2017 International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)

Compact Windings Design for Traction Induction

Motors and SCIGs
Grachev P.Yu., Bazarov A.A., Tabachinskiy A.S.
Samara State Technical University
The Department of Electrical Engineering
Samara, 443100, Russian Federation
[email protected]

Abstract—In this article winding schemes and calculation and increasing efficiency. It is able due to overhang deviation
methods for original energy efficient electric machines are and length reducing [20,21]. Construction features and design
introduced. They are intended for application in electrical methods of EEM stators are shown below.
equipment of autonomous systems. These machines winding
conductors have a rectangular cross-section. Slot connection spots II. COMPACT WINDINGS OF MULTIPOLAR ELECTRIC MOTORS
and overhang parts are reduced. This allows one to reduce copper AND GENERATORS
intensity and the machine length and improve efficiency. Specific
end-face schemes and the conductors connection diagram for the A. Squirrel-Cage Induction Generator Winding
stator windings are given. Overhang deviation and machine Let us consider construction features of squirrel-cage
characteristics calculation features are described. The thermal induction generator (SCIG) stator with rectangular cross-
simulation was undertaken for original conductors. The section winding conductors and compact overhangs. These
calculation results are compared with serial produced electric
machines.
overhangs are parallel to stator end-face [22]. Fig. 1 illustrates
sector of SCIG stator with specified overhangs parts, related to
Keywords—hybrid electric vehicle; traction induction motor; motor, mentioned in [19]. This SCIG is capable in micro hydro
squirrel-cage induction generator; material intensity; stator application. Rated current is In = 36 Ⱥ, height of stator
windings; winding scheme elementary conductor is 3,55 mm, width – 1,5 mm.
I. INTRODUCTION On the fig. 1 overhang conductors in each phase marked with
Material intensity reduction of electrical machines is the colors. SCIG has number of stator slots Z1 = 180 and number
especially relevant in vehicles’ application [1,2,3], even in of rotor slots Z2 = 154. On the figure you can see the cage ring
electric driven vehicles [4]. In wind energy material intensity, of the rotor, marked with golden color. In this one SCIG,
volume and mass reduction of electrical installations [5,6] branches of the stator compact winding connected in series,
makes able to decrease the mass and size of the towers and cut cylindrical wave winding has 30 pole-pairs and number of slot
transport costs. Efficiency of electrical machines should be per pole and phase q = 2. There is an air gap between overhangs
considered in this case. Construction optimization [7,8] and and stator to improve the thermal reliability.
innovative materials application [9] can solve the issue, as well
For the visual understanding of overhang parts modification,
as control algorithm rationalizing [10].
specific end-face schemes are proposed. Fig. 2 illustrates this
Russian industry develops induction motors series 7AVE scheme, phasing outs, branch parts connections and pole pitches
[11] for international market. This motors feature high are depicted there. Slot conductors are figured with vertical
efficiency and low noise level. However, as well as the most lines, and overhang conductors of each end-face are figured with
part of Energy Efficient Motors (EEM), 7AVE motors have oblique lines. Horizontal lines illustrate the connections of
increased level of active materials, that leads to increased cost branch parts and the full phase branches. Solid lines mark the
and material intensity. In series design, attention is paid to the conductors of upper layer, and broken lines — bottom layer.
motor’s active parts optimization [12]. New ways of design
automatization are given [13].
In paper [14] contradictions in energy savings calculation, in
case of EEM application, are showed. It is necessary to take into
consideration “additional” materials energy cost as well as
power electronics losses and operation losses. Thus, innovative
electrical machines with concentrated windings [15,16] and
cylindrical rectangular cross-section windings [17-19] are
designed. The authors offer innovative stator core construction
of electrical machines, decreasing sizes and material intensity
Fig. 1. Stator section of squirrel-cage induction generator with compact winding.
U1 and U2 are phasing outs, Ʉ1, Ʉ3, Ʉ3 – different types of connection spots.

978-1-5090-5648-417$31.00 ©2017 IEEE

 2017 International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)

− −
(1)
− ∇ ⋅ ( jω A+ σ∇V − J e ) = 0;
−
− § 1 −·
jω A+ ∇ × ¨¨ × A ¸¸ + σ∇V = J e ; (2)
© μ0μ r ¹

here: ‫ܣ‬ҧ – vector magnetic potential; V – scalar electric

potential; ‫ܬ‬ഥ௘ – current density vector; ı – specific electrical
Fig. 2. End-face scheme of SCIG compact winding conduction; ߤ଴ – magnetic constant; ߤ௥ – stator steel
permeability.
For the definite solution, magnetic potential on the
computational field boundary:

.
A S1∈S = 0; (3)

here: ܵଵ – computational field boundary.

Fig. 3. Conductors connection order for V phase of SCIG stator. Here y — winding Calculation features related with reduced cross-section of
step. connection spots between slot and overhang conductors (so-
called jumpers). Energy effective electric machine has a number
of different jumpers constructions. One construction is
For the complete understanding about overhang construction illustrated on the fig. 5. We can see the complex form of the
it is preferably to make a scheme, illustrating the connection construction. This causes irregular current density in the
order of slot and overhang conductors. The diagram, illustrated connection spots [21].
on fig. 3, helps to get the idea of slot and overhang conductors
connection, about branch parts and branches connection and Ignoring low impact of skin-effect on the rated frequency,
about winding step in each slot. Overhang conductors of the end- 3D simulation within ELCUT was made for consideration of
face with phasing outs are marked with solid lines, and irregular current density in resistance calculation. Simulation
conductors of other end-face — with broken lines. result is depicted on the fig. 5. This result allows us to calculate
the resistance amount with the use of Ohm’s law (4).
B. Traction Induction Motor Winding
Rated characteristics for the traction induction motor (TIM)
are: In = 146 Ⱥ, fn= 500 Hz, n = 2000 min-1. sn = 5,8 %, Ɇn =
310 Nm, Ɋn = 60 kW [19]. The height of stator elementary
conductor is 3,55 mm, the width – 1,5 mm. Conductors are the
same as for the considered SCIG. Active part of the machine
differs from mentioned in [19] only with overhang parts.
Because rated stator phase current of TIM exceeds SCIG stator
phase current four times, branch parts in each phase are
connected in parallel. Fig. 2,3 illustrate the series connection of
SCIG stator winding branches, so there are no conductors for
parallel connection for TIM.
3D model of the innovation machine allowed us to calculate
dimension and weight characteristics: overhang deviation
decreased from 30,7 mm to 12 mm for 61%, copper intensity
reduced for 21,6%. Reduced overhang deviation saves 22,2%
of construction steel approximately.
III. PHASE RESISTANCE CALCULATION
Fig. 4. 3D simulation of current density in the connection spot
For electromagnetic processes in induction machine,
combined equations with vector magnetic potential and scalar
electric potential are used [23]:
 2017 International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)
here: n - normal to the boundary of the computation field;
c - specific heat capacity of magnetic circuit and conductor
materials; Ȗ - the density of magnetic circuit and conductor
materials; α – convective heat transfer coefficient; k – heat
conductivity coefficient of magnetic circuit and conductor
materials, W (x, y, z , t ) - distribution function of internal heat
sources.
Equation (5) is not divided into separate subdomains
equation. Its parameters depend on the temperature of the
subdomains. Function W (x, y, z , t ) involves the distribution of
temperature in spatial coordinates. Finite element’s dimensions
Fig. 5. Conductor parts of stator compact winding with irregular current are small in the computation field. Conductor’s insulation is
density. Here ‫ܮ‬ʛଵଵ ൌ ʹܾǢ‫ˏܮ‬ଵଶ ൌൌ Ͳǡͷܾ ൌ ܿǢ‫ܮ‬ʛଶଵ ൌ ܽǢ‫ܮ‬ʛଶଶ ൌ ʹǡͷ݀Ǥ considered.
Eddy currents’ power losses are calculated for the face of
ܴ௧௨௥௡ ൌ Ͷ൫ܴത௦ ൅ ܴത௢௩ ൅ ܴത௝ ൅ ܴ෨ଵ ൅ ܴ෨ଶ ൯ ൌ the steel stator. Their impact on thermal processes is negligible.
ߩ௖ Copper bulk power density 506000 W/m3 stands out, if the
ൌ Ͷ ൤ ൫݈௦ҧ ൅ ݈௢௩
ҧ ൅ ʹ݈௝ҧ ൯ ൅ ܴ෨ଵ ൅ ܴ෨ଶ൨ ൌ nominal branch current is 36 A. Temperature of insulation and
‫ݍ‬ conductors in the middle of the slots is about 102° C. In case of
(4)
ߩ௖ natural cooling and 2 mm air gap between stator end-face and
ൌ Ͷ ൤ ൣͲǡͷሺ݈௦ െ Ͷܾሻ ൅ Ͳǡͷሺ݈௢௩ െ ͷ݀ሻ
‫ݍ‬ overhang parts, conductors and insulation temperature in the
middle of overhang parts reaches 147° C. Solid connection of
൅ ʹ൫݈௝ െ ܾ െ ܽ൯൧ ൅ ܴ෨ଵ ൅ ܴ෨ଶ ൨ǡ
the overhang parts and stator surface is possible for temperature
decrease.
here: q – slot and overhang conductors cross-section;
ܴത ƒ†݈ ҧ with s, ov and j indexes – resistances and lengths of slot, The temperature at the edges of the slot and overhang
overhang and jumper conductor parts respectively with regular conductors is presented in table 1.
current density; ls,lov,lcon – total lengths of slot, overhang and
jumper conductors; ܴ෨ଵ ƒ†ܴ ෩ ଶ – resistance of irregular cross- TABLE I. JUMPER TEMPERATURE
section conductor parts, calculated within ELCUT (fig. 5); a, b, Conductor
16 20 25 30 36
c, d – sizes of conductor parts, depicted in fig. 5. current, A
Power
Calculation and simulation results have shown, that irregular density, 105 1,56 ⋅ 10 5 2,44 ⋅ 10 5 3,51 ⋅ 10 5 5,06 ⋅ 10 5
current density consideration increases phase resistance amount W/m3
for 0,5%, but total length and resistance of winding conductors Conductors with the constant cross-section
decreases. Due to this fact, efficiency increases for almost 1%.
Top end
IV. THERMAL ANALYSIS temperature, 26,2 40,8 63,9 91,9 132,5
°ɋ
Reduced cross-section of jumpers causes growth of
Lower end
resistance and thermal losses. This is the reason for thermal temperature, 26,1 40,7 63,7 91,7 132,1
analysis and insulation screening. Comprehensive analysis of °ɋ
thermal processes in the compact winding is necessary. Double reduced jumper cross-section
Computer simulation is needed in slot parts and overhang parts
of the winding. Let us assume that processes in the stator steel Top end
temperature, 31,9 49,7 77,7 111,8 161,1
and compact winding are periodical in space and time. °ɋ
Mathematical model of thermal processes in stator steel and Lower end
compact winding with conductors in partial differential temperature, 31,6 49,4 77,1 111 160
equation: °ɋ

∂T (r , x, t ) 1 According to the results, jumpers temperature is lower, than

= ∇ ⋅ (k∇T ) + W ( x, y , z , t ) (5)
∂t c(T )γ overhangs. Double reduction of jumper cross-section leads to
increased heat dissipation and conductors temperature
Initial and boundary conditions are: increased for 22%. Resistance increasing accompanied with
­ T (x, y , z ,0 ) = T0 = Tc ;
temperature gradient changing, as shown on fig. 7.
°
® (6)
°n ⋅ (k∇T ) = α(T − T );
¯ C
 2017 International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)
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