Design of

Rotating Electrical Machines

Juha Pyrhnen, Tapani Jokinen, Valria Hrabovcov
Three-phase squirrel cage motor with a two-layer integral slot winding and totally enclosed fan
cooling
This calculation sheet is designed for analytical evaluation of a three-phase squirrel
cage motor with a two-layer integral slot winding and totally enclosed fan cooling.
While every effort has been made to ensure the accuracy of the information and technical data in this
calculation sheet, the authors cannot accept any liability for damage, injury, breakdown, or poor
performance arising from the application of this machine design or data contained in it. It is also
emphasized that the calculation example is simplified and does not take all phenomena into account. The
reader is responsible to check and supplement the calculations and the technical data and conduct such
tests as may be necessary to ensure that the machine design suggested by this publication is suitable for
the use to which it is put.
The design process follows the outline presented in Chapter 7. The table and equation numbers refer to
the numbering in the textbook.
1. Initial data of the motor
Power, W
Synchronous speed, 1/min
Line-to-line voltage star connected, V
Phase voltage, V
Number of phases
Number of pole pairs
Frequency, Hz
Stator angular frequency, rad/s
Rated power factor, estimated
Rated efficiency, estimated
Permeability of vacuum, VsA
-1
m
-1
Temperature rise in the windings, K
Conductivity of copper at 20 degrees C, S/m
P 30 10
3
:=
n
syn
1500 :=
U 690 :=
U
sph
U
3
:= U
sph
398.3717 = V
m 3 :=
p 2 :=
f
n
syn
60
p := f 50 = Hz
2 f := 314.1593 = 1 / s
cos
n
0.92 :=
0.927 :=

0
4 10
7
:=
80 :=

Cu20C
57 10
6
:=
Temperature coefficient of copper,
Density of copper, kg/m
3
Conductivity of aluminium at 20 degrees C,
S/m
Temperature coefficient of aluminium,
Density of aluminium, kg/m
3
Space factor of stator and rotor core
Density of iron, kg/m
3
S1 continuous drive
Enclosure IP 55, dust proof, water tolerant
Thermal class 130
Cooling method, surface-cooled IC 41 with an
external fan attached on the motor shaft

Cu
3.81 10
3
:=

Cu
8960 :=

Al20C
37 10
6
:=

Al
3.7 10
3
:=

Al
2700 :=
k
Fe
0.97 :=

Fe
7600 :=
Subscripts:
stator s
rotor r
We introduce the BH curve of the M800-50A lamination
material in T and A/m
B
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1

:= H
0
84.5
107
121
133
145
156
168
180
194
209
228
254
304
402
660
1480
3710
7300
15000
30000
100000

:=
The specific iron loss per mass at 1.5 T and 50 Hz with M800-50 A
P
15
6.6 := W /kg
0 5
.
10
4
1
.
10
5
0
1
2
B
H
T
BH curve of M800-50
A / m
Additional variables for drawing the
figures
j 0 10 .. := k 0 19 .. :=
k
sat
0
0.05
0.1
0.16
0.25
0.37
0.5
0.67
0.875
1.2
1.7

:=
i
2
1

0.66
0.68
0.70
0.72
0.74
0.76
0.78
0.80
0.82
0.84

:=
B
y
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9

:= c
0.72
0.72
0.72
0.72
0.72
0.72
0.71
0.70
0.67
0.63
0.57
0.48
0.40
0.33
0.26
0.20
0.17
0.16
0.15
0.14

:=
0 0.5 1 1.5 2
0.6
0.8

i
j
k
sat
j
Influence of the maximum flux density of the stator or rotor yoke on the
definition of the coefficient c, applied in the determination of magnetic
voltage (see Fig. 3.17 in the textbook)
0 0.5 1 1.5 2
0
0.5
1
c
k
B
y
k 2. Tangential stress
The determination of the main dimensions starts with choosing the appropriate
tangential stress according to the machine type (Table 6.3).

Ftan
15000
cos
n
0.8
:=
Ftan
1.725 10
4
= Pa
3. Rotor size
The rotor volume V
r
can be solved from Eq. (6.2)

2
r
tan tan r
' 2 ,
2
F F
D
T l V = =
where D
r
is the outer rotor diameter and l' the equivalent length of the rotor.
Before calculating the rotor volume we need an estimation of the rotor torque. We
assume that the rated speed of the motor is
n
n
1474 := min
-1
The rated torque estimate is
T
P
2
n
n
60
:= T 194.3547 = Nm
tan
2
r
r
2
'
4

F
T
l
D
V

= =
The volume V
r
is
V
r
T
2
Ftan
:=
V
r
5.6335 10
3
= m
3

The ratio of equivalent core length and air-gap diameter is according to Table 6.5:
3
2
'
p
p D
l
=

3
p
2 p
:= 0.9895 =
From the equations above we can solve the rotor diameter and the equivalent iron
core length:
D
r
3
4 V
r

:= D
r
0.1935 = m
We select a rounded number
D
r
0.200 := m
l D
r
:= l 0.1979 = m
4. Air gap and core length
The air-gap length is, depending on the number of pole pairs, calculated
from Eqs. (6.41) and (6.42):
m
1000
01 . 0 2 . 0
4 . 0
P +
=
for p = 1
m
1000
006 . 0 18 . 0
4 . 0
P +
=
for p > 1
In this case, p = 2 and the air gap is calculated from

0.18 0.006 P
0.4
+
1000
:= 5.5068 10
4
= m
In heavy-duty applications, the air gap is increased by 60 %. We use in this
case an increased air gap
1.6
0.18 0.006 P
0.4
+
1000
:=
8.8109 10
4
= m
We select a rounded number for the air gap
0.0008 := m
The inner diameter of the stator is
D
s
D
r
2 + := D
s
0.2016 = m D
s
1000 201.6 = mm
As there are no cooling channels, we have n
v
0 := b
v
0 := b
ve
0 :=
Core length in a machine with no cooling channels is
l l n
v
b
ve
2 + := l 0.1963 = m
5. Stator and rotor windings
The number of stator slots per pole and phase q is chosen
q 4 :=
and the winding pitch W = 5/6
p.
W
p
5
6
:=
The number of stator slots:
Q
s
2 p m q := Q
s
48 =
The stator slot pitch:

us

D
s
Q
s
:=
us
0.0132 = m
The stator pole pitch:

p

D
s
2 p
:=
p
0.1583 = m
We select a skewed rotor. According to Tables 7.3 and 7.5, we select the number of
rotor slots to be
Q
r
44 :=
The rotor slot pitch
ur
will be

ur
D
r

Q
r
:=
ur
0.0143 = m 1000
ur
14.28 = mm
According to Table 7.1, the slot pitch should be between 7 and 45 mm. Hence we
accept the value found above.
6. Air-gap flux density and linear current density
Since the tangential stress has already been selected, the amplitude of the
fundamental of the air-gap flux density has to correlate with the selected stress
value, which was the average value. According to Table 6.1, the peak value of
the fundamental air-gap flux density varies normally from 0.7 T to 0.9 T. Let us
choose for the fundamental air-gap flux peak density
B
1peak
0.80 := T
According to Table 6.2, the linear current density RMS value for air-cooled induction
machines varies between 30 and 65kA/m.
Tangential loading assuming sinusoidal flux density waveform to estimate the
mechanical torque is according to the textbook
2
cos

2
cos


tan

B A B A
F
= =
We may solve for the RMS linear current density in Mathcad format
A
2
Ftan

B
1peak
cos
n

:=
A 3.3146 10
4
= A /m
This value corresponds well to the values given in Table 6.3.
7. Number of coil turns in a phase winding
The number of coil turns in series in a phase winding can be calculated according
to Eq. (7.7) in the textbook
'

2
p i 1 w
m
m 1 w
m
l B k
E
k
E
N

= =
where E
m
is the air-gap-induced voltage that is here assumed to be
E
m
0.94
U
3
:= E
m
374.4694 = V
and k
w1
the winding factor for the fundamental (Eq. (2.61) = 1)

=
Q
p
mp
Q
m
W
sin
2

sin
2

sin 2
p

d p w
k k k =
k
w1
2 sin W
p

2

sin

m 2

Q
s
sin
p
Q
s

m p

:= k
w1
0.925 =

1i
2

:= Initial value of the saturation factor

i
N
s
2 E
m

k
w1

1i
B
1peak

p
l
:= N
s
114.1857 =
8. Number of conductors in a slot
The number of parallel branches is selected as
a 1 :=
The number of conductors in a slot is
z
Qs
2 a m
N
s
Q
s
:= z
Qs
14.2732 =
z
Q
has to be an even number in a two-layer winding. (In a one-layer winding, z
Q
has to be an even or odd number, i.e. an integer number.) As we have a four-pole
machine, we can select two parallel paths
a 2 :=
z
Qs
2 a m
N
s
Q
s
:=
z
Qs
28.5464 =
we select z
Qs
28 :=
and the number of coil turns in the phase winding will be
N
s
Q
s
z
Qs

2 a m
:= N
s
112 =
9. New B
1peak
The rounding of z
Q
influences the air-gap flux density. The saturation factor
i
in Eq. (7.7) has
to be iterated (We return from Item 13 to this point). The original unsaturated value was
i
=
2/. We insert the value found in Item 13 (e.g. after the third iteration round)

2i
0.681 :=
The new air-gap flux density is
B
1peak
2 E
m

N
s
k
w1

2i

p
l
:= B
1peak
0.7625 = T
10. Width of the stator slot
According to Table 6.1, the flux density of a stator tooth varies normally from
1.4 T to 2.1 T and the rotor tooth from 1.5 to 2.2 T. Let us choose for the
apparent flux densities
B
dapps
1.6 := T
B
dappr
1.6 := T
( )
' u
d
Fe v v d
'

l
B B
k l n b b

The apparent flux density according to the textbook is

The tooth width is
b
ds
l
us

k
Fe
l n
v
b
v

( )

B
1peak
B
dapps
:=
b
ds
6.5351 10
3
= m 1000 b
ds
6.5351 = mm
The rotor tooth width is correspondingly
b
dr
l
ur

k
Fe
l n
v
b
v

( )

B
1peak
B
dappr
:= b
dr
7.0726 10
3
= m 1000 b
dr
7.0726 = mm
11. Slot dimensions
To determine the stator slot dimensions, we have first to estimate the stator
current, Eq. (7.9a). The initial guess for the stator current is
I
s
P
m U
sph
cos
n

:= I
s
29.4336 = A
The cross-sectional area of one conductor in a stator slot is
s
cs
s
I
S
aJ
=
Selecting for the stator current density (Table 6.2) the value J
s
= 3.5
A/mm
2
we obtain
J
s
3.5 10
6
:= A /m
2
I
s
29.4336 = A
S
cs
I
s
a J
s

:=
S
cs
4.2048 10
6
= m
2
S
cs
1 10
6
4.2048 = mm
2

The wound area S
Cus
of the stator slot is obtained by
s Cu,
sc Q
Cus
k
S z
S =
where k
Cu,s
is the space factor of the slot. The space factor inside the slot
insulation is about
k
Cus
0.63 :=
With this value of the space factor, the wound area of the slot should be at least
S
Cus
z
Qs
S
cs

k
Cus
:= S
Cus
1.8688 10
4
= m
2
S
Cus
1000000 186.8803 = mm
2

The slot form and its dimensions are presented in the figure below.
h
4
b
4
b
5
b
1
h
5
h
2
h
6
h
3

h '
b
5c
b
4c
h
1
We can choose the following dimensions
b
1s
0.003 := m
h
1s
0.001 := m
h
2s
0.002 := m
h
3s
0.005 := m
h
6s
0.0005 :=
m
h
s
0.0005 :=
m
Other dimensions are determined as follows
b
4s
D
s
2 h
1s
h
2s
+
( )
+

Q
s
b
ds
:= b
4s
7.0523 10
3
= m
b
4cs
b
4s
2 h
3s

Q
s
+ 2 h
6s
:= b
4cs
6.7068 10
3
= m
The height h
5
is determined so that the tooth width b
d
is constant and the wound
area of the slot S
Cus
has the value calculated above. The following two equations
are used to solve h
5

5
5c 4
2
c
h
b b
Q
= +

2 4c 5c
cus 5 5

2 8
c
b b
S h b
+
= +
The slot separator h' is assumed zero. Its influence has been taken into account in the space
factor k
Cus
. The user must give an iteration value for h
5s
to match S
Cus
h
5s
0.02 := m S
Cus
1000000 186.8803 = mm
2

b
5cs
b
4cs
2h
5s
Q
s
+ := b
5cs
9.3248 10
3
= m
S
Cus
b
4cs
b
5cs
+
2

h
5s

8
b
5cs
2
+ := 1000000 S
Cus
194.4626 = mm
2

The value h
5s
given above satisfies the equations with sufficient accuracy. b
5s
gets the value
b
5s
b
5cs
2h
6s
+ := b
5s
0.0103 = m
h
4s
h
5s
b
5cs
2
+ := h
4s
2.47 10
2
= m
The total area of the slot is needed later in the calculations
S
slot
b
1s
h
1s
h
2s
b
4s
2
b
1s
2
+

+ h
3s
b
4s
h
3s

Q
s
+

+
b
4s
b
5s
+
2

h
5s
+

8
b
5s
2
+ :=
S
slot
2.6558 10
4
= m
2
S
slot
1000000 265.5843 = mm
2

The rotor slot dimensions are calculated next.
The rotor current referred to the stator is approximately
I'
r
I
s
cos
n
:= I'
r
27.0789 = A
The transformation ratio between the rotor and stator currents is (Eq. 7.47)
K
rs1
2 m k
w1
N
s

Q
r
:= K
rs1
14.1277 =
The squirrel cage bar current is
I
bar
K
rs1
I'
r
:= I
bar
382.5644 = A
The rotor aluminium current density is selected according to Table 6.2
J
bar
3.5 10
6
:= A / m
2
(rotor winding) 3 ... 8 A / mm
2
for copper
3 ... 6.5 A / mm
2
for aluminium
J
ring
4 10
6
:= A / m
2
(short-circuit rings)
As the die-cast-rotor slot space factor is k
Alr
= 1, the rotor slot area is equal to the bar cross-sectional area
S
bar
I
bar
J
bar
:= S
bar
1.093 10
4
= m
2
S
bar
1000000 109.3041 = mm
2

S
Alr
S
bar
:=
The rotor short-circuit ring current is calculated as (Eq. 7.38)
r
u
u
bar
ring
2
;
2
sin 2
Q
p I
I

= =

u
2
Q
r
:=
u
0.1428 = rad
I
ring
I
bar
2sin

u
2

:= I
ring
2.6813 10
3
= A
The end ring cross-sectional surface is
S
ring
I
ring
J
ring
:= S
ring
6.7033 10
4
= m
2
S
ring
1000000 670.3265 = mm
2

The rotor bar is described in the figure below
h
4
b
4
b
5
b
1
h
5
h
2
h
1
We can choose the following dimensions
b
1r
0.003 := m
h
1r
0.001 := m
h
2r
0.002 := m
Other dimensions are determined similarly as for the stator.
b
dr
7.0726 10
3
= m
b
4r
D
r
2 h
1r
h
2r
+
( )

Q
r
b
dr
:= b
4r
6.779 10
3
= m
The height h
5r
is determined so that the tooth width b
dr
remains constant and the
wound area of the slot S
Alr
has the value calculated above. The following
equations are used to solve h
5r
. We start with an initial guess for h
5r
h
5r
0.0165 := m S
Alr
1000000 109.3041 = mm
2

b
5r
b
4r
2h
5r
Q
r
:= b
5r
4.4228 10
3
= m
h
4r
h
5r
b
5r
2
+ := h
4r
0.019 = m
S
Alr
b
4r
b
5r
+
2

h
5r

8
b
5r
2
+
b
1r
b
4r
+
2
h
2r
+ := 1000000 S
Alr
109.8755 = mm
2

We see that h
5r
guessed above gives the right solution for S
Alr
with sufficient
accuracy.
12. Magnetic voltages over the stator and rotor teeth
The flux density in the tooth is obtained by solving the intersection of the BH curve
of the electric sheet in question and the line
d 0
d
u '
d d
H

S
S
B

=
where
( )
1
'
d v v Fe
u
d
u

=
b b n l k
l
S
S
In our example, the number of ventilation channels n
v
= 0 and
u u
d Fe d
'
1
S l
S k lb

=
Using the BH curve of M800-50A we get for the field strengths in the teeth
vs lspline H B , ( ) :=
lspline returns a vector, which interp uses to create a cubic, piecewise polynomial that
passes through all the (x,y) data points
Initial guess
B
es
B
dapps
:= H
es
interp vs B , H , B
es
,
( )
:= H
es
1.48 10
3
= A/m
B
er
B
dappr
:= H
er
interp vs B , H , B
er
,
( )
:= H
er
1.48 10
3
= A/m
Given
B
dapps
l
us

k
Fe
l b
ds

0
interp vs B , H , B
es
,
( )
B
es
=
B
ds
Find B
es ( )
:= B
ds
1.598 = T
H
ds
interp vs B , H , B
ds
,
( )
:= H
ds
1.4634 10
3
= A/m
Given
B
dappr
l
ur

k
Fe
l b
dr

0
interp vs H , B , B
er
,
( )
B
er
=
B
dr
Find B
er ( )
:= B
dr
1.6 = T
H
dr
interp vs B , H , B
dr
,
( )
:= H
dr
1.48 10
3
= A/m
The solution for the tooth magnetic voltage is

d
0
d
d m, d
h
U l H
We simplify and calculate as
U
mds
H
ds
h
3s
h
5s
+
( )
:= U
mds
36.5859 = A
U
mdr
H
ds
h
5r ( )
:= U
mdr
24.1467 = A
13. Magnetic voltage of the air gap and saturation factor
The magnetic voltage of the air gap is calculated according to Eqs. (3.7b) and (3.8)

atan
b
1s
2 ( )

2
b
1s
ln 1
b
1s
2

2
+

:=
0.4322 =
k
C1s

us

us
b
1s

:=
k
C1s
1.109 =
The equivalent air gap

e
k
C1s
:=
e
8.8717 10
4
= m

r
2

atan
b
1r
2
e
( )

2
e
b
1r
ln 1
b
1r
2
e

2
+

:=

r
0.4058 =
k
C1r

ur

ur
b
1r

:=
k
C1r
1.0999 =
The equivalent air gap

e
k
C1s
k
C1r
:=

e
9.7576 10
4
= m
The magnetic voltage of the air gap is according to Eq. (3.35)
U
me
B
1peak

0

e
:= U
me
592.0373 = A
According to Eq. (7.6), the saturaton factor is calculated as
k
sat1
U
mds
U
mdr
+
U
me
:=
k
sat1
0.1026 =
vs lspline k
sat

i
,
( )
:=
With Fig 7.2 we get

i2
interp vs k
sat
,
i
, k
sat1
,
( )
:=
i2
0.681 =
If this value differs from the value of
2i
used in Item 9, we must return to Item 9 and
give
2i
the value of
i2
and repeat the iteration until
2i
=
i2
14. Stator and rotor yokes
The maximum flux densities of the stator and rotor yokes are selected according to
Table 6.1.
B
ys
1.3 := B
yr
1.3 :=
The height of the stator yoke h
ys
and the height of the rotor yoke h
yr
are solved
from Eqs. (3.48) and (3.49):
( )
ys v v Fe
m
ys
m
ys
2

h b n l k S
B

= =

( )
yr v v Fe
m
yr
m
yr
2

h b n l k S
B

= =

where the air-gap flux

m

2i
B
1peak

p
l :=
m
0.0163 =
Vs
h
ys

m
2k
Fe
l n
v
b
v

( )
B
ys

:= h
ys
0.0329 = m
h
yr

m
2k
Fe
l n
v
b
v

( )
B
yr

:= h
yr
0.0329 = m
The magnetic voltages are according to Eqs. (3.51) and (3.52)
m,ys s ys ys

U c H =
m,yr r yr yr

U c H =
Stator diameters
D
ys
D
s
2 h
1s
h
2s
+ h
3s
+ h
4s
+ h
6s
+
( )
+ h
ys
+ :=
D
se
D
ys
h
ys
+ :=
where

ys
D
ys

2p
:=
ys
0.2362 = D
ys
0.3008 = m D
se
0.3337 = m
D
yr
D
r
h
yr
2 h
1r
h
2r
+ h
4r
+
( )

:= D
yr
0.1237 = m

yr
D
yr

2p
:=
yr
0.097 = m
The coefficient c can be taken from the figure below

0
0.2
0.4
0.6
0.8
c
0 0.5 1.0 1.5 2.0
T B B /

ys yr
From the BH curve of M800-50A, we get for the maximum field strengths in the stator
and rotor yokes
vs lspline B H , ( ) :=
B
ys
1.3 = H
ymaxs
interp vs B , H , B
ys
,
( )
:= H
ymaxs
304 = A /m
B
yr
1.3 = H
ymaxr
interp vs B , H , B
yr
,
( )
:= H
ymaxr
304 = A /m
Using Fig. 3.17, we get the correction factor c:
vs lspline B
y
c ,
( )
:=
c
s
interp vs B
y
, c , B
ys
,
( )
:= c
s
0.33 =
c
r
interp vs B
y
, c , B
yr
,
( )
:= c
r
0.33 =
The stator and rotor magnetic voltages are calculated as
U
mys
c
s
H
ymaxs

ys
:= U
mys
23.6995 = A
U
myr
c
r
H
ymaxr

yr
:= U
myr
9.7475 = A
15. Total magnetic voltage and magnetizing current
The magnetic voltages are
U
me
592.0373 = A
U
mds
36.5859 = A
U
mdr
24.1467 = A
U
myr
9.7475 = A
U
mys
23.6995 = A
The total magnetic voltage is
U
mtot
U
me
U
mds
+ U
mdr
+
U
mys
2
+
U
myr
2
+ := U
mtot
669.4933 = A
According to Eq. (2.13), the current linkage of a rotating field winding is calculated
according to the textbook as
I
p
Nk
I
p
Nk m
2

3
2
2
4
2

w1 w1
1
= =
from which the effective value of magnetizing current can be calculated in Mathcad format
I
m
U
mtot
p
3 N
s
k
w1
2
:=
I
m
9.5701 = A
16. Stator resistance
The average length l
av
of a coil turn (Eq. (5.2))
l
av
2l 2.4 W
p

p
+ 0.1 + := l
av
0.8093 = m
The conductivity of copper wire at 100 degrees C (the temperature rise =
80 K) is

Cu

Cu20C
1
Cu
+
:=
Cu
4.3685 10
7
= S /m
The DC resistance of a phase winding
R
s
N
s
l
av

Cu
a S
cs

:= R
s
0.2467 =
17. Rotor resistance referred to stator
The conductivity of aluminium at 100 degrees C (the temperature rise = 80
K) is

Al

Al20C
1
Al
+
:=
The DC resistance of a rotor bar is according to Eq. (5.1)
R
bar
l
S
Alr

Al

:= R
bar
6.258 10
5
=
We assume that the end ring has the same height as the rotor bar h
4
+ h
2
and is located at depth h
1
. The average end-ring diameter is
D
ring
D
r
2 h
1r
h
2r
h
4r
+
2
+

:=
D
ring
0.1773 = m
l
ring

D
ring
Q
r
:= l
ring
0.0127 = m
The cross-sectional area of the ring is
S
ring
1000000 670.3265 = mm
2

S
ring
6.7033 10
4
= m
2

R
ring
l
ring
S
ring

Al

:=
R
ring
6.6145 10
7
=
R
r
R
bar
R
ring
2 sin
p
Q
r

+ := R
r
7.891 10
5
=
The resistance of the rotor may be referred to the stator by multiplying the resistance with Eq.
(7.53)
2
r sq
s w s
r
s
4

k
k N
Q
m
According to Eq. (4.71), the skewing factor is calculated as
2

sin
p
sq
p
sq
sq

s
s
k

=
The skewing is carried out in the rotor so that it corresponds to one stator slot
pitch (Fig. 4.16)
s
sq

D
s
Q
s
:= k
sq
sin
s
sq

s
sq

:= k
sq
0.9971 =

4m
Q
r
N
s
k
w1

k
sq

2
:=

2.9441 10
3
=
R
r

R
r
:= R
r
0.2323 =
18. Magnetizing inductance and reactance
The effective air gap

ef
U
me
U
mds
+ U
mdr
+
U
mys
2
+
U
myr
2
+
U
me

e
:=

ef
1.1034 10
3
= m
Calculation of magnetizing inductance (Eq. 3.110)
L
m
m
2
2

0
l
1
2 p

ef
k
w1
N
s

( )
2
:=
L
m
1.1644 10
1
= H
The mangnetizing reactance is
X
m
L
m
:= X
m
36.5791 = N
s
112 =
19. Air-gap leakage inductances and reactances
The stator leakage factor (Eq. 4.18)
2
1
1 w
w

+ =

k
k

Pitch factor (Eq. 2.32)
Distribution factor (Eq. 2.24)

=
2

sin
p
p

W
k

( )
( ) 2 / sin
2 / sin
u
u
d

q
q
k

=

us
p 2
Q
s
:=
us
0.2618 = (Eq. 2.2)
The air-gap leakage is calculated in two parts for 600 harmonics
k
1
1
300
k
sin 1 2 k m + ( ) W
p

sin 1 2 k m + ( ) q

us
2

q sin 1 2 k m + ( )

us
2

1 2 k m + ( ) k
w1

=
:=
k
1
2.8543 10
3
=
k
12
1
300
k
sin 1 2 k m + ( ) W
p

sin 1 2 k m + ( ) q

us
2

q sin 1 2 k m + ( )

us
2

1 2 k m + ( ) k
w1

=
:=
k
12
3.3376 10
3
=
Thus, the air-gap leakage factor is

s
k
1
k
12
+ :=
s
6.1918 10
3
=
In asynchronous machines with a cage winding, the cage damps harmonics, and consequently,
the air-gap inductance becomes less significant. This can be estimated empirically by multiplying
the inductance obtained from Eq. (4.16) with a damping factor, usually of the magnitude 0.8.
Hence, the air-gap leakage inductance is
L
s
0.8
s
L
m
:= L
s
5.7676 10
4
= H
and the stator air-gap leakage reactance
X
s
L
s
2 f := X
s
0.1812 =
The rotor air-gap leakage is calculated with Eq. (4.21)
2
r
2
2
2
r
2
r
r
3
1
1
1

+
=

Q
p
c Q
p
p
cQ c c

r

2
3
p
Q
r

2
:=
r
6.7972 10
3
=
L
r

r
L
m
:= L
r
7.9144 10
4
= H
and the rotor air-gap leakage reactance referred to the stator
X
r
L
r
2 f := X
r
0.2486 =
20. Slot leakage inductances and reactances
Eq. (4.51)
1 W
p
:= 0.1667 =
Eq. (4.53)
k
1
1
9
16
:= k
1
0.9063 =
k
2
1
3
4
:= k
2
0.875 =
Eq. (4.49)

us
k
1
h
4s
h
s

3 b
4s

k
2
h
3s
b
4s
h
1s
b
1s
+
h
2s
b
4s
b
1s

ln
b
4s
b
1s

+
h
s
4 b
4s

+ :=
us
2.3339 =
Eq. (4.30)
L
us
4m
Q
s

0
l N
s
2

us
:= L
us
1.8202 10
3
= H
X
us
2 f L
us
:= X
us
0.5718 =
The leakage of a single slot
ur
2
Q 0 u1
' z l L =
In the rotor slot, there is only one bar, z
Q
= 1.
According to (4.32) we get for the rotor slot leakage

ur
h
4r
3b
4r
h
1r
b
1r
+ 0.66 + :=
L
ur

0
l 1
2

ur
:= L
ur
4.7586 10
7
= H
X
ur
2 f L
ur
:= X
ur
1.495 10
4
=
21. Tooth tip leakage inductances and reactances
Eq. (4.62)

ds
k
2
5

b
1s

5 4

b
1s
+
:=
ds
0.1923 =
where k
2
is given by Eq. (4.48)
and 'g' in it by Eq. (4.41)
Eq. (4.30)
L
ds
4m
Q
s

0
l
ds
N
s
2
:= L
ds
1.4998 10
4
= H
X
ds
2 f L
ds
:= X
ds
0.0471 =

dr
k
2
5

b
1r

5 4

b
1r
+
:=
dr
0.1923 =
L
dr

0
l
dr
:= L
dr
4.7827 10
8
= H
X
dr
2 f L
dr
:= X
dr
1.5025 10
5
=
22. End winding leakage inductances and reactances
The average length l
w
of the stator end winding

2 = q
Q
z
l
eW
W
eW
Q
z
l
ew
0.025 := m l
w
l
av
2
l := l
w
0.2083 = m
W
ew
l
w
2l
ew
:= W
ew
0.1583 = m
The permeance factors according to Table 4.1

lew
0.5 :=

W
0.2 :=

ws
2 l
ew

lew
W
ew

W
+
l
w
:=
ws
0.272 =
The end winding leakage inductance (Eq. 4.64)
L
ws
4m
Q
s
q N
s
2

0
l
w

ws
:= L
ws
8.9326 10
4
= H
X
ws
2 f L
ws
:= X
ws
0.2806 =
The rotor short-circuit ring leakage is calculated according to (4.67) as
( )

+ =
p
D
l l
p m
Q
L
2
'
'
3
1
r
s bar 2
s
r
0 ring

is 0.36 for p = 1
is 0.18 for p > 1
L
ring

0
Q
r
m p
2

1
3
l l ( ) 0.18
D
ring

2 p
+

:=
L
ring
3.6037 10
8
= H
23. Skew leakage inductance
The skew leakage inductance is found as (Eq. 4.81)

sq
1 k
sq
2
:=
Eq. (4.80)
L
sq

sq
L
m
:= L
sq
6.6351 10
4
= H
24. Inductances and reactances referred to the stator
The stator leakage inductance (Eq. 4.7)
L
s
L
s
L
us
+ L
ds
+ L
ws
+ L
sq
+ := L
s
4.1037 10
3
= H
and the leakage reactance
X
s
L
s
:= X
s
1.2892 =
The magnetizing inductance L
m
was calculated in Item 18
L
m
0.1164 = H
L
r
7.9144 10
4
=
The rotor bar leakage inductance (see Items 20 and 21)
L
ur
4.7586 10
7
=
L
bar
L
ur
L
dr
+ := L
bar
5.2369 10
7
=
L
dr
4.7827 10
8
=
The rotor end winding leakage is (see Item 22)
L
ring
3.6037 10
8
= H
The rotor total leakage inductance (Eq. 7.92)
L
r
L
bar
L
ring
2 sin
p
Q
r

+ :=
L
r
1.4133 10
6
=
The inductance may be referred to the stator by multiplying with Eq. (7.53)
2
r sq
s w s
r
s
4

k
k N
Q
m
L
r
L
r

L
r
+ :=
L
r
4.9525 10
3
= H
25. Core and mechanical losses
To calculate the core losses, we need the masses of different iron parts.
The total volume of the stator is
V
s

4
D
se
2
D
s
2
( ) l := V
s
0.0109 = m
3

The volume of the stator yoke
V
ys

D
se
2

2
D
se
2
h
ys

l :=
V
ys
6.0964 10
3
= m
3
The mass of the stator yoke
m
ys
V
ys
k
Fe

Fe
:= m
ys
44.9427 = kg
The total volume of the stator slots
V
slots
Q
s
S
slot
l :=
V
slots
2.5025 10
3
= m
3
The volume of the teeth
V
ds
V
s
V
ys
V
slots
:=
V
ds
2.2988 10
3
= m
3
The total mass of the teeth
m
ds
V
ds
k
Fe

Fe
:= m
ds
16.9467 = kg
The stator teeth (only the height h
5s
)
m
dsloss
k
Fe

Fe
Q
s
b
ds
h
5s
l := m
dsloss
9.0791 = kg
Iron loss correction coefficients (Table 3.2)
k
Fed
1.8 :=
k
Fey
1.5 :=
The core loss in the stator yoke is
P
Feys
k
Fey
P
15

B
ys
1.5

2
m
ys

f
50

3
2
:= P
Feys
334.1942 = W
The core loss of the tooth area is calculated using the mass m
dsloss
defined above
P
Feds
k
Fed
P
15

B
ds
1.5

2
m
dsloss

f
50

3
2
:=
P
Feds
122.411 = W
The total iron losses are
P
Fe
P
Feys
P
Feds
+ := P
Fe
456.6052 = W
Because of the low rotor fundamental frequency, the rotor iron losses are taken into account in the
additional losses.
The mechanical losses consisting of windage and ventilator losses are calculated
from an experimental equation (Eq. (9.19), Table 9.2)
v
r

n
syn
60
D
r
:= v
r
15.708 = m/s n
syn
1.5 10
3
= min
-1
k

15 := Ws
2
/m
4
P

D
r
l 0.6
p
+
( )
v
r
2
:= P

215.6334 = W
26. Equivalent circuit parameters
j 1 := The imaginary unit is used in the impedance calculations
The rotational speeds used in the following calculations vary from zero to
synchronous speed (from 0 min
-1
to 1500 min
-1
)
x 1 60
f
p
.. := This x is seen as a subscript in the following calculations
n
x
60 f
p
x
1500
:= n
1500
1.5 10
3
= min
-1
slip
(The latter small number is
inserted to avoid numerical
problems)
s
x
60 f n
x
p
60 f
10
10
+ :=
The rotor skin effect is evaluated assuming the rotor bar to be a
rectangle. The resistance factor is (Eqs. 5.24 and 5.26)
b
b
h
c
c 0 c
2
1
=
( )



2 cos 2 cosh
2 sin 2 sinh
R

+
= = k
We use the total conductor height in the calculation
h
c
h
2r
h
4r
+ :=
x
h
c
1
2
s
x

0

Al
1 :=
k
R
x

x
sinh 2
x
( ) sin 2
x
( ) +
cosh 2
x
( ) cos 2
x
( )
:=
Rotor slip frequency: fr
x
s
x
f :=
The corresponding rotor leakage inductance skin effect factor is (Eqs. (4.57) and (4.58))

=


2 cos 2 cosh
2 sin 2 sinh
2
3
L
k
k
L
x
3
2
x

sinh 2
x
( ) sin 2
x
( )
cosh 2
x
( ) cos 2
x
( )
:=
k
L
1500
1 =
The skin effect factors for the whole range of slip are depicted in the graph below and used for the next
calculations.
0 0.2 0.4 0.6 0.8
0.8
1
1.2
1.4
Motor slip
s
k
i
n

e
f
f
e
c
t

f
a
c
t
o
r
s
k
R
k
L
The rotor resistance referred to the stator is
R
r
x

R
bar
k
R
x

R
ring
2 sin
p
Q
r

:=
R
r
1486
0.2323 =
and the rotor leakage inductance referred to the stator is
L
r
x

L
bar
k
L
x

L
ring
2 sin
p
Q
r

:=
X
r
x
L
r
x
:=
R
r
x
R
r
x
:=
X'
r
x
X
r
x
:=
Rotor circuit impedance:
Z
r
x
R
r
x
s
x
j X'
r
x
+ := Z
r
1474
13.4048 1.3072j + =
Core loss resistance:
R
Fe
3 E
m
2

P
Fe
:= R
Fe
921.3254 =
Magnetizing circuit impedance:
Z
m
R
Fe
X
m
j
R
Fe
X
m
j +
:=
Z
m
1.45 36.5216j + =
Stator circuit impedance:
Z
s
R
s
X
s
j + := Z
s
0.2467 1.2892j + =
Total impedance of the equivalent circuit:
Z
x
Z
s
Z
m
Z
r
x

Z
m
Z
r
x
+
+ := Z
1486
16.3203 12.7902j + =
27. Rated load, stator and rotor current
The motor currents and the output power are calculated at all relevant speeds n
x
Stator current phasor: The index, e.g. 1474 (the value must be
given), corresponds to a speed in min
-1
. The
sentence below returns the corresponding
current absolute value
I
s
x
U
sph
Z
x
:= I
s
1
155.8465 = I
s
1474
30.8324 = A
Air gap voltage:
E
m
x
U
sph
I
s
x
Z
s
:= E
m
1474
373.4674 = V
E
m
1474
U
sph
0.9375 =
If the air-gap voltage differs by more than 1 % of the value used in Item 7, we should return to
Item 7 and repeat the calculations
Rotor current phasor:
I
r
x
I
s
x
Z
m
Z
m
Z
r
x
+
:= I
r
1474
27.7291 = A
No-load current:
A
I
0
x
I
s
x
I
r
x
:= I
0
1500
10.5253 =
Mechanical losses:
P
mech
x
P

n
x
n
n

3
:=
P
mech
1475
216.0725 = W
Output power:
P
mech
1474
215.6334 = W
P
x
m I
r
x
( )
2

1 s
x

s
x
R
r
x
P
mech
x
:=
P
1474
3.0169 10
4
= W
P
1475
2.9132 10
4
= W
P
1475
P
1474
+
2
2.9651 10
4
= W
We see that the rated output speed is
between 1474 and 1475 min
-1
28. Losses, efficiency, power factor and torque
P
1474
3.0169 10
4
= W
Resistive losses of the stator
P
Cus
x
m I
s
x
( )
2
R
s
:= P
Cus
1474
703.6409 = W
Resistive losses of the rotor
P
Cur
x
m I
r
x
( )
2
R
r
x
:= P
Cur
1474
535.965 = W
Power factor:
cos
x
Re I
s
x
( )
I
s
x
:= cos
1474
0.8706 =
cos
1475
0.8679 =
Additional losses:
P
ad
x
3 I
s
x
U cos
x
0.5 10
2
:= P
ad
1474
277.8111 = W
P
ad
1475
268.1306 = W
Core losses:
P
Fe
x
m
E
m
x
( )
2
R
Fe
:= P
Fe
1474
454.165 = W
Total losses:
P
losstot
x
P
Cus
x
P
Cur
x
+ P
Fe
x
+ P
ad
x
+ := P
losstot
1474
1.9716 10
3
= W
Efficiency:

x
P
x
P
x
P
losstot
x
+
:=

1474
0.9387 =

1475
0.9394 =
Torque:
T
x
m I
r
x
( )
2

1
s
x
R
r
x
P
mech
x

2
f
p

:= T
1474
195.4768 = Nm
T
1475
188.63 = Nm
Maximum torque per rated torque:
max T ( ) 504.5188 = Nm. The value is found at T
1364
504.517 = Nm
max T ( )
T
1474
2.581 =
Starting current:
I
s
1
155.8465 = A
NOTE
Please note that this calculation example is simplified and does
not take all phenomena into account. For example, the effects
of harmonics on the torque and the effects of leakage
saturation at start are neglected.
If the per unit starting current is high and the torque low:
-The rotor could be equipped with a double cage.
-The rotor resistance could be increased by using
less aluminium. This, however, results in a smaller efficiency.
-The rotor inductance could also be increased. This results
in a smaller starting torque.
I
s
1
I
s
1474
5.0546 =
Starting torque:
T
1
134.7773 = Nm
Starting torque per rated torque:
T
1
T
1474
0.6895 =
Efficiency:
Torque:
0 7500 1.5
.
10
4
2.25
.
10
4
3
.
10
4
0.7
0.77
0.85
0.93
1
Output power / W
E
f
f
i
c
i
e
n
c
y
0 500 1000 1500
0
500
rotational speed 1/s
T
o
r
q
u
e

/

N
m
Stator current Power factor:
0 500 1000 1500
0
200
rotational speed 1/s
S
t
a
t
o
r

c
u
r
r
e
n
t

/

A
1
.
10
4
2
.
10
4
3
.
10
4
0.4
0.6
0.8
Output power / W
P
o
w
e
r

f
a
c
t
o
r
The motor rated parameters differ from the initial data to some degree. It is up to the designers to decide
whether the results are valid to them. For example the calculated efficiency is better than the target, whereas
the power factor is lower. Both values are strongly affected by the air-gap length, which was selected greater
than recommended.
The figure below shows a FEM*-calculated flux plot of the machine at the rated
operation point.
*FCSMEK software