Experimental Results versus FEM Based Analysis of a Squirrel Cage Induction Motor
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1 Experimental Results versus FEM Based Analysis of a Squirrel Cage Induction Motor Sorin VLĂSCEANU, Alecsandru SIMION, Nicolae_Daniel IRIMIA, Adrian MUNTEANU, Ovidiu DABIJA Faculty of Electrical Engineering "Gheorghe Asachi" Technical University of Iaşi Bd. Mangeron nr , RO , Iaşi, Romania soryn_85@yahoo.com; Abstract. This paper focuses a comparative study on the operating characteristics of a three phase induction motor in squirrel cage classical construction. Operating characteristics of the machine were obtained by performing experimental tests on a special stand from the electrical machines laboratory. These were then compared with the characteristics obtained by simulation using computer software FLUX 2D algorithm based on FEM (Finite Element Method). After studying the obtained results, some comparative conclusions were drawn. 1 Introduction The generalization of the three phase system for transmission and distribution of the electricity during the last period, leaded to the construction of induction machines capable of operating in direct correlation with this type of system [1]. Squirrel-cage induction motors are some of the electric motors used due to the advantages they possessed. The technological advantages are: simplicity of construction, robustness, relatively high technical performance, operational stability etc. and the economic nature requiring low costs both for the construction process and also maintenance. A special attention should be paid to the design and validation results by simulation, which requires field calculation programs. Using simulation programs that operate with finite element method to achieve field calculations, represents a solution in determining the operating characteristics of the electric motors, successfully applied in this case to compare results obtained from measured parameters of the induction machines with those obtained in the simulation [2]. Therefore this paper aims to analyze an existing three-phase induction motor in electric machines laboratory. The motor initially is studied on the bench testing and drawn the operating characteristics. After measurements, the motor is simulated in a field analysis program where the results were compared with measured on the test stand. 2 Geometry Description Figure 1: The view of the studied induction motor on the laboratory stand. 1
2 The motor studied is produced by german company Quick ROTAN" Type NDK 880/12 and it was designed for laboratory tests being provided with an electromagnetic brake. To reduce any additional torque that could affect operating characteristics, this system was removed. In figure 1 is shown an image with the motor on the laboratory stand where the measurements took place. Figure 2 shows the induction machine's geometry that was realised in simulation software. Further are presented the nominal motor data and main constructive parameters: Table 1 Main parameters of the induction motor Constuctive elements Value Number of stator slots 24 The length of the machine 70 mm Outer diameter stator 136 mm Inner diameter stator 70 mm Stator yoke height 16,5 mm Stator slot height 16,5mm Stator tooth width 4 mm Number of pole pairs (p) 1 Number of rotor slots 18 Outer diameter rotor 69,4 mm Rotor yoke height 9,17 mm Rotor slot height 14 mm Rotor tooth width 5 mm Shorting ring rotor thickness 14 mm Height shorting ring rotor 15 mm Shaft diameter 22 mm Figure 2: The transversal section of the induction motor. The three phase motor parameters are: m = 3, 2p = 2, P N = 0.55 kw, U N = 380 V, being in star connection, I N = 1.6 A, f = 50/60 Hz, n = 2850/3460 rpm. Machine s stator core is made of steel laminations with a thickness of 0.5 mm, being provided with a lake isolation between them. The stator phase is curly type winding, arranged in a single layer, with the number of slots per pole and phase: y 1 =4. The four coils that make up a stator phase are disposed in series. Each motor phase resistance has the value of R f = 9.8 Ω, being measured at nominal operating temperature of the motor. Each slot of the stator core is crossed by 100 conductors of round wire with a diameter of 0.75 mm resulting a current density: I N J A / mm (1) SCu a where I N is nominal current for a stator phase, S Cu - sectional area of conductor and a 1 - number of parallel current paths. Rotor core is made also from steel laminations. The rotor has 18 oval slots and the teeth have parallel walls. The main dimensions are given in the table above. Rotor bars are made from cast aluminum and are skewed towards generating with an angle of 20 0 which corresponds to the angle between two rotor slots. Tilt rotor slots lead to the removal of odd harmonics and electromagnetic torque increase. 2
3 3 Comparative results Experimental tests of the three phase induction motor were performed on a Lucas Nulle stand (produced in Germany). Plotting operating characteristics were achieved by monitoring electrical quantities, tracked and analyzed both through analogical measuring instruments and virtual instrumentation performed by using an acquisition board (DAQ) with multiple input channels, such as NI-6062, at a sampling frequency of 500 khz, produced by National Instruments. Also, using the LabVIEW software package, the acquisition and data processing diagrams were drawn. Keeping rigorously the geometrical and electrical parameters, a simulation analysis was performed in skewed flow calculation package software produced by CEDRAT. Due to the tilt of the rotor bars, the motor geometry is divided lengthwise into 5 slices and the calculations are different for each slice independently. Figure 3 shows a detail of the meshed domain, flux lines distribution and flux density color maps. a b c Figure 3: a) Mesh domain, b) Flux lines distribution and c) Flux density color maps. The simulation software provides the magnetic induction values in different structural elements of the machine by which it can be determined the saturation degree of the magnetic circuit. From the spectral map of induction and its color scale attached thereto, it is found that the mean magnetic loading are within allowable limits of: T. From the experimental and simulated mechanical and respectively stator phase current characteristics, it can be observed that for the same values of the electromagnetic torque developed by the motor, the supply currents are lower in the simulation compared to those measured. This is because in the simulations were 3
4 not introduced any losses which usually occurs in a real type motor (ventilation losses, viscous friction, mechanical losses etc). The measured torque for the low speed values (at the beginning of the start-up process) it s not accurate represented because of the limited measuring possibilities of the working stand. Figure 4: Torque-slip characteristics Figure 5: Stator current versus slip characteristics Figure 6: Air-gap flux density and content in high order harmonics. Figure 6 shows the air-gap magnetic flux density for two poles of the motor and the high order harmonics content. The fundamental value is about 0.6 T. The presence of the stator and rotor teeth causes some oscillations in the waveform of the air gap flux. It can be observed that the nominal air gap induction waveform is approaching a sine wave, due to the high number of slots forming a pair of poles. Of a particular importance in assessing the start-up performance is the knowledge of the high order harmonics (3, 5 and 7). In case of the three-phase winding, the third harmonic, which usually draws attention, is generally suppressed by the star winding connection. In this context, the spatial harmonic of rank 5 (which is about 6 % of the fundamental) of the induction waveform will create a rotating field which speed is proportional to its rank and in the same moving sense as the rotor, while the 3 and 7 harmonics in reverse. 4
5 Figure 7: Variation of the torque and speed from start-up to the nominal speed. By analyzing the speed characteristic from the figure 7, it can be seen that the motor has a start-up time (until it reaches the nominal speed) of approximately 0.2 seconds. In the first moments of the startup process, the electromagnetic torque oscillates around 4 Nm and then stabilizes at about 0.2 Nm. In the no-load regime, the value of the I 0 current absorbed by the motor is desired to be known. This current has an active component I 0a, which is much smaller than the reactive component I 0r, the motor having in this case a lower power factor value. If the active component is being neglected, the current absorbed by the motor is equal to the reactive component (which is actually magnetizing current) for the no-load regime [3]. Figure 8: Current waveforms through the stator phases, from the start-up to the nominal speed. At startup, the stator phase currents amplitudes are about 10 times higher than the nominal value. When the rotor is stabilized at the rated speed for the no-load regime, stator currents obtained both from laboratory measurements and also from simulations, reaches a peak value of about 1.3 A, which justifies the correctness of the computer simulation program. The next figure shows the induced voltages on the rotor bar and the waveform of the current from the start-up of the motor, to the nominal speed value. 5
6 4 Conclusion Figure 9: Rotor bar current and the induced voltage from start-up to the nominal speed. Using simulation programs that operate with finite element method to achieve field calculations, represents a convenient solution in determining the operating characteristics of electric motors, successfully applied in this case to compare the results obtained from measurements with those from the simulation. The analysis by simulation confirm the data obtained on the experimental model, thus validating the accuracy of the results. In addition, the accuracy of the results obtained by the simulation program is influenced by the accuracy with which various components were calculated and defined, in order to design the study model. The improvement of the electric motors performances can be done with quite high accuracy by successive simulations, leading to significantly reducing of the production costs. Acknowledgments This paper was realised with the support of POSDRU CUANTUMDOC DOCTORAL STUDIES FOR EUROPEAN PERFORMANCES IN RESEARCH AND INOVATION ID79407 project funded by the European Social Found and Romanian Government. References [1] Simion Al., Electrical Machines (in Roumain), third volume, Induction Machine, PIM publisher, Iasi, Romania, 2012, ISBN X; [2] Weili, L. Xie Ying, Shen Jiafeng, Luo Yingli, Finite-Element Analysis of Field Distribution and Characteristic Performance of Squirrel-Cage Induction Motor With Broken Bars, Magnetics, IEEE Transactions on Harbin Univ. of Sci. & Technol., pp: , April, 2007; [3] Simion Al, Livadaru L, Munteanu A, Induction Motors - Modelling and Control, Chapter 1- Mathematical Model of the Three-Phase Induction Machine for the Study of Steady-State and Transient Duty Under Balanced and Unbalanced States, publisher InTech, pp: 3-44, November 14, 2012, ISBN ; [4] Grantham C., McKinnon D. J., Rapid Parameter Determination for Induction Motor Analysis and Control, IEEE Transactions on Industry Applications, Vol. 39, No. 4, pp: , july/august 2003; [5] Balamurugan, S., Arumugam, R., Paramasivam, S., Malaiappan, M, Transient analysis of induction motor using finite element analysis, Industrial Electronics Society Dept. of Electr. & Electron. Eng., IECON th Annual Conference of IEEE. Anna Univ., Madras, India, 2004; [6] Kometani, H., Sakabe, S. ; Kameari, A., 3-D analysis of induction motor with skewed slots using regular coupling mesh, Magnetics, IEEE Transactions on Adv. Technol. R&D Center, Mitsubishi Electr. Corp., Hyogo, pp: , Jul
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