Jnfernetional Colloquium on Rotating Electrical Machines (Under the aegis of CIGRE Study Committee A1), @agre Susteren India Development of Premium Efficiency IE3 Class Induction Motors using Same Stampings of High Efficiency IE2 Class Induction Motors S.J. Barot, R.P. Singh and Dr. S.H, Chetwani Electrical Research and Development Association, Vadodara ABSTRACT Government of India issued gazetted notification to use minimum IE2 efficiency class induction motors in all new industrial plants. Presently 1E3 class induction motors are being manufactured only by large ‘manufacturers and a few companies in India. Small and medium motor manufacturers are facing challenges {0 develop and manufacture IE3 class induction motors due to considerable investment in R&D and lack of engineering capabilities for manufacturing. Development of lE2 class induction motor requires basic changes like CRNO steel grade, increased volume of CRNO and increased volume of copper. Whereas development Of IES class induction motor requires redesigning of windings, stamping profiles, stamping dies, end rings and die cast moulds. Bearings, tooling, pattems of main body, end covers and machine fixtures need to be replaced as per new design. This is a challenge for small and medium manufacturérs in terms of time and financial investment. General difficuties faced by Small and medium motor manufacturers during design and development of IE3 class inductions motors, are covered in this paper. Changes in manufacturing process and precautions in ‘material selection for developing IE3 class induction motors are also discussed. Standard approach of reducing the losses of IE2 class induction motor is followed and how the losses are reduced is also covered. Keywords : 1E3 class induction motors, rotating machines, motor design optimization, winding design, ‘MSME, material selection for induction motor, Finite Element Analysis (FEA), ANSYS Maxwell 1. INTRODUCTION The market for low-voltage motors has been segmented into North America, Asia Pacific, Latin America, Europe, and Middle East & Africa. Asia Pacific is estimated to be a dominant region, followed by North America and Europe during {he forecast period - 2016 — 2021. Emerging economies such as India and China are expected to witness growth of the ‘pve-voltage motors market, due to the rising demand for low-voltage motors in automotive and electronics industries in {he,twe countries. Furthermore, stringent regulations regarding motor efficiency and retrofilting of aging equipment are factors likely to increase the demand for low-voltage motors during the forecast period. IE2 efficiency class induction Molors are now made mandatory for new installations in India. IE2 class motors shares a huge market and there is ore predictive share of IES class motors in next few years. From small and medium motor manufacturers’ point of view, design and development of IE3 class induction motors Peauites big investment in time and money. There would be expenses of new dyes, hydraulic press and relevant {Ranufacturing facities to be able to develop IES class induction motors. A possible way to overcome investment in time and money is to develop IES class induction motors from existing stamping profile of IE2 class motors. Small th medium manufacturers can reduce a large part of the investment by using same stampings of IE2 motors as they are easily available in market at competitive price and will not require new stamping dies. To achieve |E3 class Gicloncy using same stampings, 03 Nos. of 415 V, 4 Polo, 3 Phase 1.5 kW, 2.2 kW and 3.7 kW IE2 class molors ate redesigned at ERDA. Losses of IE2 motors were reduced by changes in design of windings, CRNO steel grade, aig, lenath and end ring dimensions using Finite Element Analysis. Losses were also reduced by using better quality Sluminum than that used for IE2 motors and by mechanical improvements. New designed motors were manufactured @ta small manufacturing facility and few variations were observed in designed and manufactured samples. Based on Ihe observed anomalies, manufacturing process were changed to achiove desired prototypes. 772 2. DESIGN OF IE3 CLASS INDUCTION MOTORS 1E3 class induction motors of ratings 415 V, 4 Pole, 3 Phase 1.5 KW, 2.2 KW and 3.7 kW were designed using same stampings of IE2 class induction motors using ANSYS RMxprt software followed by Electromagnetic analysis in Maxwell software. All three motors are aluminum rotor motors. Steel grade selection was done based on the performance requirements, 50C350 grade CRNO was selected for three induction motors based on the performance requirement of IE3 class. Fixed watt losses of steel needed to be reduced as there was no flexibility in changing the slot area of stator and rotor. Changing the area of slots would require new stamping profile and hence new dyes. Therefore, 50C350 grade CRNO steel was selected considering the balance between cost and performance. Induction motor design was carried out considering IS 12615:2018 specifications'", Increasing the slot fll factor is one of the key factors to optimize performance using existing slots. Increased volume of copper helped reducing the FR losses of windings. Motors were designed using slot fill factor of around 0.8 including insulation thickness of conductors. Winding design was cartied out in such a way that core length of stator and rotor becomes minimum. Total No. of conductors per slot and total No. of strands per conductor are ‘selected such that the balance between FR losses of windings, winding rated current, magnetization current of core and starting current stays minimum. Winding design is carried out to keep adequate rated torque and starting torque. Winding diagram is shown in Fig. 1 for in and out slot of conductors. COverhung length of designed motors were reduced in length and were kept minimum considering bulk manufacturing feasibility. Motors were designed with radial airgap of 0.25 mm (single side air gap length) for better efficiency and performance. Remaining performance of the motors was fine-tuned by designing cast aluminum end rings. Cross section area of end ring was designed to keep the starting performance of the motors within the limits. All Fig. 1 : Winding diagram ‘mentioned parameters helped reducing total losses of three motors and hence thermal performance of motors is improved. Fig. 2 to 4 shows the torque - speed characteristic of newly designed motors. Starting performance of the motor was ‘optimized by tuning the No. of tums & strands and core length. el soe Fig.2: Torque vs speed 1.5K Fig. 3; Toruo vs speed -2.2kW I Fig. 4 : Torque vs. speed - 3.7 KW73 Electromagnetic Finite Element Analysis ~ FEA was carried out for new designed motor in ANSYS Maxwell software. “Motor designs were tested in FEA for the flux density distribution, losses and starting performance of three motors. Fig. 5 to 7 show the Electromagnetic FEA of three motor designs. Fig. 7 :B plot - FEA of 3.7 kW motor Table 1 : Analytical designed values Designed Values Si Neo,.| Raseinaes, 15 kW 22kW 3.7 kW 4 Efficiency (%) 85.3 86.86 88.45 2.__| Speed (rpm) 1427 1445: 1442.00 3. [PF 0.854 0.857 0.89 4___ [FL Phase Current (A) 281 4.04 3.72 5. [Noload Current (A) 1.27 174 1.25 6. __| Stator Wag. Resi. (0) per Phase at 20°C 3.82 2.39 3.70 7___ [Starting Torque Ratio 281 2.58 278 &__| Starting Current Ratio 6.58 7.22 758 9, | Stator Copper Losses (W) 110.7 742.34 187.15 10. _ [Rotor Losses (W) 76.86 84.28 149.48 11.__ [ron Core Losses (W) 35.97 52.59 70.28 12. __|Fric. Wind. Losses (W) 7.86 13.76 17.03 13.__ | Stray Losses (W) 2 39.6 59.20 Total Losses (W) 332.54 483.454 Table 1 shows designed values of three motors al rated operation. Designs were developed considering bulk manufacturing feasibllty of the motors such as stacking factor, slt fill factor, overhung length and air g@P. 3. ANOMALIES AND REMEDIES Few variations were observed in designed and manufactured samples. Variations were in terms of matertais ang oe acai process. Following changes in manufacturing practices of 12 motors were suggested to achieve IES class efficiency: + Increasing slot fil factor upto 80% + Use of proper steel grade + Precautions to avoid porosity in aluminum die cast + Minimum taper in end rings + Uniform air gap along the core length + Possible reduction in overhung length + Uniform conductor distribution in overhung winding + Precautions to maintain stacking factor upto 95% increasing slot fill factor upto 80% : IE2 class motors generally does not require as much copper as IES class olor ie tove IE class efficiency using same stamping profile, increasing slot fil factor is only way to oreate balance Teietoon copper and core sted in 1E3 class motors. Slt fl factor was kept around 0.8 (including Conductor insulation thickness) considering the bulk manufacturing at cost of some increase in effort to insert windings in slo Use of proper steel grade : CRNO steel grade was suggested to be tested to check core losses af 1.5 1 value. CANO cheat test resulls to be compared with IEC 60404-8-4:2013 to verify the steel grade®. High toss CRNO steel Stade increases the magnetization curent ofthe circuit and the watt losses ofthe motor. Hence stee! grade ccheok for prototype manufacturing was suggested to manufacturer. Precautions to avoid porosity in aluminum die east : Porosity in aluminum die casting increases the resistance of tho sator coult, Poor conductivity of cast aluminum along with porosity makes the rotor cicult even more resistive while round be inductive forthe better performance. It decreases the speed of motor and increases the rated input current ee eee creased rated current leads to higher stator copper losses and henco reducing the thermal performance and Shreloncy of the motor. Taking precautions in aluminum die casting process and better quality cast aluminum reduces the rotor resistance, all the anomalies can be reduced to a beneficial level. Minimum tapor in end rings : Higher taper eventually increases the lrgap in overhung portion ofthe windings: Non uniform airgap in overhung portion increases the stray loss contribution. Higher taper in end rings means lesser rose aanan area of ing which leads to increase in resitivily ofthe rotor circuit, hence i was suggested to use minimum taper for 1E3 class motors. Uniform air gap along the core length : Uniform air gap along the core length inereases the power factor and performance of the motor. Motors are designed with 0.25 mm racial ar gap (single side a gap) and t wes suggested ert ahe air gap should be uniform in the prototype motors. Visible scratched on rotor surface and on surface of si 4 teat fadiestng the fiction between rotor and stator Indicates non-uniform air gap. Italso increased friction losses ofthe rae easy’ Considering the visible soratches, manufacturer was suggested fo maintain 0.26 mm air gap throughout ‘core length and to check bearing alignment in prototype motors. Possible reduction in overhung length : Increase in overhung length increases the length of the windings and hence Freveasing the resistance. It was suggested to keep overhung maximum up to 27 to 36 mm for three motors. Uniform conductor distribution in overhung winding : Uniform conductor distribution of conductors in overhung portion created uniform electromagnetic field in the vicinity. Non-uniform distribution of conductors creates non-uniform: Electromagnetic fold and leads to increased stray loss component of total losses. It was mentioned fo ‘manufacturer © keep uniform conductor distribution. Procautions to maintain stacking factor upto 95% : Suggestions were given to manufacturer to maintain at leas! (0.95 stacking factor for core to control core loss component.75 4, CONCLUSION ‘As per percentage contribution of losses, remedies were suggested to the manufacturers. CRNO steel grade, stacking factor and slot fil factor were taken care for reduction in iron and copper losses. Porosity in aluminum die cast and poor conductivity of aluminum used for casting increases rotor conductor losses. Increased resistivity of rotor makes the circuit more resistive instead of inductive, which increases stator copper loss due to increased rated current, Reduction jn overhung reduces total length of conductor leading to reduced I2R losses. Precautions for uniform distribution of ‘conductors in overhung winding were implemented to limit stray losses. Minimum taper in end rings were suggested to maintain uniform airgap in overhung portion to minimize stray losses. By taking proposed precautions in manufacturing, small manufacturers are now able to manufacture IES class induction motors using IE2 class motor stampings without any capital Investment in manufacturing facility. Approx 10 — 12% increase in manufacturing cost of IE3 class motor would occur compared to IE2 class motor's manufacturing cost due to low Watt loss CRNO steel and increased volume ‘of copper. Using the same frame sizes and stamping profiles, 85.3% IES class efficiency is achieved for 1.5 kW motor against 82.8% IE2 class efficiency and 86,86% IE3 class efficiency is achieved for 2.2 KW motor against 84.3% IE2 class efficiency. Similarly 88.45% IES class efficiency is achieved for 3.7 kW motor against 86.3% IE2 class efficiency. BIBLIOGRAPHY 4, IS 12615:2018 - Line operated three phase AC motors (IE code) “efficiency classes and performance specification” 2, IEC 60034-30-1:2014 - Efficiency classes of line operated AC motors (IE code) 8, IEC 60404-8-4:2013 - Specifications for individual materials - cold-rolled non-oriented electrical ste! strip and sheet delivered in the fully-processed state