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Efficiency improvement in induction motor by slitted tooth core design

Article in Tehnicki vjesnik - Technical Gazette · October 2017

DOI: 10.17559/TV-20140325133232

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A. G. Yetgin, M. Turan Porast učinkovitosti asinkronih motora pomoću dizajna jezgre s procijepljenim zubom

ISSN 1330-3651 (Print), ISSN 1848-6339 (Online)

https://doi.org/10.17559/TV-20140325133232

EFFICIENCY IMPROVEMENT IN INDUCTION MOTOR BY SLITTED TOOTH CORE DESIGN

Asim Gokhan Yetgin, Mustafa Turan

Original scientific paper

In this study, a new design was suggested in order to improve the performance of induction motors. In the proposed design, slits were applied in the
middle of stator and rotor teeth. In these slitted models, the depth and width of slits were optimized with Finite Element Method Magnetics (FEMM)
software using Finite Elements Method (FEM). To show performance improvement, suggested motor model and a reference motor model were compared
at the rated operating point for the values such as input and output power, input current, power factor, efficiency and losses. Because of the decreases in
both iron and copper losses, total losses in motor were reduced and the efficiency for rated operating point was improved by 1,869%. In the modelling, 3
kW squirrel-cage induction motor was used.

Keywords: induction motor efficiency; motor losses; slitted tooth core design

Porast učinkovitosti asinkronih motora pomoću dizajna jezgre s procijepljenim zubom

Izvorni zanstveni članak

U ovom istraživanju predložen je novi dizajn kako bi se poboljšala učinkovitost rada asinkronih motora. U predloženom dizajnu primjenjeni su procijepi u
sredini zubi statora i rotora. U ovim procijepljenim modelima dubina i širina procijepa su optimizirani uz pomoć programa Magnetska metoda konačnih
elemenata (FEMM) i koristeći Metodu konačnih elemenata (FEM). Za prikaz poboljšanja izvedbe, predloženi model motora i referentni model motora su
uspoređeni u definiranim pogonskim tačkama za vrijednosti kao što su ulazna i izlazna snaga, ulazna struja, faktor snage, efikasnost i gubitci. Zbog
smanjenja gubitaka željeza i bakra, ukupni gubitak u motoru je smanjen, a povećana je efikasnost za definiranu pogonsku tačku za 1,869%. U modeliranju
korišten je 3 kW kavezni asinkroni motor.

Ključne riječi: efikasnost asinkronog morota; dizajna jezgre s procijepljenim zubom; gubitci motora

1 Introduction called edge optimization, a simple off-line identification

algorithm for an induction motor. The proposed approach
Since induction motors are the most commonly used relies on the information of a hard or soft start-up of the
motors in industry, they form one of the major interest motor, in order to identify all seven induction motor
areas for the researchers both in dynamic and static state parameters: stator and rotor leakage inductances, stator
and the old discovered induction machine is still under and rotor resistances, mutual inductance, mechanical
improvement. Many different approaches have been inertia and friction coefficient. Faiz et al. [13] presented
applied in order to develop the performance of induction the negative effect of unbalanced voltage upon the losses
motor especially in the researches focused on the energy and efficiency of an induction motor. Also they
saving issues. It is possible to collect these approaches determined that the financial losses were caused by
under four titles [1]. unbalanced voltage of the power supply using an
• Improving the performance with the works on stator analytical–statistical method. Donolo et al. [14]
and rotor slot shapes by using design software [2]. investigated the influence of voltage unbalance on the
• Improving the performance with optimization performance of induction motors. They use sequence
methods such as finite elements method, artificial equivalent circuits to determine the increase in losses of
neural networks (ANN) and genetic algorithms (GA) the induction motor. They analyse motors with open and
[3, 4]. closed rotor slots. Jabr and Kar [15] presented an
• Improving the performance by developing the experimental procedure to determine the machine
materials used [5]. parameters and saturation characteristics. The adopted
• Improving the performance by using magnetic experimental procedure facilitates the measurement of
barriers, cut-outs and slits [6]. both stator and rotor leakage reactance saturation
characteristics. Rasouli et al. [16] consider the
Today several approaches have still been developed identifiability of induction motor parameters, with a
and various studies [7-12] have been carried out in order particular emphasis placed on using subset selection and
to develop the performance of induction motors. Kumar et shrinkage methods to allow the identification methods to
al. [7] presented a new approach that minimizes copper & focus on the most significant parameters.
iron losses and optimizes the efficiency of a variable Kostov et al. [17] presented an efficient approach for
speed induction motor drive. Their method is based on a determining the equivalent circuit parameters of squirrel
simple induction motor field oriented control model. It cage induction motors based on genetic algorithms. When
includes iron losses by using only conventional induction three sets of data are used, the maximum relative error of
motor parameters. Sakthivel and Subramanian [8], in their the estimated parameters with regard to analytical values
paper, a model based on modified induction motor is less than 1%.
equivalent circuit, present a new application of particle Any study about performance improvement of the
swarm optimization (PSO) approach for field efficiency squirrel cage induction motor by using slitted structure
evaluation of induction motor. Delgado et al. [9] has been found within the literature search except for the
presented an optimization scheme without derivatives, author’s previous study given in [18, 19].

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Efficiency improvement in induction motor by slitted tooth core design A. G. Yetgin, M. Turan

Yetgin and Turan [19], in their study, the motor coefficient depending on lamination sheet material quality
models reformed with the proposed shape design were and operation point on magnetizing curve [21, 22].
analyzed with FEMM software program that uses finite The pulsation losses that occur in stator and rotor
elements method. It was found at the end of the analyses teeth are calculated with Eq. (4) [21].
that when the optimum slit width value was 0,10 mm,
motor efficiency gave better results compared with other  2 2 
f   f 
slit width values. The increase in slit width caused ppul ≈ 0,5 ×10 − 4  N r 1 K p1Bp1  Gt1 +  N s 1 K p2 Bp2  Gt2  (4)
saturations in motor teeth and thus caused the motor  p   p  
 
efficiency to worsen. It was decided at the end of different
modeling that the depth of the slits used in the proposed In Eq. (4), Kp1 and Kp2 are the coefficients depending
slitted motor models should be almost the same height as on the stator and rotor tooth flux density respectively. Bp1
stator and rotor height. and Bp2 are the coefficients depending on Carter
In a loaded induction motor, rotor reaction will coefficient. Gt2, Ns and Nr represent the rotor teeth weight,
increase, causing an increase in leakage flux and decrease stator slot number and rotor slot number respectively.
in coupling flux. In this study, slitted tooth design for Total iron losses PFe are calculated with the equation
induction motor was suggested to overcome negative given below.
effects of rotor reaction. By the suggested design,
efficiency of induction motor has been improved without PFe = p t1 + p y1 + p pul (5)
using higher grade laminations in induction motor.

2 Calculation of losses Although additional load losses have constituted the

subject of many studies [23, 24], they have not been
Induction motors compose a large part of electric modelled analytically. Additional load losses can be
energy consumption of many countries. Therefore, calculated by subtracting iron and copper losses from
determining the motor losses and improving the input power [25]. Some standards suggest various
efficiency have recently been top priority for the empirical factors. IEC 34-2 provokes a long lasting debate
manufacturers. We could analyse the losses in induction by allocating a fixed 0,5% of the rated input power to the
motor in two main components as constant losses and the additional load loss. NEMA MG1 recommends 1,2% for
losses changing with load. While constant losses are induction motors rated less than 2500 HP (1864,25 kW),
composed of iron, friction and windage losses, the losses and 0,9% for 2500 HP (1864,25 kW) and above. As an
changing with load include stator and rotor copper losses improvement, IEEE 112-El/Fl provides a variable portion
and additional load losses [20]. of output power to additional load loss, depending on the
Stator and rotor copper losses can be calculated by machine ratings. Similarly, the new IEC standard 60034-
Eq. (1). In the statements, PCu1 and PCu2 represent stator 2-1 provides a range of figures which is also a function of
and rotor copper losses, I1 stator current, I2 rotor current machine power ratings, as is plotted in [26].
referred to stator, R1 and R2 stator resistance and rotor In this study, additional load losses (Padd) were
resistance referred to stator. obtained by subtracting all the calculated losses from
input power. Pin, P2, PFe, PCu1, PCu2 and Pfw represent
input power, output power, iron losses, stator copper
PCu1 = 3I12 R1 , losses, rotor copper losses and frictional and windage
(1)
PCu2 = 3I 22 R2 . losses respectively in Eq. (6) [25, 27].

Iron losses occur in iron core and they are the Padd = Pin − (P2 + PFe + PCu1 + PCu2 + Pfw ) . (6)
functions of flux density, frequency and weight. Stator
tooth losses pt1 and stator yoke losses py1 are calculated 3 Finite Element Method
with Eq. (2) and Eq. (3) respectively [21].
The finite element analysis (FEA) is an accurate and
2 widely applied method in the study and simulation of
 f 
p t1 ≈ K t p10  1  Btsx Gt1 , (2) electrical machines [28]. With the numerical magnetic
 50  field analysis, features which can be difficult, expensive
1,3 or even impossible to measure can be explored. On the
 f 
p y1 ≈ K y p10  1  Bcsx G y1. (3) other hand, a simpler equivalent circuit model for the
 50  machine is required in many applications. The
performance and applicability of the circuit model depend
In the above equations, p10 stands for specific iron on both the structure of the model and the accuracy of the
losses at 50 Hz and 1,5T in terms of W/kg, Kt represent parameters. Besides an accurate simulation method, the
coefficient value for the machine construction which is FEA can be seen as a tool for obtaining the circuit
between 1,6 and 1,8, Ky coefficient value for the machine parameters etc. [29].
In the last two decades, the developments in
construction which is between 1,6 and 1,9, Gt1 stator teeth
numerical methods and in computer have made it actical
weight, Gy1 stator yoke weight, Bts stator tooth flux
to use finite elements analysis to calculate the magnetic
density, Bcs stator yoke flux density and f1 frequency. x field in the electrical machines [30]. The FEA has many
having a value between 1,5 and 2,5 is the material advantages compared to the other numerical methods
such as handling complex geometries, nonlinearity etc.

1292 Technical Gazette 24, 5(2017), 1291-1296

A. G. Yetgin, M. Turan Porast učinkovitosti asinkronih motora pomoću dizajna jezgre s procijepljenim zubom

[31]. Therefore, FEA has been the most preferred • The more effective using of the magnetic flux in core:
numerical method in the analysis of the electrical motor. reduction of saturation, better flux distribution at the
In various studies, it was expressed in detail how three teeth, reduction of rotor reaction.
phase induction machine could be modelled with FEA • Increased zigzag path reluctance. That results in low
[32-37]. FEMM software using finite elements method additional losses.
uses Eq. (7) for the solutions of magneto static problems • Decreased saturation. That results in reduced core
involving "B-H" characteristics that are not linear and the loss.
other analyses process is given in [38]. For modelling, the • Smaller slip. That causes less rotor copper loss.
FEMM program (version 3.4) is used which is free • Lowered total losses. That results in better efficiency.
package program. Dirichlet boundary condition is also • Improved overall performance on the rated operating
used for the motor analyses.
point.
• Smaller leakage reactance. That results in a better
 1  1 speed-torque characteristic.
∇ ×  ∇ × A  = J → J = − ∇ 2 A . (7)
 µ ( B)  µ • Increased power factor. That causes improvement in
reactive power consumption.
In the Eq. (7), J, B, A and µ present the current
density, magnetic flux density, magnetic vector potential The disadvantage of the proposed slitted construction
and magnetic permeability respectively. is given below:
• For small power motors, the initial construction cost
4 Proposed slitted construction is slightly high owing to cut off the core with laser.

In the proposed design, slits were applied in the 4.2 The opening of the slits
middle of stator and rotor teeth. Reference motor model
whose analysis was carried out with FEMM software is In proposed design, slits on the teeth of rotor and
shown in Fig. 1 and the motor model on which the stator can be machined by laser cutting, wire cut EDM
proposed slitted structure was applied is shown in Fig. 2. (Electric Discharge Machining) or water jet cutting
The analyses are carried out without changing the figures machines. Sheets for small horsepower motors can be cut
such as stator and rotor slot shapes, internal-external one by one or multiple at once up to 20 mm thicknesses.
diameter, number of turns etc. The results and graphics In application of proposed slitted design to high power
are given for rated operating point. motors, it is more convenient to use die cutting technics.
Since stamping die mould is manufactured once, there
will be no additional costs for high power motors in mass
production.
Name plate values of reference motor are given in
Tab. 1.

Table 1 Parameters of the induction motor

Motor parameters Symbol Value
Rated power / kW Pn 3
Rated voltage / V U1 380
Rated current / A In 6,63
Connection type − Star
Frequency / Hz f1 50
Figure 1 The reference motor (R.M.) model (without slits) Number of phase m 3
Power factor cos φ 0,88

In the proposed models, slit depths were chosen as

6,25 mm, 7,5 mm, 11,25 mm, 13,125 mm, 15 mm, 16,875
mm, 18,75 mm, 19,6 mm, 21 mm and 23 mm where the
slit widths were changing as 0,09 mm, 0,1 mm, 0,15 mm,
0,25 mm, 0,5 mm, 1 mm, 1,5 mm and 2,5 mm. For each
slit depth with corresponding slit widths FEMM models
are constructed. In this manner, the process has been
carried out on 56 different designs [19].
After having various modelling for slitted core
design, it is concluded that optimal heights of slits are at
Figure 2 Proposed slitted motor (S.M.) model the heights of slots and optimal width of slits is 0,1mm
that is the value to beware of saturation and to keep
4.1 Advantages and disadvantages of proposed zigzag leakage flux low [1,18].
construction motor model The leakage inductances of stator and rotor, the
zigzag flux changes and distribution of the magnetic
The advantages of proposed slitted construction vector potential for both the reference and slitted motor
according to reference motor are given below [1]: are given in [18]. Coupling flux for different core points

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Efficiency improvement in induction motor by slitted tooth core design A. G. Yetgin, M. Turan

was obtained and the magnetic flux and magnetization since quadrature axis flux has decreased as a result of
inductance values are also given in details in [18]. decrease in rotor reaction. Although the slitted structured
In Tab. 2, output power, current, power factor, torque, motor and reference motor have the same weight, 5,632%
efficiency and relative differences obtained from the rated decrease was gained in stator yoke losses since there was
operating point of slitted structure motor and reference some decrease in magnetic flux density in the slitted
motor models were presented. The slitted motor model structured motor.
which has a slit width of 0,1 mm and slit depth of 15,00 Rotor tooth losses were decreased since rotor had
mm and reference motor were compared. The obtained smaller frequency for the same output power.
values from FEMM which are stator and rotor resistance Furthermore, another important point was the decrease in
values, mutual inductance value, time constant value, the additional load losses. 6,971% gain was yielded from
magnetic flux density values etc. were adapted to Matlab the slitted structured motor model in total losses in
Software. Matlab outputs are given in Tab. 2. In comparison with the reference model motor. 1,869%
calculations, number of decimal places is chosen with 12 improvement was observed in efficiency for slitted motor
digits. model because of the decreases in losses in comparison
with the reference motor model.
Table 2 Rated operating values and relative differences for reference Fig. 3 and Fig. 4 illustrate the magnetic flux density
and slitted motor models [1]
distribution of the reference and the slitted motor models.
Reference Slitted Relative
Parameters of motor
motor motor difference / %
Output power / W 3030,0 3089,0 1,947
Efficiency / % 78,965 80,441 1,869
Current / A 6,645 6,613 −0,481
Power factor / − 0,875 0,880 0,571
Torque / N·m 10,223 10,632 4,000

From Tab. 2, it is seen that the efficiency, output

power and power factor values obtained from slitted
structure motor model increased. The rated torque
obtained from slitted motor model increased by 4%
compared to the torque value of reference motor and
therefore the output power increased. The efficiency
increased by 1,869% as a result of the increase in output
power by 1,947%. A 0,481% decrease was yielded in the
current depending on the increase in the magnetizing Figure 3 Magnetic flux density distribution of the reference motor
impedance. The input power value slightly increased, model
because of increase in power factor.
All the lost power and relative differences obtained
for reference and slitted motor models are presented in
Tab. 3. The lost power ingredients were calculated by
Matlab software using the result of FEMM analysis.

Table 3 Lost power and relative differences for reference and slitted
motor models [1]
Reference Slitted Relative
motor motor difference / %
Motor losses Values / W
Stator copper 164,388 162,052 −1,417
Rotor copper 162,834 160,458 −1,456
Stator tooth 95,507 68,611 −28,161
Rotor tooth 1,903 1,761 −7,368
Stator yoke 260,776 246,088 −5,632
Pulsation 3,766 3,714 −1,380 Figure 4 Magnetic flux density distribution of the slitted motor model
Additional 28,426 18,595 −34,584 which has 15,00 mm slit depth and 0,1 mm slit width
Friction & windage 90,0 90,0 -
Total 807,6 751,3 −6,971 It can be easily seen from the figures that magnetic
field distribution in slitted motor model is more
There was not much change in stator and rotor copper conditioned. Magnetic flux density in teeth and yoke parts
losses since no changes were made for windings in the of stator and rotor is lower than the reference motor’s.
modelling. But, slight decrease was observed because of However, magnetic flux density near the teeth tips in
lowered current. slitted model is higher than the reference motor’s. This
Stator tooth loss obtained for slitted motor showed can be corrected by rounding slit tips.
28,161% decrease compared with reference motor model. Stator and rotor tooth and stator yoke weights and the
The first reason of this was 1,870% decrease occurring in relative values according to the reference motor model are
the stator tooth weight. The second and major reason was presented in Tab. 4.
decrease in magnetic flux density observed in these parts,

1294 Technical Gazette 24, 5(2017), 1291-1296

A. G. Yetgin, M. Turan Porast učinkovitosti asinkronih motora pomoću dizajna jezgre s procijepljenim zubom

Table 4 Core weight and relative differences for reference and slitted density due to flux conditioning and lowered core
motor models [1] volume.
Reference Relative Because of the decreases in both iron and copper
Slitted motor
motor difference / % losses, total losses in motor were reduced and the
Parameters Weight / kg efficiency for rated operating point was improved by
Stator tooth 2,2990 2,2560 −1,870
1,869%. Also, a small improvement in reactive power
Stator yoke 6,7904 6,7904 -
consumption for slitted core motor was yielded as a result
Rotor tooth 2,6545 2,6185 −1,356
of 0,571% increase in power factor.
Total 11,7439 11,6649 −0,672
It can be said that the proposed slitted core design
decreased worse rotor reaction effects by conditioning
Stator and rotor tooth weights decreased by 1,870% teeth flux. Thus, additional load losses or stray losses are
and 1,356% for slitted motor model respectively. Total also reduced by 34,584%. Slitted core design benefits
weight was decreased by 0,672% in slitted motor model. discussed all performance parameters of motor. To
The speed-efficiency curves for reference and slitted beware of saturation in teeth, slit width must be chosen
motor models are presented in Fig. 5. The figure shows properly small.
that slitted core motor model exhibits a better efficiency
distribution, especially around rated operating speed. Acknowledgements

This work was supported by Sakarya University

Scientific Research Project.

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