A Generalized Epstein Test Method for the
Computation of Core Losses in Induction Motors
AndrC G. TBrres
Universidade Federal de Minas Gerais
CPDEE
AV. Antonio Carlos, 662'7
Belo Horizonte, MG 31270-010 - Brazil
Atvtrnct- Modeling and deflnition of procedure:; leading
t o good estimation of core losses in induction motors from
material test data is still a challenge. Complex geometry of
the laminations, concentration of current in discrete num-
ber of dots and PWM inverter supply further inerease the
complexity of induction motor core losses model. In this
paper, it is proposed an alternative for the modeling and
computation of the stator core losses in induetior! motors
based on lab tests of samples of the magnetic
simple geometry. The proposed method accounts for effects
such as flux space harmonics, P W M inverter SUPPIY, mate-
rial anisotropy and cutting stress during the manufacturing
Models, methods and results from a
z hp, 220 v, 4 poie, high threephase induction
motor, employing E-170 steel, are presented and discussed
in detail.
Keywords- iron loss; induction motor; induction motor
design; variable speed drives.
I. INTRODUCTION
The Epstein test [l],is widely used whenever the quantifi-
cation of the losses per material volume of magnetic mate-
rials is required. Iron losses in any material can be grouped
.
in three categories [2]:
1. Histeresys Losses (af): The energy spend in the move-
.
ment of magnetic domain walls in the core magnetization,
2. Anomalous Losses ( a f ' , 5 ) :These loss are caused by
parasitic microcurrents with high frequency that circulate
around of the wall domain in the move of material magne-
.
tization,
3. Eddy Losses (af*): These losses are due to the current
circulation in the core induced by flux variation.
The Epstein test is based on establishing an alternating
magnetic flux (line,ar polarization) in samples, with sim-
ple geometry, from the material under investigatio:n. Since
these magnetic flux conditions correspond t o those found in
powcr transformers, good correspondence between calcula-
tions and measurements is obtained. However, such corre-
spondence is not observed for induction motors, where the
error from Epstein test results can be larger than 50% [3].
The flux distribution in induction motors is significantly
more complex than that in power transformers. The cur-
rent concentration in the stator slots distributed aiong the
stator periphery and PWM inverter supplies give rise to
space and time harmonic distortion in the magnetomotive
force (MMF). As result, harmonic flux distortion in all
magnetic path in the motor core, leading to an increase in
0-7803-7474-61021$17.00 02002 IEEE
Braz J. Cardoso Filho
Universitlade Federal de Minas Gerais
Depto. Engenharia Eletrica
AV. Antonio Carlos, 6627
Belo Horizonte, MG 31270-010
the iron losses [4], [Si,[6]. Metallurgical issues such as ma-
terial anisotropy (varying magnetic proprieties with respect
to the magnetization) and cutting stress (structural defor-
mation in the cutting region) also need to be included [7] in
the losses computation. The latter one further increase the
complexity of the problem at hand, since the magnetic ma-
terial will present different properties in different regions of
the motor core. There is an additional phenomenon which
further the discrepancy between the operating condition in
the core of power transformers and induction motors: mag-
netic flux of circular polarization [SI. Although the flux in
the teeth and in the " voke mesent
. linear Dolarization [radial
and tangencial directions, respectively), it is noted that at
the teeth roots a flux of circular polarization results from
the interaction of the former ones. Such differences point
out that alternatives t o the classic Epstein test suitable for
induction motors are needed.
Most of the work that has been done in this field can be
classified in two groups: experimental characterization and
electromagnetic modeling. In the first group, core losses are
characterized based on a large number of measurements,
performed under several operating conditions. Although
not suitable for the characterization of the magnetic mate-
rial in the steel plant, this approach includes the impact of
all issues pointed out earlier. The second approach is based
on searching detailed models of electric and magnetic pro-
prieties of the electric steel, implying the formulation and
solution of complex theorerical and computational prob-
lems. These two methodologies, in their present stage of
development, do not satisfy the industry demands which
.
include, but are not restricted to:
1. tests that reproduce the flux condition found induc-
.
tion motor,
2. characterization of losses based on low volume of ma-
.
terial samples with simple geometry,
3. set of curves allowing a close approximation of the
conditions found in the induction motor, including lamina-
tion geomet,ry issues.
This paper summarizes the results from a new approach
for characterization of the core losses in induction motors,
aimed at the main demands of the electric steel and motor
industries. The proposed approach is based on a general-
ization of the standard Epstein test. The flux conditions
observed in induction motors are reproduced using several
I150
 Oscilloscope

Power EPste'

Fig. 1. Implemented Measurement System

samples with simple geometry and non-sinusoidal excita- Fig. 2. Flux Density in the 2H.P. Motor (WEG)
tion. In this study, spatial harmonic, non-sinusoidal stator
voltage (PWM inverter), cutting stress and anisotropy ef-
fects are included in the characterization of the material TABLE I
performance. Models, measurement methods and results HARMONIC
AMPLITUDEOF FMM
obtained in the study of induction motor regions subjected
to magnetic flux of linear polarization are presented and
discussed in detail. Practical results were obtained from
E-170 steel samples and a three-phase, 2 HP / 22OV, high
180 Hz 19.26
performance induction motor, built with the same electri-
cal steel.

11. GENERALIZED
EPSTEIN
TEST
The standard Epstein test [l]does not include the effect
of the flux harmonics that exist in induction motors, since
sinusoidal excitation at the fundamental frequency is spec-
ified. To perform core loss measurements in electrical steel
samples under non-sinusoidal excitation, it was built an ap-
paratus based on the Epstein square in which the excitation
MMF is synthesized using a microcomputer and an low dis-
tortion audio power amplifier, depicted in fig. 1. Voltage
and current data were acquired using a TDS3054 oscillo-
scope (9-bit vertical resolution). The loss measurements
obtained from this apparatus are within a +l%range for
flux densities in the range from 0 , 3 T to 1,5T, as compared
t o the results obtained from the BrockHaus test system
(ACESITA Research Center).
111. M M F SPACEHARMONICS
The main magnetic flux path runs through various stator
core regions with widely variable geometry. Large discrep-
ancies in flux density and core losses result from motor
geometry and space flux distribution, as shown in fig. 2.
In fig. 2, the motor stator winding is distributed in 36
slots. This discrete current distribution gives rise to MMF
space harmonics. Table I list the space harmonics ampli-
tudes of the stator MMF assuming sinusoidal stator cur-
same relative amplitude between the harmonics and funda-
mental is assumed for the teeth and yoke mmf. Although
the air-gap MMF profile can he shown to be a good approx-
imation for the MMF drop in the stator teeth, the same is
not necessary true for the stator yoke. Air-gap MMF profile
is used here as a fist order approximation of the MMF drop
ou the yoke. Figure 3 shows the results for E-170 silicon
steel sample (from ACESITA), including space harmonics
effects. An increase in the losses in the magnetic material
of about 19% is observed at l . 0 T (average fundamental
component flux density).
Most of the losses in the motor core is due to histheresys.
Histheresys cycles arc exhibited in fig. 4 for E-170 silicon
steel with fundamental flux density amplitude (average)of
1.OT (60Hz), with and without the addition ofMMF space
harmonics effects.
IV. P W M INVERTER
SUPPLY

rents [4].
The effects of the MMF space harmonics are reproduced
in the generalized test setup t,hrough an equivalent MMF
synthesized from non-sinuidal currents wit,h suitable har-
monic content. The air-gap MMF frequency spectrum for
the motor analyzed in this paper is shown in table I. The
The inverter output voltage harmonic content gives rise
t,o stator current and MMF dist,ortion. In this case, how-
ever, such MMF distortion is due to time harmonics in the
stator current waveform.
The spectral energy in the inverter output voltage is con-
centrated a t the fundamental frcquency and at the switch-

1151
 Fig. 3. Iron Losses with Harmonics in FMM
Fig. 4. Histheresys Cycle Iron Losses With Harmonics in FMM
ing frequency and its harmonics. One could expect a sig-
nificant increase in the core losses in this case, considering
the high frequency of the MMF harmonics, in the several
kHz range.
The effects of the PWM inverter supply on the core losses
were studied by providing the excitation of the Epstein
square through an industrial P W M inverter. It is impor-
tant to point out here the need of a variable dc bus volt-
age to allow independent variation of the modulation index
and the amplitude of the fundamental component of the
inverter output voltage. Fig. 5 shows an increase in the
losses of E-170 steel samples with the PWM invert.er used
as the Epstein square excitation source. The inver1,er used
in this study is a CFWO9, Vectrue Technology, from WEG,
madified for variable dc bus voltage operation.
v. LAMINATION
CUTTING STRESS
The stator lamination of the induction motor has a com-
plex geometry which includes teeth, yoke and possibly ta-
pered slots. The cutting process introduces stressea in the
material that deteriorate its magnetic properties.
The quantification of the effects of the cutting stress over
a portion of the core material is made possible through the
generalized Epstein test. Non-conventional prepared from
1152
Fig. 5. Influence of the Frequency Inverter in the Iron Losses E-170
(ACESITA)
Fig. 6. Drawing of Stator Blade 2 H.P. Motor, Plus (WEG)
standard Epstein test samples are needed in this case. The
standard samples are cut down their length in stripes with
tooth and yoke width. For characterization of the yoke
region, each of the standard Epstein samples (3.0cm width
x 30.5cm length) were cut in three l.Ocm width x 30.5cm
length samples. The total material volume is the same one
used in the standard test.
Fig. 7, shows an increase in the losses in the samples
reduced to the dimensions of the stator yoke. Figure 8,
exhibits histheresys cycles for 1.0T (fundamental compo-
nent). It can be verified a significant reduction in the ma-
terial permeability as a result of the cutting process, and
significantly higher excitation currents are required to ob-
tain the required flux density.
The cutting stress effect on the tooth region was evalu-
ated by cutting each of the standard Epstein test samples
into eight 3,75 mm x 3O,5 cm samples, also keeping constant
the total volume of material. The core losses increase fur-
ther in this case, since the ratio of the area of the cutting
region to the volume of the material is increased (fig. 9).
As a result, losses in the core teeth are higher than the
losses in the core yoke even if both regions work with the
same flux density.
VI. ANISOTROPI
The electric steel has different properties for different
directions of magnetization with respect to the rolling di-
 Fig. 10. Anisothropy Influence Iron Losses of E-170
Fig 7. Influence of the Cutting Stress in the Iron Losses of Core
E-170: Strips 3 x (1,Ocm x 30,5cm)

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 TABLE I1
INFLUENCE O F CONSTRUCTIONS ClIARACTERISTlCS OF INDUCTION
Fig. 12. Anisothropy Influence in the Histheresys Cycles of E-170:
Stator Matrix Blade
1 I54
MOTORSIN ITS IRON LOSS
of constant, flux density. Gives PLoss=23;24 W. Recogniz-
ing different flux densities in the core, the computed core
loss is 19,85 W. In these two cases, the calculated loss is
significantly lower than the figure obtained from the stan-
dard induction motor test procedure: Ploss=68,1 W. It is
important to point out that in the standard test procedure
[ll] [12], the losses in the rotor bars due harmonics in the
air gap flux are not segregated from the core losses. As a
result, the figure for the core loss obtained from the stan-
dard test procedure is expected to be larger than the real
one. Table I1 summarizes the results for the core losses
following the classical approaches described above and the
procedure present in this paper.
VIII. CONCLUSIONS
The investigation of the core loss in induction motors
considering the conditions found in the regions subjected
to linear polarization flux, show clearly that the traditional
material characteristics from the standard Epstein test are
insufficient for a proper design of an induction motor.
The use of PWM inverter supply adds even more com-
plexity to the problem. The approach present in this can
be characterized as an extension of the standard Epstein
test t o include the particular characteristics of the induc-
tion motor magnetic circuit. It is important to note that
a suitable set of plots, allowing a closer approximation of
the operating conditions paper of induction motors can be
obtained from material samples of simple geometry.
Further study is still required for proper definition of
the core loss computation methodology. Continuing efforts
include the characterization of the MMF drop or teeth and
yoke, definition of the suitable set of curves for induction
motor analysis and design, methodology to account for the
effects of flux with circular polarization, among others.
ACKNOWLEDGMENTS
The authors are to Dr' da
Cunha, from ACESITA, for the E-170 silicon steel s a -
ples and technical and financial support from ACESITA;
to Mr Sebastiio Nau, from WEG Motores, for the induc-
tion motor and motor parts and t o Mr. Norton Petry, from
WEG Automa@o, for the frequency inverter used in this
study.
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APPENDICES
Parameters of 2 c.v., Plus, (WEG) in table I11
TABLE 111
INDUCTION MOTORPARAMETERS

1155