E422: ELECTRICAL DRIVES II

STANDARD SQUIRREL CAGE INDUCTION MOTOR (SCIM) DESIGN AND

PERFORMANCE

Introduction

The behaviour of an induction motor at different loads is different. The graphical representation
of various quantities of an induction motor with respect to its output represents its performance
curve.

Performance curves of 3 phase squirrel induction motor .

1. Speed-output characteristics: The speed-output (or slip-output) characteristics of a 3-

phase induction motor is shown in the figure below. It shows that the speed of the motor
decreases slightly from no-load to full-load but slip increases. Hence, it is almost a
constant speed motor, similar to a DC shunt motor.

2. Power factor characteristics: The power factor-output characteristics of a 3-phase

induction motor is shown in the figure below. At no-load, motor draws magnetising
current Imag which is very large component due to high reluctance of the air-gap and no-
load current Io lags behind the voltage by a large angle and thus power factor of the motor
is very low at no-load. As the load increases, motor draws more current from the supply
to meet with the load and the percentage of magnetising current component decreases
with respect to the total load current drawn by the motor and thus power factor improves
and goes on improving with the load, as shown in the figure.
3. The efficiency–output characteristics of a 3-phase induction motor are shown in
figure below.

Under operating conditions, at any load, there are certain fixed losses (such as iron losses
and mechanical loss) and variable losses i.e., stator and copper losses which vary as
square of the load. At light loads, fixed losses are more in comparison to variable losses
whereas, at heavy loads (near to full load) variable losses are more in comparison to fixed
losses. However, at certain load fixed losses are equal to variable loss. At this load the
efficiency of the machine is maximum. Thus, at light loads efficiency in low but increases
rapidly in the earlier stages becomes maximum and then again decreases as shown above.

4. Stator current characteristics: The stator current–output characteristics of a 3-phase

induction motor is shown in the figure above. At no-load, motor draws current to meet
with the losses and to set-up magnetic field in the core and air-gap which is nearly 20 to
30% of full-load which may be more for small motors. When load on an induction motor
increases, slip increases and motor draws extra current from the mains. Because of high
value of magnetising current this curve is not a straight line curve.

Factors Governing Performance of Induction Motors

The performance or characteristics of an induction motor are governed by its

(i) Rotor resistance,

(ii) Air-gap length

(iii) Shape of stator and rotor slots and teeth.

(i) Rotor resistance: Adding rotor resistance to an induction motor improves its starting torque
by increasing the magnitude of rotor current during the starting period. This increase in current
leads to a stronger rotating magnetic field, which in turn enhances the torque produced by the
motor.

Induction motors operate based on the principle of electromagnetic induction. They consist of
a stator, which creates a rotating magnetic field when supplied with three-phase AC power,
and a rotor, which is designed to turn due to the interaction with the stator's magnetic field.

During the starting process, when the motor is initially powered on, the rotor tends to be
stationary or at a very low speed. In this state, the rotor current induced by the rotating magnetic
field is low, resulting in a relatively weak starting torque.

To improve the starting torque, additional resistance can be added to the rotor circuit. This is
typically achieved by inserting external resistors in series with the rotor windings or using
adjustable resistors connected to the rotor windings.

The added rotor resistance increases the total resistance in the rotor circuit. According to Ohm's
Law (V = I × R), where V is the voltage across the rotor circuit, I is the current flowing through
the circuit, and R is the resistance, an increase in resistance results in a higher current for a
given voltage.

When the rotor resistance is increased, the current flowing through the rotor windings also
increases. This elevated current creates a stronger magnetic field within the rotor, which
interacts with the rotating magnetic field produced by the stator. As a result, a greater torque is
developed, leading to improved starting performance.

However, it's important to note that the added rotor resistance also causes an increase in rotor
losses and reduces the overall efficiency of the motor during normal operation. Therefore, rotor
resistance is typically designed to be reduced or eliminated once the motor reaches its rated
speed, using techniques such as star-delta starting or using external resistors that can be
bypassed. This ensures that the motor operates efficiently during normal running conditions
while still benefiting from the increased starting torque provided by the added rotor resistance.

(ii) Air-gap length: The air gap length in an induction motor plays a significant role in its
performance. The air gap refers to the distance between the stator and rotor of the motor. Here's
how the air gap length affects the motor's performance:
a. Magnetic Flux Density: The air gap length influences the magnetic flux density in the
motor. A smaller air gap length increases the flux density, resulting in a stronger magnetic
field and higher torque production. Conversely, a larger air gap length reduces the flux
density and decreases the torque output.
b. Efficiency: The air gap length affects the efficiency of the motor. A smaller air gap length
improves the motor's efficiency by reducing the magnetic reluctance and minimizing the
magnetic losses. This is because a shorter air gap offers a shorter magnetic path, reducing
the energy losses due to magnetic resistance.
c. Power Factor: The air gap length can impact the power factor of the motor. A smaller air
gap length improves the power factor by reducing the reactive power losses caused by the
leakage flux. This results in better power factor correction and increased motor efficiency.
d. Starting Torque: The air gap length affects the starting torque of the motor. A smaller air
gap length provides higher starting torque because the stronger magnetic field enables
better interaction between the stator and rotor. This is especially important for applications
where the motor needs to start under heavy load conditions.
e. Noise and Vibrations: The air gap length influences the noise and vibrations generated by
the motor. A larger air gap can cause more noise and vibrations due to increased magnetic
forces and air turbulence. Conversely, a smaller air gap reduces these effects, leading to
quieter and smoother motor operation.

It's important to note that the air gap length is typically designed and optimized during the
manufacturing process to achieve the desired motor performance characteristics. Different
motor designs and applications may require specific air gap lengths to ensure optimal
efficiency, torque, and overall performance.

(iii) Shape of stator and rotor slots and teeth: The shape of stator and rotor slots and teeth
in an induction motor can significantly impact its performance. The slots and teeth are designed
to ensure proper magnetic flux distribution, efficient energy conversion, and reduced losses
within the motor. Here are some ways in which the shape of stator and rotor slots and teeth
affects the performance of an induction motor:

a. Flux Distribution: The shape of the slots and teeth influences the distribution of magnetic
flux in the motor. Properly designed slots and teeth help in achieving a uniform flux
 distribution across the stator and rotor cores. This results in improved motor efficiency and
reduced losses.
b. Magnetic Saturation: The shape of the slots and teeth affects the magnetic saturation of
the motor's core. By optimizing the shape, it's possible to minimize the saturation effects,
ensuring that the motor operates within its desired magnetic limits. This helps in avoiding
excessive losses and maintaining efficient motor performance.
c. Cooling: The shape of the slots and teeth influences the motor's cooling capability.
Properly designed slots facilitate effective cooling by allowing proper airflow through the
motor. This helps in dissipating heat generated during operation, thereby improving the
motor's thermal performance and reliability.
d. Torque Production: The shape of the rotor slots and teeth affects the motor's torque
production. Different slot shapes can impact the rotor's magnetic field distribution,
resulting in variations in the torque characteristics of the motor. Optimized slot and tooth
shapes can enhance the motor's torque output and improve its overall performance.
e. Noise and Vibration: The shape of the slots and teeth can also influence the noise and
vibration levels of the motor. Certain slot shapes can cause undesirable electromagnetic
forces and vibrations, leading to increased noise and mechanical stresses. By carefully
designing the slots and teeth, it's possible to mitigate these effects and achieve quieter motor
operation.

Overall, the shape of stator and rotor slots and teeth plays a crucial role in determining the
performance characteristics of an induction motor. Through careful design and optimization,
it's possible to achieve improved efficiency, reduced losses, enhanced cooling, better torque
production, and lower noise and vibration levels in the motor.

Motor Enclosures

Various types of enclosure of the motor have been designed to protect the windings, bearings,
and other mechanical parts from moisture, chemicals, mechanical damage and abrasion from
grit.

NEMA (National Electrical Manufacturers Association) has suggested 7 Most Common Motor
Enclosure. These types are defined by NEMA Standards
1. Open Drip Proof (ODP) Enclosure

An open Drip Proof (ODP) enclosure for a premium efficient super-E motor is shown below.
This enclosure prevents the liquid drops to enter the motor when they fall with 15 degree angle
from the vertical but it allows air to circulate through the internal winding for cooling. These
enclosures are typically used for indoor applications in relatively clean, dry locations.

2. Totally Enclosed Fan Cooled (TEFC) Enclosure

The NEMA Premium Efficiency – Three Phase TEFC Enclosure Motor is shown below.
This enclosure prevents the free exchange of air between the inside and outside of the frame,
but the frame is not made completely air-tight. To increase the cooling efficiency, a fan is
attached to the motor shaft which circulates the air during operation. Ribs or fins are attached
on the frame to increase the surface area which further improves cooling. These enclosures are
more versatile and are used with motors for pumps, fans, compressors, general industrial belt
drive and direct connected equipment.

3. It is almost similar to a TEFC enclosure but in these enclosures, fan is not employed and
heat is dissipated only by convection. It is a tightly enclosed enclosure hence prevents free
exchange of air. Although, no vent is provided in the enclosure but it is not air-tight.
These are suitable for uses which are exposed to dirt or dampness, but not very moist or
hazardous (explosive) locations.
4. Totally Enclosed Air Over (TEAO) Enclosure

Dust-tight fan and blower duty motors designed for shaft mounted fans or belt driven fans. The
motor must be mounted within the airflow of the fan.

A1/3 HP, 24 V DC, 1800 RPM Motor with Totally Enclosed Air Over (TEAO) Enclosure is
shown below.

5. Totally Enclosed Wash Down (TEWD) Enclosure

A Motor with Totally Enclosed Wash Down (TEAO) Enclosure is shown below.
The Washdown Duty Motors are used for food processing, packaging, pharmaceuticals, or in
the applications where motors are regularly exposed to high pressure washdown. While
designing these enclosures one must take care of high wash-down pressure, humidity and wet
environment. Various enclosures have been designed for such (wet) conditions.
6. Explosion-proof Enclosures (EXPL)

A Motor with Explosion-proof enclosures (EXPL) is shown below. The Explosion-proof

enclosure (EXPL) motors are used in chemical plants, the oil industry, in gas works, wood and
plastic processing industry or in agriculture. Where there is hazardous environment, the
enclosure of explosion proof motors is designed in such a way that it can withstand heavy
pressures built inside the motor. However, if pressure is built-up more than the designed value
that must be released through the safety valve and switch off the supply simultaneously.

These motors are designed for specific hazardous purposes, such as atmospheres containing
gases or hazardous dusts. For safe operation, the maximum motor operating temperature must
be kept below the ignition temperature of surrounding gases or vapours.

Explosion proof motors are designed, manufactured and tested for particular requirements.

7. Hazardous Location (HAZ) Enclosures

These motors are used to operate Power Fans, Blowers, Pumps or Air Compressors in the
hazardous locations.

While selecting the enclosure and motor, the environment of the location is determined and
accordingly the specific material is used for the enclosure so that the enclosure’s strength may
not deteriorate.
Standard Types of Squirrel Cage Motor

With the slight variation in design as per the need, the squirrel cage induction motors have been
standardised. According to their electric characteristics and design, these are designated as
design A, B, C, D, E and F.

The commercial simple squirrel-cage induction motor with shallow slots are designated as class
A. These motors are considered to have normal slip and hence used as reference.

1. Class A Motors

Normal starting torque, normal starting current, normal slip.

Characteristics

 Have relatively normal (low) resistance and normal (low) reactance

 Rotor slots are semi-closed cut near the periphery to have small reactance.
 At rated voltage, the locked rotor current is generally more than 6 times the rated full-
load current.
 For the machines having smaller sizes and number of poles, at rated voltage, the starting
torque is twice the full-load torque
 For the machines having larger sizes and number of poles, at rated voltage, the starting
torque is 1.1 times the full-load torque.
 Full-load slip is less than 5%.

Applications

These motors can pick-up low inertia loads very quickly and can be started and stopped
frequently therefore, these are generally used for fans, pumps and conveyors etc.

2. Class B Motors

Normal starting torque, normal starting current, normal slip.

Characteristics

 Have deep and narrow bars therefore offer high reactance at start.
  Can be started at full-load. Then it draws relatively low starting current but develops
normal starting torque.
 Generally, locked-rotor current draws 5 to 6 times the full-load current at rated voltage.
 Full-load slip is less than 6%.

Applications
These motors can pick-up almost full-load while developing normal starting torque with
relatively low starting current and best suited for compressors, heavy fans having high,
machine tool applications centrifugal pumps etc.

3. Class C Motors

High starting torque, low starting current, normal slip.

Characteristics

 Have two separate cages and are called double squirrel-cage motors.
 Locked-rotor current with rated voltage is generally 5 to 6 times the full-load current
as in case of class-B motors.
 Starting torque with rated voltage is usually 2.75 times the full-load torque.
 Full-load slip is normal less than 6%.

Applications
These motors develop high torque at start nearly 2.75 times the full-load torque with low
starting current at rated voltage. Therefore, these are best suited to pick heavy loads at start
and are generally used for crushers, compression pumps, large refrigerators, conveyors,
textile industry, boring mills and wood working equipment.

4. Class D Motors

High starting torque, low starting current, high slip

Characteristics

 Have relatively high resistance to obtain high starting torque with low starting current.
  The bar conductors of the cage have relatively smaller area of cross-section to obtain
high resistance. These conductors are located very near the periphery to have low
leakage reactance.
 Locked-rotor current with rated voltage is generally 5 to 6 times the full-load current
similar to class-C.
 Full-load slip varies from 5 to 20%, depending upon the application.

Applications
These motor have the ability to develop extremely high torque at start, therefore, these are best
suited for shearing machines, pinching processes, stamping machines, bulldozers, laundry
equipment and metal drawing equipment.

5. Class E Motors

Low starting torque, low starting current, low slip

 Characteristics
Have relatively very low resistance accordingly have low starting torque and low
reactance.
 Locked-rotor current with normal rated voltage is generally 8 to 10 times the rated full-
load current, for larger sizes it may be more than this even.
 Their power factor and efficiency is relatively high.

Applications
These motor have low resistance and operate at higher power factor and efficiency, therefore,
best suited for continuous running such as exhaust fans.

6. Class F Motors

Low starting torque, low starting current, normal slip

Characteristics

 Have relatively low resistance and to reduce the starting current, rotor reactance is made
very high by embedding the rotor bar conductors deep in the slots for increasing the
leakage flux.
 Locked-rotor current with rated voltage is generally 5–6 times the rated full-load
current.
 The starting torque with full voltage is only 1.25 times the full-load torque.
 Full-load slip less than 6% depending upon the load