperature in the winding overhang of 22kW VZIM2, by ANSYS 82
5.3.4-1 2D model of the 22kW VZIM3 and meshing, by ANSYS 82
5.3.4-2 3D model of the 22kW VZIM3, by ANSYS 83
5.3.4-3 3D model meshing of the 22kW VZIM3, by ANSYS 83
5.3.4-4 The thermal solution of the 22kW VZIM3 under nominal operation, by ANSYS 85
5.3.4-5 The calculated temperature in the winding overhang of 22kW VZIM3, by ANSYS 85

xi

List of Tables
1.4-1 Stator dimensions 6
1.4-2 Stator winding details 6
1.4-3 The rotor dimensions and parameters of VZIM1 7
1.4-6 VZIM material details 8
2.4-1 B-H characteristic data of the iron sheet type M270-50A [7] 14
2.6-1 Electrical values of VZIM stator circuit 19
4.8-1 Maximum, minimum and peak to peak values of synchronous torque for
VZIM2 in two different methods of calculation (rotation and oscillation
methods) for the slip
57
57
58
VZIM1 (oscillation method)
58
VZIM3 (oscillation method)
58
VZIM1, at the slip , the comparison of the calculated values by
KLASYS and Flux2D
60
VZIM1, at the slip , the comparison of the calculated values by KLASYS
and Flux2D
60
KLASYS and Flux2D
60
KLASYS and Flux2D
60
and Flux2D
60
KLASYS and Flux2D

60
KLASYS and Flux2D
61
and Flux2D
61
KLASYS and Flux2D
61
4.9-1 Values of specific total losses according to the data sheet of the M270-
50A [7], and calculated power losses, in frequencies 50Hz, 100Hz and
200Hz
62

xii

5.2-1 Heat transfer coefficient for one side of the winding overhang close to the
centrifugal mechanism
67
5.2-2 Losses in different parts of the VZIM2 and VZIM3 in the speed equal to
1467.36 rpm
68
5.2.1-1 Thermal conductivities of the materials used in VZIM2 thermal model 69
5.2.2-1 Thermal conductivities of the materials used in VZIM3 thermal model 70
5.2.2-2 Temperature rise in the stator winding of VZIM2 and VZIM3 calculated based
on simplified thermal equivalent circuit in the nominal operating speed equal to
1467.36 rpm
71
5.3.1-1 Loss densities in different parts of the 5.5kW VZIM2 73
5.3.1-2 Heat transfer coefficient at different boundary conditions of the 5.5kW VZIM2 74
5.3.2-1 Loss densities in different parts of the 5.5kW VZIM3 76
5.3.2-2 Heat transfer coefficient at different boundary conditions of the 5.5kW VZIM3 77
5.3.2-3 Temperature rise in stator slot of 5.5kW VZIM2 and VZIM3 calculated by
ANSYS
78
5.3.3-1 Loss densities in different parts of the 22kW VZIM2 80
5.3.3-2 Heat transfer coefficient at different boundary conditions of the 22kW VZIM2 81
5.3.4-1 Loss densities in different parts of the 22kW VZIM3 83
5.3.4-2 Heat transfer coefficient at different boundary conditions of the 22kW VZIM3 84
5.3.4-3 Temperature rise in stator slot of 22kW VZIM2 and VZIM3 calculated by
ANSYS
85
5.3.4-4 Temperature rise in stator slot of 22kW VZIM2 and VZIM3 calculated by
ANSYS
86
Appendix II Synchronous harmonic torque slip 91
Appendix II Stator ordinal numbers and related asynchronous harmonic torque slips 92
Appendix II Slips which are used to perform time-stepping analysis of VZIM1 106
Appendix III Losses in VZIM1 calculated by Flux2D and KLASYS 109

- 1 -

Chapter 1: Introduction

1.1 Preface
Due to the robustness and reliability with low production and maintenance costs of the line
operated induction motors, this type of machines are used in more than 80% of motor
applications worldwide.
Making use of current displacement effect by designing induction motors with deep bar or
double cage rotors results in desirable starting torque and efficiency at nominal speed
operation, but reduction of breakdown torque is not favorable which happens in this case
because of increased rotor leakage reactance. One possible solution is Variable Impedance
Induction Motor (VZIM).
The Variable Impedance Induction Motor has high starting torque, in addition to high
efficiency at the nominal operating point. This type of induction motor includes a
sectionalized cage rotor with different bar shapes for each sub-cage section is used. At
standstill, sub-cages with high resistances are placed inside the stator bore to increase the
starting torque and reduce the starting current. By increasing the rotational speed, a
centrifugal mechanism moves the rotor in the axial direction and brings the other sections of
the rotor cage with low resistances inside the stator bore to reduce the rotor losses at rated
speed. This leads to increased efficiency at nominal operation [6]. Figures 1.1-1 and 1.1-2
show the cross section view of a 3-section VZIM motor at standstill and nominal speed.
The rotor length is 1.5 times the stator length, and it is composed of three different sub-cages
(A: starting sub-cage, B: middle sub-cage and C: final sub-cage). At standstill, the sub-
cages A and B are inside the rotor bore; means they are active at start-up of the motor).
By increasing the speed, a centrifugal axial rotor shifter mechanism pulls the rotor in the axial
direction and brings the third section of the rotor cage inside the stator bore. At the nominal
speed the sub-cage A is put completely out of the stator bore and only the sub-cages B
and C are active.

- 2 -

Fig 1.1-1: Cross-section of variable impedance induction motor, rotor position at stand still [6]

Fig 1.1-2: Cross-section of variable impedance induction motor rotor position at nominal speed [6]

- 3 -

1.2 Electromagnetic and thermal analysis of the 22kW VZIM
A 4 pole, 22kW VZIM operating with a nominal voltage of 400V and a nominal frequency of
50Hz has been designed. The rotor has 3 sections with different rotor bar shapes. The first
rotor section has round bars, the middle cage has deep bars and the final cage has wedge bars.
The electromagnetic characteristics and thermal effects of the electrical losses in this motor
has been analyzed and investigated.
With the help of Flux2D and ANSYS which are suitable tools for electromagnetic and thermal
analysis and are based on finite element method, the motors characteristics and features are
calculated and the results of the electromagnetic analysis prepared by Flux2D are compared
with analytical calculations which mostly are obtained by KLASYS tool.
In this analysis it has been assumed that there are three motors with the same stator but
different rotor bars, therefore three motors VZIM1, VZIM2 and VZIM3 are analyzed.
1.3 Introduction to finite element method [4]
In engineering and science there are many physical phenomena which can be described with
Partial Differential Equations (PDE), solving these equations with analytical methods for
arbitrary shapes is almost impossible. The Finite Element Method (FEM) is a numerical
approach by which these PDE can be approximately solved.
Solving a PDE by FEM method is done by dividing the calculation domain in finite elements
in which a known variation of the physical values is assumed. This variation is usually a
polynomial variation with an arbitrary power but in practical applications the maximal degree
Three is used. In conclusion the field distribution is assumed to be a polynomial variation of
first order in most of the cases, of second order in more rare situation and extremely rare of
the third order.
To have a good FEM calculation some general rules must be followed. After dividing the
calculation domain in finite elements with meshing the area of calculation, first of all the
finite elements have to cover the entire calculation domain, the elements must not overlap and
the nodes of one element cannot be found on the lines of the adjacent elements but must have
the same position with the adjacent elements nodes.

In case of magneto static problems, the field is described by the following Maxwell equations,

and the constitutive law for material,

From we can write B as,

because it is always true , where is called the magnetic vector potential.

From , and the differential equation that describes a magneto
static problem can be obtained,

- 4 -

Each field is defined by its sources , and by related eddies , so
may be chosen free. The coulomb gauge is often used as

Further, if a constant vector
is added to , still and are valid,

so the magnetic vector potential is defined by choosing the value for one node from
domain. This is necessary in order to obtain a correct solution. The unknown of the problem is
the value of in the grid nodes and the field source is given by the current density in the
elements volumes (areas for 2D).

After solving the linear system of equations the values of the flux density B are obtained.
Afterwards the field strength H due to is calculated and by integration over the
domain the energy and generated force can also be calculated.

In FEM the stored magnetic energy is calculated by integrating the energy density as a
volume integral for 3D-FEM or as an area integral for 2D-FEM. The volume energy density is
defined as: .
The energy density can be integrated on the calculation domain for the 3D-FEM as it follows

As is calculated as derivative of , is constant within each element. Via
also H is constant within each element. So considering that inside one element the
values for B and H are constant, can be transformed into:

For 2D-FEM the equation is valid, if we consider that we have a length of the
model in the z direction equal with m:

The energy in is measured in }m, whereas the energy in is measured in
}. In order to get the value of the stored magnetic energy in a volume from a 2D-FEM
calculation, one has to multiply the calculated value with the length of the model in the z-
direction.
For the magneto static calculation the magnetic field is considered to be constant and no eddy
currents are induced in the conductive materials. This stationary situation is sufficient to
describe only the problems with slow varying fields and problems where the effects of the
variation of the fields are considered negligible. For the rest of the problems consideration of

- 5 -

the variation of the fields is necessary and calculation in time domain or in frequency domain
is applied. The time domain calculation is actually a succession of static calculations for
different time moments. The time variable cannot be considered continuously and has to be
considered using a certain time step. Each static calculation that is performed during a
transient calculation is called a non-linear iteration and for each iteration the results from the
previous iteration are considered as starting point. The variation of magnetic field between
two iteration steps determines the variation speed of the magnetic field. In order to calculate
this influence the Maxwell equations must be written in a form that considers the magnetic
field variation in time

and the constitutive law for material

Like for magneto static problems we can write the flux density as a curl of vector potential

Using in we obtain

which is the electric field strength determined by the time-varying field. It represents the
electromotive force induced in the conductor due to the magnetic field variation. From
we can calculate the current density induced by the magnetic field variation
using

The current density
has 2 components:
-The source component
that is given as entry data for the problem at the beginning of the
calculation. It is represented by the current density in the conductors that are exciting the
primary magnetic field model.
-The component that is induced due to the magnetic field variation
.

Considering these two components results in

This is the differential equation to be solved by the FE program, in a time-step solution. In
practice with usage of a finite element tool there are some steps to solve the problem. The
geometry is prepared, then geometry must be meshed and afterwards material are assigned to
the regions, finally by linking an external electrical circuit the model is ready to be solved. To
create the geometry, symmetry and periodicity must be taken into account. If the geometry

- 6 -

has periodicity, type of the periodicity (symmetric or anti-symmetric conditions) must be
defined.

1.4 Electrical and mechanical parameters and dimensions of the 22kW VZIM

Due to three rotor sections the names VZIM1 for the first cage, VZIM2 for the middle cage
and VZIM3 for the last cage, are assigned to each part of the rotor.

Stator dimensions are given in Table 1.4-1. The stator winding details, which has a star
connection are listed in Table 1.4-2. Tables 1.4-3, 1.4-4 and 1.4-5 list the rotor dimensions
and parameters of the VZIM1, VZIM2 and VZIM3. The rotor sub-cages are not skewed. Table
1.4-6 consists of the material details used in VZIM.

Table 1.4-1: Stator dimensions
Description parameter Dimension Value
Stack length
mm 240
Inner stator diameter
mm 170
Outer stator diameter
mm 270
Air gap width mm 0.45
Number of stator slots
- 36
Width of stator slot opening
mm 3.1
Height of stator slot opening
mm 0.737
Stator slot heit
mm 22.6
Stator slot width
mm 10.277
Radius of stator slot opening
mm 3.606

Table 1.4-2: Stator winding details
Number of phases m - 3
Number of pole pairs p - 2
Number of slots per pole and phase q - 3
Number of turns per coil
- 12
Number of parallel branches a - 1
Type of winding - - Single layer
Winding pitch - - Full pitch
Number of turns per phase
- 72
Length of overhang
mm 226.6
Number of parallel wires per turn
- 9
Diameter of conductor
mm 1
Winding connection - - Star

- 7 -

Table 1.4-3: The rotor dimensions and parameters of VZIM1
Outer rotor diameter
mm 169.1
Inner rotor diameter
mm 80
Number of rotor bars
- 28
Bar shape - - Round
Bar material - - Bronze
Width of rotor slot opening
mm 4.5
Height of rotor slot opening
mm 1
Rotor bar diameter
mm 10.2
End-ring thickness
mm 4.3
End-ring height
mm 44

mm 169.1
mm 80
- 28
Bar shape - - Deep
Bar material - - Copper
mm 4
mm 1
Height of rotor bar
mm 8.2
Width of rotor bar
mm 9.2
End-ring thickness
mm 4.6
End-ring height
mm 44

mm 169.1
mm 80
- 28
Bar shape - - Inverse wedge
Bar material - - Copper
mm 2
mm 1
Height of rotor bar
mm 17.7
Width of rotor bar
mm 10.2
End-ring thickness
mm 6
End-ring height
mm 44

- 8 -

Table 1.4-6: VZIM material details
Conductivity of bronze at 110
Sm
1.69E+7
Conductivity of copper at 110
Sm
4.22E+7
Lamination type - - M270-50A
Conductivity of lamination
Sm
1.818E+6
Loss at 50Hz, 1T
W/kg 1.07
Loss at 50Hz, 1.5T
W/kg 2.52

Cross-sections of the motors have been depicted in figures 1.4-1, 1.4-2 and 1.4-3. The first
motor VZIM1 has round rotor bars made of bronze and second and third motor VZIM2 and
VZIM3 have rotor bars made of copper.

Fig 1.4-1: Cross-section of Variable Impedance Induction motor (VZIM1), prepared by ANSYS

- 9 -



- 10 -

1.5 Procedure of the project
In order to simplify the simulation, three separate induction motors have been considered, in
this simulation VZIM1, VZIM2 and VZIM3 each one has a full length rotor and stator.

With the help of Flux2D, electromagnetic analysis and with ANSYS, thermal analysis has been
done.

Two types of electromagnetic analysis have been carried out:
-Steady state magnetic AC analysis
-Time stepping analysis.

All results from Flux2D have been compared with the analytical results of KLASYS tool.

- 11 -

Chapter 2: Geometry and mesh generation with Flux2D

2.1 Introduction

Electromagnetic analysis based on finite element method is done with Flux2D. In this chapter
the creation of geometry, mesh generation, electrical circuit determination and material
assignment is explained.

2.2 Geometry creation

The variable impedance induction motor which is analyzed has 4-poles, 36-stator slots and 28
rotor bars, three different motors with the same stator but different rotors are being
considered. Based on this consideration 3 models has been created.

Because of simplicity and according to Anti-cyclic boundary condition, of the motor is
modeled. Three models which have been prepared as VZIM1, VZIM2, and VZIM3 are
depicted in Fig 2.2-1, Fig 2.2-2 and Fig 2.2-3.

Fig 2.2-1: Created geometry of VZIM1, by Flux2D Fig 2.2-2: Created geometry of VZIM2, by
Flux2D

- 12 -

Fig 2.2-3: Created geometry of VZIM3, by Flux2D

2.3 Meshing the geometry

An automatic mesh generator is in charge of meshing the faces. With the help of the mesh
points, it is possible to have fine and dense meshing in the areas which the higher accuracy is
needed. Fine mesh in the air-gap, at the top of the rotor bars, and the stator teeth, is necessary
because of accuracy of the results, air-gap must be fine meshed, to have accurate torque
calculation. The top of the rotor bars near the air gap are densely meshed, to taking into the
account the current displacement effect. In addition the stator teeth must be meshed fine
enough to consider the saturation effect because of high flux density in this area. In Fig.2.3-1
and Fig.2.3-2 generated mesh for VZIM1 is shown. The fine mesh in the air-gap is observable
in Fig.2.3-1.

Fig 2.3-1: Generated mesh of VZIM1 in the air-gap using Flux2D

- 13 -

Fig 2.3-2: Generated mesh of VZIM1 using Flux2D

- 14 -

2.4 Material assignment

Stator and rotor lamination in 22kW VZIM are made of M270-50A [7]. B (H) curve and
values are shown in Fig.2.4-1 and table 2.4-1.

Table 2.4-1: B-H characteristic data of the iron sheet type M270-50A [7]
H/(A/) B/Tesla H/(A/) B/Tesla
0 0 2119.027 1.516379
21.73374 0.454861 2668.102 1.534915
43.46748 0.7016061 3354.447 1.556988
73.65323 0.902243 4212.377 1.582977
111.3854 1.048599 5284.791 1.613156
158.5506 1.157766 6625.307 1.647613
217.5072 1.240593 8300.953 1.686154
291.2029 1.304297 10395.51 1.728191
383.3224 1.353865 13013.71 1.772635
498.472 1.392849 16286.45 1.817807
642.4088 1.42385 20377.38 1.861388
822.3299 1.448816 25491.05 1.900418
1047.231 1.469241 31883.13 1.931347
1328.358 1.486302 43860.55 1.955117

Fig.2.4-1: B-H characteristic of M270-50A iron sheets, which are used in stator and rotor lamination
[7]
0
0.5
1
1.5
2
2.5
0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000
B
/
T
e
s
l
a

H/A^()
B-H Characteristic of M270-50A iron sheets

- 15 -

VZIM1 has rotor bars which are made of bronze, VZIM2 and VZIM3 have rotor bars made of
copper. This special alloy of bronze has the electrical resistivity equal to 0.588E-07 Ohm.m.
Copper has the electrical resistivity equal to 0.237E-07 Ohm.m.

2.5 Electrical circuit of the motor
Three phase winding in 22kW VZIM is star connected. The electrical circuit which is created
in Flux2D, is depicted in Fig.2.5-1.

Fig.2.5-1: Star connected stator electrical circuit of the motor, by Flux2D
The resistances R1, R2 and R3 represent the winding overhang resistances; also the
inductances L1, L2 and L3 represent the overhang inductances. In addition stator phase
windings under stator slots are shown as BPA, BPB and BMC.
VA, VB and VC are three phase voltage sources with 230 V and 120 degree phase shift with
each other; moreover Q1 represents the squirrel cage rotor which is connected to common
point of voltage sources.

- 16 -

2.6 Calculation of values of circuits elements

The values of the circuit components are calculated and assigned to the circuit. In this section
the values of the stator resistance, inductance of stator winding overhang, rotor end-ring
leakage inductance and resistance of the end-ring segments are calculated.

2.6.1 Stator resistance

Stator winding resistance per phase
is sum of resistance of the coil under stator slots
(also

anu
) and winding overhang
(also
and
). Resistance per phase

is calculated according to [1]:

Resistance of one phase under stator slot at 20 equals to:

and the resistance of one phase under slot of stator in 110 is given by:

Resistance of the winding overhang at 20 is calculated as below:

and the resistance of winding overhang at 110 is equal to:

2.6.2 Inductance of stator winding overhang

Inductance of the winding overhang is calculated according to [1], using following equation:

where
is the length of the winding overhang and
is the permeance /unit length which is

calculated as below:

where
is the diagonal of the cross-section of the coils in the winding overhang and is
calculated as following:

- 17 -

mm
According to [1] for a single phase winding with q=3, c is equal to 0.67 and
is calculated
as below:

Therefore the inductance of the winding overhang equals to:
mB

2.6.3 Rotor end-ring leakage inductance

Rotor end-ring leakage inductance is calculated according to [1] as following:

where
and
mm, hence:
B

2.6.4 Resistance of the end-ring segment of VZIM1

First of all the mean diameter of the end-ring
is calculated which is the mean value of

the inner diameter
and the outer diameter
of the end-ring:
mm
With
the number of the rotor bars and
the mean diameter of end-ring, the length of

the end-ring segment is calculated as below:
mm
the end-ring thickens is
mm and the end-ring height is
mm using end-
ring thickness and height, the cross section area of end-ring is calculated as:
mm
.
Then resistance of the end-ring is calculated as:

2.6.5 Resistance of the end-Ring Segment VZIM2

The mean diameter of the end-ring
is calculated using the mean value of the inner

diameter
of the end-ring:

- 18 -

mm
With
the number of the rotor slots and

the end-ring segment is calculated as:
mm
end-ring thickens is,
mm .using end-
ring thickness and height, the cross section area of end-ring is calculated as:
mm

conductivity of copper in 110 is calculated as:

S
m

Then resistance of the end-ring is calculated as:

2.6.6 Resistance of the end-ring segment VZIM3
The mean diameter of the end-ring
is calculated using the mean value of the inner

diameter
of the end-ring,
mm
with
the number of the rotor slots and

the end-ring segment is calculated as:
mm
end-ring thickens is
mm .using end-ring
thickness and height, the cross section area of end-ring is calculated as:
mm

conductivity of copper in 110 is calculated as:

S
m

Then resistance of the End-Ring is calculated as:

All the values derived from formulas in sections 2.6.4 to 2.6.6 are shown in Table 2.6-1.

- 19 -

Table 2.6-1: Electrical values of VZIM stator circuit
Parameter value description
0.116 Resistance per phase of the coil under stator slot
0.1095 Resistance per phase of winding overhang
0.424 mH Inductance pre phase of winding overhang
B End-ring leakage inductance
Resistance of the end-ring segment, VZIM1

- 20 -

Chapter 3: Steady state electromagnetic analysis

3.1 Introduction

In steady state electromagnetic analysis, it is assumed that variables are changing purely
sinusoidal with time and there are no harmonics. Due to the saturation effect of magnetic
material, electromagnetic flux density B and electromagnetic field strength H, could not be
sinusoidal at the same time. If the electric circuit had voltage source the B would be
considered as sinusoidal variable and therefore because of B (H) curve, H would not be a
sinusoidal variable with time. Fig.3.1-1 shows that how B and H curves change if one of them
is sinusoidal.

Fig. 3.1-1: Nonlinearity relation of B and H [5]

The above contradictions are dealt by using an equivalent B(H) characteristic, which is
different for the original B(H) characteristic and based on the energy equivalence method, as
shown in Fig.3.1-2. For the two extreme cases of B sinusoidal and H sinusoidal the B(H)
curve is modified and shown in Fig.3.1-2 based on the above method. The results obtained
with the equivalent curves calculated in the two extreme cases most often include the exact
result. The equivalent curve can equally be calculated by means of a linear combination
between these two extreme cases as shown in Fig.3.1-2. Only the numerical values of the
post-processed quantities, that depend on energy, are correct. The instantaneous values
computed by this analysis are approximations as they are sinusoidal.

- 21 -

Fig. 3.1-2: Static and equivalent B-H curves for different cases [5]

3.2 Steady state AC analysis of the 22kW VZIM

As previously was mentioned the VZIM motor is considered as three different motors with
the same stator and different rotor bars. Therefore three different motors VZIM1, VZIM2 and
VZIM3 are analyzed and the results are compared with analytical calculations obtained from
KLASYS tool.

3.2.1 Steady state AC analysis of the VZIM1
Fig.3.2.1-1 shows the torque-slip characteristic of VZIM1, which compares the steady state
AC analysis results calculated by Flux2D and KLASYS. It is apparent that the values
calculated by KLASYS are higher than values obtained using Flux2D. In lower slips the
difference between the values of KLASYS and Flux2D are less than 10% and in slips higher
than 0.3 the difference reaches to around 12%. In addition the breakdown torque in both
calculation methods happens around slip equal to 0.65, for the unskewed rotor cage. The
calculation results for the skewed rotor with one stator slot pitch obtained by KLASYS shows
that the breakdown slip is close to one as depicted in Fig.3.2.1.2. As the rotor is equivalently
skewed by shifting the sub-cages in the circumferential direction with respect to each other
by half a stator slot pitch,
, which is equivalent to one sator slot

pitch skewing, therefore in the design phase, the optimization has been done for the skewed
rotor case to achieve the maximum starting torque at stand still.

- 22 -

The stator phase current-slip characteristics of VZIM1 which are prepared by Flux2D and
KLASYS are depicted in Fig.3.2.1-3. Maximum deviation between results of the KLASYS and
Flux2D is less than 4%, which shows a good precision.

In Fig.3.2.1-4 the normal component of the air-gap flux density of VZIM1 at a slip of 0.0253
for one pole pair or 180 mechanical degrees has been depicted.

Fig.3.2.1-5 shows the numerically calculated flux lines in VZIM1 by 2 pole pairs at a slip of
0.0253 or 1462.05min
, obtained by Flux2D.

Fig.3.2.1-1: Torque-slip characteristics of unskewed VZIM1, comparison of the steady state
calculation results of Flux2D and the analytical calculations by KLASYS

- 23 -

Fig.3.2.1-2: Torque-slip characteristics of VZIM1, comparison of skewed and unskewed rotor,
obtained by KLASYS

Fig.3.2.1-3: Phase current-slip characteristic of unskewed VZIM1, comparison of the steady
state calculation results of Flux2D and the analytical results of KLASYS

- 24 -

Fig.3.2.1-4: Normal component of air gap flux density in the center of the air gap, for one
pole pair of VZIM1 at a slip of 0.0253, calculated by Flux2D

- 25 -

Fig.3.2.1-5: Numerically calculated flux lines in VZIM1 at a slip of 0.0253, obtained by
Flux2D

- 26 -

calculated by KLASYS are higher than values obtained using Flux2D. The difference between
values of KLASYS and Flux2D are around 15%. In addition the breakdown torque in both
calculation methods happens at around a slip of 0.3.

In Fig.3.2.2-2 stator phase current-slip characteristics of VZIM2 which are calculated by
Flux2D and KLASYS are shown. In lower slips the difference of the values in KLASYS and
Flux2D is around 12%, but in higher values of slips the difference is lower than 4%.

In Fig.3.2.2-3 the normal component of air-gap flux density of VZIM2 at a slip of 0.0294 for
one pole pair or 180 mechanical degrees has been depicted.

Fig.3.2.2-4 shows the numerically calculated flux lines in VZIM2 at a slip of 0.0294 or
1455.8min


- 27 -

Fig.3.2.2-2: Phase current-slip characteristic of unskewed VZIM2, comparison of the steady state

Fig.3.2.2-3: Normal component of air gap flux density in the center of the air gap, for one pole
pair of VZIM2 at a slip of 0.0253, calculated by Flux2D

- 28 -

Flux2D

- 29 -

calculated by KLASYS are higher than values obtained using Flux2D. The difference between
values of KLASYS and Flux2D are around 12%. In addition the breakdown torque in both
calculation methods happens at around a slip of 0.2.

In Fig.3.2.3-2 stator phase current-slip characteristics of VZIM3 which are prepared by
Flux2D and KLASYS are shown. In lower slips the difference of the values in KLASYS and
Flux2D is around 11%, but in higher values of slips the difference is lower than 3%.

In Fig.3.2.3-3 the normal component of the air gap flux density of VZIM3 at a slip of 0.0169
for one pole pair or 180 mechanical degrees has been depicted.

Fig.3.2.3-4 shows the numerically calculated flux lines in VZIM3 at a slip of 0.0169 or
1474.65min


- 30 -

Fig.3.2.3-2: Phase current-slip characteristic of unskewed VZIM3, comparison of the steady state

Fig.3.2.3-3: Normal component of air gap flux density in the center of the air gap, for one pole
pair of VZIM3 at a slip of 0.0253, calculated by Flux2D

- 31 -

Flux2D

- 32 -

Chapter 4: Time stepping analysis

4.1 Introduction
Despite the fact that stator voltage and current are sinusoidal, spatial distribution of flux
density in the air gap is not sinusoidal but step-like, as winding is located in slots.

In steady state analysis only the fundamental sine wave of air gap flux density distribution
was considered which gives a rough estimation of motor characteristics, but more precise and
accurate results are obtained by consideration of higher space harmonics of the stator and
rotor field distribution.

4.2 Stator and rotor field spatial harmonics

The step-like air gap flux density distribution generated by stator,
along stator
circumference co-ordinate
is represented by Fourier series [2]
cos

Furthermore the step-like air gap flux density distribution generated by rotor
along
rotor circumference co-ordinate
is represented by Fourier series [2]
cos

.

4.3 Asynchronous harmonic torques

Rotor harmonic currents
produce not only additional cage losses, but also due to Lorentz
forces with stator field harmonic
additional torque, which is called asynchronous

harmonic torque. For the special case this is the asynchronous torque of KLOSS

- 33 -

function. The stator harmonic field induces the rotor harmonic current and the rotor harmonic
current produces torque with the stator harmonic field.

Asynchronous harmonic torque follows a KLOSS function, depending on harmonic slip
, at
this torque is zero. At
torque is positive and adds to fundamental torque. At
the torque is negative and is breaking the machine. At harmonic break down slip:

torque reaches positive and negative maximum values. As
harmonic break
down slip is small.

Fig.4.3-1: Asynchronous harmonic torques of the 5
th
and 7
th
stator field harmonics, which are
superimposed on fundamental asynchronous torque [2]

4.4 Synchronous harmonic torques

Rotor field harmonic of step like air gap flux density distribution, excited by rotor
fundamental current
, Will also produce parasitic torque with the stator field harmonics.
Like asynchronous harmonic torque, the condition for constant torque generation is:
-the same wave length
-the same velocity (means also same direction of movement) of the stator and rotor field
wave.
Therefore conditions for slip where synchronous harmonic torque occurs are as following:

- 34 -

Fig.4.4-1: Typical effects of synchronous and asynchronous harmonic torques in induction machines
[2]
Time stepping simulation of the motors is done in the slip range from 0 to 2. In between of
these 2 operating points some important slips corresponding to synchronous and
asynchronous torques are taken into account.
Asynchronous and synchronous harmonic torques happen in slips that have been calculated in
Appendix II and they are considered in the simulation of the motors (VZIM1, VZIM2, and
VZIM3). Fig.4.4-1 shows typical effects of synchronous and asynchronous harmonic torques
in induction machines.

4.5 Derived slips used for time stepping analysis

The sets of slips to perform the time stepping analysis of VZIM1, VZIM2 and VZIM3 motors
have been derived and are given in Table V, Table VI and Table VII in Appendix II. In these
sets of slips the asynchronous and synchronous harmonic torque slips and breakdown slips of
asynchronous harmonic torques are included.

- 35 -

4.6 Time-stepping analysis of induction motors
Time-stepping analysis of the VZIM motor has been done to observe the transients and
harmonic effects on the characteristics of the motor. When the time step is in the order of
1/32th of the electrical cycle, fairly accurate and good results are provided. In our analysis the
motor is line fed and the frequency is 50Hz, and the corresponding electrical cycle is
1/50=0.02s; therefore with consideration of 40 time steps per one cycle,
s would be an acceptable time step. Time stepping analysis has been done for some
speeds of the motor, in the range of -1500rpm to 1500rpm corresponding to the slips given in
Table II, Table III and Table IV in Appendix II. In this analysis the friction and windage
losses and load inertia are neglected.

4.6.1 Time-stepping analysis of VZIM1

Time stepping analysis of the VZIM1 motor has been done in different speeds which are
given in Table V in Appendix II. The results consist of the output torque, input phase current,
input power, efficiency, and power factor which have been compared with the results of the
KLASYS tool. The synchronous harmonic torques which happen at slips, ,
and are calculated with Flux2D as explained in the section 4.8 of this chapter.

In Fig.4.6.1-1 the torque slip characteristic of VZIM1, derived from time stepping analysis
with Flux2D, is shown. The effects of the synchronous harmonic torques at slips ,
and are clearly observed. In Fig.4.6.1-2 the torque slip characteristic of
VZIM1, derived from KLASYS, is shown. The effects of the synchronous harmonic torques at
slips , and are clearly observed.

The values of synchronous torque calculated by Flux2D and KLASYS at slips ,
and , are compared in Table 4.8-6, Table 4.8-7 and Table 4.8-8. It is
noticeable that the synchronous torque values calculated by KLASYS are in most of the cases
much higher than the values calculated by Flux2D. The values of Flux2D are more reasonable
and acceptable.

- 36 -

Fig.4.6.1-1: Torque-slip characteristic of unskewed VZIM1, calculated with Flux2D time-stepping, the
effects of the synchronous harmonic torques at slips , and of the
the motor are observable

Fig.4.6.1-2: Torque-slip characteristic of unskewed VZIM1, calculated with KLASYS, the effects of
the synchronous harmonic torques at slips , and of the the motor
are observable

In Fig.4.6.1-3 the torque slip characteristics calculated by time stepping and steady state AC
analysis are compared. The effects of the field harmonics lead to considerable deviations in
the calculated values.

In Fig.4.6.1-4 the fundamental phase current prepared by Flux2D and KLASYS are compared.
The results match very well and maximum difference is less than 5.5%.

- 37 -

Fig.4.6.1-5 shows the input power-slip characteristic of VZIM1 obtained from Flux2D and
KLASYS. At lower slips the calculated results of KLASYS are lower than Flux2D and at higher
slips results of KLASYS are higher. The values match well and the maximum difference is less
than 5%. In addition Fig.4.6.1-6 shows the output power-slip characteristic of VZIM1
obtained from Flux2D and KLASYS.

Fig.4.6.1-7 shows the efficiency calculated by Flux2D and KLASYS. Maximum efficiency
achieved from Flux2D results is 91.41% at a slip of 0.3 and maximum efficiency calculated
by KLASYS is 90.5% at the slip equal to 0.3. The results match very well.

Fig.4.6.1-8 compares the power factor values obtained from Flux2D and KLASYS. The
maximum power factor calculated by KLASYS equals 0.924 which at slip equal to 0.12
happens, and in Flux2D maximum power factor is equal to 0.962 which at slip equal to 0.1
happens, which is higher than KLASYS maximum power factor.

Fig.4.6.1-3: Torque-slip characteristic of unskewed VZIM1, time-stepping and AC analysis results
obtained by Flux2D, the harmonic torque effects at lower speeds of the motor are obvious

- 38 -

Fig.4.6.1-4: Stator phase current of unskewed VZIM1, time stepping analysis results calculated by
Flux2D and KLASYS

Fig.4.6.1-5: Input power-slip of unskewed VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS

- 39 -

Fig.4.6.1-6: Output power-slip of unskewed VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS

Fig.4.6.1-7: Efficiency-slip of unskewed VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS

- 40 -

Fig.4.6.1-8: Power factor-slip of unskewed VZIM1, comparison of the analysis results calculated by
Flux2D and KLASYS


Similar to VZIM1, time-stepping analysis of VZIM2 has been done with Flux2D and results
have been compared with results of the KLASYS tool. In this analysis the considered slips
similarly vary from 0 to 2 and in between additional 50 slips have been considered for
calculations, which have been given in table VI in Appendix II. The synchronous harmonic
torques which happen at slips, , and are calculated with Flux2D as
explained in the section 4.8 of this chapter.

VZIM2, derived from KLASYS, has been shown. The effects of the synchronous harmonic
torques at slips , and are clearly observed.

and acceptable.

- 41 -

Fig.4.6.2-1: Torque-slip characteristic of unskewed VZIM2, obtained by KLASYS and Flux2D time-
stepping calculations, the harmonic torque effects at lower speeds of the motor are observable

are observable

To observe the effect of the harmonics, the torque-slip characteristic of VZIM2 prepared from
time-stepping and steady state AC analysis have been depicted in Fig.4.6.2-3. A considerable

- 42 -

difference happens at the slip 0.857 and 1.071 due to the synchronous harmonics at these
points.

Fig.4.6.2-4 depicts the comparison between fundamental stator phase current calculated by
KLASY and Flux2D. The difference between results is below 10% which mostly happens at
high values of slip ( ).

Fig.4.6.2-5 shows the input power-slip characteristic of VZIM2, calculated by KLASYS and
Flux2D. At higher slips the values of Flux2D are around 11% lower than values of KLASYS.
In addition Fig.4.6.2-6 shows the output power-slip characteristic of VZIM2 obtained from
Flux2D and KLASYS

Fig.4.6.2-7 depicts the efficiency-slip characteristic of VZIM2, prepared by KLASYS and
Flux2D. The efficiency calculated by Flux2D at rated speed of VZIM2 (1455.8 rpm) is equal
to 0.9104 is higher than that of KLASYS which is equal to 0.905.

Fig.4.6.2-8 depicts the power factor-slip characteristic of VZIM2, prepared by KLASYS and
Flux2D.


- 43 -

Fig.4.6.2-4: Stator phase current of unskewed VZIM2, comparison of the time stepping analysis
results calculated by Flux2D and KLASYS

Flux2D and KLASYS

- 44 -

Flux2D and KLASYS

Flux2D and KLASYS

- 45 -

Fig.4.6.2-8: Power factor-slip of unskewed VZIM2, comparison of the analysis results calculated by
Flux2D and KLASYS


Similar to VZIM1 and VZIM2, time-stepping analysis of VZIM3 has been done with Flux2D
and results have been compared with the results of the KLASYS tool. In this analysis the
considered slips similarly vary from 0 to 2 and in between additional 50 slips have been
considered for calculations, which are given in table VII in Appendix II. The synchronous
harmonic torques which happen at slips, , and are calculated with
Flux2D as explained in the section 4.8 of this chapter.

VZIM3, derived from KLASYS, is shown. The effects of the synchronous harmonic torques at
slips , and are clearly observed.

and acceptable.

To observe the effect of the harmonics, the torque-slip characteristic of VZIM3 prepared from
time-stepping and steady state AC analysis have been depicted in Fig.4.6.2-2. A considerable
difference happens at the slip equal to 0.857 and 1.071 due to the synchronous harmonics at
these points.

Fig.4.6.3.3 shows the comparison between fundamental phase current prepared by KLASYS
and Flux2D. The difference between the results is below 5% which mostly happens at high
slip values ( ).

- 46 -

Fig.4.6.3-1: Torque-slip characteristic of unskewed VZIM3, calculated with Flux2D time-stepping, the
effects of the synchronous harmonic torques at slips , and of the
the motor are observable

are observable

- 47 -


Fig.4.6.3-4: Stator phase current of unskewed VZIM2, comparison of the analysis results calculated by
Flux2D and KLASYS

Fig.4.6.3-4 depicts the input power-slip characteristic of VZIM3, prepared by KLASYS and
Flux2D. At higher slips the values of Flux2D are around 4% lower than values of KLASYS. In
addition Fig.4.6.3-5 shows the output power-slip characteristic of VZIM3 obtained from
Flux2D and KLASYS.

- 48 -

Flux2D and KLASYS

Flux2D and KLASYS

Fig.4.10.3-6 depicts the efficiency-slip characteristic of VZIM3, prepared by KLASYS and
Flux2D. The efficiency calculated by Flux2D at rated speed of VZIM3 (1474.65 rpm) is equal
to 0.912 is lower than that of KLASYS which is equal to 0.925.

- 49 -

Flux2D and KLASYS

Fig.4.6.3-7 depicts the input power factor-slip characteristic of VZIM3, prepared by KLASYS
and Flux2D.The maximum power factor is equal to 0.956 which happens at a slip equal to
0.025 in Flux2D calculated results and in case of KLASYS the maximum power factor is equal
to 0.937 which happens at a slip equal to 0.03.

Fig.4.6.3-8: Power factor of unskewed VZIM3, comparison of the analysis results calculated by
Flux2D and KLASYS

- 50 -

4.7 Instantaneous torque wave forms at different rotor speeds

In order to draw the torque-slip characteristic, the average value of the torque over one period
of the stator electrical cycle has been considered. In order to observe the oscillations and
ripple of the torque over time in some sample operating speeds of the motors, the torque-time
characteristics are shown in Fig.4.7-1 to Fig.4.7-7.

From these figures the influence of the harmonics on the torque characteristics is clearly
observable, the lower the speed, the higher the influence of the harmonics and therefore the
ripple on the torque-time characteristics increases. At the speed equal to 1462 in Fig.4.7-1 the
average torque is lower than the average torque at the speed equal to 1200 in Fig.4.7-4 and the
ripple has also lower amplitude. At the speed equal to 205.5 rpm in Fig.4.7-7 the influence of
the synchronous harmonic torques is quite clear. This operating point where the peak of the
7
th
asynchronous harmonic torque occurs, is quite near the slip where the
synchronous harmonic torque happens. Therefore the result is a quite oscillating torque-time
characteristic.

Fig.4.7-1: Torque-time characteristic of unskewed VZIM2 at 1462rpm, calculated by Flux2D, torque

- 51 -

Fig.4.7-2: Torque-time characteristic of unskewed VZIM2 at 1462rpm, calculated by Flux2D, zoomed
view after steady state is reached


- 52 -


oscillates around a constant mean value

- 53 -


Fig.4.7-7: Torque-time of unskewed VZIM2 at 205.5rpm, calculated by Flux2D, where break down
slip of the 7
th
asynchronous torque harmonic happens at slip 0.863 or 205.5rpm

- 54 -

4.8 Synchronous harmonic torque assessment in VZIM

Synchronous harmonic torques of VZIM, happen at the slips, , and
. In this section the torque time characteristics of VZIM1, VZIM2 and VZIM3 at these
slips are studied. For VZIM2 the synchronous harmonic torques are studied and derived by
varying the rotor position with respect to a fixed stator position, for a rotor slot pitch (we call
this method the rotation method). The step for each position is taken as one tenth of a rotor
slot pitch i.e. = 360/28/10 = 1.2857 mechanical degrees. The average torque for a stator
period is calculated for each of the eleven steps. Fig.4.8.1 shows first and second positions of
the rotor bars with fixed stator position.

Fig.4.8-1: First and second positions of the rotor bars with fixed stator position to calculate the
synchronous harmonic torques, prepared by Flux2D

Fig.4.8.2 to Fig.4.8.4 show the variation of the torque for the rotor position steps 1, 5 and 7 of
VZIM2 at the slip respectively. It is clear that the average value of the
synchronous torque at each step is a constant value. Similar procedure has been done for
VZIM2 at slips and , and the torque time values have been calculated for
eleven positions. The calculated synchronous torques, for three different slips of VIM2 are
shown in Fig.4.8-5 to Fig.4.8-7.

Fig.4.8-2: Torque-time of unskewed VZIM2 at , calculated by Flux2D, rotor position step
1

- 55 -

5

7

- 56 -

Fig.4.8-5: Variation of synchronous torque at as a function of rotor position

Fig.4.8-6: Variation of synchronous torque at a function of rotor position

Fig.4.8-7: Variation of synchronous torque at as a function of rotor position

-100
0
100
200
300
400
500
0 20 40 60 80 100
T
o
r
q
u
e
/
N
.
m

Rotor position at percentage of rotor slot pitch
440
460
480
500
520
540
560
580
0 20 40 60 80 100
T
o
r
q
u
e
/
N
.
m

250
270
290
310
330
350
0 20 40 60 80 100
T
o
r
q
u
e
/
N
.
m


- 57 -

Furthermore the synchronous torque of the VZIM2 has been calculated with another method
(we call this method the oscillation method). The torque time characteristics of VZIM2 have
been calculated in three different speeds and each speed is 10 rpm higher than the speed
where synchronous harmonic torque happens. For VZIM2 the synchronous harmonic torques
happen at 214.28 rpm ( ), 0 rpm ( ) and -107.1428 ( ). Therefore the
torque time characteristic of the VZIM2 at speeds 224.28 rpm, 10 rpm and -97.1428 are
calculated. As the oscillation of the torque time characteristic occurs because of the
synchronous harmonic torque; therefore the maximum and minimum of the variation of the
average torque in the torque time characteristic, equals to the maximum and minimum values
of the synchronous harmonic torques.

Fig.4.8.8 to Fig.4.8.10 show the torque time characteristic of VZIM2 at three different speeds
224.28 rpm, 10 rpm and -97.1428. At speed 224.28 rpm the maximum value of the average
torque is 438.4 Nm and the minimum value is -20.88 Nm and the peak to peak value is
459.28Nm. On the other hand the maximum value of synchronous harmonic torque calculated
by changing the position of the rotor related to fixed stator method is 448.24 Nm and the
minimum value is -20.8 Nm with the peak to peak value equal to 469.04 Nm. The difference
between two methods of synchronous torque calculation of peak to peak value is around 2.1%
at speed 224.28 rpm. The values are summarized in Table 4.8-1.

The torque values for speeds 10 rpm and -97.1428 rpm are calculated in similar way and are
shown in Table 4.8-2 and Table 4.8-3. Clearly the calculated values with two different
methods (rotation and oscillation methods) have a maximum difference of 7.66%.

Due to the reasonable differences of the results of two calculation methods for VZIM2, the
calculation of the maximum and minimum and peak to peak values of synchronous torques at
the slips where synchronous torques of VZIM1 and VZIM2 happen are done by the
oscillation method due to the low calculation time of this method. Table 4.8-4 and Table 4.8-5
show the values of synchronous torques for VZIM1 and VZIM3, calculated by oscillation
method in three different slips, where synchronous harmonic torques happen ( ,
and ).

Table 4.8-1: Maximum, minimum and peak to peak values of synchronous torque for VZIM2 in two
different methods of calculation (rotation and oscillation methods) for the slip
Oscillation method Rotation method Difference %
Maximum torque (N.m) 438.4 448.24 2.19%
Minimum torque(N.m) -20.88 -20.8 0.3%
Peak to peak value (N.m) 459.28 469.04 2.08%

Minimum torque(N.m) 244.56 262.16 6.7%

- 58 -

Minimum torque(N.m) 470.88 461.4 2.01%

Table 4.8-4: Maximum, minimum and peak to peak values of synchronous torque for VZIM1
(oscillation method)

Maximum torque (N.m) 605.56 456.24 629.72
Minimum torque(N.m) 130.8 406.28 499.8
Peak to peak value (N.m) 474.76 49.96 129.92

Table 4.8-5: Maximum, minimum and peak to peak values of synchronous torque for VZIM3
(oscillation method)

Maximum torque (N.m) 370 300.88 458.32
Minimum torque(N.m) -42.44 185.68 351.72
Peak to peak value (N.m) 412.44 114.32 107.6

Fig.4.8-8: Torque-time of unskewed VZIM2 at speed 224.28 rpm, calculated by Flux2D

- 59 -

Fig.4.8-9: Torque-time of unskewed VZIM2 at speed 10 rpm, calculated by Flux2D

Fig.4.8-10: Torque-time of unskewed VZIM2 at speed -97.14 rpm, calculated by Flux2D

In addition, the values of synchronous harmonic torques for VZIM1, VZIM2 and VZIM3 in
three different slips, where synchronous harmonic torques happen are calculated by KLASYS.
In Table 4.8-6 to Table 4.8-14 the calculated values with KLASYS and Flux2D are compared.
It is noticeable that the synchronous torque values calculated by KLASYS are in the most of
the cases much higher than the values calculated by Flux2D.The values of Flux2D are more
reasonable and acceptable.

- 60 -

Table 4.8-6: Maximum, minimum and peak to peak values of synchronous torque for VZIM1, at the
slip , the comparison of the calculated values by KLASYS and Flux2D
Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 606.56 130.8 474.76
KLASYS 1165.215 -208.695 1373.91
Difference 558.655 338.659 899.15

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 456.24 406.28 49.96
KLASYS 526.085 473.915 52.17
Difference 69.845 67.635 2.21

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 629.72 499.8 129.92
KLASYS 899.99 230.427 669.564
Difference 270.27 269.373 539.644

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 438.4 -20.88 459.28
KLASYS 1083.33 -316.67 1400
Difference 644.93 296.67 940.72

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 313.32 244.56 68.76
KLASYS 474.995 341.665 133.33
Difference 161.675 70.105 64.57

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 574.2 470.88 103.32
KLASYS 624.995 291.665 333.33
Difference 50.795 179.215 230.01

- 61 -

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 370 -42.44 412.44
KLASYS 907.13 -464.29 1371.42
Difference 537.13 421.85 958.98

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 300.88 185.68 114.32
KLASYS 358.925 198.215 160.71
Difference 58.045 12.535 46.39

Maximum torque
(N.m)
Minimum torque
(N.m)
Peak to peak value
(N.m)
Flux2D 458.32 351.72 106.6
KLASYS 353.57 246.43 107.14
Difference 104.75 105.29 0.54

4.9 Power losses in different parts of the motor

In order to determine the efficiency of the motor, it is necessary to calculate the losses in
different parts of the motor, these loss components are:
-stator and rotor ohmic losses
-friction and windage losses
-iron losses (mainly in stator iron)
-additional no-load losses such as tooth pulsation and surface losses
-additional load losses such as stator and rotor eddy current losses in conductors.

In simulation by Flux2D the mechanical losses are neglected.

Tables I, II and III in Appendix III show the iron losses which include eddy-current losses and
hysteresis losses in addition to the stator and rotor ohmic losses, which have been calculated
by Flux2D and compared with the results of KLASYS tool.

In Flux2D regarding the iron losses, the volume density of the instantaneous power loss
, is written as [5]:

W
m

which is composed of losses by hysteresis, classical losses and losses in excess, where

- 62 -

-
is the coefficient by hysteresis

-
is the coefficient of losses in excess

- is the conductivity of the material
-d is the thickness of the lamination
-
is the peak value of the magnetic flux density

Within the frame of the flux computation,

W
m
is the stack fill factor (close to 1), this coefficient considers the electrical insulation of the
lamination of the magnetic core.

In addition, in steady state AC magnetic application the volume density of the average power
is:

W
m

where:
-
is the coefficient by hysteresis

-
is the coefficient of losses in excess

- is the conductivity of the material
-d is the thickness of the lamination
-f is frequency
-
is the peak value of the magnetic flux density

Coefficients
, and
are necessary to calculate the iron losses with Flux2D, according to

the data sheet of the M270-50A [7] which is the material of the stator and rotor lamination
and with consideration of the
equal to 1.5T and with solving , in three different

frequencies 50Hz, 100Hz and 200Hz the values of
, and
are calculated.

The values of the specific total losses
in frequencies 50Hz, 100Hz and 200Hz, according

to the data sheet of the M270-50A [7] are given in Table 4.9-1. In addition the density of the
iron sheet M270-50A is
and the power loss is
, the calculated
values of the power losses for the frequencies 50Hz, 100Hz and 200Hz and are shown in
Table 4.9-1.

Table 4.9-1: Values of specific total losses according to the data sheet of the M270-50A [7],
and calculated power losses, in frequencies 50Hz, 100Hz and 200Hz
50Hz 100Hz 200Hz

19.45

- 63 -

after the calculations the following results are obtained:
(Ws/(T
))
(1/(Ohm.m)), (W/(m
T s
))
When these values are available with the help of the Flux2D iron losses are calculated.

4.9.1 Losses of VZIM at different speeds

In this section the losses of VZIM1, VZIM2 and VZIM3 in three different speeds which have
been calculated by Flux2D and KLASYS are compared. Here the components of stator and
rotor iron and copper losses have been considered.

Tables I, II and III in Appendix III show the losses of VZIM1, VZIM2 and VZIM3.
Apparently there are differences between losses calculated by KLASYS and Flux2D, at 22kW
nominal output power operation. In VZIM2 the stator copper losses are around 14%, the rotor
copper losses about 30% and stator iron losses about 11%, calculated by Flux2D are higher
than values calculated by KLASYS. In VZIM3 the stator copper losses are around 18%, the
rotor copper losses about 30% and stator iron losses about 21%, calculated by Flux2D are
higher than values calculated by KLASYS.

Fig.4.9.1-1 shows the comparison between losses of VZIM1 at rated speed equal to 1390.9
rpm calculated with Flux2D and KLASYS, Fig.4.9.1-2 shows the comparison between losses
of VZIM2 at the rated speed equal to 1455.8 rpm calculated with Flux2D and KLASYS and
Fig.4.9.1-3 shows the comparison between losses of VZIM3 at the rated speed equal to
1474.65 rpm calculated with Flux2D and KLASYS.

Fig.4.9.1-1: Comparison between losses of VZIM1 at speed equal to 1390.9 rpm calculated

- 64 -



- 65 -

Chapter 5: Thermal analysis

5.1 Preface

Calculating the temperature rise in electrical machines which occurs due to electrical and
mechanical losses, is one of the important steps in design of electrical machines. According to
Arrhenius law, velocity of chemical decomposition of materials increases exponentially with
temperature and for solid insulation materials Montsingers rule is valid, that the insulation
life span L decreases by 50% with increase of temperature by K. Due to the high
sensitivity of insulation materials to over-temperature, thermal classes for different types of
insulation materials are defined, which gives the maximum permissible temperature limit in
hot spot of insulation. For example in class F maximum temperature rise K is 105 K for
the machines in the power range of
NW [1].

Cooling system of electrical machines influences their thermal utilization and with a high
efficient cooling system, power per mass of electrical machines can be raised. There are
different possibilities to propel the coolant flow in electrical machines. In case of motors
without fan, cooling is done due to the natural convection and heat radiation. With shaft
mounted fan motors the speed of air flow depends on the velocity of motor. The external fan
is another way for cooling the electrical machine.

According to the second fundamental law of thermodynamics, the natural heat flow is only
possible from a hot to a cold region. Basic principles for heat transfer are
-Conduction, by heat conducting materials
-Convection, by moving coolants like air or water
-Radiation, which does not need any medium for heat transfer.

Calculating the temperature in electrical machines may be done either by numerical methods
or equivalent circuits. Calculation by numerical method in this project has been done by
ANSYS tool.

5.2 Temperature rise calculation by thermal equivalent circuits
To have an estimation of temperature rise in the stator winding simplified thermal networks
are used.

- 66 -

In a simplified thermal network only copper and iron losses in the stator and thermal
resistances between copper and iron due to the slot insulation, heat convection from winding
overhang to air and heat convection from the stator iron to air are considered. Stator copper
losses in the winding (
) and stator iron losses in the stator iron stack (
) are loss sources.

Fig.5.2-1 shows the simplified thermal equivalent network for an induction motor.

Fig.5.2-1: The simplified thermal equivalent network for an induction motor

Heat resistances are,
between stator iron and ambient cooling air, given by convection,

according to [1]
where
is the surface of the stator iron housing and is

the heat transfer coefficient which describes the cooling effect of flowing coolant.

between slot conductor copper and iron stack, mainly determined by heat resistance of the slot
insulation, according to [1]
, where
is the slot surface,
is the
thermal conductivity of the slot insulation and is the thickness of the slot insulation.

and
are thermal resistances between winding overhang and surrounding air given by
convection. Due to special structure of the VZIM, as this motor is totally enclosed, at one side
of the winding overhang, the heat transfer coefficient is considered as for natural
convection and heat radiation and at the other side, the rotating centrifugal mechanism leads
to a better cooling due to the convection. Therefore in order to calculate the heat transfer
coefficient, with try and error and comparison with measured values, is estimated for the
5.5kW VZIM ( Wm
K). For the 22kW VZIM due to similar structure with the
5.5kW VZIM, a proportional ratio of was considered, the calculations are presented in
Appendix IV and the values are shown in Table 5.2-1.

- 67 -

Table 5.2-1: Heat transfer coefficient for one side of the winding overhang close to the centrifugal
mechanism
Winding overhang VZIM2 22kW VZIM3 22kW
Heat transfer
coefficient

63.32 62.86

and
are unknown temperature rises, which
is the temperature
difference between motor local temperature and ambient temperature of surrounding air. In
this calculation ambient temperature is considered to be 20.

With consideration of the steady state temperature rise only two algebraic linear equations
have to be solved,

As VZIM2 and VZIM3 are active in rated operating speed of the motor, thermal calculations
of VZIM2 and VZIM3 are done in an operating speed which the average of the output power
produced by VZIM2 and VZIM3 in this speed is equal to 22kW.Therefore as it is depicted in
Fig.5.2-2, the average of output power of VZIM2 and VZIM3 versus slip is calculated and at
a speed of 1467.36 rpm the average power is equal to 22kW. The losses of VZIM2 and
VZIM3 in this speed (1467.36 rpm) have been calculated and are shown in Table 5.2-2. Based
on those losses the temperature rise
and
for VZIM2 and VZIM3 are calculated in

the following sections.

Fig.5.2-2: Calculated output power-slip characteristics of 22kW VZIM2 and VZIM3 and the average
of the powers

-60000
-40000
-20000
0
20000
40000
60000
80000
0 0.5 1 1.5 2 2.5
O
u
t
p
u
t

p
o
w
e
r
/
W

Slip
Power-Slip characteristic
VZIM2 power
VZIM3 power
Average power

- 68 -

Table 5.2-2: Losses in different parts of the VZIM2 and VZIM3 in the speed equal to 1467.36 rpm

/W
//W
/W
/W
/W
VZIM2 492.073 466.2 192.6 31.36 16894.2
VZIM3 1395.6 760.52 159.64 33.8 27374.75
Average 943.83 613.36 162.62 32.58 22134.47

In calculation of the average output power in Fig.5.2-2, it is assumed that the equivalent
output power of the VZIM motor can be estimated using super-position method. More
accurate calculations based on an equivalent circuit model [6] show that the super-position
method overestimates the equivalent torque and output power of the VZIM motor, especially
at lower speeds. But it is quite accurate at the rated operating region of the motor, as shown in
Fig.5.2-3. As here, only the calculation of the output power in the operating region of the
VZIM motor is required, hence more simple method of super-positioning is used.

Fig.5.2-3: Calculated output power of the VZIM motor with the supper-position and equivalent circuit
methods

- 69 -

and
for VZIM2 (22kW)

The materials used in construction of VZIM2 and the related thermal conductivities are shown
in Table 5.2.1-1.

Table 5.2.1-1: Thermal conductivities of the materials used in VZIM2 thermal model
Material Air Iron stack Insulation Copper
Thermal
conductivity,

W/(m.K)
0.031 40 0.2 380

After determination of materials, calculation of thermal resistances is done as following.
is the heat resistance between the stator iron stack and the ambient cooling
air,
is the surface of the stator iron housing and is the heat transfer coefficient,
is
equal to 203472
, and according to [1] is calculated by

( in
Wm
K, in
m
s
) for moving air over bare metallic hot surface. The speed of wind flow
over the stator body, based on an empirical rule [9], is equal to 70 percent of the linear speed
of the top point of the fan blade, therefore

m
s

R is the radius of the fan blade and n is the rotational speed of the VZIM2 with 22kW output
power. Consequently heat transfer coefficient can be calculated as:

Wm
K,

K
W

where
is slot surface,
is thermal conductivity of slot insulation and

is the thickness of the slot insulation.
KW
KW
KW
W
According to equations (5.2-1) and (5.2-2) we get:
K
The maximum temperature rise for class F of insulations is 105 K. Here the value is much
lower than the maximum allowable temperature rise; therefore insulation is in the safe side.
The reason for this low temperature rise is the fact that the middle cage (VZIM2) is working
under rated load (16.89kW instead of 22kW) at the rated speed of 1467.36 rpm. The final
temperature rise will be the average value of both VZIM2 and VZIM3.

- 70 -

and
for VZIM3 (22kW)

The materials used in construction of VZIM3 and the related thermal conductivities are shown
in Table 5.2.2-1.

Table 5.2.2-1: Thermal conductivities of the materials used in VZIM3 thermal model
Material Air Iron stack Insulation Copper
Thermal
conductivity,

W/(m.K)
0.031 40 0.2 380

Calculations are similar to calculations for VZIM2 in the previous section.

is the heat resistances between the stator iron stack and the ambient cooling air,
is the
surface of the stator iron housing and is the heat transfer coefficient,
is equal to 203472
, and according to [1] can be calculated by

( in Wm
K, in
m
s
)
for moving air over bare metallic hot surface. The speed of wind flow over the stator body,
based on an empirical rule [9], is equal to 70 percent of the linear speed of the top point of the
fan blade, therefore

m
s

R is the radius of the fan blade and n is the rotational speed of the VZIM2 with 22kW output
power. Consequently heat transfer coefficient can be calculated:

Wm
K,
KW
where
is slot surface,
is thermal conductivity of slot insulation and

is the thickness of slot insulation.
KW
KW
KW
W
According to equations (5.2-1) and (5.2-2) we get:
K
The calculated temperature rise in the winding
is lower than the temperature rise limit

105 K for class F insulations used in this motor. Therefore the insulation operates in the safe
side, although the motor operates at overload condition (27.37kW instead of 22kW).

Table 5.2.2-2 shows the temperature rise in the stator winding and iron of VZIM2 and VZIM3
calculated based on simplified thermal equivalent circuit and the average values.

- 71 -

Table 5.2.2-2: Temperature rise in the stator winding of VZIM2 and VZIM3 calculated based on
simplified thermal equivalent circuit in the nominal operating speed equal to 1467.36 rpm
VZIM2 VZIM3 Average value
K K K
K K K

The average value of the temperature rise of VZIM2 and VZIM3, which is equal to K,
is considered as the temperature rise of the 22kW VZIM motor, which is well below the
temperature rise limit of the used insulation materials (Thermal class F).

5.3 Numerical calculation of temperature rise

In ANSYS as a finite element tool, first of all the geometry of the model has to be prepared,
assigning the materials and meshing the areas are next steps. The loss density is used as heat
source, therefore based on the different losses of the motor, the loss densities for different
parts of the motor are calculated using the formula , where P is the calculated losses
in each part, and V is the volume in which the losses occur.

Electromagnetic analysis of 22kW VZIM is done with Flux2D in previous chapters and just
2D model of the VZIM motors was prepared but in this section for thermal analysis 3D
models of VZIM2 and VZIM3 are built to consider the thermal effect of the winding-
overhangs and end-rings. As usual, the number of the stator teeth and rotor teeth are not equal,
hence a symmetry can be considered if for the simplification, the number of rotor teeth is
assumed to be 36 instead of the 28 which is the real number of rotor teeth. With this
simplification simulation of a half of the stator and rotor slots is enough to do the thermal
analysis of the VZIM motor. In order to take into account the extra losses which appear due to
the simplification in this new model, the rotor copper losses are multiplied by the factor
to
compensate the extra losses added to the simulating model.

In this section, first of all the numerical calculation of the temperature rise based on the finite
element method with ANSYS tool for the 5.5kW VZIM is done and compared with measured
values, because the 5.5kW VZIM was already manufactured and tested. Afterwards the
numerical calculation of temperature rise in 22kW VZIM has been carried out using ANAYS
tool.

In three dimensional models considered for thermal analysis of 5.5kW and 22kW VZIM, the
convection heat transfer at the stator outer surface, the outer surface of the winding overhang
and the end rings are considered as the boundary conditions of the thermal model. For
simplification the heat transfer due to heat conduction, through the motor shaft is neglected.
Clearly due to the thermal conduction between the motor shaft and rotor, in case of modeling
the motor shaft, the calculated rotor temperature would be lower than values are presented
with the simplified model in following sections.

- 72 -

5.3.1 Thermal analysis of 5.5 kW VZIM2
First a 2D geometry of 5.5kW VZIM2 is prepared and after assigning the material and
meshing the geometry, by extruding the 2D model, the 3D model is constructed.
In Fig.5.3.1-1 the 2D model and meshing of VZIM2 are depicted, the 3D model and meshing
are depicted in Fig.5.3.1-2 and Fig.5.3.1-3.

Fig.5.3.1-1: 2D model of the 5.5kW VZIM2 and meshing, by ANSYS

Fig.5.3.1-2: 3D model of the 5.5kW VZIM2, by ANSYS

- 73 -

Fig.5.3.1-3: 3D model meshing of the 5.5kW VZIM2, by ANSYS

Loss densities in all volumes of VZIM2 have been calculated and assigned to the simulation
model before solving the thermal model. Table 5.3.1-1 shows the thermal loss densities in
VZIM2 5.5kW.

Table 5.3.1-1: Loss densities in different parts of the 5.5kW VZIM2
Stator
winding
Winding
overhang
Rotor bars Stator iron Rotor iron
Loss density
W/

0.000453318 0.00023955 0.00082892 0.000045299 0.000000566
The air flow in three areas including, the stator outer surface, winding overhang and end-rings
surfaces are considered and the heat transfer coefficients due to the convection are calculated
for those areas.
- The heat transfer coefficient for the stator outer surface is calculated as below:

Wm

m
s

-The heat transfer coefficients for winding overhangs are considered as below:
For one side of the motor the heat transfer coefficient over winding overhang is
Wm
K for natural convection and heat radiation, but for the other side of the motor,
because of the rotating centrifugal mechanism, the heat transfer coefficient for winding
overhang was drawn with try and error, considering the value of the maximum temperature
rise of the winding overhang, already measured. By choosing the heat transfer coefficient
Wm
K, the calculated and measured values match well together, hence

consideration of Wm
K is acceptable.

- 74 -

-The heat transfer coefficient for the end-ring surface is considered as below:
As in area near the end ring air is nearly not moving, therefore Wm
K is
considered.

Table 5.3.1-2 shows the heat transfer coefficient at different boundary conditions of the 5.5kW
VZIM2.

Table 5.3.1-2: Heat transfer coefficient at different boundary conditions of the 5.5kW VZIM2

Stator outer
surface
End ring
Winding
overhang far
from
centrifugal
mechanism
Winding
overhang close
to centrifugal
mechanism

83.11 15 15 50

Fig.5.3.1-4 shows the thermal solution of the 5.5kW VZIM2, temperature changes from
84.5 on the stator body to 147.89 inside the rotor. For thermal class F of insulations the
maximum allowable temperature rise is 105 K. For VZIM2 the maximum temperature rise in
the stator winding is 72.28 K as it has been shown in Fig.5.3.1-5, and assures that insulation
lies in a safe side. The measured value of the maximum overhang temperature rise is 67.7 K,
which is 6.3% lower than the finite element calculated value. The ambient temperature is
considered to be 20.

Fig.5.3.1-4: The thermal solution of the 5.5kW VZIM2 under nominal operation, by ANSYS

- 75 -

Fig.5.3.1-5: The calculated temperature in the winding overhang of VZIM2, by ANSYS

5.3.2 Thermal analysis of 5.5kW VZIM3

Similar to 5.5kW VZIM2, first a 2D geometry of 5.5kW VZIM3 is prepared and after
assigning the material and meshing the geometry, by extruding the 2D model, the 3D model is
constructed.

In Fig.5.3.2-1 2D model and meshing of 5.55kW VZIM3 are depicted, also in Fig.5.3.2-2 and
Fig.5.3.2-3 the 3D model and meshing are depicted.

Fig.5.3.2-1: 2D model of the 5.5kW VZIM3 and meshing, by ANSYS

- 76 -

Fig.5.3.2-2: 3D model of the 5.5kW VZIM3, by ANSYS

Fig.5.3.2-3: 3D model meshing of the 5.5kW VZIM3, by ANSYS

5.5kW VZIM3.

Table 5.3.2-1: Loss densities in different parts of the 5.5kW VZIM3
Stator
winding
Winding
overhang
Loss density
W/

0.00047015 0.00024844 0.0003707 0.00004544 0.000000461
The air flow in three areas including the stator outer surface, winding overhang and end-rings
surfaces are considered and the heat transfer coefficient due to the convection are calculated
for those areas.

- 77 -

- The heat transfer coefficient for the stator outer surface is calculated as below:

Wm

m
s

- The heat transfer coefficients for winding overhangs are considered as below:
For one side of the motor the heat transfer coefficient over winding overhang is
Wm
K, for the other side of the motor, because of the rotating centrifugal mechanism,
the heat transfer coefficient for winding overhang was drawn with try and error, considering
the value of the maximum temperature rise of the winding overhang was already measured,
by consideration of heat transfer coefficient Wm
K the calculated values and

measured values match well together, hence consideration of Wm
K is acceptable.

As in this area air is nearly not moving, therefore Wm
K is considered.

Table 5.3.2-2 shows the heat transfer coefficient at different boundary conditions of the 5.5kW
VZIM3.

Table 5.3.2-2: Heat transfer coefficient at different boundary conditions of the 5.5kW VZIM3

Stator outer
surface
End ring
Winding
overhang far
from
centrifugal
mechanism
Winding
overhang close
to centrifugal
mechanism

83.65 15 15 50

Fig.5.3.2-4 shows the thermal solution of the VZIM3, temperature changes from 80.17 on
the stator body to 121.969 inside the rotor. For thermal class F of insulations the maximum
allowable temperature is 105 K. For VZIM3 the maximum temperature rise in stator winding
overhang is 63.35 K as it has been shown in Fig.5.3.2-5, and assures that insulation lies in a
safe side. The measured value of the maximum overhang temperature rise is 67.7 K, which is
6.42% higher than the calculated value by finite element method. The ambient temperature is
considered to be 20.

- 78 -

Fig.5.3.2-4: The thermal solution of the 5.5kW VZIM3 under nominal operation, by ANSYS

Fig.5.3.2-5: The calculated temperature in winding overhang of 5.5kW VZIM3, by ANSYS

Table 5.3.2-3 shows the temperature rise in stator slot of 5.5kW VZIM2 and VZIM3 stator
slot calculated by ANSYS.

Table 5.3.2-3: Temperature rise in stator slot of 5.5kW VZIM2 and VZIM3 calculated by ANSYS
K K K

The average value of the temperature rise of VZIM2 and VZIM3 which is equal to K, is
considered as the temperature rise of the 5.5kW VZIM motor. The measured value of the
maximum overhang temperature is K which obviously shows a very good fitting
between the measured value and calculated values of temperature rise by ANSYS tool.

- 79 -

5.3.3 Thermal analysis of 22kW VZIM2

First a 2D geometry of 22kW VZIM2 is prepared and after assigning the material and
meshing the geometry, by extruding the 2D model, the 3D model is constructed. In Fig.5.3.3-
1 2D model and meshing of it are depicted, also in Fig.5.3.3-2 and Fig.5.3.3-3 the 3D model
and its meshing are depicted.

Fig.5.3.3-1: 2D model of the 22kW VZIM2 and meshing, by ANSYS

Fig.5.3.3-2: 3D model of the 22kW VZIM2, by ANSYS

- 80 -

Fig.5.3.3-3: 3D model meshing of the 22kW VZIM2, by ANSYS

22kW VZIM2.

Table 5.3.3-1: Loss densities in different parts of the 22kW VZIM2
Stator
winding
Winding
overhang
Loss density
W/

0.000169 0.0001074 0.0007152 0.00002834 0.000007678

The air flow in three areas including the stator outer surface, winding over hang and end-rings
for those areas.
-The heat transfer coefficient for the stator outer surface is calculated as below:

Wm

m
s

At one side, the heat transfer coefficient for winding overhang is Wm
K , for the
other side of the motor due to the rotating centrifugal mechanism, as already was
discussed Wm
K .
K is considered.

Table 5.3.3-2 shows the heat transfer coefficient at different boundary conditions of the 22kW
VZIM2.

- 81 -

Table 5.3.3-2: Heat transfer coefficient at different boundary conditions of the 22kW VZIM2

Stator outer
surface
End ring
Winding
overhang far
from
centrifugal
mechanism
Winding
overhang close
to centrifugal
mechanism

102.52 15 15 63.32

Fig.5.3.3-4 shows the thermal solution of the 22kW VZIM2, temperature changes from
59.7929 on the stator body to 150.95 inside the rotor. For thermal class F of insulations
the maximum allowable temperature rise is 105 K. For VZIM2 the maximum temperature rise
in the stator winding overhang is 42.73 K as it has been shown in Fig.5.3.3-5, and assures that
insulation lies in a safe side. The calculated value of the stator winding temperature rise is
35.31 K which is 17.3% lower than finite element calculated value.

Fig.5.3.3-4: The thermal solution of the 22kW VZIM2 under nominal operation, by ANSYS

- 82 -

Fig.5.3.3-5: The calculated temperature in the winding overhang of 22kW VZIM2, by ANSYS

5.3.4 Thermal analysis of 22kW VZIM3

Similar to 22kW VZIM2, first a 2D geometry of 22kW VZIM3 is prepared and after
assigning the material and meshing the geometry, by extruding the 2D model, the 3D model is
constructed. In Fig.5.3.4-1 2D model and meshing of 22kW VZIM3 are depicted, also in
Fig.5.3.4-2 and Fig.5.3.4-3 the 3D model and meshing are depicted.

Fig.5.3.4-1: 2D model of the 22kW VZIM3 and meshing, by ANSYS

- 83 -

Fig.5.3.4-2: 3D model of the 22kW VZIM3, by ANSYS

Fig.5.3.4-3: 3D model meshing of the 22kW VZIM3, by ANSYS

22kW VZIM3.

Table 5.3.4-1: Loss densities in different parts of the 22kW VZIM3
Stator
winding
Winding
overhang
Loss density
W/

0.00048 0.000304 0.000606 0.00002349 0.00000934

- 84 -

The air flow in three areas including the stator outer surface, winding over hang and end-rings
for those areas.
-The heat transfer coefficient for the stator outer surface is calculated as below:

Wm

m
s

At one side, the heat transfer coefficient for winding overhang is Wm
K , for the
other side of the motor due to the rotating centrifugal mechanism, as already was
discussed Wm
K .

- The heat transfer coefficient for the end-ring surface is considered as below:
K is considered.

Table 5.3.4-2 shows the heat transfer coefficient at different boundary conditions of the 22kW
VZIM3.

Table 5.3.4-2: Heat transfer coefficient at different boundary conditions of the 22kW VZIM3

Stator outer
surface
End ring
Winding
overhang far
from
centrifugal
mechanism
Winding
overhang close
to centrifugal
mechanism

102.52 15 15 62.86

Fig.5.3.4-4 shows the thermal solution of the 22kW VZIM3, temperature changes from
98.7877 on the stator body to 224.19 inside the rotor. For thermal class F of insulations
the maximum allowable temperature rise is 105 K. For VZIM3 the temperature in stator
winding overhang is 85.72 K as it has been shown in Fig.5.3.4-5, and assures that insulation
lies in a safe side. The calculated value of the stator winding temperature rise is 90.57 K
which is 5.5% higher than calculated value by finite element method.

- 85 -

Fig.5.3.4-4: The thermal solution of the 22kW VZIM3 under nominal operation, by ANSYS

Fig.5.3.4-5: The calculated temperature in the winding overhang of 22kW VZIM3, by ANSYS
Table 5.3.4-3 shows the temperature rise in stator slot of 22kW VZIM2 and VZIM3 stator slot
calculated by ANSYS.

Table 5.3.4-3: Temperature rise in stator slot of 22kW VZIM2 and VZIM3 calculated by ANSYS
K K K

- 86 -

The average value of the temperature rise of VZIM2 and VZIM3 ( K) is considered as
the temperature rise of the 22kW VZIM motor which is well below the maximum temperature
rise for the insulation class F ( K). The mean value of the calculated values of the
maximum overhang temperature with simplified equivalent thermal circuit is K, which
shows a 1.99% difference between finite element method calculations and the calculations
based on the simplified thermal circuits.
In order to summarize the thermal calculations of 5.5kW and 22kW VZIM, the values of the
stator maximum winding temperature rise and the rotor maximum temperature rise are shown
in Table 5.3.4-4. The thermal analyses of 5.5kW VZIM2 and VZIM3 motors are done in the
operation point of the motor where the output power of each motor is 5.5kW. But the thermal
analyses of 22kW VZIM2 and VZIM3 motors are done in an operation point of the motor,
where the average output power of 22kW motors (VZIM2 and VZIM3) is 22kW. Therefore
according to the previous description and calculation in section 5.2, as it is shown in Table
5.2-2, the 22kW VZIM2 is analyzed in an operation point, that its output power is 16.89kW
and the 22kW VZIM3 is analyzed in an operation point, where its output power is 27.37kW.
Therefore the 22kW VZIM3 motor with the output power 27.37kW is clearly overloaded,
therefore the temperature rise of the rotor and stator of 22kW VZIM3 is relatively high. As
previously mentioned, the average temperature rise of VZIM2 and VZIM3 in the rated
operating point of the VZIM is important and shows the temperature rise of the real motor.

Table 5.3.4-4: Temperature rise in stator slot of 22kW VZIM2 and VZIM3 calculated by ANSYS

5.5kW
VZIM2
5.5kW
VZIM3
Average
value of
5.5kW
VZIM
22kW
VZIM2
22kW
VZIM3
Average
value of
22kW
VZIM
Stator max.
winding
temperature
rise
K K K K K K
Rotor max.
temperature
rise
K K K K K K

- 87 -

Chapter 6: Conclusion

Electromagnetic and thermal analyses of Variable Impedance Induction Motor (VZIM) have
been done for a 4 pole 22kW motor. The electromagnetic analyses show that the expected
goals of the high starting torque and high efficiency at the rated operating point of the VZIM
motor are fulfilled.

Electromagnetic analysis of the 22kW VZIM motor is carried out with consideration of three
independent motors VZIM1, VZIM2 and VZIM3, using the finite element software Flux2D
and the results are compared with the analytical calculations performed by KLASYS tool. In
the steady state AC analysis the torque-slip, stator phase current-slip, normal air-gap flux
density and flux lines in the electromagnetically active parts of the motors are drawn. The
results of the analytical and finite element method, are compared which shows a good match
between them. Moreover in time stepping analysis torque-slip, fundamental stator phase
current-slip, input power-slip, efficiency-slip and power factor-slip characteristics are drawn
and compared.

Comparison of torque-slip characteristics in steady state AC and time stepping analysis show
that the KLASYS tool always predicts higher values than Flux2D. The efficiency-slip, phase
current-slip, input power-slip and power factor-slip characteristics of the VZIM motor in time
stepping and steady state AC analysis, calculated by Flux2D and KLASYS match very well in
all slips.

Thermal calculations have been done for VZIM with the help of the ANSYS tool which is a
finite element method tool. Comparing the results obtained by ANSYS and simplified thermal
circuits of the 22kW VZIM motor shows a low difference about 1.99%, and the results assure
that the insulation of the stator winding always stays in a safe side, and the temperature never
exceeds the critical values. In addition, the average value of the temperature rise of VZIM2
and VZIM3 ( K calculated by ANSYS, is considered as the temperature rise of the
22kW VZIM motor which is well below the maximum temperature rise for the Thermal Class
F ( K).

- 88 -

Bibliography
[1] Binder, A. ,CAD and system dynamics of electrical machines, Lecture script, TU
Darmstadt, 2010.

[2] Binder, A. ,Motor development for electrical drive systems, Lecture script, TU
Darmstadt, 2010.

[3] Binder, A. ,Electrical Machines and Drives, Lecture script, TU Darmstadt, 2009.

[4] Binder, A. ; Funieru, B. Design of Electrical Machines and Actuators with Numerical
Field Calculations, Seminary notes, TU Darmstadt, 2010.

[5] Flux2D ApplicationInduction machine tutorial calculations in Flux2D, Cedrat
corporation, 2011.

[6] Gholizad, H. ; Binder, A. ,Analytical Modeling of Variable Impedance Induction
Motors, in proc. IEEE IEMDC, 15-18 May 2011, Niagara Falls, Canada, pp. 1504-1509.

[7] Data sheet, Power Core M270-50A, Elektroband NO / NGO electrical steel.

[8] Xyptras, J. ; Hatziathanassiou, V. ,Thermal analysis of an electrical machine taking into
the account the iron losses and the deep bar effect, IEEE Transactions on Energy
Conversion vol. 14, no. 4, December 1999, pp. 996-1003.

[9] Huai, Y. ; Melnik, R. ; Thogersen, P. ,Computational analysis of temperature rise
phenomena in induction motors, Applied Thermal engineering vol. 23, no. 7, May 2003, pp.
779-795.

- 89 -

8. Appendix

8.1 Appendix I: Calculation of magnetizing main and stray inductances

Magnetizing main inductance
for infinite iron permeability is only determined by air

gap. According to [1] the magnetizing main inductance
is calculated as:
sin
sin
m
Stator harmonic stray inductance is calculated as:
mB
where stator harmonic stray coefficient is calculated:

where rotor stray harmonic inductance is calculated as:
B
Rotor harmonic stray coefficient is calculated:
sin
sin

Inductance of stator winding overhang is calculated as below:
mB

mm

End-ring stray inductance of the rotor cage is calculated:
B
Slot stray inductance of stator winding is calculated:
B

- 90 -

m

Rotor slot stray inductance of VZIM1 (Round bar) calculation:

Rotor slot stray inductance of VZIM1 (round bar) is calculated according to [1]

Rotor slot stray inductance of VZIM2 (Deep bar) calculation:

Rotor slot stray inductance of VZIM2 (Deep bar) is calculated according to [1]
B
where:

Bz (At standstill)

sinh sin
cosh cos

sinh sin
cosh cos

Rotor slot stray inductance of VZIM3 (Wedge bar) calculation:

Rotor slot stray inductance of VZIM2 (Wedge bar) is calculated according to [1]

where:

Bz (At standstill)

- 91 -

8.2 Appendix II: a) Calculation of slips, where a synchronous harmonic torque of
VZIM1, VZIM2, VZIM3 happens

In order to derive the slips that synchronous harmonics of the VZIM occur, according to [2],
Stator ordinal numbers are derived as,

Rotor ordinal numbers are derived as,

Condition for slip where synchronous harmonic occurs is derived as,

After deriving the slips, the related speeds of synchronous harmonic torque is calculated as

In Table I synchronous harmonic torque slips which are the same for VZIM1, VZIM2, and
VZIM3 are shown.

Table I: Synchronous harmonic torque slip
Harmonic slip Rotor speed(rpm)
13 0.857 214.5
-29 1.071 -106.5

b) Calculation of the slips which asynchronous harmonic torque happens in VZIM1
Slips that asynchronous harmonic torques of the VZIM1 occur are calculated according to [2].
Stator ordinal numbers are derived as

The asynchronous harmonic slips are derived as

- 92 -

Table II: Stator ordinal numbers and related asynchronous harmonic torque slips
1 -5 7 -11 13 -17 19 -23 25 -29 31 -35 37
0 1.2 0.857 1.09 0.92 1.0588 0.947 1.043 0.96 1.034 0.96 1.028 0.072

Harmonic break down slips, are calculated for each asynchronous harmonic torque, according
to [2] as

where
is calculated as
.
For all ordinal numbers the breakdown slips are calculated as following:

For :

For :

- 93 -

For :

For :

- 94 -

For :

For :

- 95 -

For :

For :

For :

- 96 -

All slips, in which asynchronous harmonic torques happen, and the related slips of the
breakdown harmonic torques, in addition to selected slips for time stepping calculation of the
VZIM1, are shown in Table V.

c) Calculation of the slips, where an Asynchronous harmonic torque happens in VZIM2

Similar to VZIM1 all the calculations have been done for VZIM2.

The asynchronous harmonic slips are derived as

Table III: Stator ordinal numbers and related asynchronous harmonic torque slips
1 -5 7 -11 13 -17 19 -23 25 -29 31 -35 37
0 1.2 0.857 1.09 0.92 1.0588 0.947 1.043 0.96 1.034 0.96 1.028 0.972

Harmonic break down slips are calculated for each asynchronous harmonic torque, according
to [2] as

where
is calculated as
,

:

- 97 -

- 98 -

- 99 -

- 100 -

- 101 -

VZIM2 are shown in Table VI.

d) Calculation of the slips where an Asynchronous harmonic torque happens in VZIM3
Similar to VZIM1and VZIM2 all the calculations have been done for VZIM3.

The asynchronous harmonic slips are derived as,

Table IV: Stator ordinal numbers and related asynchronous harmonic torque slips
1 -5 7 -11 13 -17 19 -23 25 -29 31 -35 37
0 1.2 0.857 1.09 0.92 1.0588 0.947 1.043 0.96 1.034 0.96 1.028 0.972

Harmonic break down slips are calculated for each asynchronous harmonic torque, according
to [2] as

where
is calculated as
.

:

- 102 -

:

- 103 -

- 104 -

- 105 -

VZIM2, are shown in Table VII.

- 106 -

Table V: Slips, which are used to perform time-stepping analysis of VZIM1
Slip Speed(rpm)
0.00001 1500
0.01 1485
0.02 1470
0.0253 1462
0.03 1455
0.04 1440
0.05 1425
0.06 1410
0.08 1380
0.1 1350
0.12 1320
0.15 1275
0.2 1200
0.3 1050
0.45 825
0.65 525
0.843 235.5
0.857 214.5
0.871 193.5
0.917 124.5
0.92 120
0.923 115.5
0.94 90
0.947 79.5
0.954 69
0.958 63
0.96 60
0.962 57
0.987 19.5
1 0
1.013 -19.5
1.034 -51
1.0344 -51.6
1.0348 -52.2
1.037 -55.5
1.043 -64.5
1.054 -81
1.0588 -88.2
1.063 -94.5
1.071 -106.5
1.077 -115.5
1.084 -126
1.09 -135
1.096 -144
1.174 -261
1.2 -300
1.226 -339
1.33 -495
1.66 -990
2 -1500

- 107 -

Table VI: Slips, which are used to perform time-stepping analysis of VZIM2
Slip Speed(rpm)
0.00001 1500
0.01 1485
0.02 1470
0.0253 1462
0.03 1455
0.04 1440
0.05 1425
0.06 1410
0.08 1380
0.1 1350
0.12 1320
0.15 1275
0.2 1200
0.3 1050
0.45 825
0.65 525
0.85 225
0.857 214.5
0.8633 205.05
0.9166 125.1
0.92 120
0.9234 114.9
0.944 84
0.947 79.5
0.95 75
0.9587 61.95
0.96 60
0.961 58.5
0.995 7.5
1.0044 -6.6
1.013 -19.5
1.0344 -51
1.03432 -51.48
1.03463 -51.94
1.041 -61.5
1.043 -64.5
1.045 -73.5
1.057 -85.5
1.0588 -88.2
1.0606 -90.9
1.0643 -96.45
1.071 -106.5
1.077 -115.5
1.088 -132
1.09 -135
1.093 -139.5
1.1887 -283.05
1.211 -316.5
1.33 -495
1.66 -990
2 -1500

- 108 -

Table VII: Slips, which are used to perform time-stepping analysis of VZIM3
Slip Speed(rpm)
0.00001 1500
0.01 1485
0.02 1470
0.0253 1462
0.03 1455
0.04 1440
0.05 1425
0.06 1410
0.08 1380
0.1 1350
0.12 1320
0.15 1275
0.2 1200
0.3 1050
0.45 825
0.65 525
0.855 217.5
0.859 211.5
0.8633 205.05
0.9168 124.5
0.92 120
0.9232 115.2
0.9466 80.1
0.947 79.5
0.9474 78.9
0.9595 60.75
0.96 60
1.34 -51
1.03438 -51.57
1.0344 -51.6
1.034418 -51.62
1.042 -63
1.043 -64.5
1.044 -66
1.058 -87
1.0588 -88.2
1.0596 -89.4
1.071 -106.5
1.089 -133.5
1.09 -135
1.091 -136.5
1.191 -286.5
1.2 -300
1.209 -313.5
1.33 -495
1.66 -990
2 -1500

-

1
0
9

-

8
.
3

A
p
p
e
n
d
i
x

I
I
I
:

C
a
l
c
u
l
a
t
e
d

l
o
s
s
e
s

o
f

V
Z
I
M
1
,

V
Z
I
M
2

a
n
d

V
Z
I
M
3

T
a
b
l
e

I
:

L
o
s
s
e
s

i
n

V
Z
I
M
1

c
a
l
c
u
l
a
t
e
d

b
y

F
l
u
x
2
D

a
n
d

K
L
A
S
Y
S

M
e
t
h
o
d

S
p
e
e
d
/
r
p
m

I
1
/
A

C
o
s
(
F
i
)

P
i
n
/
W

I
2
'
/
A

P
o
u
t
/
W

T
o
r
q
u
e
/
N
m

E
f
f
i
c
i
e
n
c
y

L
O
S
S
c
u
1
/
W

L
O
S
S
c
u
2
/
W

L
O
S
S
f
e
s
/
W

L
O
S
S
f
e
r
/
W

F
l
u
x
2
D

1
3
9
0
,
9

3
7
,
3
9

0
,
9
6
7

2
5
0
5
3
,
7

3
7
,
1
3
4
3

2
1
6
0
5
,
2
3

1
4
8
,
4
6
8

0
,
8
6

9
4
6
,
1
7

1
4
9
7
,
4
4

1
6
1
,
1
2

2
5
,
3
2

K
l
a
s
y
s

3
7
,
4

0
,
9
1
5

2
3
6
9
5
,
5

3
5
,
6
6

2
0
4
9
2
,
4

1
4
0
,
7

0
,
8
6
5

9
4
7

1
6
4
5
,
6

1
1
6

2
,
0
3
4

F
l
u
x
2
D

1
4
6
2

1
5
,
4
9

0
,
8
7
2

9
3
6
8
,
9
7

1
2
,
8
2

9
1
7
5
,
2
3
9

5
5
,
6
4

0
,
9
7
9
3

1
6
2
,
3
9

1
9
7
,
7
6

1
2
6
,
5
2

1
2
,
5
2

K
l
a
s
y
s

1
6
,
3
6

0
,
7
6
9

8
7
2
2
,
3

1
2
,
8
4

7
8
9
2

5
1
,
5
5

0
,
9
0
5

1
8
1
,
2

2
1
3
,
3

1
1
9
,
7

0
,
6
6
9

F
l
u
x
2
D

5
2
5

2
0
0
,
9
9

0
,
8
0
7
1

1
1
2
4
0
0

2
0
3
,
1
7

2
4
2
1
9
,
7
6
2

4
4
3
,
7
2

0
,
2
1
5
4

2
7
3
4
0
,
6
7

4
3
0
3
1
,
4
8

1
3
6
,
2
8
8

3
8
,
4
4

K
l
a
s
y
s

2
0
8
,
6

0
,
8
0
5

1
1
5
4
3
9
,
3

2
0
7
,
2

2
9
8
7
3
,
1

5
4
3
,
4

0
,
2
0
8

2
9
4
4
0
,
1

5
5
8
3
6
,
4

7
8
,
0
2

1
5
,
7
2

F
l
u
x
2
D

-
1
5
0
0

2
9
0
,
9
7

0
,
6
1

1
2
3
1
0
0

2
8
8
,
0
6

-
5
8
1
2
7
,
6
8

3
5
5
,
5
2

-
0
,
4
7
2

5
7
3
0
0
,
2
8

9
5
5
8
0

3
1
9
,
1

1
2
4
,
9
2

K
l
a
s
y
s

3
0
6
,
6

0
,
5
9
5

1
2
6
1
0
4
,
2

3
0
5

-
6
3
3
9
2
,
4

4
0
3
,
6

-
0
,
5
0
3

6
3
6
4
4
,
6

1
2
4
6
9
3
,
8

5
8
,
8

2
6
,
5
1

T
a
b
l
e

I
I
:

L
o
s
s
e
s

i
n

V
Z
I
M
2

c
a
l
c
u
l
a
t
e
d

b
y

F
l
u
x
2
D

a
n
d

K
L
A
S
Y
S

M
e
t
h
o
d

S
p
e
e
d
/
r
p
m

I
1
/
A

C
o
s
(
F
i
)

P
i
n
/
W

I
2
'
/
A

P
o
u
t
/
W

T
o
r
q
u
e
/
N
m

E
f
f
i
c
i
e
n
c
y

L
O
S
S
c
u
1
/
W

L
O
S
S
c
u
2
/
W

L
O
S
S
f
e
s
/
W

L
O
S
S
f
e
r
/
W

F
l
u
x
2
D

1
4
5
5
,
8

3
5
,
9
1

0
,
9
7

2
4
1
8
8

3
4
,
3
1

2
2
0
2
1
,
0
5
1

1
4
4
,
5
2

0
,
9
1
0
4

8
7
2
,
7
5

8
3
3
,
2
4

2
0
0
,
0
8

3
7
,
3
2

K
l
a
s
y
s

3
2
,
3
8

0
,
9
1
6

2
0
4
2
5
,
1

3
0
,
4
4

1
8
4
8
6
,
2

1
2
1
,
3

0
,
9
0
5

7
0
9
,
8

5
7
5
,
7

1
7
7
,
9

0
,
7
2
4

F
l
u
x
2
D

1
4
6
2

3
1
,
2
0
2

0
,
9
7

2
1
1
0
0

3
0
,
6
1

2
0
1
0
1
,
0
5
7

1
2
6
,
0
4

0
,
9
5

6
5
8
,
9
0
8

6
2
5
,
1
7
2

2
0
1
,
8
5
2

3
3
,
5
6

K
l
a
s
y
s

2
8
,
4
3

0
,
9
0
4

1
7
7
0
4
,
8

2
6
,
3
2

1
6
0
9
8
,
2

1
0
5
,
1

0
,
9
0
9

5
4
6
,
9

4
3
0
,
1

1
7
9
,
2

0
,
6
1
5

F
l
u
x
2
D

5
2
5

2
8
4
,
0
4

0
,
6
7

1
3
3
0
0
0

2
8
7
,
5

1
7
1
9
0
,
5
5
8

3
1
8
,
7
6

0
,
1
2
9
2

5
4
6
0
3
,
3
5

4
0
9
3
8
,
5
2

1
2
7
,
0
1
6

3
8
,
7
2

K
l
a
s
y
s

3
0
0
,
6

0
,
7
1
4

1
4
7
7
8
9
,
1

2
9
8
,
8

3
0
1
3
3
,
2

5
4
8
,
1

0
,
2
0
4

6
1
1
5
0
,
9

5
6
2
2
2
,
1

8
8
,
0
1

7
,
9
7
6

F
l
u
x
2
D

-
1
5
0
0

3
3
6
,
3
6

0
,
5
3

1
2
4
0
0
0

3
3
3
,
5
7
7

-
3
9
4
1
3
,
2
8

2
3
6
,
3
6

-
0
,
3
1
7

7
6
5
7
1
,
8
3

6
8
3
8
2
,
8
9
2

2
9
1
,
7
7
6

1
3
1
,
0
8

K
l
a
s
y
s

3
6
9
,
2

0
,
5
4
6

1
3
9
3
7
8
,
3

3
6
7
,
1

-
4
7
1
6
8
,
6

3
0
0
,
3

-
0
,
3
3
8

9
2
2
4
8
,
7

9
3
3
7
3

7
3
,
8
9

1
3
,
0
5

-

1
1
0

-

T
a
b
l
e

I
I
I
:

L
o
s
s
e
s

i
n

V
Z
I
M
3

c
a
l
c
u
l
a
t
e
d

b
y

F
l
u
x
2
D

a
n
d

K
L
A
S
Y
S

M
e
t
h
o
d

S
p
e
e
d
/
r
p
m

I
1
/
A

c
o
s
(
F
i
)

P
i
n
/
W

I
2
'
/
A

P
o
u
t
/
W

T
o
r
q
u
e
/
N
m

E
f
f
i
c
i
e
n
c
y

L
O
S
S
c
u
1
/
W

L
O
S
S
c
u
2
/
W

L
O
S
S
f
e
s
/
W

L
O
S
S
f
e
r
/
W

F
l
u
x
2
D

1
4
7
4
,
6
5

3
6
,
6
2

0
,
9
5
2
5

2
4
1
6
6
,
0
1

3
0
,
3
4

2
2
0
4
0
,
7

1
4
3
,
1
3
2

0
,
9
1
2

9
0
7
,
6
0
5

4
8
7
,
8
1
6

1
4
0
,
1
2
4

2
3
,
7
5
6

K
l
a
s
y
s

3
3
,
0
2

0
,
9
1
8

2
0
9
3
1
,
6

3
1
,
3
3

1
9
3
6
7
,
3

1
2
5
,
4

0
,
9
2
5

7
3
8
,
1

3
3
8
,
2

1
7
8
,
2

0
,
6
0
7

F
l
u
x
2
D

1
4
6
2

5
2
,
6
3

0
,
9
5
7

3
4
9
0
0

5
3
,
0
8

3
1
7
4
9
,
1
4

2
0
2
,
4
4

0
,
9
0
9

1
8
7
4
,
6
7

9
9
8
,
4
5

1
6
7
,
1
6

3
6
,
9
2

K
l
a
s
y
s

4
7
,
4

0
,
9
3
2

3
0
3
8
1
,
1

4
5
,
9
1

2
7
6
1
2

1
8
0
,
4

0
,
9
0
9

1
5
2
0
,
9

7
2
6
,
7

1
7
3
,
2

0
,
9
4
4

F
l
u
x
2
D

5
2
5

3
0
3
,
9
2
9

0
,
5
9
3

1
2
5
0
0
0

3
0
2
,
9

1
1
2
7
7
,
9
3
8

2
0
8
,
8
8

0
,
0
9
2

6
2
5
1
7
,
9
3

3
0
4
4
5
,
9
2
8

1
1
0
,
2
8

3
3
,
9
6

K
l
a
s
y
s

3
1
8
,
6

0
,
5
8
4

1
2
8
4
8
6
,
7

3
1
6
,
5

2
0
7
7
4
,
3

3
7
7
,
9

0
,
1
6
2

6
8
7
1
3
,
5

3
8
7
7
6
,
4

8
2
,
2
9

7
,
7
9
9

F
l
u
x
2
D

-
1
5
0
0

3
4
2
,
6
1

0
,
5
2
2

1
2
4
0
0
0

3
3
7
,
7
5

-
3
6
2
7
3
,
2
8

2
3
1
,
0
4

-
0
,
2
9
2

7
9
4
4
3
,
8
7
5

6
3
6
5
7
,
0
5
2

2
2
2
,
4
4

1
1
2
,
8
8

K
l
a
s
y
s

3
6
0

0
,
5
0
7

1
2
6
3
0
7
,
7

3
5
8
,
1

-
3
8
8
3
8
,
9

2
4
7
,
3

-
0
,
3
0
7

8
7
7
3
7
,
7

7
6
7
3
2
,
1

7
6
,
2
2

1
8
,
5
2

- 111 -

8.4 APPENDIX IV: Estimation of the heat transfer coefficient at the winding-overhang
close to the centrifugal mechanism
Although VZIM motor is totally enclosed, at one side of the winding overhang, heat transfer
coefficient is considered as
for the natural convection and heat radiation, but

at the other side of the motor, the rotating centrifugal mechanism leads to a better cooling due
to the forced convection. Therefore in order to calculate the heat transfer coefficient for this
winding overhang close to the centrifugal mechanism, with try and error and comparison with
measured values, is calculated for 5.5kW VZIM (
) and for 22kW VZIM

due to the similar structure with 5.5kW VZIM, a proportional value of is considered. In the
following, it is described how the value of heat transfer coefficient is derived.

Measured values at the rated load thermal test for 5.5kW VZIM shows that the maximum
temperature rise for the winding overhang is 67.7. According to this value a finite element
model of 5.5kW VZIM is prepared using ANSYS, and the value of is adjusted, and finally
with a heat transfer coefficient about
the calculated values, based on the

finite element method with ANSYS and measured values are matched together. For 5.5kW
VZIM2 (nominal speed for 5.5kW VZIM2 is equal to 1455.2rpm) with consideration of the
centrifugal mechanism as a standard fan, the heat transfer coefficient is equal to
, besides for 22kW VZIM2 motor (nominal speed

for 22kW VZIM2 is equal to 1467.36 rpm) the heat transfer coefficient for winding overhang
with considering the mechanical part of the motor, as a standard fan, is equal to

. Therefore due to the similarity of the 2 types of the motor

(5.5kW and 22kW) the applied value of for VZIM2 22kW is
.

For 5.5kW VZIM3 (nominal speed for 5.5kW VZIM3 is equal to 1470rpm) with
consideration of the centrifugal mechanism as a standard fan, the heat transfer coefficient is
equal to

. Besides for 22kW VZIM3 motor

(nominal speed for 22kW VZIM3 is equal to 1467.36rpm) the heat transfer coefficient for the
winding overhang, with considering the mechanical part of the motor as a standard fan, is
equal to

. Therefore due to the similarity of

the 2 types of the motor (5.5kW and 22kW) the applied value of for VZIM2 22kW is

Induction Motor Analysis

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Induction Motor Analysis

Enviado por

Direitos autorais:

Formatos disponíveis

Master Thesis

Time-stepping FE-analysis of a 22kW Variable

for VZIM2 (22kW) 69

for VZIM3 (22kW) 70

- parallel wires per turn

m inner stator diameter

- slot fill factor, frequency coefficient

- permeance /unit length

m length of the winding overhang

m mean diameter of the end-ring

m length of the end-ring segment

m cross section area of end-ring

- number of turns per phase

- number of turns per coil

- current/voltage transformation ratio

K/W Heat resistance

) heat transfer coefficient

1/(Ohm.m)) coefficient of losses in excess

T peak value of the magnetic flux density

W/(m.) Thermal conductivity

is added to , still and are valid,

is sum of resistance of the coil under stator slots

) and winding overhang

). Resistance per phase

is the length of the winding overhang and

is the permeance /unit length which is

is calculated which is the mean value of

and the outer diameter

the number of the rotor bars and

the mean diameter of end-ring, the length of

mm and the end-ring height is

is calculated using the mean value of the inner

and the outer diameter

the number of the rotor slots and

the mean diameter of end-ring, the length of

mm and the end-ring height is

is calculated using the mean value of the inner

and the outer diameter

the number of the rotor slots and

the mean diameter of end-ring, the length of

mm and the end-ring height is

0.116 Resistance per phase of the coil under stator slot

0.1095 Resistance per phase of winding overhang

0.424 mH Inductance pre phase of winding overhang

B End-ring leakage inductance

Resistance of the end-ring segment, VZIM1

Resistance of the end-ring segment, VZIM2

Resistance of the end-ring segment, VZIM3

, which is equivalent to one sator slot

is represented by Fourier series [2]

is represented by Fourier series [2]

additional torque, which is called asynchronous

this torque is zero. At

torque is positive and adds to fundamental torque. At

is the coefficient by hysteresis

is the coefficient of losses in excess

is the peak value of the magnetic flux density

is the coefficient by hysteresis

is the coefficient of losses in excess

is the peak value of the magnetic flux density

are necessary to calculate the iron losses with Flux2D, according to

equal to 1.5T and with solving , in three different

in frequencies 50Hz, 100Hz and 200Hz, according

and the power loss is