Power Manufacturing Series

Design and
Calculations of
Stringing Machine
For High Voltage
Cable
Engr. Qazi Arsalan Hamid

Scholars Talk
Contents
Designing of 3 phase induction motor: ......................................................................................................... 2
Mechanical design on induction motor: ................................................................................................... 2
Stator Design ................................................................................................................................................. 5
Rotor Design.................................................................................................................................................. 5
Crawling: ................................................................................................................................................... 6
Cogging:..................................................................................................................................................... 6
Rotor Bar Current:..................................................................................................................................... 6
Cross sectional area of Rotor bar:............................................................................................................. 6
Shape and Size of the Rotor slots: ............................................................................................................ 7
Copper loss in rotor bars:.......................................................................................................................... 7
End Ring Current: ...................................................................................................................................... 7
Area of end ring: ....................................................................................................................................... 8
Copper loss in End Rings: .......................................................................................................................... 8
Equivalent Rotor Resistance: .................................................................................................................... 8
Design of wound Rotor: ............................................................................................................................ 8
Number of rotor slots: .............................................................................................................................. 8
Number of rotor turns: ............................................................................................................................. 9
Calculations: .................................................................................................................................................. 9
Rotor Peripheral Speed:-......................................................................................................................... 10
CONCLUSION............................................................................................................................................... 11

1
Designing of 3 phase induction motor:
Assumptions:
1) Length of 4 core armored cable of 240 mm2 = 1000m=1 Km

For 240mm2 cable weight of 1000 m cable is 2460kg

2) Let us suppose power of 1 kg is 1.5 watt. Then

Power for 2460 kg=3730 watt=3.73 KW = 5 horse power (hp)

Now we have to design a 5 hp 3 phase induction motor:

Mechanical design on induction motor:

Material:

Stator and rotor are made up of thin silicon steel lamination.

Synchronized speed for 4 poles =1500 rpm

Measured speed =1420 rpm

For Mechanical Design of Induction motor

Power = output Q= Co D2 L Ns (KW)

Output co efficient Co= 11 Bar q kwcos 10^-3

Bav=Average flux density

q = Specific electric loading
Kw =winding factor
=efficiency
Cos= power factor
D= Diameter of stator
L= Gross core length
Ns= Synchronized speed in rpm= 1500rpm
i) Bav =
In teeth, Bav = 1.7 Tesla
In Core, Bav =1.4 Tesla
ii) q range =10,000 ac/m 450,000 ac/m=20,000 ac/m
iii) Cos=.80
iv) D^2L product#

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 (/)/L=0.18 / (/)
i.eD= 0.135 P
DL=1.5m
Peripheral speed= 30 m/s
v) Kw =0.955
vi) =0.83=83.4%

Assume #

Three phase voltage = V = 415v

Rated current= 7.9A
Power factor= 0.80 =cos

For 5 hppowers , all losses are

Input power:

P in = 3 VL IL cos = 3*415*7.9*0.8 = 4542.80W

The input power of induction motor is 4542.80W

Efficiency calculation:

= (1 - P losses/pin)*100%

Losses calculation:

P losses =P scl + P rcl + P core + P f+w + P stray

Stator copper loss:

P scl = 3 I1 R1

Rotor copper loss:

P rcl = 3 I2 R2

The shaft load torque:

3730
load = = =3730/148.75=25.08
14202(1 )
60

P ag = 3 I2 R2/s

Per- phase stator core loss resistance:

3
 R c= V L-L 3 /2fs Im

Per- phase stator Magnetizing inductor:

R c= V L-L 3 / Ic

Based on IEEE 112-B standard P stray , Value at 1 kw is 2.5 % of the full-load input power,
dropping at 10 kW to 2% at 100kw to 1.5 % at 1000 kW to 1% and at 10 MW to 0.5 %

Therefore,

P stray(IEEE) =4542.8 *2.5%=113.57 W

In the IEC 34-2 standard ,these losses are not measured and are arbitrarily estimated to be
equal to 0.5 % of the full-load input power.

Therefore,
P stray(IEEE) = 4542.8*0.5 %= 22.7W
Input power 4542.8 w
Stator copper losses 363.3 w
Stray + core losses 114 w
Friction and winding losses 159 w
Strag losses ( P strag) 22.7 w
Total losses 749.72 w =0.7497 Kw

Assumption#
Total Output Power = 3730 watt= 3.7 kw = 5 hp
Input Power = Pin = 3 V I cos
=3 * 415*7.9*0.8= 4542.80 w

Efficiency Calculation :

= (1- Plosses/pin)*100%
= 1 (749.72/4542.80)*100
=83.4%

4
Stator Design

Stator volume and size

V= 9 in for 5 hp

Frame diameter estimation= Df = 9.38 from (NEMP STD)

Air gap =2.4 mm

According to NEMA stator slot design for 415 V is 0.030 in coil separator

Stator conductor size = Aa = I rated/Jsa

Air coiled = 4 A/mm2v Jsn8 A/mm2

I rated = (pout/) / 3 V rated p.f
=(3730 / 0.83) /3*415*4*50 = 0.018A
=0.018 / 6 = 3*10^-3 mm2

No of turns per coil on stator = E1 = 4.44 Neff m

Stator volume and size:

V= 9v in 3 phase for 5 hp

No. of turns per coil on stator :

E1 = 0.97 V rated = 402.5 V

1.07 415
Nc = 2 3.14 50 4 0.955 5.37 103

Nc = 34

Rotor Design
Number of slots: Proper numbers of rotor slots are to be selected in relation to number of
stator slots otherwise undesirable effects will be found at the starting of the motor. Cogging
and Crawling are the two phenomena which are observed due to wrong combination of
number of rotor and stator slots. In addition, induction motor may develop unpredictable
hooks and cusps in torque speed characteristics or the motor may run with lot of noise. Let us
discuss Cogging and Crawling phenomena in induction motors.

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Crawling: The rotating magnetic field produced in the air gap of the will be usually non-
sinusoidal and generally contains odd harmonics of the order 3rd, 5th and 7th. The third
harmonic flux will produce the three times the magnetic poles compared to that of the
fundamental. Similarly the 5th and 7th harmonics will produce the poles five and seven times
the fundamental respectively. The presence of harmonics in the flux wave affects the torque
speed characteristics. The Fig. 16 below shows the effect of 7th harmonics on the torque speed
characteristics of three phase induction motor. The motor with presence of 7th harmonics is to
have a tendency to run the motor at one seventh of its normal speed. The 7th harmonics will
produce a dip in torque speed characteristics at one seventh of its normal speed as shown in
torque speed characteristics.

Cogging: In some cases where in the number of rotor slots are not proper in relation to
number of stator slots the machine refuses to run and remains stationary. Under such
conditions there will be a locking tendency between the rotor and stator. Such a phenomenon
is called cogging. Hence in order to avoid such bad effects a proper number of rotor slots are to
be selected in relation to number of stator slots. In addition rotor slots will be skewed by one
slot pitch to minimize the tendency of cogging, torque defects like synchronous hooks and
cusps and noisy operation while running. Effect of skewing will slightly increase the rotor
resistance and increases the starting torque. However this will increase the leakage reactance
and hence reduces the starting current and power factor.

Rotor Bar Current: Bar current in the rotor of a squirrel cage induction motor
may be determined by comparing the mmf developed in rotor and stator. Hence the current
per rotor bar is given by Ib = ( KwsxSs x Z's ) x I'r / ( KwrxSr x Z'r ) ; where Kws winding factor
for the stator, Ss number of stator slots, Z's number of conductors / stator slots, Kwr
winding factor for the rotor, Sr number of rotor slots, Z'r number of conductors / rotor slots
and I'r equivalent rotor current in terms of stator current and is given by I'r= 0.85 Is where is
stator current per phase.

Cross sectional area of Rotor bar: Sectional area of the rotor

conductor can be calculated by rotor bar current and assumed value of current density for rotor
bars. As cooling conditions are better for the rotor than the stator higher current density can be
assumed. Higher current density will lead to reduced sectional area and hence increased
resistance, rotor cu losses and reduced efficiency. With increased rotor resistance starting
torque will increase. As a guide line the rotor bar current density can be assumed between 4 to
7 Amp/mm2 or may be selected from design data Hand Book. Hence sectional area of the rotor

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bars can be calculated as Ab= Ib /_b mm2. Once the cross sectional area is known the size of
the conductor may be selected form standard table given in data hand book.

Shape and Size of the Rotor slots: Generally semi-closed slots or

closed slots with very small or narrow openings are employed for the rotor slots. In case of fully
closed slots the rotor bars are force fit into the slots from the sides of the rotor. The rotors with
closed slots are giving better performance to the motor in the following way. (i) As the rotor is
closed the rotor surface is smooth at the air gap and hence the motor draws lower magnetizing
current. (ii) reduced noise as the air gap characteristics are better (iii) increased leakage
reactance and (iv) reduced starting current. (v) Over load capacity is reduced (vi) Undesirable
and complex air gap characteristics. From the above it can be concluded that semi-closed slots
are more suitable and hence are employed in rotors.

Copper loss in rotor bars: Knowing the length of the rotor bars and
resistance of the rotor bars cu losses in the rotor bars can be calculated.

Length of rotor bar lb= L + allowance for skewing

Rotor bar resistance = 0.021 x lb / Ab

Copper loss in rotor bars = Ib

2 x rbx number of rotor bars.

End Ring Current: All the rotor bars are short circuited by connecting them to
the end rings at both the end rings. The rotating magnetic field produced will induce an emf in
the rotor bars which will be sinusoidal over one pole pitch. As the rotor is a short circuited
body, there will be current flow because of this emf induced. The distribution of current and
end rings are as shown in Fig. 17 below. Referring to the figure considering the bars under one
pole pitch, half of the number of bars and the end ring carry the current in one direction and
the other half in the opposite direction. Thus the maximum end ring current may be taken as
the sum of the average current in half of the number of bars under one pole.

Maximum end ring current Ie(max) = ( Number rotor bars / pole) Ib(av)

= x Sr/P x Ib/1.11

Hence rms value of Ie= 1/2_2 x Sr/P x Ib/1.11

= 1/_ x Sr/P x Ib/1.11

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Area of end ring: Knowing the end ring current and assuming suitable value for
the current density in the end rings cross section for the end ring can be calculated as

Area of each end ring Ae= Ie / _e mm2, current density in the end ring may be assume as 4.5 to
7.5 amp/mm2.

Copper loss in End Rings: Mean diameter of the end ring (Dme) is
assumed as 4 to 6 cms less than that of the rotor.

Mean length of the current path in end ring can be calculated as lme= _Dme. The resistance of
the end ring can be calculated as

re= 0.021 x lme / Ae

Total copper loss in end rings = 2 x Ie

2 xre

Equivalent Rotor Resistance: Knowing the total copper losses in the

rotor circuit and the equivalent rotor current equivalent rotor resistance can be calculated as
follows.

Equivalent rotor resistance r'

r = Total rotor copper loss / 3 x (Ir' )2

Design of wound Rotor: These are the types of induction motors where in
rotor also carries distributed star connected 3 phase winding. At one end of the rotor there are
three slip rings mounted on the shaft. Three ends of the winding are connected to the slip rings.
External resistances can be connected to these slip rings at starting, which will be inserted in
series with the windings which will help in increasing the torque at starting. Such type of
induction motors are employed where high starting torque is required.

Number of rotor slots: As mentioned earlier the number of rotor slots

should never be equal to number of stator slots. Generally for wound rotor motors a suitable
value is assumed for number of rotor slots per pole per phase, and then total number of rotor
slots are calculated. So selected number of slots should be such that tooth width must satisfy
the flux density limitation. Semi-closed slots are used for rotor slots.

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Number of rotor turns: Number of rotor turns is decided based on the
safety consideration of the personal working with the induction motors. The voltage between
the slip rings on open circuit must be limited to safety values. In general the voltage between
the slip rings for low and medium voltage machines must be limited to 400 volts. For motors
with higher voltage ratings and large size motors this voltage must be limited to 1000 volts.
Based on the assumed voltage between the slip rings comparing the induced voltage ratio in
stator and rotor the number of turns on rotor winding can be calculated. Voltage ratio Er/ Es =
(Kwr x Tr) / (Kws x Ts )

Hence rotor turns per phase Tr = (Er/Es) (Kws/Kwr) Ts

Er = open circuit rotor voltage/phase

Es = stator voltage /phase

Kws = winding factor for stator

Kwr = winding factor for rotor

Ts = Number of stator turns/phase

Rotor Current Rotor current can be calculated by comparing the amp-cond on stator and rotor

Ir = (KwsxSs x Z's )xI'r / ( KwrxSr x Z'r ) ;

Kws winding factor for the stator,

Ss number of stator slots,

Z's number of conductors / stator slots,

Kwr winding factor for the rotor,

Sr number of rotor slots,

Z'r number of conductors / rotor slots and

I'r equivalent rotor current in terms of stator current

I'r= 0.85 IswhereIs is stator current per phase.

Calculations:
Air gap length = lg= 0.2 +2DL =2.66 mm

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Air of rotor conductor = Ar = Ir/v mm2

Ar = 4.5 mm2

Size of Rotor slot:

= 4 mm

Outer dia of rotor

Dr = D 2 lg

Dr = 0.328 m

End Ring Current :-

Ie = 765.8 amps

Area of End ring = 5 amp/mm2

Rotor Speed = 250 m/s

Rotor Peripheral Speed:-

The max Allowable peripheral speed is 30 m/s

Maximum Flux :-
0.003 0.08
m= (0.00145 + )( )

m = 2.2x10-3 x2.44 = 5.37x10-3

5HP Induction Motor Parameters Calculated Value

Stator current (11) 7.9A

Rotor current (12) 3.95-4.0A

Stator resistance (RI) 1.9 -2.4

Rotor resistance (R2) 1.8 -1.946

Stator core loss current (1c) 6.356A

Magnetizing current (Hm) 4.74A

Excitation =Tent (lo) 2.72A

10
Stator core loss resistance (Rc) 37.72

Stator magnetizing inductor (Lan) 0.1542 H

Magnetizing reactance (Xm) 48.44

Slip 5.30%

Rotor frequency (f) 2.65 Hz

Shaft load torque (T) 25.08 N-m

CONCLUSION
The following conclusion could be made on this paper,

A proper parameter calculation is needed to obtain the range of specification of the induction

motor such as the total resistance, reactance, the losses estimation, stator current, rotor
current, etc.

It is noted that if the horse power rating of the induction motors increases the value of
resistance decreases.

All the data that calculated can be used for FEM designer to design the complete model of AC
induction motor

Proper rating should be set in order to obtain the exact efficiency of the Induction Motor.

11