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Analysis of mechanical losses in three-phase squirrel-cage induction motors

Conference Paper · February 2001

DOI: 10.1109/ICEMS.2001.970604 · Source: IEEE Xplore

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 Analysis of Mechanical Losses in
Three-Phase Squirrel-Cage Induction Motors

Konrad Dabala
Electrotechnical Institute, Electrical Machines Department
04-703 Warsaw, Poland
E-mail: k.dabala@iel.waw.pl

Abstract- The results of calculation and experimental B. Windage Losses of Outside Fan
determination of mechanical losses in several motors of
rated power 2,2 kW-15 kW and number of poles 2-6, degree In induction motors of middle power are used radial
protection IP 54 are presented in the paper. There were fan very often. For this kind of fan its pressure is equal
determined friction and windage losses in these motors and
taken into consideration the influence of seals on the value  Q2 
H = H 0 1 − 2  = H 0 − Z w Q 2 in Pa (2)
of friction losses. There was done an analysis of test results
and the influence of the mechanical losses on motor
 Q max 
efficiency.
Keywords- Induction squirrel-cage motors, losses, where:
mechanical losses. Q – volume output coolant in work state in m3/s;
H
I. INTRODUCTION Z w = 20 (3)
Qmax
Pa ⋅ s
Designer of high efficiency motors wants to achieve - aerodynamic resistance (internal) of fan in ;
losses reduction by decrease of all components of losses m6

( ) ( )
2
(for example stray losses [2]) among others mechanical  n 
losses, too. It is necessary to analyse of all components H 0 = η a 0δ u 22 − u12 = k H ε ⋅ 32,9  D2 − D1
2 2
(4)
 100 
of mechanical losses in order to do it.
- static pressure of fan in no-load state i.e. when Q=0 in
Pa;
II. REASONS OF MECHANICAL LOSSES
ηa0 - aerodynamic efficiency of fan in no-load state, for
fan with radial blades the values of this efficiency
The main reasons of mechanical losses appearing are
include in range (0,2-0,6) no unit. The bigger value is for
friction and windage losses. Particularly in squirrel-cage
bigger motors and for bigger number of fan blades.
induction motors we can separate some components of
these losses as follows: δ - mass density of air in kg/m3 (about 1,2 kg/m3);
1) friction losses in bearings Pbe; u2 and u1 - perimeter speeds on outside D2 (m) and inside
2) windage losses of outside fan Pmw; D1 (m) diameters of fan blades in m/s;
D D
3) friction air losses of rotor and windage losses of k H = 1 when 1 ≤ 0,5 (5)
two internal fans (casted with rotor rings) Pmwin; D2 D2
4) friction losses of V-ring seals Ps if degree of
protection is IP 54. and
2
D1 D  D
III. METHODS OF MECHANICAL LOSSES CALCULATION kH + 3 1 − 0,5  when 1 > 0,5 (6)
D2 D
 2  D2
The methods of mechanical losses calculation are - aerodynamic coefficient, no unit;
approximate and they often use empirical formulas. 1
ε=
0,7π (7)
1+
A. Friction Losses in Bearings
( )
2 z 1 − DD12
Friction losses for induction motors with roller - coefficient depended on a number of fan blades z and
bearings we can calculate by approximate formula (in W relation of outside D2 and inside D1 diameters of fan
for one bearing) as in [1]: blades, no unit;
v n - rotational speed of motor in rot/min;
Pmbe = 1,5F 10 − 5 (1) Qmax = 0,412u2S2 (8)
d be
- maximum value of volume output coolant when
where: aerodynamic resistance (external) is equal 0 in m3/s;
F - radial force in the bearing in N; S2 = 0,92πD2b (9)
v - perimeter speed on the bearing race surface in m/s; b – width of fan blades in m.
dbe - average diameter of roller elements in m.
Windage losses of outside fan is equal F - force between rubber V-ring seal and endshield in N.
HQ Z m Q 3 The force was measured and its value includes in range
Pmw = = in W (10) (1N-10N).
ηe ηe
n - rotational speed of motor in rot/min;
where: ds - average diameter of seal in m.
Zm – aerodynamic resistance (external) of fan circuit in
Pa ⋅ s IV. RESULTS OF MEASUREMENTS
;
m6
ηe - energetic efficiency of fun in no unit. The function Experimental researches were carried out on:
of this efficiency and Q/Qmax for closed motors is - motor of size 160 L-4B which was supplied
presented on fig. 1. from variable frequency source;
0.16 - 24 motors of different size and different
numbers of poles.

A. Dependence of Different Components of Mechanical

0.12 Losses on Rotational Speed
Fan efficiency (-)

In order to separate of mechanical losses components

were carried out no-load tests in normal and without fan
0.08 states of motor. Motor was supplied from variable
frequency source. The results of this investigation are
Polynomial Coefficients
Degree 0: 0.00113287
presented on fig. 2.
0.04 Degree 1: 0.600932
Degree 2: -0.600932 Polynomial coefficients normal Polynomial coefficients
Degree 0: -0.173601 without fan
Degree 1: 0.0190937 Degree 0: 0.135715
Degree 2: -1.74534E-005 Degree 1: 0.00993333
Degree 3: 2.37923E-008 Degree 2: 7.38095E-006
0.00 Polynomial Coefficients Pmw
0.00 0.20 0.40 0.60 0.80 1.00 Degree 0: -0.0723594
Q/Qmax (-) Degree 1: 0.00405262
Degree 2: -1.69358E-005
Fig. 1. Relationship between fun efficiency and Q/Qmax Degree 3: 2.08669E-008
for fan with radial blades 120.00

normal
C. Friction Air Losses of Rotor and Windage Losses of
Two Internal Fans normal-fit
without fan
Conditions of work of these two internal fans are that 80.00
without fan-fit
Losses (W)

as if the fans work near maximum of their volume output

coolant Qmax. It means that aerodynamic resistance Pmw
(external) Zm of inside circuit is equal near 0 and
Pmw-fit
energetic efficiency of fun ηe equals near 0. The losses of
40.00
one internal fan Pmwin are equal
Pmwin = 2pPmw in W (11)
where:
p - number of poles pairs;
Pmw - losses calculated according to formulas (2)-(10) 0.00
with taking into consideration the above remarks. 0.00 400.00 800.00 1200.00 1600.00 2000.00
Approximated formula (11) was invented on the rotation speed (rot/min)
experimental researches results basis. Fig. 2. Relationship between measured mechanical losses
and rotational speed in different states of motor 160 L-
D. Friction Losses of V-ring Seals 4B and their approximation

This kind of losses appears between rubber V-ring Windage losses of outside fan Pmw depend on third
seals and endshield. We can calculate them by formula: power of rotational speed. The sum of friction losses in
Ps = 52,33µFnds10−3 in W (11) bearings Pbe and friction air losses of rotor and windage
where: losses of two internal fans Pmwin depend on first and
µ - coefficient of friction the values of this coefficient second power of rotational speed in the same degree.
include in range (0,2-0,3), no unit;
B. Results of Measurements of Motors with Seals Different measured losses components in different
motors are presented on fig. 4. Generally external fan
There were carried out no-load tests on 24 motors in losses Pmw are the biggest in 2-poles (4 times than in 4-
normal, without of seals and without of seals and fan poles and 9 times in 6-poles) but in motors of size 160 2-
states. The results of these investigations are presented poles were applied special fans which have little losses
on fig. 3. Pmw so fans in 2-poles 160 motors have the same losses
like in 4-poles 160. Seals losses Ps are very diversified
180 L-6 without of seals and even in motors of the same time. The reason of scatter of
180 L-6 fan
160 L-6 results is caused by different values of force F in (11).
160 L-6 without of seals Losses Pbe+Pmwin show little correlation to rotational
132 M-6
132 M-6 speed. For example these losses in motors 132 M-2A and
normal in 132 M-4A are almost the same. Exception is motor
180 M-4
180 M-4 160 M-2B, which has bearings with big losses Pbe.
160 L-4
Type of motor

160 L-4 On fig. 5 are presented the part of different measured

132 M-4A losses components in total mechanical losses Pm of each
132 M-4A
100 L-4A motor. Generally in 2-poles motors the three components
100 L-4A have the same part in Pm (on 33 %). In 4-poles
180 M-2 predominate Pbe+Pmwin losses (about 50 %), Ps and Pmw
180 M-2 on 25 %. In 6-poles part of Pbe+Pmwin losses are the same
160 L-2
160 M-2B as in 4-poles but Ps 35 % and Pmw 15 %.
132 M-2A
132 M-2A
132 S-2B
132 S-2B 180 L-6
90 L-2 180 L-6
90 L-2 160 L-6
160 L-6
0 200 400 600 132 M-6
132 M-6
Losses (W) 180 M-4
180 M-4
160 L-4
Type of motor

Fig. 3. The results of mechanical losses measurements in 160 L-4

132 M-4A
different states of motors 132 M-4A
100 L-4A
100 L-4A
Total mechanical losses Pm depend on size of motor
180 M-2
and number of poles. Motors with 2-poles have Pm twice 180 M-2
bigger than 4-poles and 6-poles motors of the same size. 160 L-2
160 M-2B
Difference of Pbe+Pmwin (without of seals and fan) is 132 M-2A
considerably less and averages to 50 %. 132 M-2A
132 S-2B
132 S-2B
180 L-6 90 L-2
180 L-6 Ps 90 L-2
160 L-6
160 L-6 Ps 0% 25% 50% 75% 100%
132 M-6 Pmw
132 M-6 Pmw
Losses (%)
180 M-4 Pbe+Pmwin Pbe+Pmwin
180 M-4
Type of motor

160 L-4
160 L-4 Fig. 5. The part of different measured losses components
132 M-4A
132 M-4A in total mechanical losses Pm of each motors
100 L-4A
100 L-4A
180 M-2 B. Influence of the Mechanical Losses on Motor
180 M-2
160 L-2 Efficiency
160 M-2B
132 M-2A
132 M-2A The influence is presented on fig. 6. Generally the part
132 S-2B
132 S-2B of mechanical losses Pm in power input Pin is the biggest
90 L-2
90 L-2 in 2-poles motors. Top value in small motors is 2,7 %,
0 200 400 600
average value about 1,6 %. In 4-poles motor average
value is 0,8 % and in 6-poles motors about 0,6 %. The
Losses (W) part of mechanical losses Pm in power input Pin means a
part of these losses in efficiency of motor so the biggest
Fig. 4. Different measured losses components in different possibilities to increase of efficiency are in 2-poles and
motors small motors.
 180 L-6 250
180 L-6

Pbe+Pmwin (W)
160 L-6 200 measured
160 L-6
132 M-6 150 calcul.
132 M-6 100
180 M-4 50
180 M-4
160 L-4 0
Type of motor

160 L-4 160 160 160 160 160 160

132 M-4A
132 M-4A M-2 L-2 L-4 L-4 L-6 L-6
100 L-4A Type of motor
100 L-4A
180 M-2
180 M-2 Fig. 9. Comparison of Pbe+Pmwin losses values from
160 L-2 measurements and calculations
160 M-2B
132 M-2A
132 M-2A On fig. 7, 8, 9 are presented comparisons of results of
132 S-2B
132 S-2B measurement and calculation. The comparisons were
90 L-2 done for 160 size motors. Calculations were made by
90 L-2
formulas presented in section II.
0 1 2 3 The best agreement is achieved for Pmw losses, worse
Pm/Pin (%) for Pbe+Pmwin losses and the worst for Ps especially for 2-
poles motors. Reasons of discrepancy are in approximate
formulas and in less degree in results of measurements.
Fig. 6. The influence of total measured mechanical losses Formulas for different components of mechanical losses
Pm on motor efficiency in induction squirrel-cage motors with fan with radial
blades presented in this paper can be used to estimate of
C. Comparison of results of measurement and value of these losses components.
calculation
V. CONCLUSION
200
measured Mechanical losses are connected with complicated
150
calcul. aerodynamic and friction phenomena and it is necessary
Ps (W)

100 experimental verification.

50 Total mechanical losses Pm depend on size of motor
and number of poles.
0 It is possible to decrease external fan losses even four
160 160 160 160 160 160 times. This is shown on example of 160 size 2-poles
M-2 L-2 L-4 L-4 L-6 L-6 motor.
Type of motor The biggest possibilities to increase of efficiency by
decrease of mechanical losses are in 2-poles and small
Fig. 7. Comparison of Ps losses values from motors (to 1 point of % of efficiency).
measurements and calculations Formulas for different components of mechanical
losses in induction squirrel-cage motors with fan with
radial blades presented in this paper can be used to
70 estimate of value of these losses components and can be
60 measured used in design of this type of electrical machines.
50
Pmw (W)

calcul.
40 REFERENCES
30
20
10 [1] M. Dabrowski, “Design of electrical machines”,
0 WNT, Warsaw, 1997, (in polish).
160 160 160 160 160 160 [2] K. Dabala “Reduction of Stray Losses in Three
M-2 L-2 L-4 L-4 L-6 L-6 Phase Squirrel-Cage induction Motors”. Procc. of
Type of motor The Third Chinese International Conference on
Electrical Machines, Xi’an (China), August 29-31,
Fig. 8. Comparison of Pmw losses values from 1999, pp. 56- 59.
measurements and calculations

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