UNDERSTANDING THE DESIGN OF STATORS AND ROTORS

OF SQUIRREL CAGE INDUCTION MOTORS

Copyright Material IEEE
Paper No. PCIC-2008-02

Howard Barr Austin Bonnett Chuck Yung

Member, IEEE Life Fellow, IEEE Senior Member, IEEE
Emerson Electric Emerson Electric, retired Electrical Apparatus Service Association
500 N. Morrow St 25341 July Ave. 1331 Baur Blvd.
Mena, AR 71953 Galatin, MO 64640 St Louis, MO 63132
Howard.barr@emerson.com Austin.bonnett@emotors.com cyung@easa.com

Abstract- In order to enhance squirrel cage 2. Efficiency vs. starting current - torque
induction motor (SCIM) operation and performance as characteristics
a new machine or a repaired machine, it is important 3. Motor size and insulation systems vs.
to have a basic knowledge of the design and operating temperature
manufacturing elements that go into the stator and 4. Cost vs. performance
rotor. The SCIM is basically a converter of electrical 5. Enclosure vs. performance characteristics
energy (stator) to mechanical energy (rotor/shaft
assembly) via mutual inductance. This paper provides The bottom line is that achieving a good motor
those who specify, purchase, install, operate and design that satisfies both the user and manufacturer
repair SCIM’s with a basic understanding of what is requires balancing various performance
required to make this energy conversion. The factors characteristics.
that may impact the motor performance and longevity
are highlighted. The scope of product covered is from
75kw (100hp) to 3 750kw (5000hp), 400 volts to 6.6kV
typically used in the petroleum and chemical industry.

Index Terms: Stator, rotor, design, performance

Introduction

The electric motor is still the workhorse of the

petroleum and chemical industries. Approximately
60% of all generated electricity is used to drive Fig. 1. Centrifugal pump application
electric motors, which are very efficient converters of
electrical energy into mechanical energy. The ..
conversion process is in the 92% efficiency range or Motor Fundamentals
better for this industry. The basic design process is
outlined in this paper to provide those involved in the
It is assumed that the reader has a fundamental
application and use of these motors with a better
grasp of the electric motor equations and curves
understanding of the elements that go into the design
shown in Figure 2. This paper will walk the reader
and construction of these machines.
through the basic steps of the motor design process,
A sample motor which meets the proposed IEEE
summarized here:
841- 2007 standard was selected to illustrate the
1. Review customer specs & Standards
basic elements of design. For the design engineer to
2. Chose frame size & enclosure
have a clear understanding of the application 2
3. D L estimate
requirements, the IEEE 841 application data sheet
4. Lamination diameter selection
(PIP) has been used (Appendix A). In summary the
5. Choose stator/rotor slot combination
motor is a 500 hp,1500 rpm, 3 phase, 50 Hz, 400 volt
6. Electrical steel selection
horizontal motor designed for centrifugal pump
7. Winding configuration
application (Fig. 1). Although space will not allow for
8. Rotor construction
the full development of the many trade-offs in the
9. Flux density calculations
design of an electric motor, the key ones are listed
10. Proposed design
here:
11. Performance analysis
1. Efficiency vs. power factor

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Fig. 2. Electric motor fundamentals

A. Selection of Frame Size and Enclosure oversized motor would have used more active
materials than necessary.
The application dictates a severe duty enclosure
and although there are a number of choices such as
Weather-Proof, Totally-Enclosed Water-Air Cooled, or
Tube-Cooled, the logical choice to comply with IEEE
841 is a Totally Enclosed Fan Cooled (TEFC) with an
all cast iron construction. There are several frame
sizes available but for this analysis a NEMA 5809
frame was selected. Figure 3 depicts the motor
envelope and thermal circuits for this enclosure.
There is a direct relationship between the stator
2
diameter squared times the stator stack length ( D L)
and output torque. If a 5009 frame had been chosen,
2
the smaller D would require a much longer lamination
stack length for the same output rating (KW/HP). If a Fig. 3. Typical enclosure and thermal circuits of a
larger frame had been chosen, the needlessly 5809 frame TEFC motor

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B. Selection of Stator and Rotor Laminations
The selection of the frame size normally dictates
the outside diameter (OD) of the stator laminations.
Each manufacturer has standard lamination
dimensions by frame size and poles. For a typical 4-
pole motor, the stator inside diameter (ID) is
approximately 2/3 that of the stator lamination OD.
The ID of the rotor lamination may be affected by
mechanical considerations, such as the need for a
specific shaft diameter. Figure 4 illustrates typical
stator and rotor lamination blanks.
After the initial lamination diameters are
determined, the number of stator slots, the stator-rotor
slot combination, and grade of electrical steel must be
determined. These choices are influenced by the
KW/HP rating, RPM, winding type, rotor construction,
and performance criteria.
Fig. 4. Stator and rotor lamination blanks
C. Stator / rotor slot combination
The magnetic flux in a motor is composed of the
rotating fundamental sine-wave and the harmonic
components. Only the fundamental wave or field
actually provides useful tangential forces and usable
rotating torque. The harmonic components of the
wave produce only parasitic torques, which distort the
accelerating speed-torque characteristic of the motor.
The presence of these non- sinusoidal fields in the
airgap of the motor can result in any of the following
detrimental effects:
1. Starting or running noise
2. Synchronous locking torques
3. Dead points at zero speed
4. Torque dips
5. Stray losses
Although it is not practical to eliminate all parasitic
torques, the proper combination of stator and rotor
slots can minimize their influences. The proper
selection of the stator winding span and rotor skew
can further reduce these influences.
It is desirable that each coil group have the same
number of coils, as that allows the greatest selection
of parallel circuits. A higher number of stator slots
gives fewer harmonics in the flux, but uses a greater
portion of the available winding area for insulation.
Possible choices for this rating (3 phases x 4 poles
= 12 Groups) are summarized in table I.
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TABLE I
COILS/GROUP FOR 4 POLE STATORS
Coils/group 3 4 5 6 7
Stator slots 36 48 60 72 84
D. Selection of electrical steel grade
There are four major considerations in selecting the
grade of electrical steel. They include the watts loss
(per unit weight), permeability, thermal conductivity
and thickness of the steel.
Low-carbon steels have slightly better thermal
conductivity and are usually easier to magnetize,
while silicon steel has lower hysteresis losses. Eddy-
current losses are proportional to the square of the
thickness, but thicker steel has a higher stacking
factor (more steel per unit of stack length) and is
easier to physically handle. Figure 5 shows the
relationship between losses and thickness of several
different grades of electrical steels.
Fig. 5. Effect of lamination thickness on eddy-current
losses
Reasonable options for this design are American
Iron & Steel Institute (AISI) Grades M-45, M-36, and
M-15, in thicknesses ranging from 0.4mm – 0.8 mm
(.018” to .031”). From these, a 0.46mm (0.018”) thick
M36 fully processed (C5 coreplate) with a watts loss
of 1.7 watts/lb was selected.
E. Winding Configurations
Two choices of stator configurations (Fig. 6) were
considered: one for a random wound and one for a
form wound design.
The form coil option (Fig. 6, right) is mechanically
more robust, better sealed against environmental
threats, and tends to be more durable than a random
winding (Fig. 6, left) in the same rating. The random
winding is slightly more efficient. It is also less
expensive and faster to both produce and repair.

Fig. 6. Random (left) and form coil (right) windings
For a random winding, there is a further choice
between a concentric (Fig. 7) winding, which is
usually machine wound; and lap winding (Fig. 8)
which usually must be inserted by hand. The lap
winding chosen for this application was selected for
its slightly better MMF curve and possibly lower
losses. These options would be discussed with the
customer, in the ever-present effort to balance cost,
efficiency and reliability.
Fig. 7. Concentric winding (1 pole-phase group)
The midpoint of each coil in a concentric winding is
also the midpoint of the coil group, hence the winding
is ‘concentrated’ on a common centerline. The coils in
a lap winding group are ‘distributed’ – they do not
share a common center point. Flux density
calculations must take into account the difference in
distribution factor (kd ) for the winding type selected.
Kd for a traditional concentric winding is 1.0; for a lap
winding the value of kd varies inversely with the
number of coils per pole-phase group.
Fig. 8. Lap winding during insertion
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F. Chord factor (Kp)
The chord or pitch factor (Fig. 9) is calculated as
follows:
⎛ span ⎞
K p = sin ⎜⎜ 90 o * ⎟ 1)
⎝ slots / pole ⎟⎠
By selecting the optimal chord factor the time-
sequence harmonics are minimized. The higher the
chord factor (closer to 1.0) the more effective each
turn, and the fewer turns are required per coil. The
lower the kp the easier the coils are to insert. The
design engineer must balance efficiency and
windability.
Fig. 9. Chord factor (Kp) with a 1-16 coil pitch (15
teeth spanned)
G. Rotor Design
For the rotor there are also several options. The
rotor cage can be a die-cast (Fig. 10) or fabricated
design (Fig. 11), using aluminum or copper. The cage
can be designed as either a single-cage or double-
cage construction (Fig. 12).
There are two options in the selection of the
number of rotor bars. They are: a rotor with fewer
bars than stator slots (N2 < N1) or with more rotor
bars than stator slots (N2 > N1).
Fig. 10. Cast aluminum rotor
 The cast rotor is inherently more rugged,
particularly when numerous starts are required, and
offers the greatest variety of bar shapes to optimize
the starting characteristics.
Fig. 11. Fabricated copper rotor with air ducts
Fig. 12. Single and double cage bar profile
It is beyond the scope of the paper to present the
merits of the various bar materials and their alloys.
Suffice it to say that copper has twice the conductivity
but 3.2 times the weight as a raw material and that
there are advantages to both materials depending
upon the application requirements.
For this application, a die cast aluminum
construction was selected for its starting
characteristics, full load performance characteristics,
rugged construction, and ease of dynamic balancing.
H. Magnetic Flux Densities
The rotating magnetic field in the squirrel-cage
induction motor consists of the fundamental flux field
and harmonics of this fundamental. It is the
fundamental field that produces the useful torque.
The winding is inserted and connected in such a
way that, when energized with 3-phase power, the
desired number of magnetic poles are created to
rotate around the stator. Figure 13 depicts the
fundamental flux paths of a 4-pole SCIM. As the
magnetic poles rotate, they “pull” the rotor cage along,
with a small amount of slip developing the output
torque.
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Fig. 13. Flux path of a 4-pole machine
In one cycle of the AC power, the field rotates
through one pole pair. For the 4-pole winding, this
one cycle would encompass 180 mechanical degrees
of rotation. The speed at which the field rotates
around the stator is called the synchronous speed
(SRPM), and is a function of the number of poles and
the frequency of the applied power.
SRPM = 120 * frequency / poles (2)
Because the fundamental flux at the airgap
produces the power output of the motor, the magnetic
flux requires a closed path (Fig. 14) encompassing
the stator and rotor conductors.
Fig. 14. Simplified flux paths
An important term for analyzing the fundamental
magnetic flux in the motor is the flux density (flux per
unit area). One convenient unit of measure of flux
density is kilolines per square inch. Ferrous materials
have a limited range of linear relationship between the
flux density and the magnetizing current required to
generate that flux. Higher flux densities require
significantly greater magnetizing current, as the
laminated steel core saturates.
The magnetization of the airgap is a linear
relationship between the current, the airgap flux
density, and the length of the airgap (Fig.15). Air is
much harder to magnetize than is the steel, hence a
significant amount of the magnetizing current is
associated with the magnetic field crossing the airgap.

Fig. 15. Airgap is the physical separation between the
rotor and stator (exaggerated for clarity)
The motor designer must account for the effects of
magnetic flux density in the temperature rise and the
efficiency of the motor, balancing these factors
against the efficient use of materials.
Without doing rigorous derivations here, the basic
equation for induced voltage in a coil of N turns and
the peak sinusoidal magnetic flux of Φm is:
2π * f * N * Φ m *10 -8
E eff = (3)
2 engineer can fine tune the design to optimize the
(Terms legend)
2
The airgap magnetic flux density (kilolines/in ) can be
established:
E * n * P * m * 10 5 (4)
Bg =
4.44 * π * f * T * N 1 * D * L g * K p * K d
2
The flux densities (kilolines/in ) in the stator and
rotor core backiron and teeth can be determined from
the airgap flux density by equations:
5.485 * D * B g
Bt1 =
N 1 * Wt1
1.745 * D * B g
Bc1 =
P * H c1
It should be noted that the engineer would rarely
revert to the basic equations when establishing a new
design. Instead, he/she would start with an existing
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design that is as close as possible to the new
requirements and would then “ratio” to the first
approximation of the design.
In general, the motor’s full load torque is
2
proportional to the D L at the airgap. From there, the
winding turns can be calculated to the new rating
requirements by using ratios:
En HPo fo L t
Tn = To * * * * o * o (7)
Eo HPn fn Ln tn
Subscripts: o = old, n = new
Equation 7 shows the relationship between turns,
output power rating, frequency, stack length, and
starting torque (as percentage of full load torque). To
summarize, higher voltage rating and/or lower HP
rating require more turns/coil, and lower frequency
requires longer stack length, other factors being
constant.
To produce the same flux density, a delta
connection requires √3 times as many turns/coil as a
wye connection. Also, the number of turns and the
number of parallel circuits can be changed in direct
proportion to each other and maintain the same flux
density. The engineer selects a combination of
circuits and turns, and wye or delta connection, to
produce the required flux density.
2
Once the base D L and turns are established, the
performance characteristics and will consider the
number of circuits and type of connection to get
discrete windable turns and wire size. Fine tuning
may involve changing the airgap distance, lamination
steel grade, the quantity, size, and shape of rotor and
stator slots, rotor conductor resistivity, stack length,
ventilation, and a number of other less significant
factors.
I. Stator Slots and Coils per Group Options
If the flux density is too high, saturation of the steel
results in higher losses and lower power factor. Low
flux densities may reflect an inefficient use of the
lamination material. The target flux densities
2
(kilolines/in ) for starting the design are provided in
Table II.
TABLE II
2
TARGET FLUX DENSITIES, IN KILOLINES/IN
Component Stator Rotor
Airgap 25-35 ---
Teeth 110-130 110-130
Backiron 110-130 110-130
(5)
(Airgap density reported in rms; teeth and backiron
densities as peak values.)
The stator slot: tooth width ratio (Table III) is a
(6) compromise of the conflicting desires for a better
magneto-motive force (MMF) curve, conservative flux
densities in the teeth to minimize core losses, and low
2
current density to minimize I R losses. The more
slots, the more space is mortgaged to insulation and
the more coils there are to insert.
 TABLE III radial blades, was selected to meet the required
OPTIONS FOR SLOT AND TOOTH WIDTHS sound level. The backward curved blades maximize
Stator Slot Tooth Ratio air flow and minimize fan losses. The unidirectional
slots width width (slot: tooth) fan is compatible with the centrifugal pump
48 .712” .368” 1.93 application.
60 .496 .295 1.68 After a trial calculation, the airgap was changed
72 .352 .246 1.47 from 0.080 on the reference design to 0.090 on the
84 .249 .210 1.19 sample design. Table IV summarizes the performance
characteristics of the proposed design, for both
A slot: tooth width ratio of approximately 1.5:1 is random and form coil options.
reasonable for inserting the winding, therefore 72
stator slots were selected. TABLE IV
Certain combinations of stator slots and rotor slots PERFORMANCE CHARACTERISTICS
can result in electrical noise or torque-related Random Form IEEE 841
problems. Cogging (a condition where starting torque Efficiency 97.0 96.8 95.4 (nom.)
varies depending on the relative position of the rotor Power Factor 89.5 88.5
bars on start-up) and cusp (a dip in the torque curve) o o o
Temp. Rise 71 C 66 C 80 C (max.)
can be predicted based on the difference between
stator and rotor slots, factoring in the number of poles Starting 5.6 5.7 5.77 (max.)
and phases. KVA/HP
Avoidance of electrical noise is part science and % Slip 0.72 0.74 --
part ‘black art.’ The selection of 57 rotor bars for this dBA 88 88 90 (max.)
motor was based on empirical data. Hence, N1 = 72, Starting torq. 98% 100% 80% (min.)
N2 = 57.
Major Electrical Noise and Vibration
J. Calculations of Trial Winding
Considerations
2
From empirical data, the required airgap D L is
3 A. Stator / Rotor Slot Combinations
approximately 6,000 in . Starting with the objective of
keeping the stack length approximately 1.3 times the
airgap diameter, the cube root of (6,000/1.3) = 16.65, Certain stator /rotor slot combinations are known to
cause electrical noise and/or torque anomalies, and
an airgap diameter of 42cm (16.5 inches) and stack
are routinely avoided by designers. Beyond that basic
length of 54.6cm (21.5 inches) was selected. For a 4-
pole design, the stator OD will be approximately 1.5 consideration, certain length to diameter ratios with
times the airgap diameter, or 63cm (24.75 inches). specific skews may not perform as ideally.
The closest existing design is a 500 HP 4-Pole 460 Combinations that yield satisfactory performance in
some designs may not be suitable for all mechanical
volts 60 Hz with an airgap diameter of 16.5 inches
and stack length of 17.5 inches. The winding has 6 configurations. Another factor that must be
turns connected as a 4-circuit delta configuration, considered is the geometry and stability of the core
2
using a coil pitch of 1-15. The stator / rotor slot and frame. Longer cores within the same D L family
require a stiffer shaft to control flexing that might
combination is 72 / 57. The airgap length is 2 mm
(0.080”). The rotor is not skewed. The stator is otherwise lead to unacceptable vibration problems.
random wound. The stator backiron flux density is
B. Rotor Skew
low enough to allow increased stator slot depth if
necessary to meet performance requirements.
The decision whether or not to skew the rotor (Fig.
Using the variables that changed in equation 7 to
calculate the new turns for the 400v 50 Hz rating 16) is influenced by experience. The primary
gives 5 turns/coil: advantage of a rotor skew is that it reduces the effect
of airgap flux harmonics on the speed-torque curve.
The trade-off is that the skew increases stray load
Tn = 6 *
400
*
60
*
17.5
= 6 * .826 * 1.095 * .902 = 5.156
(8) losses, adversely affecting efficiency.
460 50 21.5

th th
The optimum coil pitch for suppressing 5 and 7
harmonics is 83% pitch, or 1-16 coil pitch. Increasing
the pitch to 1-16 lowers the total flux, which offsets
the slight increase in flux caused by rounding the
turns to the nearest integer. The first trial calculation
was run with 5 turns, 4-delta, 400 volts, 50 Hz, and a
1-16 coil pitch. The size and number of parallel wires
was adjusted to optimize slot fill with the reduced
number of turns per coil, resulting in four #14 AWG
and fourteen #15 ½ AWG wires in hand.
The IEEE 841 specification limits the sound power
level to 90 dBA. The reference design had a large
external fan which exceeds the specification sound Fig.16. Rotor bars are skewed to smooth out the
level. A smaller diameter fan, with backward-curved torque curve.

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 Harmonic analysis of the 72/57 slot combination
shows low harmonic amplitudes and no locking
torques between zero and rated speed. It seems
reasonably safe to eliminate skewing of the rotor
cage, and thereby realize the improved operating
efficiency.

C. Insulation system and coil bracing

The treatment system selection is influenced by the

winding type (form versus random winding). The
benefits of vacuum pressure impregnation (VPI) are
greater for form coil designs because the coils are
fully taped. That enhances resin retention as
compared to the random winding, which is by nature
open. The rigidity and chemical/moisture resistance of
VPI-treated form coil windings are generally superior Fig. 17. Effect of load on efficiency and power factor
to random windings.

A preference for VPI- sealed windings might be

dictated by environment factors, voltage source, Figures 17 and 18 illustrate the very real, but often
improved thermal transfer, end-user specifications overlooked, effect of variations in load or voltage on
requiring the NEMA water-immersion test, etc. motor performance. This effect occurs even within the
plus/minus 10% of rated voltage dictated by NEMA
Winding bracing requirements range from MG1.
‘standard’ procedures to additional bracing for severe
applications such as extended- or frequent-starting,
reversing loads, or reclosure resistant windings.
The many options for mechanical bracing of both
random- and form coil windings are beyond the scope
of this paper.

The winding treatment may be dictated by the need

for chemical resistance due to environmental
conditions. Manufacturers and repairers alike often
use insulating materials of a higher insulation class
than indicated by the nameplate temperature rise. For
example, it is common for a manufacturer to use class
F or H materials, yet label the motor for a class B
temperature rise.
Communication of special requirements should be
made to the manufacturer and/or repairer.

Operational Considerations

There are numerous elements of the design that
may impact the quality of the motor operation and
performance. The major ones are:
1. The ability to operate satisfactory over a wide
range of voltage conditions, including: under and
over voltage, unbalanced voltage, and inverter duty
or voltage transients.
2. The ability to perform under a wide range of loads
(light or heavy), cyclic loading, or extreme starting
conditions.
3. Other factors include: environmental extremes,
noise under heavy loads or over-voltage conditions,
and operational and maintenance costs while
operating beyond the nominal or optimum
conditions.
Fig.18. Effect of applied voltage on performance
characteristics.
Repair Considerations
With effective root cause failure analysis, the
underlying cause of most failures can be determined.
That leads to an opportunity to make improvements
during the repair process. If the root cause of failure is
correctly identified, it is often possible to enhance the
suitability of a motor for its unique environment. For
example, if condensation or moisture is identified as
the root cause of a failure, the improvement might be
as simple as installing a condensate drain, sealing the
lead opening at the terminal box, or sealing the
windings better.

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 rotor bars in their slots. Such changes may elicit
understandable concern. Brazing techniques and
materials may be required to meet with the motor
users mandate that all repairs be phosphorous-free,
for reasons of chemical compatibility.

In the case of a motor with a fabricated rotor cage,

and starting frequency (figure 20) that greatly exceeds
the original manufacturers expectations, it may be
necessary to alter the endring resistivity and cross-
sectional area, with the goal of a larger endring (larger
thermal mass) at the same resistance so as to not
adversely impact the starting characteristics of the
motor.

Fig. 19. The symmetrical pattern indicates that this

stator was single-phased.

A form-wound machine may have greater reliability

due to the more robust winding.
A correctly identified ‘root cause’ (Figure 19) may
lead the user to improved maintenance practices.
The use of multiple circuits raises the possibility of
unbalanced magnetic circuits in the motor. Within the
2
winding, these circulating currents can increase I R
losses, electrical noise, and electro-magnetic
vibration. The symmetry of the winding and
mechanical parts (specifically the airgap) is critical in Fig. 21. This ODP motor was not suitable for an
minimizing these factors. Common corrective environment with heavy contamination.
measures include equalizing parallel circuits or the
use of special intra-phase connections to balance the Misapplication
magnetic force in opposing pole-phase groups. When the enclosure is not appropriate for the
Whether the motor is repaired or replaced, the environment (fig. 21), it behooves the service center
repairer can often add accessories to increase the to recommend a more appropriate replacement
suitability of the motor for its unique application. motor. Likewise, if a Design B motor is being used in
Vibration proximity probes, winding or bearing RTD’s, an application that calls for a Design C or even
special connectors and other devices can be installed Design D motor, the result of an attempted repair is
to improve the end users ability to monitor the motor likely to be unsatisfactory.
and provide advanced warning of possible problems.

CONCLUSIONS

These 11 steps summarize the motor design

process:
1. Review customer specs & Standards
2. Chose frame size & enclosure
2
3. D L estimate
4. Lamination diameter selection
5. Choose stator/rotor slot combination
6. Electrical steel selection
7. Winding configuration
8. Rotor construction
9. Flux density calculations
10. Proposed design
Fig. 20. This rotor was damaged when the motor 11. Performance analysis
was started too many times in a short time period.
The information required to successfully accomplish
Rotors require less frequent repair than other a design or repair should not be under-estimated.
components, and have less structured design Performance and environmental factors differ for each
parameters. Because torque and rotor cage motor, requiring nuanced adjustments to standard
resistance are interlinked, the cross-sectional area designs, in order to best meet the unique
and resistivity of rotor material must be duplicated in requirements of a vast number of different
the event of a rotor cage replacement. applications.
The repairer may have to choose between
duplicating an early OEM design and making
improvements, particularly with respect to the fit of

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 To summarize the key aspects of this motor design:
The full load efficiency of 97% results in 6.45 Kw-Hr
savings per hour of operation when compared to the
95.4 efficiency specified in IEEE 841.
The full load power factor of 89.5% will meet most
utility minimum requirements with little or no
correction. The insulation system uses Class F and
Class H components, allowing some unusual service
conditions without the winding temperature exceeding
its rating. The 98% starting torque assures reliable
starting even at voltages below the specified 90%
starting voltage.
Should the end user specify a motor suitable for an
ASD application (PWM drive), there are two options:
either the random winding can be produced using
inverter-grade insulation and wire, or the form wound
variation can be selected for even better durability. If
there is not an available spare, the random wound
motor can be repaired or replaced more quickly than
the form coil counterpart in event of winding failure,
minimizing downtime.
The engineer must design a motor to meet
requirements for efficiency, torque, frame size,
enclosure, and reliability, while at the same time
balancing cost against performance; all this while
recognizing that other designers are competing for the
same sale. There are literally hundreds of
manufacturers of electric motors worldwide.
The end-user must recognize that a successful
design depends in part upon full disclosure of the
expected operating conditions of the motor.
REFERENCES
[1] NEMA MG 1; 2006
[2] M. Liwschitz-Garik and C.C. Wipple, Alternating
Current Machines, Van Nostrand, 1961
[3] P. L. Alger, The Nature of Polyphase Induction
Machines, John Wiley & Sons, 1951[4] C. Siskind,
Induction Motors; McGraw, 1958
[5] AC Redesign; EASA, 1990
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VITAE
Howard E. Barr is an IEEE Member and is a design
engineer with Fluid Services Division of Emerson
Motor Company. Barr started his large motor design
career with The Louis Allis Company in 1969, and
moved to U.S. Electric Motors Division of Emerson
Electric in 1973 and has served in engineering and
management positions in integral horsepower motor
design and manufacture since that time. He is
currently resident engineering manager at the Mena,
Arkansas facility. Barr has BSEE and MSEE degrees
from Purdue University and is a registered electrical
engineer in Arkansas.
Austin H. Bonnett is a Life Fellow of the IEEE. His
honors include the Tesla Award, the IEEE Industry
Applications Society Outstanding Achievement
Award, the 2007 EASA Outstanding Achievement
Award, the IEEE Meritorious Award, the NEMA Kite
and Key Award and numerous prize paper awards.
He is Technology and Education Consultant for the
Electrical Apparatus Service Association (EASA), and
vice-president of technology emeritus at Emerson
Electric.
Chuck Yung is a Senior Member of IEEE and a
technical support specialist for the Electrical
Apparatus Service Association (EASA). He worked in
the electrical machinery repair industry from 1974
until joining the staff of EASA in 1998. He holds one
patent and is the author of more than 100 technical
articles and papers, including three published in IEEE
Industry Applications magazine.
 Appendix A
IEEE 841 / PIP data
sheet

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