Analysis of Siingle-Phase Induction Motors

M
withh Centrifuged Rotors
Claudia. A. da Silva, Gersson B. Gibelli, Josmar F. Pereira, Alex Alvey, Renato Carlson

improves the quality and efficiencyy of induction motors and

Abstract—The centrifugal casting process is a recognized was largely used in the past in large integral horsepower
technology that improves the quality and efficiiency of induction motors [6-7]. Recently this processs caught the attention of
motors and was largely used in the past in large integral small induction motors manufacturrers and was implemented
horsepower motors. Recently this process caught the attention of
by some hermetic compressors manu ufacturers [8].
small induction motors manufacturers and waas implemented by
some manufacturers of hermetic compressoors for domestic This paper analyses the effect of centrifugal casting process
refrigeration. Although some benefits of the ccentrifugal casting on the efficiency of single-phase innduction motors. First are
process are the same in small and large inductioon motors, there is presented detailed information of centrifugal
c casting process
one important contribution that is more pron nounced in single- and next experimental results ob btained with single-phase
phase motors without run capacitors and it w ill be discussed in induction motors with and without run capacitor.
this paper. This work presents information of ccentrifugal casting
process and experimental results obtained withh induction motors
with and without run capacitor. II. THE CENTRIFUGAL CA
ASTING PROCESS

A. Main characteristics
Index Terms— centrifugal casting, efficiency,, induction motor
The traditional high pressure castt (horizontal or vertical) is
I. INTRODUCTION the most widely used process to produce induction rotors.
Generally speaking, the injection machine
m has one fixed and
A ccording to international Energy Ageency and United
Nations Industrial Development organizzation the electric
motor driven systems account for up to 466% of all global
one movable mold as shown in n Fig.1. The rotor stack
lamination is put inside the cavitty of movable mold that
electricity consumption [1-2] and althoughh different motor couples the fixed mold resulting in a rotor cage forming area.
technologies are available in the market, the induction motor
is still the most used. Although the motoor systems were
submitted to energy efficiency policy in rrecent years it is
known that there is still considerable opportunnity to reduce the
electricity consumption by investing in moree efficient motors
or installing inverters to control the inducttion motors. The
permanent magnet motors came to rest but thheir cost is still an
important barrier to have them largely replaccing the induction
motors in a short time. Additionally, the use oof high efficiency
steel, copper rotor, reduced slot opening and ccentrifuged rotors
have been greatly evaluated by the iinduction motor
Fig.1. Simplified view of a standard high pressure injection machine
manufacturers since they help to reach higherr efficiency in the
actual product with only some changes in thhe line production The aluminum is injected (shot) in one end of the rotor only
[3-5]. The centrifugal casting is a recognizedd technology that (fixed mold), passing through the axial
a channels (rotor slots)
of the lamination stack and goes to
o the end of movable mold
Claudia. A. da Silva is with Tecumseh Company, R& &D Department, Ann to form the another end ring. In thiis process the aluminum is
Arbor, MI, 48-108, USA (corresponding author phonee: 734-585-9609; fax: injected a high pressure and high sppeed that create turbulence
734-352-3714; e-mail: claudia.silva@tecumseh.com).
Gerson B. Gibelli is with Tecumseh do Brasil, R& &D Department, Sao in the flow of aluminum and consequently gases that remains
Carlos, S.P, 13570-820, Brazil (e-mail: gerson.gibelli@teecumseh.com). entrapped during the solidificationn. This entrapped gas and
Josmar F. Pereira is with Tecumseh do Brasil, R& &D Department, Sao also the contact of aluminum with grease and release agents
Carlos, S.P, 13570-820, Brazil (e-mail: gerson.gibelli@teecumseh.com).
Alex Alvey is with Tecumseh Company, R&D Deppartment, Ann Arbor,
that are used in the molds create metallurgical defects (voids)
MI, 48-108, USA ( e-mail: alex.alvey@tecumseh.com). and aluminum oxides in the rotorr cage. That results in an
Renato Carlson is with Technological University of P Parana, Ponta Grossa, aluminum cage of lower conductiviity (higher resistance) that
P.R, 84016-210, Brazil (e-mail: renato.carlson@gmail.coom).
impacts the motor performance. Ad dditionally the high speed
and high pressure of aluminum rem move the internal protection
of rotor slot (bluing oxide) and gen
nerates a hot metalizing in
this area (the aluminum clings the rotor lam minate) that means
there is an electrical contact between the alum minum rotor cage
and rotor stack. The currents that are gennerated due such
contact of cage and steel are called inter-barr currents and the
effects of such currents have been largely discussed in the
literature last years [9-10]. Since this electriccal contact affects
the motor performance an additional heat treatment
(annealing) is usually made in the final rotor in way to detach
the aluminum bars of rotor stack.
In this casting process it is necessary the uuse of gates in the
injection machine to fill the rotors with alum minum. When the
injection step is finished the aluminum thatt remained in the
gates (scrap) and shown in Fig. 2 needs to bee taken out. Since
the metallurgical efficiency in this process is 50% (the scrap
represents half of aluminum volume necessarry to produce the
rotor) this remaining aluminum is normally reused (added in
the aluminum melting furnace). The reuse off aluminum scrap
is important economically in the total mottor cost however
impacts the motor efficiency since the sccrap (even after
possible cleaning process) still has entrappeed gas and other
impurities that will be added in the aluminum m melting furnace.
Fig.2. View of high pressure die casting gates and the aluuminum scrap
The centrifugal casting is a form of low pressure casting
that offers distinct advantages regarding the hhigh pressure one.
In this process the rotor lamination stack, witth its longitudinal
axis vertically disposed is positioned in the iinterior of a mold
that defines a lower annular cavity close to thhe external face of
the lower end lamination and upper cavity cloose to the external
face of the upper lamination. The upper cavitty is substantially
cylindrical or conical opened to a channel for the entry of
aluminum into the mold as shown in Fig.3.
Fig.3. View of a centrifugal casting machine and some paarts
After the rotor is coupled in the lower mold (manually or
automatic) the set (rotor plus mold)
m is moved up by a
suspension system and coupled to the upper mold. The axial
system where the lower mold is fixedf starts spinning. The
ladle with liquid aluminum starts po
ouring the aluminum in the
upper cavity as shown in Fig. 4. To compensate for the lack of
pressure and low velocity of alumin num, the rotor pack is pre-
heated at specific temperature. Th he aluminum flow rate is
calculated to allow the solidification front always meet
aluminum liquid to compensate th he contractions and suck
back. The aluminum pass through the axial channels of the
lamination stack to the lower cavity, filling the latter, the axial
channels and the upper cavity, in th
his order, and solidifying in
a radial inward upward pattern, as the mold rotates around it
vertical axis and the metal cools.
Fig.4. View of centrifugal machine - aluminu
um pouring
Upon the completion of aluminum a pouring and
solidification the set stop spinning and
a the suspension system
down to original position. The rotorr is then taken out from the
mold and goes to more one or two t simple operations of
finishing (eliminating of gates and if necessary some
brushing). The gate scrap is shown ini Fig.5. In the centrifugal
casting process the metallurgical effficiency is 90% (the scrap
represents 10% of aluminum volum me necessary to produce the
rotor). In this process the annealinng to detach the aluminum
from rotor steel stack is not necessary. The low pressure and
better contraction of aluminum allows
a a better insulation
between aluminum and steel.
Fig.5. Gate scrap for centrifugal casted rottor
The resulting of centrifugal castting process is a rotor of
high quality due to absence of shrin
nkage porosity as shown in
Fig. 6 that improves the bar conducttivity and consequently the
motor efficiency. The Table I show some results obtained with
parts of rotor having 60 mm of external diaameter and stack
length of 50 mm for high efficiency motors, llike those used in
hermetic compressors.
Fig.6. Microstructure analysis of rotor parts-Die Casteed and Centrifugal
B. Process Performance Analysis
As presented before the centrifugal castiing has a higher
metallurgical performance when compared to the standard
high pressure casting. Although motor mannufacturers try to
reuse as maximum as possible the aluminuum scrap of high
pressure cast there are always loss of materiall and additionally
it is necessary clean the scrap and that m means additional
process cost. Another gain is the use of a smaaller rotor stack to
have a final finished rotor as shown in Fig.7.
Fig.7. Rotor pack necessary for 50 mm finished rotor
The high force that happens durring the high pressure cast
(up to 50 Tons) requires a rotor lamination pack up to 5%
larger than the one to be used in thhe centrifugal casting. The
suppression of rotor heat bluing, rottor annealing after casting,
longer life time of cavities represen
nt also additional reduction
cost of centrifugal casting when co ompared to traditional cast
as presented in Table II.
III. EXPERIMENTAL
L RESULTS
A. Dynamometer Results
In way to evaluate the benefiits of centrifugal casting
process some prototypes of rotors were built and tested. All
was done in way to eliminate posssible variables during the
study and then the following care were taken: all core pack
rotors are of same length and same turnaround, same
aluminum, same standard rotors and d dynamometer tests made
by the same person and at same tiime. Motors with run and
without run capacitor were testeed with centrifuged and
standard casted rotors of Fig.8. Th he standard stator of each
motor model is used to test five stan ndard high pressure casted
rotors and five centrifuged rotors in dynamometer.
The first motor tested is a single-p
phase, 2 pole, 220V/50 Hz,
1.23 N.m and without run capacitorr. The dynamometer results
are presented in Table III and show w that the use of centrifugal
casting improved the motor efficiency in 2..5% and also the
maximum torque of main winding in 2.8%. T he starting torque
decreased in 1.25% as a result of lower rotor rresistance.
The second motor tested is a single-phase,, 2 pole, 115V/60
Hz, 1.26 N.m with run capacitor. This motor did not show the
same tendency in gain of efficiency. The improvement in
efficiency was only 0.23% when comparedd to the standard
motor and the improvement in maximum torqque was of 1.4%.
The starting torque was reduced in 3% due lower rotor
resistance.
Fig.8. High pressure and centrifugal casted rotors
As already presented before, one impoortant benefit of
centrifugal cast is the reduction of rotor baars and end ring
porosity and consequently the increase of thheir conductivity.
How much the conductivity of such parts willl increase will be
dependent on quality of original aluminuum casted rotor.
According to a commercial manufacturerr of centrifugal
casting machines the increase of conductivvity can reach up
10% (cases where the original cast motors are not of high
quality) [11]. The other big benefit of centrifuugal casting is the
better insulation between laminates and lamiinates rotor-cage.
It is well known that the use of distributed sslots and winding
in induction motors lead to harmonic leakagee flux (ripple) that
generates several types of additional losses [12]. Some parts of
leakage flux remain in the surface of the rrotor and internal
surface of stator and generates the calledd surface losses.
Another part of such leakage flux penetratees the rotor teeth
and links the rotor cage. Each rotorr tooth is surrounded by a
high conductivity damper circuit which opposes the ripple
flux. There is a significant damping action which tends to
reduce the ripple flux penetration intto the teeth but resulting in
appreciable induced current losses in the rotor cage. If the
inter-bar and inter-laminates resistannces are low, the pulsating
flux generates high currents that cannot
c generate torque but
only losses. Following the basic motor
m theory, the pulsating
losses are proportional to the squaare of pulsating amplitude
divided by the resistance (Vp2/R).. Since in the centrifugal
rotors the inter-bar and inter-lamin nate resistance tends to be
infinite (close to perfect insulation) these pulsating losses will
tend to zero and represent an imp portant reduction of rotor
losses. The motor with run cap pacitor will work as an
equilibrated two-phase motor and d consequently have less
pulsating losses than a motor withou ut a run capacitor. Then the
use of centrifugal casting tends to t show larger rotor loss
reduction in single-phase motor with hout a capacitor.
However it is also important to remember that motors have
several types of losses (stator joulee losses, rotor joule losses,
steel losses and so forth) and their impact in motor
performance will be strongly depend dent of motor power range.
Consequently the benefit of centrifu ugal casting may vary also
depending of motor size. Table V sh hows results obtained with
a 2 pole motor, 115V/60 Hz, 0.28 N.m N with run capacitor. The
gain in efficiency in this motor tessted with centrifuged rotor
was of 0.6% when compared to standard motor. Another 2
pole motor, 115V/60 Hz, 1.72 N.m without run capacitor was
also tested and the gain in efficiencyy in this motor when tested
with centrifuged rotor was of 1.0% as a Table VI.
B. Calorimeter Results
As already presented the electrical motors represent a high
percentage of total electrical energy
y consumed worldwide and
some appliances as refrigerators an nd air conditioners became
the goal of international legislaations that require more
efficiency of such appliances. Maanufacturers look then for
new opportunities to improve the efficiencyy of refrigeration
systems and push hermetic compressors mannufactures to have
more efficient products.
fugal casting in a
In way to evaluate the benefit of centrifu
final application the motors of Table IIII and IV were
assembled in single-phase hermetic reciprocaating compressors
as the one presented in Fig.9. The compressoors were tested in
calorimeter at nominal condition of applicatioon and results are
presented in Table VII and VIII. It is posssible to see that
compressors using motor with centrifuged rootors presented a
higher efficiency than one using motors with the standard high
pressure casting. This higher efficiency w was expected due The authors thank to all people evolved
lower power consumption already shown in tthe dynamometer Tecumseh do Brasil and also Mr.
results. The increase of speed of motor in thee application also Tecumseh Europe who devoted a huge time testing the
helped to improve the efficiency because the compressor motors. Sincere thanks also to Mr. Rivio
removes more heat from the cabinet of refrigerator. Metsa Industrial that supplied in nformation of centrifugal
Refrigerating capacity is measured in Wattts, Kcal/hour or casting process.
Btu/hour according on test condition (ASHR RAE or ARI)[13-
14]. The increase in efficiency of compresssor of Table VII
without run capacitor and using the centriffuged rotor is of [1]
3.2% regarding the standard one that uses hhigh pressure cast
rotor. The compressor that uses capacitor hhad only 2.2% of
gain in efficiency but this gain is associaated more to the
increase of capacity (higher speed) than reeduction of input [2]
power.
The use of centrifuged rotors shows anothher benefit in the
final application. Since the input currents ttend be lower in
[3]
such motors the winding temperature of com mpressors tends to
be reduced when compared to standard one using high
pressure cast rotor. The compressor of Table VII with
centrifuged rotor did show a main windingg temperature of [4]
95oC and the one with normal high pressuree cast did show a
temperature of 99 oC. The lower temperaturre of operation is
very important to final product.
[5]
[6]
[7]
[8]
[9]
[10]
Fig.9. Hermetic reciprocating compressor used in refrrigerator
[11]
[12]
[13]
[14]
ACKNOWLEDGM
MENT
e in such research at
M Remi Kropfeld from
R Arturo Ramirez from
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