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DESIGN OF ROTATING
ELECTRICAL
MACHINES

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6

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DESIGN OF ROTATING
ELECTRICAL
MACHINES

Juha Pyrhönen
Department of Electrical Engineering, Lappeenranta University of Technology, Finland

Tapani Jokinen
Department of Electrical Engineering, Helsinki University of Technology, Finland

Valéria Hrabovcová
Department of Power Electrical Systems, Faculty of Electrical Engineering,
University of Žilina, Slovak Republic

Translated by
Hanna Niemelä
Department of Electrical Engineering, Lappeenranta University of Technology, Finland

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This edition first published 2008

C 2008 John Wiley & Sons, Ltd

Adapted from the original version in Finnish written by Juha Pyrhönen and published by Lappeenranta University
of Technology

C Juha Pyrhönen, 2007

Registered office
John Wiley & Sons Ltd, The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, United Kingdom

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Library of Congress Cataloging-in-Publication Data

Pyrhönen, Juha.
Design of rotating electrical machines / Juha Pyrhönen, Tapani Jokinen, Valéria Hrabovcová ; translated by
Hanna Niemelä.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-470-69516-6 (cloth)
1. Electric machinery–Design and construction. 2. Electric generators–Design and construction. 3. Electric
motors–Design and construction. 4. Rotational motion. I. Jokinen, Tapani, 1937– II. Hrabovcová, Valéria.
III. Title.
TK2331.P97 2009
621.31 042–dc22
2008042571

A catalogue record for this book is available from the British Library.

ISBN: 978-0-470-69516-6 (H/B)

Typeset in 10/12pt Times by Aptara Inc., New Delhi, India.

Printed in Great Britain by CPI Antony Rowe, Chippenham, Wiltshire

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Contents
About the Authors xi

Preface xiii

Abbreviations and Symbols xv

1 Principal Laws and Methods in Electrical Machine Design 1

1.1 Electromagnetic Principles 1
1.2 Numerical Solution 9
1.3 The Most Common Principles Applied to Analytic Calculation 12
1.3.1 Flux Line Diagrams 17
1.3.2 Flux Diagrams for Current-Carrying Areas 22
1.4 Application of the Principle of Virtual Work in the Determination
of Force and Torque 25
1.5 Maxwell’s Stress Tensor; Radial and Tangential Stress 33
1.6 Self-Inductance and Mutual Inductance 36
1.7 Per Unit Values 40
1.8 Phasor Diagrams 43
Bibliography 45

2 Windings of Electrical Machines 47

2.1 Basic Principles 48
2.1.1 Salient-Pole Windings 48
2.1.2 Slot Windings 52
2.1.3 End Windings 53
2.2 Phase Windings 54
2.3 Three-Phase Integral Slot Stator Winding 56
2.4 Voltage Phasor Diagram and Winding Factor 63
2.5 Winding Analysis 71
2.6 Short Pitching 72
2.7 Current Linkage of a Slot Winding 81
2.8 Poly-Phase Fractional Slot Windings 92
2.9 Phase Systems and Zones of Windings 95
2.9.1 Phase Systems 95
2.9.2 Zones of Windings 98

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2.10 Symmetry Conditions 99

2.11 Base Windings 102
2.11.1 First-Grade Fractional Slot Base Windings 103
2.11.2 Second-Grade Fractional Slot Base Windings 104
2.11.3 Integral Slot Base Windings 104
2.12 Fractional Slot Windings 105
2.12.1 Single-Layer Fractional Slot Windings 105
2.12.2 Double-Layer Fractional Slot Windings 115
2.13 Single- and Two-Phase Windings 122
2.14 Windings Permitting a Varying Number of Poles 126
2.15 Commutator Windings 127
2.15.1 Lap Winding Principles 131
2.15.2 Wave Winding Principles 134
2.15.3 Commutator Winding Examples, Balancing Connectors 137
2.15.4 AC Commutator Windings 140
2.15.5 Current Linkage of the Commutator Winding and
Armature Reaction 142
2.16 Compensating Windings and Commutating Poles 145
2.17 Rotor Windings of Asynchronous Machines 147
2.18 Damper Windings 150
Bibliography 152

3 Design of Magnetic Circuits 153

3.1 Air Gap and its Magnetic Voltage 159
3.1.1 Air Gap and Carter Factor 159
3.1.2 Air Gaps of a Salient-Pole Machine 164
3.1.3 Air Gap of Nonsalient-Pole Machine 169
3.2 Equivalent Core Length 171
3.3 Magnetic Voltage of a Tooth and a Salient Pole 173
3.3.1 Magnetic Voltage of a Tooth 173
3.3.2 Magnetic Voltage of a Salient Pole 177
3.4 Magnetic Voltage of Stator and Rotor Yokes 177
3.5 No-Load Curve, Equivalent Air Gap and Magnetizing Current
of the Machine 180
3.6 Magnetic Materials of a Rotating Machine 183
3.6.1 Characteristics of Ferromagnetic Materials 187
3.6.2 Losses in Iron Circuits 193
3.7 Permanent Magnets in Rotating Machines 200
3.7.1 History and Characteristics of Permanent Magnets 200
3.7.2 Operating Point of a Permanent Magnet Circuit 205
3.7.3 Application of Permanent Magnets in Electrical Machines 213
3.8 Assembly of Iron Stacks 219
3.9 Magnetizing Inductance 221
Bibliography 224
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Contents vii

4 Flux Leakage 225

4.1 Division of Leakage Flux Components 227
4.1.1 Leakage Fluxes Not Crossing an Air Gap 227
4.1.2 Leakage Fluxes Crossing an Air Gap 228
4.2 Calculation of Flux Leakage 230
4.2.1 Air-Gap Leakage Inductance 230
4.2.2 Slot Leakage Inductance 234
4.2.3 Tooth Tip Leakage Inductance 245
4.2.4 End Winding Leakage Inductance 246
4.2.5 Skewing Factor and Skew Leakage Inductance 250
Bibliography 253

5 Resistances 255
5.1 DC Resistance 255
5.2 Influence of Skin Effect on Resistance 256
5.2.1 Analytical Calculation of Resistance Factor 256
5.2.2 Critical Conductor Height 265
5.2.3 Methods to Limit the Skin Effect 266
5.2.4 Inductance Factor 267
5.2.5 Calculation of Skin Effect Using Circuit Analysis 267
5.2.6 Double-Sided Skin Effect 274
Bibliography 280

6 Main Dimensions of a Rotating Machine 281

6.1 Mechanical Loadability 291
6.2 Electrical Loadability 293
6.3 Magnetic Loadability 294
6.4 Air Gap 297
Bibliography 300

7 Design Process and Properties of Rotating Electrical Machines 301

7.1 Asynchronous Motor 313
7.1.1 Current Linkage and Torque Production of an
Asynchronous Machine 315
7.1.2 Impedance and Current Linkage of a Cage Winding 320
7.1.3 Characteristics of an Induction Machine 327
7.1.4 Equivalent Circuit Taking Asynchronous Torques and Harmonics
into Account 332
7.1.5 Synchronous Torques 337
7.1.6 Selection of the Slot Number of a Cage Winding 339
7.1.7 Construction of an Induction Motor 342
7.1.8 Cooling and Duty Types 343
7.1.9 Examples of the Parameters of Three-Phase Industrial
Induction Motors 348
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7.1.10 Asynchronous Generator 351

7.1.11 Asynchronous Motor Supplied with Single-Phase Current 353
7.2 Synchronous Machine 358
7.2.1 Inductances of a Synchronous Machine in Synchronous Operation
and in Transients 359
7.2.2 Loaded Synchronous Machine and Load Angle Equation 370
7.2.3 RMS Value Phasor Diagrams of a Synchronous Machine 376
7.2.4 No-Load Curve and Short-Circuit Test 383
7.2.5 Asynchronous Drive 386
7.2.6 Asymmetric-Load-Caused Damper Currents 391
7.2.7 Shift of Damper Bar Slotting from the Symmetry Axis of the Pole 392
7.2.8 V Curve of a Synchronous Machine 394
7.2.9 Excitation Methods of a Synchronous Machine 394
7.2.10 Permanent Magnet Synchronous Machines 395
7.2.11 Synchronous Reluctance Machines 400
7.3 DC Machines 404
7.3.1 Configuration of DC Machines 404
7.3.2 Operation and Voltage of a DC Machine 405
7.3.3 Armature Reaction of a DC Machine and Machine Design 409
7.3.4 Commutation 411
7.4 Doubly Salient Reluctance Machine 413
7.4.1 Operating Principle of a Doubly Salient Reluctance Machine 414
7.4.2 Torque of an SR Machine 415
7.4.3 Operation of an SR Machine 416
7.4.4 Basic Terminology, Phase Number and Dimensioning of
an SR Machine 419
7.4.5 Control Systems of an SR Motor 422
7.4.6 Future Scenarios for SR Machines 425
Bibliography 427

8 Insulation of Electrical Machines 429

8.1 Insulation of Rotating Electrical Machines 431
8.2 Impregnation Varnishes and Resins 436
8.3 Dimensioning of an Insulation 440
8.4 Electrical Reactions Ageing Insulation 443
8.5 Practical Insulation Constructions 444
8.5.1 Slot Insulations of Low-Voltage Machines 445
8.5.2 Coil End Insulations of Low-Voltage Machines 445
8.5.3 Pole Winding Insulations 446
8.5.4 Low-Voltage Machine Impregnation 447
8.5.5 Insulation of High-Voltage Machines 447
8.6 Condition Monitoring of Insulation 449
8.7 Insulation in Frequency Converter Drives 453
Bibliography 455
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Contents ix

9 Heat Transfer 457

9.1 Losses 458
9.1.1 Resistive Losses 458
9.1.2 Iron Losses 460
9.1.3 Additional Losses 460
9.1.4 Mechanical Losses 460
9.2 Heat Removal 462
9.2.1 Conduction 463
9.2.2 Radiation 466
9.2.3 Convection 470
9.3 Thermal Equivalent Circuit 476
9.3.1 Analogy between Electrical and Thermal Quantities 476
9.3.2 Average Thermal Conductivity of a Winding 477
9.3.3 Thermal Equivalent Circuit of an Electrical Machine 479
9.3.4 Modelling of Coolant Flow 488
9.3.5 Solution of Equivalent Circuit 493
9.3.6 Cooling Flow Rate 495
Bibliography 496

Appendix A 497

Appendix B 501

Index 503
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About the Authors

Juha Pyrhönen is a Professor in the Department of Electrical Engineering at Lappeenranta
University of Technology, Finland. He is engaged in the research and development of electric
motors and drives. He is especially active in the fields of permanent magnet synchronous ma-
chines and drives and solid-rotor high-speed induction machines and drives. He has worked on
many research and industrial development projects and has produced numerous publications
and patents in the field of electrical engineering.
Tapani Jokinen is a Professor Emeritus in the Department of Electrical Engineering at
Helsinki University of Technology, Finland. His principal research interests are in AC ma-
chines, creative problem solving and product development processes. He has worked as an
electrical machine design engineer with Oy Strömberg Ab Works. He has been a consul-
tant for several companies, a member of the Board of High Speed Tech Ltd and Neorem
Magnets Oy, and a member of the Supreme Administrative Court in cases on patents. His
research projects include, among others, the development of superconducting and large per-
manent magnet motors for ship propulsion, the development of high-speed electric motors
and active magnetic bearings, and the development of finite element analysis tools for solving
electrical machine problems.
Valéria Hrabovcová is a Professor of Electrical Machines in the Department of Power
Electrical Systems, Faculty of Electrical Engineering, at the University of Žilina, Slovak
Republic. Her professional and research interests cover all kinds of electrical machines, elec-
tronically commutated electrical machines included. She has worked on many research and
development projects and has written numerous scientific publications in the field of electrical
engineering. Her work also includes various pedagogical activities, and she has participated
in many international educational projects.

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Preface
Electrical machines are almost entirely used in producing electricity, and there are very few
electricity-producing processes where rotating machines are not used. In such processes,
at least auxiliary motors are usually needed. In distributed energy systems, new machine
types play a considerable role: for instance, the era of permanent magnet machines has now
commenced.
About half of all electricity produced globally is used in electric motors, and the share of
accurately controlled motor drives applications is increasing. Electrical drives provide proba-
bly the best control properties for a wide variety of processes. The torque of an electric motor
may be controlled accurately, and the efficiencies of the power electronic and electromechan-
ical conversion processes are high. What is most important is that a controlled electric motor
drive may save considerable amounts of energy. In the future, electric drives will probably
play an important role also in the traction of cars and working machines. Because of the
large energy flows, electric drives have a significant impact on the environment. If drives
are poorly designed or used inefficiently, we burden our environment in vain. Environmen-
tal threats give electrical engineers a good reason for designing new and efficient electric
drives.
Finland has a strong tradition in electric motors and drives. Lappeenranta University of
Technology and Helsinki University of Technology have found it necessary to maintain and
expand the instruction given in electric machines. The objective of this book is to provide stu-
dents in electrical engineering with an adequate basic knowledge of rotating electric machines,
for an understanding of the operating principles of these machines as well as developing el-
ementary skills in machine design. However, due to the limitations of this material, it is not
possible to include all the information required in electric machine design in a single book,
yet this material may serve as a manual for a machine designer in the early stages of his or
her career. The bibliographies at the end of chapters are intended as sources of references
and recommended background reading. The Finnish tradition of electrical machine design is
emphasized in this textbook by the important co-authorship of Professor Tapani Jokinen, who
has spent decades in developing the Finnish machine design profession. An important view of
electrical machine design is provided by Professor Valéria Hrabovcová from Slovak Republic,
which also has a strong industrial tradition.
We express our gratitude to the following persons, who have kindly provided material for
this book: Dr Jorma Haataja (LUT), Dr Tanja Hedberg (ITT Water and Wastewater AB),
Mr Jari Jäppinen (ABB), Ms Hanne Jussila (LUT), Dr Panu Kurronen (The Switch Oy),
Dr Janne Nerg (LUT), Dr Markku Niemelä (ABB), Dr Asko Parviainen (AXCO Motors Oy),

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xiv Preface

Mr Marko Rilla (LUT), Dr Pia Salminen (LUT), Mr Ville Sihvo and numerous other col-
leagues. Dr Hanna Niemelä’s contribution to this edition and the publication process of the
manuscript is highly acknowledged.

Juha Pyrhönen
Tapani Jokinen
Valéria Hrabovcová
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Abbreviations and Symbols

A linear current density [A/m]
A magnetic vector potential [V s/m]
A temperature class 105 ◦ C
AC alternating current
AM asynchronous machine
A1–A2 armature winding of a DC machine
a number of parallel paths in windings without commutator: per phase, in
windings with a commutator: per half armature, diffusivity
B magnetic flux density, vector [V s/m2 ], [T]
Br remanence flux density [T]
Bsat saturation flux density [T]
B temperature class 130 ◦ C
B1–B2 commutating pole winding of a DC machine
b width [m]
b0c conductor width [m]
bc conductor width [m]
bd tooth width [m]
bdr rotor tooth width [m]
bds stator tooth width [m]
br rotor slot width [m]
bs stator slot width [m]
bv width of ventilation duct [m]
b0 slot opening [m]
C capacitance [F], machine constant, integration constant
C temperature class >180 ◦ C
C1–C2 compensating winding of a DC machine
Cf friction coefficient
c specific heat capacity [J/kg K], capacitance per unit of length, factor,
divider, constant
cp specific heat capacity of air at constant pressure
cth heat capacity
CTI Comparative Tracking Index
cv specific volumetric heat [kJ/K m3 ]
D electric flux density [C/m2 ], diameter [m]
DC direct current

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xvi Abbreviations and Symbols

Dr outer diameter of the rotor [m]

Dri inner diameter of the rotor [m]
Ds inner diameter of the stator [m]
Dse outer diameter of the stator [m]
D1–D2 series magnetizing winding of a DC machine
d thickness [m]
dt thickness of the fringe of a pole shoe [m]
E electromotive force (emf) [V], RMS, electric field strength [V/m], scalar, elastic
modulus, Young’s modulus [Pa]
Ea activation energy [J]
E electric field strength, vector [V/m]
E temperature class 120 ◦ C
E irradiation
E1–E2 shunt winding of a DC machine
e electromotive force [V], instantaneous value e(t)
e Napier’s constant
F force [N], scalar
F force [N], vector
F temperature class 155 ◦ C
FEA finite element analysis
Fg geometrical factor

Fm magnetomotive force H · dl [A], (mmf)
F1–F2 separate magnetizing winding of a DC machine or a synchronous machine
f frequency [Hz], Moody friction factor
g coefficient, constant, thermal conductance per unit length
G electrical conductance
G th thermal conductance
H magnetic field strength [A/m]
Hc , HcB coercivity related to flux density [A/m]
HcJ coercivity related to magnetization [A/m]
H temperature class 180 ◦ C, hydrogen
h height [m]
h 0c conductor height [m]
hc conductor height [m]
hd tooth height [m]
hp height of a subconductor [m]
h p2 height of pole body [m]
hs stator slot height [m]
h yr height of rotor yoke [m]
h ys height of stator yoke [m]
I electric current [A], RMS, brush current, second moment of an area, moment
of inertia of an area [m4 ]
IM induction motor
Ins counter-rotating current (negative-sequence component) [A]
Io current of the upper bar [A]
Is conductor current
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Abbreviations and Symbols xvii

Iu current of the lower bar, slot current, slot current amount [A]
IC classes of electrical machines
IEC International Electrotechnical Commission
Im imaginary part
i current [A], instantaneous value i(t)
J moment of inertia [kg m2 ], current density [A/m2 ], magnetic polarization
J Jacobian matrix
Jext moment of inertia of load [kg m2 ]
JM moment of inertia of the motor, [kgm2 ]
Jsat saturation of polarization [V s/m2 ]
Js surface current, vector [A/m]
j difference of the numbers of slots per pole and phase in different layers
j imaginary unit
K transformation ratio, constant, number of commutator segments
KL inductance ratio
k connecting factor (coupling factor), correction coefficient, safety factor, ordinal
of layers
kC Carter factor
kCu , kFe space factor for copper, space factor for iron
kd distribution factor
kE machine-related constant
kFe ,n correction factor
kk short-circuit ratio
kL skin effect factor for the inductance
kp pitch factor
kpw pitch factor due to coil side shift
kR skin effect factor for the resistance
ksat saturation factor
ksq skewing factor
kth coefficient of heat transfer [W/m2 K]
kv pitch factor of the coil side shift in a slot
kw winding factor
kσ safety factor in the yield
L self-inductance [H]
L characteristic length, characteristic surface, tube length [m]
LC inductor–capacitor
Ld tooth tip leakage inductance [H]
Lk short-circuit inductance [H]
Lm magnetizing inductance [H]
L md magnetizing inductance of an m-phase synchronous machine, in d-axis [H]
L mn mutual inductance [H]
L pd main inductance of a single phase [H]
Lu slot inductance [H]
L transient inductance [H]
L  subtransient inductance [H]
L1, L2, L3, network phases
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xviii Abbreviations and Symbols

l length [m], closed line, distance, inductance per unit of length, relative
inductance, gap spacing between the electrodes
l unit vector collinear to the integration path
l effective core length [m]
lew average conductor length of winding overhang [m]
lp wetted perimeter of tube [m]
lpu inductance as a per unit value
lw length of coil ends [m]
M mutual inductance [H], magnetization [A/m]
Msat saturation magnetization [A/m]
m number of phases, mass [kg],
m0 constant
N number of turns in a winding, number of turns in series
Nf1 number of coil turns in series in a single pole
Nu Nusselt number
Nu1 number of bars of a coil side in the slot
Nk number of turns of compensating winding
Np number of turns of one pole pair
Nv number of conductors in each side
N Nondrive end
N set of integers
Neven set of even integers
Nodd set of odd integers
n normal unit vector of the surface
n rotation speed (rotation frequency) [1/s], ordinal of the harmonic (sub),
ordinal of the critical rotation speed, integer, exponent
nU number of section of flux tube in sequence
nv number of ventilation ducts
n number of flux tube
P power, losses [W]
Pin input power [W]
PAM pole amplitude modulation
PMSM permanent magnet synchronous machine (or motor)
PWM pulse width modulation
P1 , Pad , P additional loss [W]
Pr Prandtl number
Pρ friction loss [W]
p number of pole pairs, ordinal, losses per core length
pAl aluminium content
p∗ number of pole pairs of a base winding
pd partial discharge
Q electric charge [C], number of slots, reactive power [VA],
Q av average number of slots of a coil group
Qo number of free slots
Q number of radii in a voltage phasor graph
Q∗ number of slots of a base winding
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Abbreviations and Symbols xix

Q th quantity of heat
q number of slots per pole and phase, instantaneous charge, q(t) [C]
qk number of slots in a single zone
qm mass flow [kg/s]
qth density of the heat flow [W/m2 ]
R resistance [], gas constant, 8.314 472 [J/K mol], thermal resistance,
reactive parts
Rbar bar resistance []
RM reluctance machine
RMS root mean square
Rm reluctance [A/V s = 1/H]
Rth thermal resistance [K/W]
Re real part
Re Reynolds number
Recrit critical Reynolds number
RR Resin-rich (impregnation method)
r radius [m], thermal resistance per unit length
r radius unit vector
S1–S8 duty types
S apparent power [VA], cross-sectional area
SM synchronous motor
SR switched reluctance
SyRM synchronous reluctance machine
Sc cross-sectional area of conductor [m2 ]
Sp pole surface area [m2 ]
Sr rotor surface area facing the air gap [m2 ]
S Poynting’s vector [W/m2 ], unit vector of the surface
s slip, skewing measured as an arc length
T torque [N m], absolute temperature [K], period [s]
Ta Taylor number
Tam modified Taylor number
Tb pull-out torque, peak torque [N m]
tc commutation period [s]
TEFC totally enclosed fan-cooled
TJ mechanical time constant [s]
Tmec mechanical torque [N m]
Tu pull-up torque [N m]
Tv counter torque [N m]
Tl locked rotor torque, [N m]
t time [s], number of phasors of a single radius, largest common divider,
lifetime of insulation
t tangential unit vector
tc commutation period [s]
tr rise time [s]
t* number of layers in a voltage vector graph for a base winding
U voltage [V], RMS
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xx Abbreviations and Symbols

U depiction of a phase
Um magnetic voltage [A]
Usj peak value of the impulse voltage [V]
Uv coil voltage [V]
U1 terminal of the head of the U phase of a machine
U2 terminal of the end of the U phase of a machine
u voltage, instantaneous value u(t) [V], number of coil sides in a layer
u b1 blocking voltage of the oxide layer [V]
uc commutation voltage [V]
um mean fluid velocity in tube [m/s]
V volume [m3 ], electric potential
V depiction of a phase
Vm scalar magnetic potential [A]
VPI vacuum pressure impregnation
V1 terminal of the head of the V phase of a machine
V2 terminal of the end of the V phase of a machine
v speed, velocity [m/s]
v vector
W energy [J], coil span (width) [m]
W depiction of a phase
Wd energy returned through the diode to the voltage source in SR drives
Wfc energy stored in the magnetic field in SR machines
Wmd energy converted to mechanical work while de-energizing the phase
in SR drives
Wmt energy converted into mechanical work when the transistor is conducting
in SR drives
WR energy returning to the voltage source in SR drives
W coenergy [J]
W1 terminal of the head of the W phase of a machine
W2 terminal of the end of the W phase of a machine
WΦ magnetic energy [J]
w length [m], energy per volume unit
X reactance []
x coordinate, length, ordinal number, coil span decrease [m]
xm relative value of reactance
Y admittance [S]
Y temperature class 90 ◦ C
y coordinate, length, step of winding
ym winding step in an AC commutator winding
yn coil span in slot pitches
yφ coil span of full-pitch winding in slot pitches (pole pitch expressed in
number of slots per pole)
yv coil span decrease in slot pitches
y1 step of span in slot pitches, back-end connector pitch
y2 step of connection in slot pitches, front-end connector pitch
yC commutator pitch in number of commutator segments
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Abbreviations and Symbols xxi

Z impedance [], number of bars, number of positive and negative phasors of the
phase
ZM characteristic impedance of the motor []
Zs surface impedance []
Z0 characteristic impedance []
z coordinate, length, integer, total number of conductors in the armature winding
za number of adjacent conductors
zb number of brushes
zc number of coils
zp number of parallel-connected conductors
zQ number of conductors in a slot
zt number of conductors on top each other
α angle [rad], [◦ ], coefficient, temperature coefficient, relative pole width of the
pole shoe, convection heat transfer coefficient [W/K]
1/α depth of penetration
α DC relative pole width coefficient for DC machines
αi factor of the arithmetical average of the flux density
αm mass transfer coefficient [(mol/sm2 )/(mol/m3 ) = m/s]
α ph angle between the phase winding
α PM relative permanent magnet width
αr heat transfer coefficient of radiation
α SM relative pole width coefficient for synchronous machines
α str angle between the phase winding
α th heat transfer coefficient [W/m2 K]
αu slot angle [rad], [◦ ]
αz phasor angle, zone angle [rad], [◦ ]
αρ angle of single phasor [rad], [◦ ]
β angle [rad], [◦ ], absorptivity
Γ energy ratio, integration route
Γc interface between iron and air
γ angle [rad], [◦ ], coefficient
γc commutation angle [rad], [◦ ]
γD switch conducting angle [rad], [◦ ]
δ air gap (length), penetration depth [m], dissipation angle [rad], [◦ ], load angle
[rad], [◦ ]
δc the thickness of concentration boundary layer [m]
δe equivalent air gap (slotting taken into account) [m]
δ ef effective air gap(influence of iron taken into account)
δv velocity boundary layer [m]
δT temperature boundary layer [m]
δ load angle [rad], [◦ ], corrected air gap [m]
δ0 minimum air gap [m]
ε permittivity [F/m], position angle of the brushes [rad], [◦ ], stroke angle [rad],
[◦ ], amount of short pitching
εth emissitivity
ε0 permittivity of vacuum 8.854 × 10−12 [F/m]
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xxii Abbreviations and Symbols

ζ phase angle [rad], [◦ ], harmonic factor

η efficiency, empirical constant, experimental pre-exponential constant,
reflectivity
Θ current linkage [A], temperature rise [K]
Θk compensating current linkage [A]
Θ total current linkage [A]
θ angle [rad], [◦ ]
ϑ angle [rad], [◦ ]
κ angle [rad], [◦ ], factor for reduction of slot opening, transmissivity
Λ permeance, [Vs/A], [H]
λ thermal conductivity [W/m K], permeance factor, proportionality factor,
inductance factor, inductance ratio
µ permeability [V s/A m, H/m], number of pole pairs operating simultaneously per
phase, dynamic viscosity [Pa s, kg/s m]
µr relative permeability
µ0 permeability of vacuum, 4π × 10−7 [V s/A m, H/m]
ν ordinal of harmonic, Poisson’s ratio, reluctivity [A m/V s, m/H], pulse velocity
ξ reduced conductor height
ρ resistivity [ m], electric charge density [C/m2 ], density [kg/m3 ], reflection
factor, ordinal number of a single phasor
ρA absolute overlap ratio
ρE effective overlap ratio
ρν transformation ratio for IM impedance, resistance, inductance
σ specific conductivity, electric conductivity [S/m], leakage factor, ratio of the
leakage flux to the main flux
σF tension [Pa]
σ Fn normal tension [Pa]
σ Ftan tangential tension [Pa]
σmec mechanical stress [Pa]
σSB Stefan–Boltzmann constant, 5.670 400 × 10−8 W/m2 /K4
τ relative time
τp pole pitch [m]
τ q2 pole pitch on the pole surface [m]
τr rotor slot pitch [m]
τs stator slot pitch [m]
τu slot pitch [m]
τv zone distribution
τd direct-axis transient short-circuit time constant [s]

τd0 direct-axis transient open-circuit time constant [s]

τd0 direct-axis subtransient open-circuit time constant [s]
τq quadrature-axis subtransient short-circuit time constant [s]

τq0 quadrature-axis subtransient open-circuit time constant [s]
υ factor, kinematic viscosity, µ/ρ, [Pa s/(kg/m3 )]
Φ magnetic flux [V s, Wb]
Φth thermal power flow, heat flow rate [W]
Φδ air gap flux [V s], [Wb]
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Abbreviations and Symbols xxiii

φ magnetic flux, instantaneous value φ(t) [V s], electric potential [V]

ϕ phase shift angle [rad], [◦ ]
ϕ function for skin effect calculation
 magnetic flux linkage [V s]
ψ electric flux [C],
ψ function for skin effect calculation
χ length/diameter ratio, shift of a single pole pair
Ω mechanical angular speed [rad/s]
ω electric angular velocity [rad/s], angular frequency [rad/s]
T temperature rise [K, ◦ C]
∇T temperature gradient [K/m, ◦ C/m]
p pressure drop [Pa]

Subscripts

0 section
1 primary, fundamental component, beginning of a phase, locked rotor torque,
2 secondary, end of a phase
Al aluminium
a armature, shaft
ad additional (loss)
av average
B brush
b base value, peak value of torque, blocking
bar bar
bearing bearing (losses)
C capacitor
Cu copper
c conductor, commutation
contact brush contact
conv convection
cp commutating poles
cr, crit critical
D direct, damper
DC direct current
d tooth, direct, tooth tip leakage flux
EC eddy current
e equivalent
ef effective
el electric
em electromagnetic
ew end winding
ext external
F force
Fe iron
f field
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xxiv Abbreviations and Symbols

Hy hysteresis
i internal, insulation
k compensating, short circuit, ordinal
M motor
m mutual, main
mag magnetizing, magnetic
max maximum
mec mechanical
min minimum
mut mutual
N rated
n nominal, normal
ns negative-sequence component
o starting, upper
opt optimal
PM permanent magnet
p pole, primary, subconductor, pole leakage flux
p1 pole shoe
p2 pole body
ph phasor, phase
ps positive-sequence component
pu per unit
q quadrature, zone
r rotor, remanence, relative
res resultant
S surface
s stator
sat saturation
sj impulse wave
sq skew
str phase section
syn synchronous
tan tangential
test test
th thermal
tot total
u slot, lower, slot leakage flux, pull-up torque
v zone, coil side shift in a slot, coil
w end winding leakage flux
x x-direction
y y-direction, yoke
ya armature yoke
yr rotor yoke
ys stator yoke
z z-direction, phasor of voltage phasor graph
δ air gap
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Abbreviations and Symbols xxv

γ ordinal of a subconductor
ν harmonic
ρ ordinal number of single phasor
ρ friction loss
ρw windage (loss)
σ flux leakage
Φ flux

Subscripts

ˆ peak/maximum value, amplitude


imaginary, apparent, reduced, virtual
* base winding, complex conjugate
Boldface symbols are used for vectors with components parallel to the unit
vectors i, j and k
A vector potential, A = i Ax + j Ak + k Az
B flux density, B = i Bx + j Bk + k Bz
I complex phasor of the current
I bar above the symbol denotes average value
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1
Principal Laws and Methods in
Electrical Machine Design

1.1 Electromagnetic Principles

A comprehensive command of electromagnetic phenomena relies fundamentally on
Maxwell’s equations. The description of electromagnetic phenomena is relatively easy when
compared with various other fields of physical sciences and technology, since all the field
equations can be written as a single group of equations. The basic quantities involved in the
phenomena are the following five vector quantities and one scalar quantity:

Electric field strength E [V/m]

Magnetic field strength H [A/m]
Electric flux density D [C/m2 ]
Magnetic flux density B [V s/m2 ], [T]
Current density J [A/m2 ]
Electric charge density, dQ/dV ρ [C/m3 ]

The presence of an electric and magnetic field can be analysed from the force exerted by
the field on a charged object or a current-carrying conductor. This force can be calculated by
the Lorentz force (Figure 1.1), a force experienced by an infinitesimal charge dQ moving at a
speed v. The force is given by the vector equation

dQ
dF = dQ(E + v × B) = dQE + dl × B = dQE + idl × B. (1.1)
dt

In principle, this vector equation is the basic equation in the computation of the torque for
various electrical machines. The latter part of the expression in particular, formulated with a
current-carrying element of a conductor of the length dl, is fundamental in the torque produc-
tion of electrical machines.

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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2 Design of Rotating Electrical Machines

dF

dl

Figure 1.1 Lorentz force dF acting on a differential length dl of a conductor carrying an electric cur-
rent i in the magnetic field B. The angle β is measured between the conductor and the flux density vector
B. The vector product i dl × B may now be written in the form i dl × B = idlB sin β

Example 1.1: Calculate the force exerted on a conductor 0.1 m long carrying a current of
10 A at an angle of 80◦ with respect to a field density of 1 T.
Solution: Using (1.1) we get directly for the magnitude of the force

F = |il × B| = 10 A · 0.1 m · sin 80◦ · 1 Vs/m2 = 0.98 V A s/m = 0.98 N.

In electrical engineering theory, the other laws, which were initially discovered empirically
and then later introduced in writing, can be derived from the following fundamental laws
presented in complete form by Maxwell. To be independent of the shape or position of the
area under observation, these laws are presented as differential equations.
A current flowing from an observation point reduces the charge of the point. This law of
conservation of charge can be given as a divergence equation

∂ρ
∇ ·J=− , (1.2)
∂t

which is known as the continuity equation of the electric current.

Maxwell’s actual equations are written in differential form as

∂B
∇ ×E = − , (1.3)
∂t
∂D
∇ ×H = J+ , (1.4)
∂t
∇ · D = ρ, (1.5)

∇ · B = 0. (1.6)
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Principal Laws and Methods in Electrical Machine Design 3

The curl relation (1.3) of an electric field is Faraday’s induction law that describes how
a changing magnetic flux creates an electric field around it. The curl relation (1.4) for mag-
netic field strength describes the situation where a changing electric flux and current pro-
duce magnetic field strength around them. This is Ampère’s law. Ampère’s law also yields a
law for conservation of charge (1.2) by a divergence Equation (1.4), since the divergence of
the curl is identically zero. In some textbooks, the curl operation may also be expressed as
∇ × E = curl E = rot E.
An electric flux always flows from a positive charge and passes to a negative charge. This
can be expressed mathematically by the divergence Equation (1.5) of an electric flux. This law
is also known as Gauss’s law for electric fields. Magnetic flux, however, is always a circulating
flux with no starting or end point. This characteristic is described by the divergence Equation
(1.6) of the magnetic flux density. This is Gauss’s law for magnetic fields. The divergence
operation in some textbooks may also be expressed as ∇ · D = div D.
Maxwell’s equations often prove useful in their integral form: Faraday’s induction law


d dΦ
E · dl = B · dS = − (1.7)
dt dt
l S

states that the change of a magnetic flux Φ penetrating an open surface S is equal to a negative
line integral of the electric field strength along the line l around the surface. Mathematically,
an element of the surface S is expressed by a differential operator dS perpendicular to the
surface. The contour line l of the surface is expressed by a differential vector dl parallel to
the line.
Faraday’s law together with Ampère’s law are extremely important in electrical machine
design. At its simplest, the equation can be employed to determine the voltages induced in the
windings of an electrical machine. The equation is also necessary for instance in the determi-
nation of losses caused by eddy currents in a magnetic circuit, and when determining the skin
effect in copper. Figure 1.2 illustrates Faraday’s law. There is a flux Φ penetrating through a
surface S, which is surrounded by the line l.

dS l

Figure 1.2 Illustration of Faraday’s induction law. A typical surface S, defined by a closed line l, is
penetrated by a magnetic flux Φ with a density B. A change in flux density creates an electric current
strength E. The circles illustrate the behaviour of E. dS is a vector perpendicular to the surface S
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4 Design of Rotating Electrical Machines

The arrows in the circles point the direction of the electric field strength E in the case
where the flux density B inside the observed area is increasing. If we  place a short-circuited
metal wire around the flux, we will obtain an integrated voltage l E · dl in the wire, and
consequently also an electric current. This current creates its own flux that will oppose the
flux penetrating through the coil.
If there are several turns N of winding (cf. Figure 1.2), the flux does not link all these turns
ideally, but with a ratio of less than unity. Hence we may denote the effective turns of winding
by kw N, (kw < 1). Equation (1.7) yields a formulation with an electromotive force e of a
multi-turn winding. In electrical machines, the factor kw is known as the winding factor (see
Chapter 2). This formulation is essential to electrical machines and is written as


d dΦ dΨ
e = −kw N B · dS = −kw N =− . (1.8)
dt dt dt
S

Here, we introduce the flux linkage Ψ = kw NΦ = LI, one of the core concepts of electrical
engineering. It may be noted that the inductance L describes the ability of a coil to produce
flux linkage Ψ . Later, when calculating the inductance, the effective turns, the permeance Λ
or the reluctance Rm of the magnetic circuit are needed (L = (kw N)2 Λ = (kw N)2 /Rm ).

Example 1.2: There are 100 turns in a coil having a cross-sectional area of 0.0001 m2 .
There is an alternating peak flux density of 1 T linking the turns of the coil with a winding
factor of kw = 0.9. Calculate the electromotive force induced in the coil when the flux
density variation has a frequency of 100 Hz.
Solution: Using Equation (1.8) we get

dΨ dΦ d
e=− = −kw N = −kw N B̂S sin ωt
dt dt dt
 
d Vs 100
= −0.9 · 100 · 1 2 · 0.0001 m2 sin · 2πt
dt m s

200 200
e = −90 · 2π V cos πt = −565 V cos πt.
s s
Hence, the peak value of √ the voltage is 565 V and the effective value of the voltage
induced in the coil is 565 V/ 2 = 400 V.

Ampère’s law involves a displacement current that can be given as the time derivative of
the electric flux ψ. Ampère’s law

 
d dψe
H · dl = J · dS + D · dS = i (t) + (1.9)
dt dt
l S S
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Principal Laws and Methods in Electrical Machine Design 5

B, H l
dS

ψe = E ⋅ dS
J ∫ S 0

ψe = E ⋅ dS
∫
S 0

Figure 1.3 Application of Ampère’s law in the surroundings of a current-carrying conductor. The line
l defines a surface S, the vector dS being perpendicular to it

indicates that a current i(t) penetrating a surface S and including the change of electric flux
has to be equal to the line integral of the magnetic flux H along the line l around the surface
S. Figure 1.3 depicts an application of Ampère’s law.
The term

d dψe
D · dS =
dt dt
S

in (1.9) is known as Maxwell’s displacement current, which ultimately links the electromag-
netic phenomena together. The displacement current is Maxwell’s historical contribution to
the theory of electromagnetism. The invention of displacement current helped him to explain
the propagation of electromagnetic waves in a vacuum in the absence of charged particles or
currents. Equation (1.9) is quite often presented in its static or quasi-static form, which yields

 
H · dl = J · dS = i (t) = Θ (t) . (1.10)
l S

The term ‘quasi-static’ indicates that the frequency f of the phenomenon in question is low
enough to neglect Maxwell’s displacement current. The phenomena occurring in electrical
machines meet the quasi-static requirement well, since, in practice, considerable displace-
ment currents appear only at radio frequencies or at low frequencies in capacitors that are
deliberately produced to take advantage of the displacement currents.
The quasi-static form of Ampère’s law is a very important equation in electrical machine
design. It is employed in determining the magnetic voltages of an electrical
 machine and
the required current linkage. The instantaneous value of the current sum i (t) in Equation
(1.10), that is the instantaneous value of current linkage Θ, can, if desired, be assumed to
involve also the apparent current linkage of a permanent magnet ΘPM = Hc h PM . Thus, the
apparent current linkage of a permanent magnet depends on the calculated coercive force Hc
of the material and on the thickness hPM of the magnetic material.
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6 Design of Rotating Electrical Machines

The corresponding differential form of Ampère’s law (1.10) in a quasi-static state (dD/dt
neglected) is written as

∇ × H = J. (1.11)

The continuity Equation (1.2) for current density in a quasi-static state is written as

∇ · J = 0. (1.12)

Gauss’s law for electric fields in integral form


D · dS = ρV dV (1.13)
S V

indicates that a charge inside a closed surface

 S that surrounds a volume V creates an electric
flux density D through the surface. Here V ρV dV = q (t) is the instantaneous net charge
inside the closed surface S. Thus, we can see that in electric fields, there are both sources and
drains. When considering the insulation of electrical machines, Equation (1.13) is required.
However, in electrical machines, it is not uncommon that charge densities in a medium prove
to be zero. In that case, Gauss’s law for electric fields is rewritten as


D · dS = 0 or ∇ · D = 0 ⇒ ∇ · E = 0. (1.14)
S

In uncharged areas, there are no sources or drains in the electric field either.
Gauss’s law for magnetic fields in integral form


B · dS = 0 (1.15)
S

states correspondingly that the sum of a magnetic flux penetrating a closed surface S is zero;
in other words, the flux entering an object must also leave the object. This is an alternative way
of expressing that there is no source for a magnetic flux. In electrical machines, this means for
instance that the main flux encircles the magnetic circuit of the machine without a starting or
end point. Similarly, all other flux loops in the machine are closed. Figure 1.4 illustrates the
surfaces S employed in integral forms of Maxwell’s equations, and Figure 1.5, respectively,
presents an application of Gauss’s law for a closed surface S.
The permittivity, permeability and conductivity ε, µ and σ of the medium determine the de-
pendence of the electric and magnetic flux densities and current density on the field strength.
In certain cases, ε, µ and σ can be treated as simple constants; then the corresponding pair
of quantities (D and E, B and H, or J and E) are parallel. Media of this kind are called
isotropic, which means that ε, µ and σ have the same values in different directions. Other-
wise, the media have different values of the quantities ε, µ and σ in different directions, and
may therefore be treated as tensors; these media are defined as anisotropic. In practice, the
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Principal Laws and Methods in Electrical Machine Design 7

dS S

dS
S
V

dl
(a) (b)

Figure 1.4 Surfaces for the integral forms of the equations for electric and magnetic fields. (a) An
open surface S and its contour l, (b) a closed surface S, enclosing a volume V. dS is a differential surface
vector that is everywhere normal to the surface

permeability in ferromagnetic materials is always a highly nonlinear function of the field

strength H: µ = f (H).
The general formulations for the equations of a medium can in principle be written as

D = f (E), (1.16)
B = f (H), (1.17)
J = f (E). (1.18)

E S

dS

(a) (b)

Figure 1.5 Illustration of Gauss’s law for (a) an electric field and (b) a magnetic field. The charge Q
inside a closed object acts as a source and creates an electric flux with the field strength E. Correspond-
ingly, a magnetic flux created by the current density J outside a closed surface S passes through the
closed surface (penetrates into the sphere and then comes out). The magnetic field is thereby sourceless
(div B = 0)
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8 Design of Rotating Electrical Machines

The specific forms for the equations have to be determined empirically for each medium
in question. By applying permittivity ε [F/m], permeability µ [V s/A m] and conductivity
σ [S/m], we can describe materials by the following equations:

D = εE, (1.19)
B = µH, (1.20)
J = σ E. (1.21)

The quantities describing the medium are not always simple constants. For instance, the
permeability of ferromagnetic materials is strongly nonlinear. In anisotropic materials, the
direction of flux density deviates from the field strength, and thus ε and µ can be tensors. In a
vacuum the values are

ε0 = 8.854 · 10−12 F/m, A s/V m and

µ0 = 4π · 10−7 H/m, V s/A m.

Example 1.3: Calculate the electric field density D over an insulation layer 0.3 mm thick
when the potential of the winding is 400 V and the magnetic circuit of the system is at
earth potential. The relative permittivity of the insulation material is εr = 3.
Solution: The electric field strength across the insulation is E = 400 V/0.3 mm =
133 kV/m. According to Equation (1.19), the electric field density is

D = εE = εr ε0 E = 3 · 8.854 · 10−12 A s/V m · 133 kV/m = 3.54 µA s/m2 .

Example 1.4: Calculate the displacement current over the slot insulation of the previous
example at 50 Hz when the insulation surface is 0.01 m2 .
Solution: The electric field over the insulation is ψ e = DS = 0.0354 µA s.
The time-dependent electric field over the slot insulation is

ψe (t) = ψ̂ e sin ωt = 0.0354 µA s sin 314t.

Differentiating with respect to time gives

dψe (t)
= ωψ̂ e cos ωt = 11 µA cos 314t.
dt
√
The effective current over the insulation is hence 11/ 2 = 7.86 µA.

Here we see that the displacement current is insignificant from the viewpoint of the ma-
chine’s basic functionality. However, when a motor is supplied by a frequency converter and
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Principal Laws and Methods in Electrical Machine Design 9

the transistors create high frequencies, significant displacement currents may run across the
insulation and bearing current problems, for instance, may occur.

1.2 Numerical Solution

The basic design of an electrical machine, that is the dimensioning of the magnetic and elec-
tric circuits, is usually carried out by applying analytical equations. However, accurate per-
formance of the machine is usually evaluated using different numerical methods. With these
numerical methods, the effect of a single parameter on the dynamical performance of the
machine can be effectively studied. Furthermore, some tests, which are not even feasible
in laboratory circumstances, can be virtually performed. The most widely used numerical
method is the finite element method (FEM), which can be used in the analysis of two- or
three-dimensional electromagnetic field problems. The solution can be obtained for static,
time-harmonic or transient problems. In the latter two cases, the electric circuit describing the
power supply of the machine is coupled with the actual field solution. When applying FEM
in the electromagnetic analysis of an electrical machine, special attention has to be paid to the
relevance of the electromagnetic material data of the structural parts of the machine as well as
to the construction of the finite element mesh.
Because most of the magnetic energy is stored in the air gap of the machine and important
torque calculation formulations are related to the air-gap field solution, the mesh has to be
sufficiently dense in this area. The rule of thumb is that the air-gap mesh should be divided
into three layers to achieve accurate results. In the transient analysis, that is in time-stepping
solutions, the selection of the size of the time step is also important in order to include the
effect of high-order time harmonics in the solution. A general method is to divide one time
cycle into 400 steps, but the division could be even denser than this, in particular with high-
speed machines.
There are five common methods to calculate the torque from the FEM field solution. The
solutions are (1) the Maxwell stress tensor method, (2) Arkkio’s method, (3) the method
of magnetic coenergy differentiation, (4) Coulomb’s virtual work and (5) the magnetizing
current method. The mathematical torque formulations related to these methods will shortly
be discussed in Sections 1.4 and 1.5.
The magnetic fields of electrical machines can often be treated as a two-dimensional case,
and therefore it is quite simple to employ the magnetic vector potential in the numerical so-
lution of the field. In many cases, however, the fields of the machine are clearly three dimen-
sional, and therefore a two-dimensional solution is always an approximation. In the following,
first, the full three-dimensional vector equations are applied.
The magnetic vector potential A is given by

B = ∇ × A; (1.22)

Coulomb’s condition, required to define unambiguously the vector potential, is written as

∇ · A = 0. (1.23)
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10 Design of Rotating Electrical Machines

The substitution of the definition for the magnetic vector potential in the induction law (1.3)
yields

∂
∇ × E = −∇ × A. (1.24)
∂t

Electric field strength can be expressed by the vector potential A and the scalar electric
potential φ as

∂A
E=− − ∇φ (1.25)
∂t

where φ is the reduced electric scalar potential. Because ∇ × ∇φ ≡ 0, adding a scalar po-
tential causes no problems with the induction law. The equation shows that the electric field
strength vector consists of two parts, namely a rotational part induced by the time dependence
of the magnetic field, and a nonrotational part created by electric charges and the polarization
of dielectric materials.
Current density depends on the electric field strength

∂A
J = σ E = −σ − σ ∇φ. (1.26)
∂t

Ampère’s law and the definition for vector potential yield

 
1
∇× ∇ × A = J. (1.27)
µ

Substituting (1.26) into (1.27) gives

 
1 ∂A
∇× ∇ ×A +σ + σ ∇φ = 0. (1.28)
µ ∂t

The latter is valid in areas where eddy currents may be induced, whereas the former is valid
in areas with source currents J = Js , such as winding currents, and areas without any current
densities J = 0.
In electrical machines, a two-dimensional solution is often the obvious one; in these cases,
the numerical solution can be based on a single component of the vector potential A. The field
solution (B, H) is found in an xy plane, whereas J, A and E involve only the z-component.
The gradient ∇φ only has a z-component, since J and A are parallel to z, and (1.26) is valid.
The reduced scalar potential is thus independent of x- and y-components. φ could be a linear
function of the z-coordinate, since a two-dimensional field solution is independent of z. The
assumption of two-dimensionality is not valid if there are potential differences caused by
electric charges or by the polarization of insulators. For two-dimensional cases with eddy
currents, the reduced scalar potential has to be set as φ = 0.
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Principal Laws and Methods in Electrical Machine Design 11

In a two-dimensional case, the previous equation is rewritten as

 
1 ∂ Az
−∇ · ∇ Az + σ = 0. (1.29)
µ ∂t

Outside eddy current areas, the following is valid:

 
1
−∇ · ∇ Az = Jz . (1.30)
µ

The definition of vector potential yields the following components for flux density:

∂ Az ∂ Az
Bx = , By = − . (1.31)
∂y ∂x

Hence, the vector potential remains constant in the direction of the flux density vector. Con-
sequently, the iso-potential curves of the vector potential are flux lines. In the two-dimensional
case, the following formulation can be obtained from the partial differential equation of the
vector potential:
   

∂ ∂ Az ∂ ∂ Az
−k ν + ν = kJ. (1.32)
∂x ∂x ∂y ∂y

Here ν is the reluctivity of the material. This again is similar to the equation for a static electric
field

∇ · (ν∇A) = −J. (1.33)

Further, there are two types of boundary conditions. Dirichlet’s boundary condition indi-
cates that a known potential, here the known vector potential

A = constant, (1.34)

can be achieved for a vector potential for instance on the outer surface of an electrical machine.
The field is parallel to the contour of the surface. Similar to the outer surface of an electrical
machine, also the centre line of the machine’s pole can form a symmetry plane. Neumann’s
homogeneous boundary condition determined with the vector potential

∂A
ν =0 (1.35)
∂n

can be achieved when the field meets a contour perpendicularly. Here n is the normal unit
vector of a plane. A contour of this kind is for instance part of a field confined to infinite
permeability iron or the centre line of the pole clearance.
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12 Design of Rotating Electrical Machines

Dirichlet
Φ12
A is constant,
corresponds to a flux line
Neumann y
∂A
ν =0 A1,A z
∂n 2 x

A is constant,
corresponds to Dirichlet´s
boundary condition

Figure 1.6 Left, a two-dimensional field and its boundary conditions for a salient-pole synchronous
machine are illustrated. Here, the constant value of the vector potential A (e.g. the machine’s outer
contour) is taken as Dirichlet’s boundary condition, and the zero value of the derivative of the vector po-
tential with respect to normal is taken as Neumann’s boundary condition. In the case of magnetic scalar
potential, the boundary conditions with respect to potential would take opposite positions. Because of
symmetry, the zero value of the normal derivative of the vector potential corresponds to the constant
magnetic potential V m , which in this case would be a known potential and thus Dirichlet’s boundary
condition. Right, a vector-potential-based field solution of a two-pole asynchronous machine assuming
a two-dimensional field is presented

The magnetic flux penetrating a surface is easy to calculate with the vector potential.
Stoke’s theorem yields for the flux
 

Φ= B · dS = (∇ × A) · dS = A · dl. (1.36)
S S l

This is an integral around the contour l of the surface S. These phenomena are illustrated with
Figure 1.6. In the two-dimensional case of the illustration, the end faces’ share of the integral
is zero, and the vector potential along the axis is constant. Consequently, for a machine of
length l we obtain a flux

Φ12 = l (A1 − A2 ) . (1.37)

This means that the flux Φ 12 is the flux between vector equipotential lines A1 and A2 .

1.3 The Most Common Principles Applied to Analytic Calculation

The design of an electrical machine involves the quantitative determination of the magnetic
flux of the machine. Usually, phenomena in a single pole are analysed. In the design of a mag-
netic circuit, the precise dimensions for individual parts are determined, the required current
linkage for the magnetic circuit and also the required magnetizing current are calculated, and
the magnitude of losses occurring in the magnetic circuit are estimated.
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Principal Laws and Methods in Electrical Machine Design 13

If the machine is excited with permanent magnets, the permanent magnet materials have to
be selected and the main dimensions of the parts manufactured from these materials have to
be determined. Generally, when calculating the magnetizing current for a rotating machine,
the machine is assumed to run at no load: that is, there is a constant current flowing in the
magnetizing winding. The effects of load currents are analysed later.
The design of a magnetic circuit of an electrical machine is based on Ampère’s law (1.4)
and (1.8). The line integral calculated around the magnetic circuit of an electrical machine,
that is the sum of magnetic potential differences Um,i , is equal to the surface integral of the
current densities over the surface S of the magnetic circuit. (The surface S here indicates the
surface penetrated by the main flux.) In practice, in electrical machines, the current usually
flows in the windings, the surface integral of the current density corresponding to the sum of
these currents (flowing in the windings), that is the current linkage Θ. Now Ampère’s law can
be rewritten as



Um,tot = Um,i = H · dl = J · dS = Θ = i. (1.38)
l S

The sum of magnetic potential differences U m around the complete magnetic circuit is
equal to the sum of the magnetizing currents in the circuit,
 that is the current linkage Θ. In
simple applications, the current sum may be given as i = kw N i, where kw N is the effective
number of turns and i the current flowing in them. In addition to the windings, this current
linkage may also involve the effect of the permanent magnets. In practice, when calculating
the magnetic voltage, the machine is divided into its components, and the magnetic voltage
U m between points a and b is determined as
 b
Um,ab = H · dl. (1.39)
a

In electrical machines, the field strength is often in the direction of the component in ques-
tion, and thus Equation (1.39) can simply be rewritten as
 b
Um,ab = H dl. (1.40)
a

Further, if the field strength is constant in the area under observation, we get

Um,ab = Hl. (1.41)

In the determination of the required current linkage Θ of a machine’s magnetizing winding,

the simplest possible integration path is selected in the calculation of the magnetic voltages.
This means selecting a path that encloses the magnetizing winding. This path is defined as the
main integration path and it is also called the main flux path of the machine (see Chapter 3).
In salient-pole machines, the main integration path crosses the air gap in the middle of the
pole shoes.
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14 Design of Rotating Electrical Machines

Example 1.5: Consider a C-core inductor with a 1 mm air gap. In the air gap, the flux
density is 1 T. The ferromagnetic circuit length is 0.2 m and the relative permeability of
the core material at 1 T is µr = 3500. Calculate the field strengths in the air gap and the
core, and also the magnetizing current needed. How many turns N of wire carrying a 10 A
direct current are needed to magnetize the choke to 1 T? Fringing in the air gap is neglected
and the winding factor is assumed to be kw = 1.
Solution: According to (1.20), the magnetic field strength in the air gap is
 
Hδ = Bδ /µ0 = 1 V s/m2 / 4π · 10−7 V s/A m = 795 kA/m.

The corresponding magnetic field strength in the core is

 
HFe = BFe (µr µ0 ) = 1 V s/m2 3500 · 4π · 10−7 V s/A m = 227 A/m.

The magnetic voltage in the air gap (neglecting fringing) is

Um,δ = Hδ δ = 795 kA/m · 0.001 m = 795 A.

The magnetic voltage in the core is

Um,Fe = HFelFe = 227 A/m · 0.2 m = 45 A.

The magnetomotive force (mmf) of the magnetic circuit is


H · dl = Um,tot = Um,i = Um,δ + Um,Fe = 795 A + 45 A = 840 A.
l

The current linkage Θ of the choke has to be of equal magnitude with the mmf U m,tot ,

Θ= i = kw N i = Um,tot .

We get

Um,tot 840 A
N= = = 84 turns.
kw i 1 · 10 A

In machine design, not only does the main flux have to be analysed, but also all the leakage
fluxes of the machine have to be taken into account.
In the determination of the no-load curve of an electrical machine, the magnetic voltages of
the magnetic circuit have to be calculated with several different flux densities. In practice, for
the exact definition of the magnetizing curve, a computation program that solves the different
magnetizing states of the machine is required.
According to their magnetic circuits, electrical machines can be divided into two main cate-
gories: in salient-pole machines, the field windings are concentrated pole windings, whereas in
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Principal Laws and Methods in Electrical Machine Design 15

nonsalient-pole machines, the magnetizing windings are spatially distributed in the machine.
The main integration path of a salient-pole machine consists for instance of the following
components: a rotor yoke (yr), pole body (p2), pole shoe (p1), air gap (δ), teeth (d) and ar-
mature yoke (ya). For this kind of salient-pole machine or DC machine, the total magnetic
voltage of the main integration path therefore consists of the following components

Um,tot = Um,yr + 2Um,p2 + 2Um,p1 + 2Um,δ + 2Um,d + Um,ya . (1.42)

In a nonsalient-pole synchronous machine and induction motor, the magnetizing winding

is contained in slots. Therefore both stator (s) and rotor (r) have teeth areas (d)

Um,tot = Um,yr + 2Um,dr + 2Um,δ + 2Um,ds + Um,ys . (1.43)

With Equations (1.42) and (1.43), we must bear in mind that the main flux has to flow twice
across the teeth area (or pole arc and pole shoe) and air gap.
In a switched reluctance (SR) machine, where both the stator and rotor have salient poles
(double saliency), the following equation is valid:

Um,tot = Um,yr + 2Um,rp2 + 2Um,rp1 (α) + 2Um,δ (α) + 2Um,sp1 (α) + 2Um,sp2 + Um,ys .
(1.44)

This equation proves difficult to employ, because the shape of the air gap in an SR machine
varies constantly when the machine rotates. Therefore the magnetic voltage of both the rotor
and stator pole shoes depends on the position of the rotor α.
The magnetic potential differences of the most common rotating electrical machines can be
presented by equations similar to Equations (1.42)–(1.44).
In electrical machines constructed of ferromagnetic materials, only the air gap can be
considered magnetically linear. All ferromagnetic materials are both nonlinear and often
anisotropic. In particular, the permeability of oriented electrical steel sheets varies in different
directions, being highest in the rolling direction and lowest in the perpendicular direction.
This leads to a situation where the permeability of the material is, strictly speaking, a tensor.
The flux is a surface integral of the flux density. Commonly, in electrical machine design,
the flux density is assumed to be perpendicular to the surface to be analysed. Since the area
of a perpendicular surface S is S, we can rewrite the equation simply as

Φ= BdS. (1.45)

Further, if the flux density B is also constant, we obtain

Φ = BS. (1.46)

Using the equations above, it is possible to construct a magnetizing curve for each part of
the machine
   
Φab = f Um,ab , B = f Um,ab . (1.47)
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16 Design of Rotating Electrical Machines

In the air gap, the permeability is constant µ = µ0 . Thus, we can employ magnetic conduc-
tivity, that is permeance Λ, which leads us to

Φab = Λab Um,ab . (1.48)

If the air gap field is homogeneous, we get

µ0 S
Φab = Λab Um,ab = Um,ab . (1.49)
δ

Equations (1.38) and (1.42)–(1.44) yield the magnetizing curve for a machine

Φδ = f (Θ), Bδ = f (Θ), (1.50)

where the term Φ δ is the air-gap flux. The absolute value for flux density Bδ is the maximum
flux density in the air gap in the middle of the pole shoe, when slotting is neglected. The mag-
netizing curve of the machine is determined in the order Φ δ , Bδ → B → H → Um → Θ
by always selecting a different value for the air-gap flux Φ δ , or for its density, and by cal-
culating the magnetic voltages in the machine and the required current linkage Θ. With the
current linkage, it is possible to determine the current I flowing in the windings. Correspond-
ingly, with the air-gap flux and the winding, we can determine the electromotive force (emf)
E induced in the windings. Now we can finally plot the actual no-load curve of the machine
(Figure 1.7)

E = f (I ). (1.51)

E Ψ

0 0
0 Im 0 Im

Figure 1.7 Typical no-load curve for an electrical machine expressed by the electromotive force E or
the flux linkage Ψ as a function of the magnetizing current I m . The E curve as a function of I m has been
measured when the machine is running at no load at a constant speed. In principle, the curve resembles
a BH curve of the ferromagnetic material used in the machine. The slope of the no-load curve depends
on the BH curve of the material, the (geometrical) dimensions and particularly on the length of the
air gap
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Principal Laws and Methods in Electrical Machine Design 17

Φ3

S3

S2

Φ2

S1

Φ1

Figure 1.8 Laminated tooth and a coarse flux tube running in a lamination. The cross-sections of the
tube are presented with surface vectors Si . There is a flux Φ flowing in the tube. The flux tubes
follow the flux lines in the magnetic circuit of the electrical machine. Most of the tubes constitute the
main magnetic circuit, but a part of the flux tubes forms leakage flux paths. If a two-dimensional field
solution is assumed, two-dimensional flux diagrams as shown in Figure 1.6 may replace the flux tube
approach

1.3.1 Flux Line Diagrams

Let us consider areas with an absence of currents. A spatial magnetic flux can be assumed to
flow in a flux tube. A flux tube can be analysed as a tube of a quadratic cross-section S. The
flux does not flow through the walls of the tube, and hence B · dS = 0 is valid for the walls.
As depicted in Figure 1.8, we can see that the corners of the flux tube form the flux lines.
When calculating a surface integral along a closed surface surrounding the surface of a flux
tube, Gauss’s law (1.15) yields


B · dS = 0. (1.52)

Since there is no flux through the side walls of the tube in Figure 1.8, Equation (1.52) can
be rewritten as




B1 · dS1 = B2 · dS2 = B3 · dS3 , (1.53)
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18 Design of Rotating Electrical Machines

indicating that the flux of the flux tube is constant

Φ1 = Φ2 = Φ3 = Φ. (1.54)

A magnetic equipotential surface is a surface with a certain magnetic scalar potential V m .

When travelling along any route between two points a and b on this surface, we must get

b
H · dl = Um,ab = Vma − Vmb = 0. (1.55)
a

When observing a differential route, this is valid only when H · dl = 0. For isotropic materials,
the same result can be expressed as B · dl = 0. In other words, the equipotential surfaces are
perpendicular to the lines of flux.
If we select an adequately small area S of the surface S, we are able to calculate the flux

Φ = BS. (1.56)

The magnetic potential difference between two equipotential surfaces that are close enough
to each other (H is constant along the integration path l) is written as

Um = Hl. (1.57)

The above equations give the permeance Λ of the cross-section of the flux tube

Φ B · dS dS
Λ= = =µ . (1.58)
Um Hl l

The flux line diagram (Figure 1.9) comprises selected flux and potential lines. The selected
flux lines confine flux tubes, which all have an equal flux Φ. The magnetic voltage between
the chosen potential lines is always the same, U m . Thus, the magnetic conductivity of each
section of the flux tube is always the same, and the ratio of the distance of flux lines x to the
distance of potential lines y is always the same. If we set

x
= 1, (1.59)
y

the field diagram forms, according to Figure 1.9, a grid of quadratic elements.
In a homogeneous field, the field strength H is constant at every point of the field. According
to Equations (1.57) and (1.59), the distance of all potential and flux lines is thus always the
same. In that case, the flux diagram comprises squares of equal size.
When constructing a two-dimensional orthogonal field diagram, for instance for the air gap
of an electrical machine, certain boundary conditions have to be known to be able to draw
the diagram. These boundary conditions are often solved based on symmetry, or also because
the potential of a certain potential surface of the flux tube in Figure 1.8 is already known.
For instance, if the stator and rotor length of the machine is l, the area of the flux tube can,
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Principal Laws and Methods in Electrical Machine Design 19

S1
z Um
ines x
l
flux y

Vm
2
Vm
1

potential line S2

Figure 1.9 Flux lines and potential lines in a three-dimensional area with a flux flowing across an area
where the length dimension z is constant. In principle, the diagram is thus two dimensional. Such a
diagram is called an orthogonal field diagram

without significant error, be written as dS = l dx. The interface of the iron and air is now
analysed according to Figure 1.10a. We get

dΦ y = B yδ ldx − B yFeldx = 0 ⇒ B yδ = B yFe . (1.60)

Here, Byδ and ByFe are the flux densities of air in the y-direction and of iron in the y-direction.

y
y By
Bx
air

air gap µ0 dy
δ µ0
By
dx l
Bx

x x
Φy
iron, e.g. rotor surface iron
z µFe z µFe

(a) (b)

Figure 1.10 (a) Interface of air δ and iron Fe. The x-axis is tangential to the rotor surface. (b) Flux
travelling on iron surface
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20 Design of Rotating Electrical Machines

In Figure 1.10a, the field strength has to be continuous in the x-direction on the iron–air
interface. If we consider the interface in the x-direction and, based on Ampère’s law, assume
a section dx of the surface has no current, we get

Hxδ dx − HxFe dx = 0, (1.61)

and thus

BxFe
Hxδ = HxFe = . (1.62)
µFe

By assuming that the permeability of iron is infinite, µFe → ∞, we get HxFe = Hxδ = 0
and thereby also Bxδ = µ0 Hxδ = 0.
Hence, if we set µFe → ∞, the flux lines leave the ferromagnetic material perpendicularly
into the air. Simultaneously, the interface of iron and air forms an equipotential surface. If
the iron is not saturated, its permeability is very high, and the flux lines can be assumed to
leave the iron almost perpendicularly in currentless areas. In saturating areas, the interface of
the iron and air cannot strictly be considered an equipotential surface. The magnetic flux and
the electric flux refract on the interface.
In Figure 1.10b, the flux flows in the iron in the direction of the interface. If the iron is not
saturated (µFe → ∞) we can set Bx ≈ 0. Now, there is no flux passing from the iron into air.
When the iron is about to become saturated (µFe → 1), a significant magnetic voltage occurs
in the iron. Now, the air adjacent to the iron becomes an appealing route for the flux, and
part of the flux passes into the air. This is the case for instance when the teeth of electrical
machines saturate: a part of the flux flows across the slots of the machine, even though the
permeability of the materials in the slot is in practice equal to the permeability of a vacuum.
The lines of symmetry in flux diagrams are either potential or field lines. When drawing a
flux diagram, we have to know if the lines of symmetry are flux or potential lines. Figure 1.11
is an example of an orthogonal field diagram, in which the line of symmetry forms a potential
line; this could depict for instance the air gap between the contour of an magnetizing pole of
a DC machine and the rotor.
The solution of an orthogonal field diagram by drawing is best started at those parts of the
geometry where the field is as homogeneous as possible. For instance, in the case of
Figure 1.11, we start from the point where the air gap is at its narrowest. Now, the surface
of the magnetizing pole and the rotor surface that is assumed to be smooth form the potential
lines together with the surface between the poles. First, the potential lines are plotted at equal
distances and, next, the flux lines are drawn perpendicularly to potential lines so that the area
under observation forms a grid of quadratic elements. The length of the machine being l, each
flux tube created this way carries a flux of Φ.
With the field diagram, it is possible to solve various magnetic parameters of the area under
observation. If nΦ is the number (not necessarily an integer) of contiguous flux tubes carrying
a flux Φ, and U m is the magnetic voltage between the sections of a flux tube (nU sec-
tions in sequence), the permeance of the entire air gap Λδ assuming that b = δ can be
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Principal Laws and Methods in Electrical Machine Design 21

symmetry line
Φ in the middle of pole

symmetry line
between poles
δ H0, B0
DC machine stator pole
Um potential line Φ

b δ0 δ U
0 m

23 20 15 10 5 1
b0
potential line DC machine rotor surface
−τp/2 x 0

pole pitch

Figure 1.11 Drawing an orthogonal field diagram in an air gap of a DC machine in the edge zone of a
pole shoe. Here, a differential equation for the magnetic scalar potential is solved by drawing. Dirichlet’s
boundary conditions for magnetic scalar potentials created on the surfaces of the pole shoe and the rotor
and on the symmetry plane between the pole shoes. The centre line of the pole shoe is set at the origin
of the coordinate system. At the origin, the element is dimensioned as δ 0 , b0 . The δ and b in
different parts of the diagram have different sizes, but the Φ remains the same in all flux tubes. The
pole pitch is τ p . There are about 23.5 flux tubes from the pole surface to the rotor surface in the figure

written as
Um
Φ n Φ Φ n Φ blµ0
Λδ = = = δ = n Φ µ l. (1.63)
0
Umδ n U Um n U Um nU

The magnetic field strength in the enlarged element of Figure 1.11 is

Um
H= , (1.64)
δ
and correspondingly the magnetic flux density

Um Φ
B = µ0 = . (1.65)
δ bl
With Equation (1.56), it is also possible to determine point by point the distribution of flux
density on a potential line; in other words, on the surface of the armature or the magnetizing
pole. With the notation in Figure 1.11, we get

Φ0 = B0 b0l = Φ(x) = B(x)b(x)l. (1.66)

In the middle of the pole, where the air-gap flux is homogeneous, the flux density is

Um Um,δ
B0 = µ0 H0 = µ0 = µ0 . (1.67)
δ0 δ0
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22 Design of Rotating Electrical Machines

Thus, the magnitude of flux density as a function of the x-coordinate is

b0 b0 Um,δ

B(x) = B0 = µ0 . (1.68)
b(x) b(x) δ0

Example 1.6: What is the permeance of the main flux in Figure 1.11 when the air gap
δ = 0.01 m and the stator stack length is l = 0.1 m? How much flux is created with Θf =
1000 A?
Solution: In the centre of the pole, the orthogonal flux diagram is uniform and we see that
δ 0 and b0 have the same size; δ 0 = b0 = 2 mm. The permeance of the flux tube in
the centre of the pole is

b0l 0.02 m · 0.1 m Vs

Λ0 = µ0 = µ0 = 4π · 10−8 .
δ0 0.02 m A

As we can see in Figure 1.11, about 23.5 flux tubes travel from half of the stator pole
to the rotor surface. Each of these flux tubes transmits the same amount of flux, and hence
the permeance of the whole pole seen by the main flux is

Vs µV s
Λ = 2 · 23.5 · Λ0 = 47 · Λ0 = 47 · 4π · 10−8 = 5.9 .
A A
If we have Θf = 1000 A current linkage magnetizing the air gap, we get the flux

µV s
Φ = ΛΘf = 5.9 · 1000 A = 5.9 mV s.
A

1.3.2 Flux Diagrams for Current-Carrying Areas

Let us first consider a situation in which an equivalent linear current density A [A/m] covers
the area under observation. In principle, the linear current density corresponds to the surface
current Js = n × H0 induced in a conducting medium by an alternating field strength H0
outside the surface. The surface normal unit vector is denoted by n.
In an electrical machine with windings, the ‘artificial surface current’, that is the local value
of the linear current density A, may for instance be calculated as a current sum flowing in a
slot divided by the slot pitch. Equivalent linear current density can be employed in approxima-
tion, because the currents flowing in the windings of electrical machines are usually situated
close to the air gap, and the current linkages created by the currents excite mainly the air gaps.
Thus, we can set µ = µ0 in the observed area of equivalent linear current density. The utiliza-
tion of equivalent linear current density simplifies the manual calculation of the machine by
idealizing the potential surfaces, and does not have a crucial impact on the field diagram in
the areas outside the area of linear current density. Figure 1.12 illustrates an equivalent linear
current density.
The value for equivalent linear current density A is expressed per unit length in the direc-
tion of observation. The linear current density A corresponds to the tangential magnetic field
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Principal Laws and Methods in Electrical Machine Design 23

Neumann's condition
linear current density
Neumann's condition
Hy

symmetry line,
dy H yFe

symmetry line,
dΘ

µ0 µFe
linear pole surface
current Dirichlet's condition
density A x

current flowing
rotor surface, Dirichlet's boundary condition
(a) (b)

Figure 1.12 (a) General representation of linear current density A [A/m] and (b) its application to the
field diagram of a magnetizing pole of a DC machine. It is important to note that in the area of the
pole body, the potential lines now pass from air to iron. Dirichlet’s boundary conditions indicate here a
known equiscalar potential surface

strength H yδ . Assuming the permeability of iron to be infinite, Ampère’s law yields for the
element dy of Figure 1.12a


H · dl = dΘ = Hyair dy − HyFe dy = Ady. (1.69)

Further, this gives us

Hyair = A and B yair = µ0 A. (1.70)

Equation (1.70) indicates that in the case of Figure 1.12 we have a tangential flux density
on the pole body surface. The tangential flux density makes the flux lines travel inclined to
the pole body surface and not perpendicular to it as in currentless areas.
If we assume that the phenomenon is observed on the stator inner surface or on the
rotor outer surface, the x-components may be regarded as tangential components and the
y-components as normal components. In the air gap δ, there is a tangential field strength Hxδ
along the x-component, and a corresponding component of flux density Bxδ created by the
linear current density A. This is essential when considering the force density, the tangential
stress σ Ftan , that generates torque (Maxwell stresses will be discussed later). On iron surfaces
with linear current density, the flux lines no longer pass perpendicularly from the iron to the
air gap, as Figure 1.12 depicting the field diagram of a DC machine’s magnetizing pole also
illustrates. The influence of a magnetizing winding on the pole body is illustrated with the
linear current density. Since the magnetizing winding is evenly distributed over the length
of the pole body (the linear current density being constant), it can be seen that the potential
changes linearly in the area of linear current density in the direction of the height of the pole.
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24 Design of Rotating Electrical Machines

Vm3

Vm4
rotor µFe

Vm2
leakage
flux
H=0
Ha Hb
S c
Ha Hb
H=0 S S Vm2
d b h b
∫ H ⋅ dl ≈ Hbb+0–Hab+0
o
a
= (Hb − Ha)b = Um ≈ SJ
= Vm3 −Vm2

p
e air ga Vm2
ing a cross th
x line flow stator
main flu
Vm0 µFe
Vm1

Figure 1.13 Current-carrying conductor in a slot and its field diagram. The illustration on the left
demonstrates the closed line integral around the surface S; also some flux lines in the iron are plotted.
Note that the flux lines travelling across the slot depict leakage flux

As evidence of this we can see that in Figure 1.12 the potential lines starting in the air gap
enter the area of linear current density at even distances.
In areas with current densities J, the potential lines become gradient lines. This can be seen
in Figure 1.13 at points a, b and c. We could assume that the figure illustrates for instance a
nonsalient-pole synchronous machine field winding bar carrying a DC density. The magnetic
potential difference between V m4 and V m0 equals the slot current.
 The gradient lines meet the slot leakage flux lines orthogonally, which means that
H · dl = 0 along a gradient line. In the figure, we calculate a closed line integral around
the area S of the surface S


H · dl = Vm3 − Vm2 = J · dS, (1.71)
S

where we can see that when the current density J and the difference of magnetic potentials
U m are constant, the area S of the surface S also has to be constant. In other words, the
selected gradient lines confine areas of equal size from the surface S with a constant current
density. The gradient lines meet at a single point d, which is called an indifference point. If
the current-carrying area is confined by an area with infinite permeability, the border line is a
potential line and the indifference point is located on this border line. If the permeability of
iron is not infinite, then d is located in the current-carrying area, as in Figure 1.13. If inside a
current-carrying area the line integral is defined for instance around the area S, we can see
that the closer to the point d we get, the smaller become the distances between the gradient
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Principal Laws and Methods in Electrical Machine Design 25

lines. In order to maintain the same current sum in the observed areas, the heights of the areas
S have to be changed.
Outside the current-carrying area, the following holds:

h
Φ = ΛUm = µ0l J · dS. (1.72)
b S

Inside the area under observation, when a closed line integral according to Equation (1.71)
is written only for the area S (<S), the flux of a flux tube in a current-carrying area becomes
  
h
Φ  = µ0l J · dS (1.73)
b S

and thus, in that case, if (h/b) = (h/b), then in fact Φ  < Φ. If the current density J in
the current-carrying area is constant, Φ  = ΦS/S is valid. When crossing the bound-
ary between a current-carrying slot and currentless iron, the flux of the flux tube cannot
change. Therefore, the dimensions of the line grid have to be altered. When J is constant and
Φ  = Φ, Equations (1.72) and (1.73) yield for the dimensions in the current-carrying area
 
h Sh
= . (1.74)
b Sb

This means that near the indifference point d the ratio (h/b) increases. An orthogonal field dia-
gram can be drawn for a current-carrying area by correcting the equivalent linear current den-
sity by iterating the created diagram. For a current-carrying area, gradient lines are extended
from potential lines up to the indifference point. Now, bearing in mind that the gradient lines
have to divide the current-carrying area into sections of equal size, next the orthogonal flux
lines are plotted by simultaneously paying attention to changing dimensions. The diagram is
altered iteratively until Equation (1.74) is valid to the required accuracy.

1.4 Application of the Principle of Virtual Work in the Determination

of Force and Torque
When investigating electrical equipment, the magnetic circuit of which changes form during
operation, the easiest method is to apply the principle of virtual work in the estimation of force
and torque. Examples of this kind of equipment are double-salient-pole reluctant machines,
various relays and so on.
Faraday’s induction law presents the voltage induced in the winding, which creates a current
that tends to resist the changes in flux. The voltage equation for the winding is written as

dΨ d
u = Ri + = Ri + Li, (1.75)
dt dt

where u is the voltage connected to the coil terminals, R is the resistance of the winding and
Ψ is the coil flux linkage, and L the self-inductance of the coil consisting of its magnetizing
inductance and leakage inductance: L = Ψ /i = NΦ/i = N 2 Λ = N 2 /Rm (see also Section 1.6).
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26 Design of Rotating Electrical Machines

If the number of turns in the winding is N and the flux is Φ, Equation (1.75) can be rewritten
as

dΦ
u = Ri + N . (1.76)
dt

The required power in the winding is written correspondingly as

dΦ
ui = Ri 2 + N i , (1.77)
dt

and the energy

dW = P dt = Ri 2 dt + N i dΦ. (1.78)

The latter energy component Ni dΦ is reversible, whereas Ri2 dt turns into heat. Energy cannot
be created or destroyed, but may only be converted to different forms. In isolated systems,
the limits of the energy balance can be defined unambiguously, which simplifies the energy
analysis. The net energy input is equal to the energy stored in the system. This result, the first
law of thermodynamics, is applied to electromechanical systems, where electrical energy is
stored mainly in magnetic fields. In these systems, the energy transfer can be represented by
the equation

dWel = dWmec + dWΦ + dWR (1.79)

where
dW el is the differential electrical energy input,
dW mec is the differential mechanical energy output,
dWΦ is the differential change of magnetic stored energy,
dW R is the differential energy loss.

Here the energy input from the electric supply is written equal to the mechanical energy
together with the stored magnetic field energy and heat loss. Electrical and mechanical energy
have positive values in motoring action and negative values in generator action. In a magnetic
system without losses, the change of electrical energy input is equal to the sum of the change
of work done by the system and the change of stored magnetic field energy

dWel = dWmec + dWΦ , (1.80)

dWel = ei dt. (1.81)

In the above, e is the instantaneous value of the induced voltage, created by changes in
the energy in the magnetic circuit. Because of this electromotive force, the external electric
circuit converts power into mechanical power by utilizing the magnetic field. This law of
energy conversion combines a reaction and a counter-reaction in an electrical and mechanical
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Principal Laws and Methods in Electrical Machine Design 27

FΦ F

R i

Ψ, e N turns
u Φ

Figure 1.14 Electromagnetic relay connected to an external voltage source u. The mass of a moving
yoke is neglected and the resistance of the winding is assumed to be concentrated in the external resistor
R. There are N turns in the winding and a flux Φ flowing in the magnetic circuit; a flux linkage Ψ ≈
NΦ is produced in the winding. The negative time derivative of the flux linkage is an emf, e. The force
F pulls the yoke open. The force is produced by a mechanical source. A magnetic force FΦ tries to close
the air gap

system. The combination of Equations (1.80) and (1.81) yields

dΨ
dWel = ei dt = i dt = i dΨ = dWmec + dWΦ . (1.82)
dt

Equation (1.82) lays a foundation for the energy conversion principle. Next, its utilization
in the analysis of electromagnetic energy converters is discussed.
As is known, a magnetic circuit (Figure 1.14) can be described by an inductance L deter-
mined from the number of turns of the winding, the geometry of the magnetic circuit and the
permeability of the magnetic material. In electromagnetic energy converters, there are air gaps
that separate the moving magnetic circuit parts from each other. In most cases – because of
the high permeability of iron parts – the reluctance Rm of the magnetic circuit consists mainly
of the reluctances of the air gaps. Thus, most of the energy is stored in the air gap. The wider
the air gap, the more energy can be stored. For instance, in induction motors this can be seen
from the fact that the wider is the gap, the higher is the magnetizing current needed.
According to Faraday’s induction law, Equation (1.82) yields

dWel = i dΨ. (1.83)

The computation is simplified by neglecting for instance the magnetic nonlinearity and iron
losses. The inductance of the device now depends only on the geometry and, in our example,
on the distance x creating an air gap in the magnetic circuit. The flux linkage is thus a product
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28 Design of Rotating Electrical Machines

of the varying inductance and the current

Ψ = L(x)i. (1.84)

A magnetic force FΦ is determined as

dWmec = FΦ dx. (1.85)

From Equations (1.83) and (1.85), we may rewrite Equation (1.80) as

dWΦ = i dΨ − FΦ dx. (1.86)

Since it is assumed that there are no losses in the magnetic energy storage, dWΦ is deter-
mined from the values of Ψ and x. dWΦ is independent of the integration path A or B, and the
energy equation can be written as
 
WΦ (Ψ0 , x0 ) = dWΦ + dWΦ . (1.87)
path A path B

With no displacement allowed (dx = 0), Equations (1.86) now (1.87) yield

Ψ
WΦ (Ψ, x0 ) = i (Ψ, x0 )dΨ. (1.88)
0

In a linear system, Ψ is proportional to current i, as in Equations (1.84) and (1.88). We there-

fore obtain

Ψ Ψ
Ψ 1 Ψ2 1
WΦ (Ψ, x0 ) = i (Ψ, x0 )dΨ = dΨ = = L (x0 ) i 2 . (1.89)
L (x0 ) 2 L (x0 ) 2
0 0

The magnetic field energy can also be represented by the energy density wΦ = WΦ /V =
B H/2 [J/m3 ] in a magnetic field integrated over the volume V of the magnetic field. This
gives

1
WΦ = (H · B) dV . (1.90)
2
V

Assuming the permeability of the magnetic medium constant and substituting B = µH

gives

1 B2
WΦ = dV . (1.91)
2 µ
V
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Principal Laws and Methods in Electrical Machine Design 29

This yields the relation between the stored energy in a magnetic circuit and the electrical
and mechanical energy in a system with a lossless magnetic energy storage. The equation for
differential magnetic energy is expressed in partial derivatives

∂ WΦ ∂ WΦ
dWΦ (Ψ, x) = dΨ + dx. (1.92)
∂Ψ ∂x

Since Ψ and x are independent variables, Equations (1.86) and (1.92) have to be equal at all
values of dΨ and dx, which yields

∂ WΦ (Ψ, x)
i= , (1.93)
∂Ψ

where the partial derivative is calculated by keeping x constant. The force created by the
electromagnet at a certain flux linkage level Ψ can be calculated from the magnetic energy

∂ WΦ (Ψ, x)
FΦ = − . (1.94a)
∂x

The minus sign is due to the coordinate system in Figure 1.14. The corresponding equation is
valid for torque as a function of angular displacement θ while keeping flux linkage Ψ constant

∂ WΦ (Ψ, θ )
TΦ = − . (1.94b)
∂θ

Alternatively, we may employ coenergy (see Figure 1.15a), which gives us the force directly
as a function of current. The coenergy WΦ is determined as a function of i and x as

WΦ (i, x) = iΨ − WΦ (Ψ, x) . (1.95)

Ψ Ψ B

energy energy st. energy

on
t.

density
ns

x,c
co

W W
x,

W' W'

coenergy
coenergy coenergy density
0 i 0 i 0 H
(a) (b) (c)

Figure 1.15 Determination of energy and coenergy with current and flux linkage (a) in a linear case
(L is constant), (b) and (c) in a nonlinear case (L saturates as a function of current). If the figure is used
to illustrate the behaviour of the relay in Figure 1.14, the distance x remains constant
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30 Design of Rotating Electrical Machines

In the conversion, it is possible to apply the differential of iΨ

d(iΨ ) = i dΨ + Ψ di. (1.96)

Equation (1.95) now yields

dWΦ (i, x) = d (iΨ ) − dWΦ (Ψ, x) . (1.97)

By substituting Equations (1.86) and (1.96) into Equation (1.97) we obtain

dWΦ (i, x) = Ψ di + FΦ dx. (1.98)

The coenergy WΦ is a function of two independent variables, i and x. This can be represented
by partial derivatives

∂ WΦ ∂ WΦ
dWΦ (i, x) = di + dx. (1.99)
∂i ∂x

Equations (1.98) and (1.99) have to be equal at all values of di and dx. This gives us

∂ WΦ (i, x)
Ψ = , (1.100)
∂i

∂ WΦ (i, x)
FΦ = . (1.101a)
∂x

Correspondingly, when the current i is kept constant, the torque is

∂ WΦ (i, θ )
TΦ = . (1.101b)
∂θ

Equation (1.101) gives a mechanical force or a torque directly from the current i and dis-
placement x, or from the angular displacement θ . The coenergy can be calculated with i
and x

i
WΦ (i 0 , x0 ) = Ψ (i, x0 )di. (1.102)
0

In a linear system, Ψ and i are proportional, and the flux linkage can be represented by the
inductance depending on the distance, as in Equation (1.84). The coenergy is

i
1
WΦ (i, x) = L (x)i di = L (x) i 2 . (1.103)
2
0
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Principal Laws and Methods in Electrical Machine Design 31

Using Equation (1.91), the magnetic energy can be expressed also in the form

1
WΦ = µH 2 dV . (1.104)
2
V

In linear systems, the energy and coenergy are numerically equal, for instance 0.5Li2 =
0.5Ψ 2 /L or (µ/2)H 2 = (1/2µ)B2 . In nonlinear systems, Ψ and i or B and H are not pro-
portional. In a graphical representation, the energy and coenergy behave in a nonlinear way
according to Figure 1.15.
The area between the curve and flux linkage axis can be obtained from the integral i dΨ ,
and it represents the energy stored in the magnetic circuit WΦ . The area between the curve
and the current axis can be obtained from the integral Ψ di, and it represents the coenergy WΦ .
The sum of these energies is, according to the definition,

WΦ + WΦ = iΨ. (1.105)

In the device in Figure 1.14, with certain values of x and i (or Ψ ), the field strength has to
be independent of the method of calculation; that is, whether it is calculated from energy or
coenergy – graphical presentation illustrates the case. The moving yoke is assumed to be in
a position x so that the device is operating at the point a, Figure 1.16a. The partial derivative
in Equation (1.92) can be interpreted as WΦ /x, the flux linkage Ψ being constant and
x → 0. If we allow a change x from position a to position b (the air gap becomes smaller),
the stored energy change −WΦ will be as shown in Figure 1.16a by the shaded area, and
the energy thus becomes smaller in this case. Thus, the force FΦ is the shaded area divided by
x when x → 0. Since the energy change is negative, the force will also act in the negative
x-axis direction. Conversely, the partial derivative can be interpreted as WΦ x, i being
constant and x → 0.

Ψ Ψ c
b Ψ b
a a
after after
displ. displ.

x− x x− x + W'Φ
− WΦ

i
initial state
initial state
x, const.
x, const.

0 i 0 i
(a) Ψ is constant, i decreases (b) i is constant, flux linkage increases

Figure 1.16 Influence of the change x on energy and coenergy: (a) the change of energy, when Ψ is
constant; (b) the change of coenergy, when i is constant
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32 Design of Rotating Electrical Machines

The shaded areas in Figures 1.16a and b differ from each other by the amount of the small
triangle abc, the two sides of which are i and Ψ . When calculating the limit, x is allowed
to approach zero, and thereby the areas of the shaded sections also approach each other.
Equations (1.94) and (1.101) give the mechanical force or torque of electric origin as partial
derivatives of the energy and coenergy functions WΦ (Ψ, x) and WΦ (x, i).
Physically, the force depends on the magnetic field strength H in the air gap; this will be
studied in the next section. According to the study above, the effects of the field can be repre-
sented by the flux linkage Ψ and the current i. The force or the torque caused by the magnetic
field strength tends to act in all cases in the direction where the stored magnetic energy de-
creases with a constant flux, or the coenergy increases with a constant current. Furthermore,
the magnetic force tends to increase the inductance and drive the moving parts so that the
reluctance of the magnetic circuit finds its minimum value.
Using finite elements, torque can be calculated by differentiating the magnetic coenergy W 
with respect to movement, and by maintaining the current constant:

 H
dW  d
T =l = (B · dH) dV . (1.106)
dα dα
V 0

In numerical modelling, this differential is approximated by the difference between two suc-
cessive calculations:
 
l W  (α + α) − W  (α)
T = . (1.107)
α

Here, l is the machine length and α represents the displacement between successive field
solutions. The adverse effect of this solution is that it needs two successive calculations.
Coulomb’s virtual work method in FEM is also based on the principle of virtual work. It
gives the following expression for the torque:

 
 H
  dJ d |J| 
T = l  −Bt J−1 H+ B dH |J|−1 dΩ, (1.108)
dϕ dϕ
Ω 0

where the integration is carried out over the finite elements situated between fixed and moving
parts, having undergone a virtual deformation. In Equation (1.108), l is the length, J denotes
the Jacobian matrix, dJ/dϕ is its differential representing element deformation during the
displacement dϕ, |J| is the determinant of J and d |J| /dϕ is the differential of the determinant,
representing the variation of the element volume during displacement dϕ. Coulomb’s virtual
work method is regarded as one of the most reliable methods for calculating the torque and it
is favoured by many important commercial suppliers of FEM programs. Its benefit compared
with the previous virtual work method is that only one solution is needed to calculate the
torque.
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Principal Laws and Methods in Electrical Machine Design 33

Figure 1.17 Flux solution of a loaded 30 kW, four-pole, 50 Hz induction motor, the machine rotating
counterclockwise as a motor. The figure depicts a heavy overload. The tangential field strength in this
case is very large and produces a high torque. The enlarged figure shows the tangential and normal
components of the field strength in principle. Reproduced by permission of Janne Nerg

1.5 Maxwell’s Stress Tensor; Radial and Tangential Stress

Maxwell’s stress tensor is probably the most generic idea of producing magnetic stresses,
forces and torque. We discussed previously that the linear current density A on a metal sur-
face creates tangential field strength components on the metal surfaces. Such tangential field
strength components are essential in both tangential stress generation and torque generation
in rotating-field electrical machines.
In numerical methods, Maxwell’s stress tensor is often employed in the calculation of forces
and torque. The idea is based on Faraday’s statement according to which stress occurs in the
flux lines. Figures 1.17 depict the flux solution for an air gap of an asynchronous machine,
when the machine is operating under a heavy load. Such a heavy load condition is selected in
order to illustrate clearly the tangential routes of the flux lines. When we compare Figure 1.17
with Figure 1.6, we can see the remarkable difference in the behaviour of the flux lines in the
vicinity of the air gap.
In the figures, the flux lines cross the air gap somewhat tangentially so that if we imagine
the flux lines to be flexible, they cause a notable torque rotating the rotor counterclockwise.
According to Maxwell’s stress theory, the magnetic field strength between objects in a vacuum
creates a stress σ F on the object surfaces, given by

1
σF = µ0 H 2 . (1.109)
2

The stress occurs in the direction of lines of force and creates an equal pressure perpendic-
ularly to the lines. When the stress term is divided into its normal and tangential components
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34 Design of Rotating Electrical Machines

with respect to the object in question, we obtain

1  2 
σ Fn = µ0 Hn − Htan
2
, (1.110)
2
σ Ftan = µ0 Hn Htan . (1.111)

Considering torque production, the tangential component σ Ftan is of the greatest interest.
The total torque exerted on the rotor can be obtained by integrating the stress tensor for in-
stance over a cylinder Γ that confines the rotor. The cylinder is dimensioned exactly to enclose
the rotor. The torque is obtained by multiplying the result by the radius of the rotor. Note that
no steel may be left inside the surface to be integrated. The torque can be calculated by the
following relationship:
  
l B2n
T = r × (B · n) BdS − dΓ , (1.112)
µ0 2
Γ

where l is the length, B is the flux density vector, n the normal unit vector in the elements
and r the lever arm, in other words the vector which connects the rotor origin to the midpoint
of the segment dΓ . The former term contains the tangential force contributing to the torque.
Since n and r are parallel the latter term does not contribute to the torque but represents the
normal stress.
Maxwell’s stress tensor illustrates well the fundamental principle of torque generation. Un-
fortunately, because of numerical inaccuracies, for instance in the FEM, the obtained torque
must be employed with caution. Therefore, in the FEM analysis, the torque is often solved
by other methods, for instance Arkkio’s method, which is a variant of Maxwell’s stress tensor
and is based on integrating the torque over the whole volume of the air gap constituted by the
layers of radii rs and rr . The method has been presented with the following expression for the
torque:

l
T = r Bn Btan dS, (1.113)
µ0 (rs − rr )
S

in which l is the length, Bn and Btan denote the radial and tangential flux densities in the
elements of surface S and formed between radii rr and rs . dS is the surface of one element.
The magnetizing current method is yet another variant of Maxwell’s stress method used in
FEM solvers. This method is based on the calculation of the magnetizing current and the flux
density over the element edges that constitute the boundary between the iron or permanent
magnet and the air. Here the torque can be determined by the following expression:

l      
T = r× 2
Btan,Fe − Btan,air
2
n − Btan,Fe Btan,air − Bn,air
2
t dΓc , (1.114)
µ0
Γc

where l is the machine length, Γc denotes all the interfaces between the iron or permanent
magnet and the air, and dΓc is the length of the element edge located at the boundary. The
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Principal Laws and Methods in Electrical Machine Design 35

vector r is the lever arm, in other words the vector connecting the rotor origin to the midpoint
of dΓc . Btan and Bn denote the tangential and normal flux densities with respect to dΓ c . The
subscript Fe refers to the iron or permanent magnet. The normal unit vector is n and tangential
unit vector t.
Equation (1.70) states that a linear current density A creates a tangential field strength in an
electrical machine: Htan,δ = A and Btan,δ = µ0 A. According to Equation (1.111), the tangen-
tial stress in an air gap is given by

σ Ftan = µ0 Hn Htan = µ0 Hn A = Bn A. (1.115)

This equation gives a local time-dependent value for the tangential stress when local instanta-
neous values for the normal flux density Bn and the linear current density A are given. Air-gap
flux density and linear current density thereby determine the tangential stress occurring in
electrical machines. If we want to emphasize the place and time dependence of the stress, we
may write the expression in the form

σ Ftan (x, t) = µ0 Hn (x, t) Htan (x, t) = µ0 Hn (x, t) A (x, t) = Bn (x, t) A (x, t) . (1.116)

This expression is a very important starting point for the dimensioning of an electrical ma-
chine. The torque of the machine may be directly determined by this equation when the rotor
dimensions are selected.

Example 1.7: Assume a sinusoidal air-gap flux density distribution having a maximum
value of 0.9 T and a sinusoidal linear current density with a maximum value of 40 kA/m
in the air gap. To simplify the case, also assume that the distributions are overlapping; in
other words, there is no phase shift. This condition may occur on the stator surface of a
synchronous machine; however, in the case of an induction machine, the condition never
takes place in the steady state, since the stator also has to carry the magnetizing current. In
our example, both the diameter and the length of the rotor are 200 mm. What is the power
output, if the rotation speed is 1450 min−1 ?
Solution: Because σ Ftan (x) = B̂ n sin (x) Â sin (x), the average tangential stress becomes
σ Ftan (x) = 0.5 B̂ n  = 18 kPa. The active surface area of the rotor is πDl = 0.126 m2 .
When we multiply the rotor surface area by the average tangential stress, we obtain
2270 N. This tangential force occurs everywhere at a radial distance of 0.1 m from the
centre of the axis, the torque being thus 227 N m. The angular velocity is 151 rad/s, which
produces a power of approximately 34 kW. These values are quite close to the values of a
real, totally enclosed 30 kW induction machine.

In electrical machines, the tangential stresses typically vary between 10 and 50 kPa de-
pending on the machine construction, operating principle and especially on the cooling. For
instance, the values for totally enclosed, permanent magnet synchronous machines vary typi-
cally between 20 and 30 kPa. For asynchronous machines, the values are somewhat lower. In
induction machines with open-circuit cooling, the value of 50 kPa is approached. Using direct
cooling methods may give notably higher tangential stresses.
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36 Design of Rotating Electrical Machines

Example 1.8: Calculate the force between two iron bodies when the area of the air gap
between the bodies is 10 cm2 , and the flux density is 1.5 T. The relative permeability of
iron is assumed to be 700. It is also assumed that the tangential component of the field
strength is zero.
Solution:
 2  2
1  2 1 Bn 5 Vs A
σ Fn = µ0 Hn = µ0 = 8.95 · 10
2 2 µ0 Am m
5VAs 5 N
= 8.95 · 10 = 8.95 · 10 2 .
m3 m
This is the stress in the air gap. The force acting on the iron can be approximated by
multiplying the stress by the area of the air gap. Strictly speaking, we should investigate
the permeability difference of the iron and air, the force acting on the iron therefore
being
   
1 1 N
FFn = Sσ Fn 1− = 1− 0.001 m2 · 8.95 · 105 2 = 894 N.
µrFe 700 m

No magnetic force is exerted on the air (a nonmagnetic material (µr = 1)), although some
stress occurs in the air because of the field strength. Only the part of air-gap flux that is caused
by the magnetic susceptibility of the iron circuit creates a force. By applying the stress tensor,
we may now write for a normal force

 
B 2 Sδ 1
FFn = δ 1− . (1.117)
2 µ0 µr

For iron, 1/µr  1, and thus, in practice, the latter term in Equation (1.117) is of no sig-
nificance, unless the iron is heavily saturated.
From this example, we may conclude that the normal stress is usually notably higher than
the tangential stress. In these examples, the normal stress was 895 000 Pa, and the tangential
stress 18 000 Pa. Some cases have been reported in which attempts have been made to apply
normal stress in rotating machines.

1.6 Self-Inductance and Mutual Inductance

Self-inductances and mutual inductances are the core parameters of electrical machines. Per-
meance is generally determined by

Φ Φ
Λ= = (1.118)
Θ Ni
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Principal Laws and Methods in Electrical Machine Design 37

and inductance by

Φ Ψ
L=N = = N 2 Λ. (1.119)
i i

Inductance describes a coil’s ability to produce flux linkage. Therefore, also its unit H
(henry) is equal to V s/A. Correspondingly, the mutual inductance L12 is determined from the
flux linkage Ψ 12 , created in winding 1 by the current i2 that flows in winding 2,

Ψ12
L 12 = . (1.120)
i2

In the special case where the flux Φ 12 , created by the current of winding 2, penetrates all
the turns of windings 1 and 2, the mutual permeance between the windings is written as

Φ12
Λ12 = , (1.121)
N2 i 2

and the mutual inductance as

L 12 = N1 N2 Λ12 . (1.122)

Here, N 1 is the number of turns of the winding in which the voltage is induced, and N 2 is the
number of turns of the winding that produces the flux.
The energy equation for a magnetic circuit can be written with the flux linkage as

t t Ψ
di dΨ
WΦ = i L dt = i dt = i dΨ . (1.123)
dt dt
0 0 0

If an integral has to be calculated, the volume under observation can be divided into flux
tubes. A flux flowing in such a flux tube is created by the influence of N turns of the winding.
By taking into account
 the fact that the field strength H is created by the current i according
to the equation H · dl = kw N i, the equation for the sum of the energies of all flux tubes in
the volume observed, that is the total energy of the magnetic circuit that was previously given
by the current and flux linkage, may be written as

Ψ Φ B
B   B
WΦ = i dΨ = kw N i dΦ = H · dl · S dB = H dV dB = H dB dV .
V V
0 0 0 0 0
(1.124)
The volume integration has to be performed over the volume V in which the flux in question
is passing. Energy per volume is thus written in the familiar form

B
dWΦ
= H dB, (1.125)
dV
0
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38 Design of Rotating Electrical Machines

the energy stored in the complete magnetic circuit being

 B
WΦ = H dB dV. (1.126)
V
0

As the flux linkage is proportional to the current i, Ψ = Li, the energy can be given also as

i
WΦ = L i di = 1/2 Li 2 . (1.127)
0

Equation (1.126) yields

dWΦ 1
= HB, (1.128)
dV 2 
1 1
WΦ = HB dV = µH 2 dV . (1.129)
2 V 2 V

From Equations (1.119), (1.127) and (1.129), we can calculate an ideal overall magnetic
permeance for a magnetic circuit of volume V
 
1 1
Λ= HB dV = µH 2 dV . (1.130)
N 2i 2 V N 2i 2 V

Let us now investigate two electric circuits with a common magnetic energy of

Ψ1 Ψ2
WΦ = i 1 dΨ1 + i 2 dΨ2 . (1.131)
0 0

Also in this case, the magnetic energy can be calculated from Equations (1.125) and (1.126).
We can see that the common flux flowing through the flux tube n is

Ψn1 Ψn2
Φn = = = B Sn . (1.132)
N1 N2

This flux tube is magnetized by the sum current linkage of two windings N 1 and N 2


H · dl = i 1 N1 + i 2 N2 . (1.133)

In a linear system, the fluxes are directly proportional to the sum magnetizing current link-
age i 1 N1 + i 2 N2 , and thus we obtain an energy

1 1
WΦ = (i 1 Ψ1 ) + (i 2 Ψ2 ) . (1.134)
2 2
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Principal Laws and Methods in Electrical Machine Design 39

Because the flux linkages are created with two windings together, they can be divided into
parts

Ψ1 = Ψ11 + Ψ12 and Ψ2 = Ψ22 + Ψ21 . (1.135)

Now, the flux linkages and inductances can be linked

Ψ11 = L 11 i 1 , Ψ12 = L 12 i 2 , Ψ22 = L 22 i 2 , Ψ21 = L 21 i 1 . (1.136)

In Equation (1.136), there are the self-inductances L11 and L22 , and the mutual inductances
L12 and L21 . The magnetic energy can now be rewritten as
 
WΦ = 1
2
L 11 i 12 + L 12 i 1 i 2 + L 22 i 22 + L 21 i 2 i 1
(1.137)
= W11 + W12 + W22 + W21 .

The magnetic energy of the magnetic field created by the two current circuits can thus be
divided into four parts, two parts representing the energy of the self-inductances and two parts
representing the energy of the mutual inductances. Correspondingly, the magnetic energy den-
sity in a certain volume can be written according to Equation (1.128), after the substitution

H = H1 + H2 and B = B1 + B2 , (1.138)

in the form
dWΦ 1
= (H1 B1 + H1 B2 + H2 B2 + H2 B1 ) . (1.139)
dV 2
Since in this equation H 1 B2 = H 2 B1 , the energies and inductances have to behave as W 12 =
W 21 and L12 = L21 . This gives

1 1
WΦ = W11 + 2W12 + W22 = L 11 i 12 + L 12 i 1 i 2 + L 22 i 22 . (1.140)
2 2
Equations (1.137) and (1.139) yield

1 1
W12 = L 12 i 1 i 2 = H1 B2 dV. (1.141)
2 2 V

Now, we obtain for the permeance between the windings Λ12 = Λ21 , which corresponds to
the mutual inductance, by comparing Equation (1.122),

1
Λ12 = µH1 H2 dV. (1.142)
N1 i 1 N2 i 2 V

If the field strengths are created by sinusoidal currents with a phase difference γ

i 1 = iˆ1 sin ωt and i 2 = iˆ2 sin (ωt + γ ) , (1.143)

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40 Design of Rotating Electrical Machines

the mutual average energy of the fields created by these currents is obtained from

2π
1 1 1
W12av = L 12 iˆ1 î 2 dωt = L 12 iˆ1 î 2 cos γ . (1.144)
2 2π 2
0

Correspondingly, the permeance between the windings is


2
Λ12 = µH1 H2 cos γ dV. (1.145)
N1 i 1 N2 iˆ2
ˆ V

In these equations, γ is the time-dependent phase angle either between the currents in two
windings or between the partial field strengths created by these currents.
Mutual inductances are important in rotating electrical machines. A machine is, however,
usually treated using an equivalent electric circuit in which all the machine windings are
presented at the same voltage level. In such cases the mutual inductances are replaced by
the magnetizing inductance Lm , which can be calculated using the transformation ratio K as
Lm = KL12 . Further discussion of the magnetic circuit properties and inductances, such as
magnetizing inductance Lm , will be given in Chapter 3.

1.7 Per Unit Values

When analysing electrical machines, especially in electric drives, per unit values are often
employed. This brings certain advantages to the analysis, since they show directly the relative
magnitude of a certain parameter. For instance, if the relative magnetizing inductance of an
asynchronous machine is lm = 3, it is quite high. On the other hand, if it is lm = 1, it is
rather low. Now it is possible to compare machines, the rated values of which differ from each
other.
Relative values can be obtained by dividing each dimension by a base value. When consid-
ering electric motors and electric drives, the base values are selected accordingly:

r Peak value for rated stator phase current iˆN . (It is, of course, also possible to select the root
mean square (RMS) stator current as a base value, instead. In such a case the voltage also
has to be selected accordingly.)
r Peak value for rated stator phase voltage û N .
r Rated angular frequency ωN = 2π f sN .
r Rated flux linkage, corresponding also to the rated angular velocity Ψ̂N .
r Rated impedance Z N .
r Time in which 1 radian in electrical degrees, tN = 1 rad/ωN , is travelled at a rated angular
frequency. Relative time τ is thus measured as an angle τ = ωN t.
r Apparent power SN corresponding to rated current and voltage.
r Rated torque T N corresponding to rated power and frequency.
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Principal Laws and Methods in Electrical Machine Design 41

When operating with sinusoidal quantities, the rated current of the machine is I N and the
line-to-line voltage is U N :
√
The base value for current Ib = î N = 2IN . (1.146)
√ UN
The base value for voltage Ub = û N = 2 √ . (1.147)
3
Angular frequency ωN = 2π f sN . (1.148)
û N
The base value for flux linkage Ψb = ΨN = . (1.149)
ωN
û N
The base value for impedance Z b = Z N = . (1.150)
î N
û N
The base value for inductance L b = L N = . (1.151)
ωN î N
î N
The base value for capacitance Cb = CN = . (1.152)
ωN û N
3 √
The base value for apparent power Sb = SN = î N û N = 3UN IN . (1.153)
2 √
3 3UN IN
The base value for torque Tb = TN = î N û N cos ϕN = cos ϕN .
2ωN ωN
(1.154)

The relative values to be used are

us
u s,pu = , (1.155)
û N
is
i s,pu = , (1.156)
î N
Rs î N
rs,pu = , (1.157)
û N
ωN Ψs
Ψs,pu = , (1.158)
û N
ω n
ωpu = = = n pu , (1.159)
ωN fN

where n is the rotational speed per second, and

τ = ωN t. (1.160)

The relative values of inductances are the same as the relative values of reactances. Thus,
we obtain for instance
Lm Lm î N
lm.pu = = = X m = xm,pu , (1.161)
Lb û N û N
ωN î N
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42 Design of Rotating Electrical Machines

where X m is the magnetizing reactance.

We also have a mechanical time constant

 2
ωN 2J
TJ = ωN , (1.162)
p 3û N î N cos ϕN

where J is the moment of inertia. According to (1.162), the mechanical time constant is the
ratio of the kinetic energy of a rotor rotating at synchronous speed to the power of the machine.

Example 1.9: A 50 Hz star-connected, four-pole, 400 V induction motor has the following
nameplate values: PN = 200 kW, ηN = 0.95, cosϕ N = 0.89, I N = 343 A, I S /I N = 6.9,
T max /T N = 3, and rated speed 1485 min−1 . The no-load current of the motor is 121 A.
Give an expression for the per unit inductance parameters of the motor.
Solution:

The base angular frequency ωN = 2π f sN = 314/s.

√
û N 2 · 230 V
The base value for flux linkage Ψb = Ψ̂N = = = 1.036 V s.
ωN 314/s

Ψ̂N 1.036 V s
The base value for inductance L b = L N = =√ = 2.14 mH.
î N 2 · 343 A

The no-load current of the machine is 121 A, and the stator inductance of the machine is
thereby about Ls = 230 V/(121 A · 314/s) = 6.06 mH. We guess that 97% of this belongs
to the magnetizing inductance. Lm = 0.97 · 6.06 mH = 5.88 mH.
The per unit magnetizing inductance is now Lm /Lb = 5.88/2.14 = 2.74 = lm,pu and the
stator leakage lsσ = 0.03 · 6.06 mH = 0.18 mH. lsσ,pu = 0.18/2.14 = 0.084.
We may roughly state that the per unit short-circuit inductance of the motor is, according
to the starting current ratio, lk ≈ 1/ (IS /IN ) = 0.145. Without better knowledge, we divide
the short-circuit inductance 50:50 for the stator and rotor per unit leakages: lsσ,pu = lrσ,pu
= 0.0725. This differs somewhat from the above-calculated lsσ,pu = 0.18/2.14 = 0.084.
However, the guess that 97% of the stator inductance ls,pu = lsσ,pu + lm,pu seems to be
correct enough.
The motor per unit slip is s = (n syn − n)n syn = (1500 − 1485)/1500 = 0.006 73. The
motor per unit slip at low slip values is directly proportional to the per unit rotor resistance.
Thus, we may assume that the rotor per unit resistance is of the same order, rr,pu ≈ 0.0067.
The rated efficiency of the motor is 95%, which gives 5% per unit losses to the system.
If we assume 1% stator resistance rs,pu ≈ 0.01, and 0.5% excess losses, we have 2.8%
(5 − 1 − 0.5 − 0.67 = 2.8%) per unit iron losses in the motor. Hence, the losses in the
machine are roughly proportional to the per unit values of the stator and rotor resistances.
For more detailed information, the reader is referred to Chapter 7.
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Principal Laws and Methods in Electrical Machine Design 43

1.8 Phasor Diagrams

When investigating the operation of electrical machines, sinusoidally alternating currents,
voltages and flux linkages are often illustrated with phasor diagrams. These diagrams are
based either on generator logic or on motor logic; the principle of the generator logic is that for
instance the flux linkage created by the rotor magnetization of a synchronous machine induces
an electromotive force in the armature winding of the machine. Here, Faraday’s induction law
is applied in the form

dΨ
e=− . (1.163)
dt

The flux linkage for a rotating-field machine can be presented as

Ψ (t) = Ψ̂ ejωt . (1.164)

The flux linkage is derived with respect to time

dΨ
= −jωΨ̂ ejωt = e−j 2 ωΨ̂ ejωt = ωΨ̂ ej(ωt− 2 ) .
π π
e=− (1.165)
dt

The emf is thus of magnitude ωΨ̂ and its phase angle is 90 electrical degrees behind the
phasor of the flux linkage. Figure 1.18 illustrates the basic phasor diagrams according to
generator and motor logic.
As illustrated in Figure 1.18 for generator logic, the flux linkage Ψ m generated by the
rotor of a synchronous machine induces a voltage Em in the armature winding of the machine
when the machine is rotating. The stator voltage of the machine is obtained by reducing the
proportion of the armature reaction and the resistive voltage loss from the induced voltage. If
the machine is running at no load, the induced voltage Em equals the stator voltage U s .

E m (Us) Us

Ψm Ψs

Generator logic Motor logic

Es

Figure 1.18 Basic phasor diagrams for generator and motor logic
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44 Design of Rotating Electrical Machines

Motor logic represents the opposite case. According to the induction law, the flux linkage
can be interpreted as an integral of voltage.

 
1 1
û s ejωt = û s ej(ωt− 2 ) .
π
Ψs = u s dt = û s ejωt dt = (1.166)
jω ω

The phasor of the flux linkage is 90 electrical degrees behind the voltage phasor. Again,
differentiating the flux linkage with respect to time produces an emf. In the case of Figure
1.18, a flux linkage is integrated from the voltage, which further leads to the derivation of
a back emf now cancelling the supply voltage. As is known, this is the case with inductive
components. In the case of a coil, a major part of the supply voltage is required to overcome
the self-inductance of the coil. Only an insignificant voltage drop takes place in the winding
resistances. The resistive losses have therefore been neglected in the above discussion.

Example 1.10: A 50 Hz synchronous generator field winding current linkage creates at

no load a stator winding flux linkage of Ψ̂s = 15.6 V s. What is the internal induced phase
voltage (and also the stator voltage) of the machine?
Solution: The induced voltage is calculated as

dΨs
eF = − = −jωΨ̂s ejωt = −j314/s · 15.6 V s · ejωt = 4900 V · ejωt .
dt
Thus 4900 V is the peak value of the stator phase voltage, which gives an effective value
of the line-to-line voltage:

4900 V √
Ull = √ 3 = 6000 V.
2

Hence, we have a 6 kV machine at no load ready to be synchronized to the network.

Example 1.11: A rotating-field motor is supplied by a frequency converter at 25 Hz

and 200 V fundamental effective line-to-line voltage. The motor is initially a 400 V star-
connected motor. What is the stator flux linkage in the inverter supply?
Solution: The stator flux linkage is found by integrating the phase voltage supplied to the
stator
  √
1 2 · 200 V jωt
e = 1.04 V s · ej(ωt− 2 ) .
π
Ψs ≈ u s dt = û s e dt =
jωt
√
j25 · 2π 3

Consequently, the flux linkage amplitude is 1.04 V s and it is lagging in a 90◦ phase shift
the voltage that creates the flux linkage.
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Principal Laws and Methods in Electrical Machine Design 45

Bibliography
Arkkio, A. (1987) Analysis of Induction Motors Based on the Numerical Solution of the Magnetic Field and Circuit
Equations, Dissertation, Electrical Engineering Series No. 59. Acta Polytechnica Scandinavica, Helsinki Univer-
sity of Technology.
Carpenter, C.J. (1959) Surface integral methods of calculating forces on magnetised iron parts, IEE Monographs,
342, 19–28.
Johnk, C.T.A. (1975) Engineering Electromagnetic Fields and Waves, John Wiley & Sons, Inc., New York.
Sadowski, N., Lefevre, Y., Lajoie-Mazenc, M. and Cros, J. (1992) Finite element torque calculation in electrical
machines while considering the movement. IEEE Transactions on Magnetics, 28 (2), 1410–13.
Sihvola, A. and Lindell, I. (2004) Electromagnetic Field Theory 2: Dynamic Fields (Sähkömagneettinen kenttäteoria.
2. dynaamiset kentät), Otatieto, Helsinki.
Silvester, P. and Ferrari, R.L. (1988) Finite Elements for Electrical Engineers, 2nd edn, Cambridge University Press,
Cambridge.
Ulaby, F.T. (2001) Fundamentals of Applied Electromagnetics, Prentice Hall, Upper Saddle River, NJ.
Vogt, K. (1996) Design of Electrical Machines (Berechnung elektrischer Maschinen), Wiley-VCH Verlag GmbH,
Weinheim.
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2
Windings of Electrical Machines

The operating principle of electrical machines is based on the interaction between the mag-
netic fields and the currents flowing in the windings of the machine. The winding construc-
tions and connections together with the currents and voltages fed into the windings determine
the operating modes and the type of the electrical machine. According to their different func-
tions in an electrical machine, the windings are grouped for instance as follows:

r armature windings;
r other rotating-field windings (e.g. stator or rotor windings of induction motors);
r field (magnetizing) windings;
r damper windings;
r commutating windings; and
r compensating windings.

Armature windings are rotating-field windings, into which the rotating-field-induced volt-
age required in energy conversion is induced. According to IEC 60050-411, the armature
winding is a winding in a synchronous, DC or single-phase commutator machine, which, in
service, receives active power from or delivers active power to the external electrical sys-
tem. This definition also applies to a synchronous compensator if the term ‘active power’
is replaced by ‘reactive power’. The air-gap flux component caused by the armature current
linkage is called the armature reaction.
An armature winding determined under these conditions can transmit power between an
electrical network and a mechanical system. Magnetizing windings create a magnetic field
required in the energy conversion. All machines do not include a separate magnetizing wind-
ing; for instance, in asynchronous machines, the stator winding both magnetizes the machine
and acts as a winding, where the operating voltage is induced. The stator winding of an asyn-
chronous machine is similar to the armature of a synchronous machine; however, it is not
defined as an armature in the IEC standard. In this material, the asynchronous machine stator
is therefore referred to as a rotating-field stator winding, not an armature winding. Voltages
are also induced in the rotor of an asynchronous machine, and currents that are significant
in torque production are created. However, the rotor itself takes only a rotor’s dissipation
power (I 2 R) from the air-gap power of the machine, this power being proportional to the slip;

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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48 Design of Rotating Electrical Machines

therefore, the machine can be considered stator fed, and, depending on the rotor type, the
rotor is called either a squirrel cage rotor or a wound rotor. In DC machines, the function of
a rotor armature winding is to perform the actual power transmission, the machine being thus
rotor fed. Field windings do not normally participate in energy conversion, double-salient-pole
reluctance machines possibly being excluded: in principle, they have nothing but magnetizing
windings, but the windings also perform the function of the armature. In DC machines, com-
mutating and compensating windings are windings the purpose of which is to create auxiliary
field components to compensate for the armature reaction of the machine and thus improve
its performance characteristics. Similar to the previously described windings, these windings
do not participate in energy conversion in the machine either. The damper windings of syn-
chronous machines are a special case among different winding types. Their primary function
is to damp undesirable phenomena, such as oscillations and fields rotating opposite to the
main field. Damper windings are important during the transients of controlled synchronous
drives, in which the damper windings keep the air-gap flux linkage instantaneously constant.
In the asynchronous drive of a synchronous machine, the damper windings act like the cage
windings of asynchronous machines.
The most important windings are categorized according to their geometrical characteristics
and internal connections as follows:

r phase windings;
r salient-pole windings; and
r commutator windings.

Windings in which separate coils embedded in slots form a single- or poly-phase wind-
ing constitute a large group of AC armature windings. However, a similar winding is also
employed in the magnetizing of nonsalient-pole synchronous machines. In commutator wind-
ings, individual coils contained in slots form a single or several closed circuits, which are
connected together via a commutator. Commutator windings are employed only as armature
windings of DC and AC commutator machines. Salient-pole windings are normally concen-
trated field windings, but may also be used as armature windings in for instance fractional slot
permanent magnet machines and in double-salient reluctance machines. Concentrated stator
windings are used as an armature winding also in small shaded-pole motors.
In the following, the windings applied in electrical machines are classified according to
the two main winding types, namely slot windings and salient-pole windings. Both types are
applicable to both DC and AC cases, Table 2.1.

2.1 Basic Principles

2.1.1 Salient-Pole Windings
Figure 2.1 illustrates a synchronous machine with a salient-pole rotor. To magnetize the ma-
chine, direct current is fed through brushes and slip rings to the windings located on the salient
poles. The main flux created by the direct current flows from the pole shoe to the stator and
back simultaneously penetrating the poly-phase slot winding of the stator. The dotted lines in
 c02
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Table 2.1 Different types of windings or permanent magnets used instead of a field winding in the most common machine types
Compensating Commutating
Stator winding Rotor winding winding winding Damper winding
P2: ABC
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Salient-pole Poly-phase distributed Salient-pole winding — — Short-circuited cage

synchronous rotating-field slot winding
machine winding
Nonsalient-pole Poly-phase distributed Slot winding — — Solid-rotor core or
synchronous rotating-field slot short-circuited
machine winding cage winding
Synchronous Poly-phase distributed — — — Short-circuited cage
November 25, 2008

Windings of Electrical Machines

reluctance machine rotating-field slot winding possible

winding
PMSM, q > 0.5 Poly-phase distributed Permanent magnets — — Solid-rotor or
16:47

rotating-field slot short-circuited

winding cage winding, or,
for example,
aluminium plate on
rotor surface
PMSM, q ≤ 0.5 Poly-phase concentrated Permanent magnets — — Damping should be
pole winding harmful because of
excessive losses
Double-salient Poly-phase concentrated — — — —
reluctance machine pole winding
Printer Name: Yet to Come

IM Poly-phase distributed Cast or soldered cage — — —

rotating-field slot winding, squirrel cage
winding winding
Solid-rotor IM Poly-phase distributed Solid rotor made of steel, — — —
rotating-field slot may be equipped with
winding squirrel cage
Slip-ring Poly-phase distributed Poly-phase distributed — — —
asynchronous rotating-field slot rotating-field slot
motor winding winding
DC machine Salient-pole winding Rotating-field commutator Slot winding Salient-pole —
49

slot winding winding

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50 Design of Rotating Electrical Machines

q d q
τp
d

(a) (b)

Figure 2.1 (a) Salient-pole synchronous machine (p = 4). The black areas around two pole bodies
form a salient-pole winding. (b) Single poles with windings: d, direct axis; q, quadrature axis. In salient-
pole machines, these two magnetically different, rotor-geometry-defined axes have a remarkable effect
on machine behaviour (this issue will be discussed later)

the figure depict the paths of the main flux. Such a closed path of a flux forms the magnetic
circuit of a machine.
One turn of a coil is a single-turn conductor, through which the main flux travelling in the
magnetic circuit passes. A coil is a part of winding that consists of adjacent series-connected
turns between the two terminals of the coil. Figure 2.1a illustrates a synchronous machine
with a pole with one coil per pole, whereas in Figure 2.1b the locations of the direct (d) and
quadrature (q) axes are shown.
A group of coils is a part of the winding that magnetizes the same magnetic circuit. In
Figure 2.1a, the coils at the different magnetic poles (N and S alternating) form in pairs a
group of coils. The number of field winding turns magnetizing one pole is N f .
The salient-pole windings located on the rotor or on the stator are mostly used for the DC
magnetizing of a machine. The windings are then called magnetizing or sometimes excitation
windings. With a direct current, they create a time-constant current linkage Θ. The part of
this current linkage consumed in the air gap, that is the magnetic potential difference of the
air gap U m,δ , may be, for simplicity, regarded as constant between the quadrature axes, and it
changes its sign at the quadrature axis q, Figure 2.2.
A significant field of application for salient-pole windings is double-salient reluctance ma-
chines. In these machines, a solid salient pole is not utilizable, since the changes of flux are
rapid when operating at high speeds. At a simple level, DC pulses are fed to the pole wind-
ings with power switches. In the air gap, the direct current creates a flux that tries to turn
the rotor in a direction where the magnetic circuit of the machine reaches its minimum re-
luctance. The torque of the machine tends to be pulsating, and to reach an even torque, the
current of a salient-pole winding should be controllable so that the rotor can rotate without
jerking.
Salient-pole windings are employed also in the magnetizing windings of DC machines. All
series, shunt and compound windings are wound on salient poles. The commutating windings
are also of the same type as salient-pole windings.
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Windings of Electrical Machines 51

Βδ

Θf

0
Um, U m,Fe

current linkage is created

R m, R m,Fe
Θf Θf −π/2 π/2

U m,Fe Um,

q d q

(a) (b)

Figure 2.2 (a) Equivalent magnetic circuit. The current linkages Θ f created by two adjacent salient-
pole windings. Part U m,δ is consumed in the air gap. (b) The behaviour of the air-gap flux density Bδ .
Due to the appropriate design of the pole shoe, the air-gap flux density varies cosinusoidally even though
it is caused by the constant magnetic potential difference in the air gap U m,δ . The air-gap magnetic flux
density Bδ has its peak value on the d-axis and is zero on the q-axis. The current linkage created by the
pole is accumulated by the ampere turns on the pole

Example 2.1: Calculate the field winding current that can ensure a maximum magnetic
flux density of Bδ = 0.82 T in the air gap of a synchronous machine if there are 95 field
winding turns per pole. It is assumed that the air-gap magnetic flux density of the ma-
chine is sinusoidal along the pole shoes and the magnetic permeability of iron is infinite
(µFe = ∞) in comparison with the permeability of air µ0 = 4π × 10−7 H/m. The mini-
mum length of the air gap is 3.5 mm.

Solution: If µFe = ∞, the magnetic reluctance of iron parts and the iron magnetic potential
difference is zero. Now, the whole field current linkage Θf = Nf If is spent in the air gap
to create the required magnetic flux density:

Bδ 0.82
Θf = Nf If = Um,δ = Hδ δ = δ= 3.5 · 103 A
µ0 4π · 10−7

If the number of turns is N f = 95, the field current is

Θf 0.82 1
If = = 3.5 · 10−3 A = 24 A
Nf 4π · 10−7 95
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52 Design of Rotating Electrical Machines

It should be noted that calculations of this kind are appropriate for an approximate
calculation of the current linkage needed. In fact, about 60–90% of the magnetic potential
difference in electrical machines is spent in the air gap, and the rest in the iron parts.
Therefore, in a detailed design of electrical machines, it is necessary to take into account
all the iron parts with appropriate material properties. A similar calculation is valid for DC
machines, with the exception that in DC machines the air gap is usually constant under the
poles.

2.1.2 Slot Windings

Here we concentrate on symmetrical, three-phase AC distributed slot windings, in other words
rotating-field windings. However, first, we discuss the magnetizing winding of the rotor of a
nonsalient-pole synchronous machine, and finally turn to commutator windings, compensat-
ing windings and damper windings. Unlike in the salient-pole machine, since the length of the
air gap is now constant, we may create a cosinusoidally distributed flux density in the air gap
by producing a cosinusoidal distribution of current linkage with an AC magnetizing winding,
Figure 2.3. The cosinusoidal distribution, instead of the sinusoidal one, is used because we
want the flux density to reach its maximum on the direct axis, where α = 0.
In the case of Figure 2.3, the function of the magnetic flux density approximately follows
the curved function of the current linkage distribution Θ (α). In machine design, an equivalent
air gap δ e is applied, the target being to create a cosinusoidally alternating flux density in the
air gap

µ0
B (α) = Θ (α) . (2.1)
δe

The concept of equivalent air gap δe will be discussed later.

d
α

If
rotor current linkage

zQ If

q
0 π α

If
zQ q d q d

Figure 2.3 Current linkage distribution created by two-pole nonsalient-pole winding and the funda-
mental of the current linkage. There are zQ conductors in each slot, and the excitation current in the
winding is I f . The height of a single step of the current linkage is zQ I f
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Windings of Electrical Machines 53

The slot pitch τ u and the slot angle α u are the core parameters of the slot winding. The
slot pitch is measured in metres, whereas the slot angle is measured in electrical degrees. The
number of slots being Q and the diameter of the air gap D, we may write

πD 2π
τu = ; αu = p . (2.2)
Q Q

As the slot pitch is usually constant in nonsalient-pole windings, the current sum (zQ I f )
in a slot has to be of a different magnitude in different slots (in a sinusoidal or cosinusoidal
manner to achieve a sinusoidal or cosinusoidal variation of current linkage along the surface
of the air gap). Usually, there is a current of equal magnitude flowing in all turns in the slot,
and therefore the number of conductors zQ in the slots has to be varied. In the slots of the
rotor in Figure 2.3, the number of turns is equal in all slots, and a current of equal magnitude
is flowing in the slots. We can see that by selecting zQ slightly differently in different slots,
we can improve the stepped waveform of the figure to approach better the cosinusoidal form.
The need for this depends on the induced voltage harmonic content in the stator winding. The
voltage may be of almost pure sinusoidal waveform despite the fact that the air-gap flux den-
sity distribution should not be perfectly sinusoidal. This depends on the stator winding factors
for different harmonics. In synchronous machines, the air gap is usually relatively large, and,
correspondingly, the flux density on the stator surface changes more smoothly (neglecting
the influence of slots) than the stepped current linkage waveform of Figure 2.3. Here, we ap-
ply the well-known finding that if two-thirds of the rotor surface are slotted and one-third is
left slotless, not only the third harmonic component but any of its multiple harmonics called
triplen harmonics are eliminated in the air-gap magnetic flux density, and also the low-order
odd harmonics (fifth, seventh) are suppressed.

2.1.3 End Windings

Figure 2.4 illustrates how the arrangement of the coil end influences the physical appearance
of the winding. The windings a and b in the figure are of equal value with respect to the main
flux, but their leakage inductances diverge from each other because of the slightly different
coil ends. When investigating winding a of Figure 2.4a, we note that the coil ends form two
separate planes at the end faces of the machine. This kind of a winding is therefore called
a two-plane winding. The coil ends of this type are depicted in Figure 2.4e. In the winding
of Figure 2.4b, the coil ends are overlapping, and therefore this kind of winding is called
a diamond winding (lap winding). Figures 2.4c and d illustrate three-phase stator windings
that are identical with respect to the main flux, but in Figure 2.4c the groups of coil are
not divided, and in Figure 2.4d the groups of coils are divided. In Figure 2.4c, an arbitrary
radius r is drawn across the coil end. It is shown that at any position, the radius intersects
only coils of two phases, and the winding can thus be constructed as a two-plane winding. A
corresponding winding constructed with distributed coils (Figure 2.4d) has to be a three-plane
arrangement, since now the radius r may intersect the coil ends of the windings of all the three
phases.
The part of a coil located in a single slot is called a coil side, and the part of the coil outside
the slot is termed a coil end. The coil ends together constitute the end windings of the winding.
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54 Design of Rotating Electrical Machines

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

(a)

(e)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

(b)
ding
win
coil span end
coil side (f )

r r

1 1
23 24 2 3 23 24 2 3
22 4 22 4
21 5 21 5
20 6 20 6
19 7 19 7
18 8 18 8
17 9 17 9
16 10 16 10
15 14 12 11 15 14 12 11
13 13

(c) (d)

Figure 2.4 (a) Concentric winding and (b) a diamond winding. In a two-plane winding, the coil spans
differ from each other. In the diamond winding, all the coils are of equal width. (c) A two-plane, three-
phase, four-pole winding with nondivided groups of coil. (d) A three-plane, three-phase, four-pole wind-
ing with divided groups of coils. Figures (c) and (d) also illustrate a single main flux path. (e) Profile
of an end winding arrangement of a two-plane winding. (f) Profile of an end winding of a three-plane
winding. The radii r in the figures illustrate that in a winding with nondivided groups, an arbitrary radius
may intersect only two phases, and in a winding with divided groups, the radius may intersect all three
phases. The two- or three-plane windings will result correspondingly

2.2 Phase Windings

Next, poly-phase slot windings that produce the rotating field of poly-phase AC machines
are investigated. In principle, the number of phases m can be selected freely, but the use of a
three-phase supply network has led to a situation in which also most electrical machines are of
the three-phase type. Another, extremely common type is two-phase electrical machines that
are operated with a capacitor start and run motor in a single-phase network. A symmetrical
two-phase winding is in principle the simplest AC winding that produces a rotating field.
A configuration of a symmetrical poly-phase winding can be considered as follows: the
periphery of the air gap is evenly distributed over the poles so that we can determine a pole
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Windings of Electrical Machines 55

τp

-U V
W
-W

o
120 τv
-V U

p = 2
U -V
m = 3

-W W
o
180
V -U
120 o

Figure 2.5 Division of the periphery of a three-phase, four-pole machine into phase zones of positive
and negative values. The pole pitch is τ p and phase zone distribution τ v . When the windings are lo-
cated in the zones, the instantaneous currents in the positive and negative zones are flowing in opposite
directions

arc, which covers 180 electrical degrees and a corresponding pole pitch, τ p , which is expressed
in metres
πD
τp = . (2.3)
2p

Figure 2.5 depicts the division of the periphery of the machine into phase zones of positive
and negative values. In the figure, the number of pole pairs p = 2 and the number of phases
m = 3.
The phase zone distribution is written as
τp
τv = . (2.4)
m
The number of zones will thus be 2pm. The number of slots for each such zone is expressed
by the term q, as a number of slots per pole and phase

Q
q= . (2.5)
2 pm

Here Q is the number of slots in the stator or in the rotor. In integral slot windings, q is an
integer. However, q can also be a fraction. In that case, the winding is called a fractional slot
winding.
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56 Design of Rotating Electrical Machines

The phase zones are distributed symmetrically to different phase windings so that the phase
zones of the phases U, V, W, . . . are positioned on the periphery of the machine at equal
distances in electrical degrees. In a three-phase system, the angle between the phases is 120
electrical degrees. This is illustrated by the periphery of Figure 2.5, where we have 2 × 360
electrical degrees because of four poles. Now, it is possible to label every phase zone. We start
for instance with the positive zone of the phase U. The first positive zone of the phase V will
be 120 electrical degrees from the first positive zone of the phase U. Correspondingly, the first
positive zone of the phase W will be 120 electrical degrees from the positive zone of the phase
V and so on. In Figure 2.5, there are two pole pairs, and hence we need two positive zones for
each phase U, V and W. In the slots of each, now labelled phase zones, there are only the coil
sides of the labelled phase coil, in all of which the current flows in the same direction. Now,
if their direction of current is selected positive in the diagram, the unlabelled zones become
negative. Negative zones are labelled by starting from the distance of a pole pitch from the
position of the positive zones. Now U and −U, V and −V, W and −W are at distances of 180
electrical degrees from each other.

2.3 Three-Phase Integral Slot Stator Winding

The armature winding of a three-phase electrical machine is usually constructed in the stator,
and it is spatially distributed in the stator slots so that the current linkage created by the stator
currents is distributed as sinusoidally as possible. The simplest stator winding that produces
a noticeable rotating field comprises three coils, the sides of which are divided into six slots,
because if m = 3, p = 1, q = 1, then Q = 2pmq = 6; see Figures 2.6 and 2.7.

Example 2.2: Create a three-phase, two-pole stator winding with q = 1. Distribute the
phases in the slots and illustrate the current linkage created based on the instant values of
phase sinusoidal currents. Draw a phasor diagram of the slot voltage and sum the voltages
of the individual phases. Create a current linkage waveform in the air gap for the time
instant t1 when the phase U voltage is at its positive maximum and for t2 , which is shifted
by 30◦ .
Solution: If m = 3, p = 1, q = 1, then Q = 2pmq = 6, which is the simplest case of
three-phase windings. The distribution of the phases in the slots will be explained based
on Figure 2.6. Starting from slot 1, we insert there the positive conductors of the phase U
forming zone U1. The pole pitch expressed by the number of slots per pole, or in other
words ‘the coil span expressed in the number of slot pitches yQ ’, is

Q 6
yQ = = = 3.
2p 2

Then, zone U2 will be one pole pitch shifted from U1 and will be located in slot 4,
because 1 + yQ = 1 + 3 = 4. The beginning of the phase V1 is shifted by 120◦ from
U1, which means slot 3 and its end V2 are in slot 6 (3 + 3 = 6). The phase W1 is again
shifted from V1 by 120◦ , which means that it is in slot 5 and its end is in slot 2; see
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Windings of Electrical Machines 57

U1
1
V2 W2
2 α
6
1 2 3 4 5 6
p=1
m=3
W1 5 3 V1
4
U2
U1 U2
(a) (b)

U1

V2 W2

U V W
i

W1 V1 t

t1
U2
(c) (d)
1
UU
α u = 60 o –4
6 2
1
5 3
–2 –6
5 3 UW UV

4
(e) (f )

Figure 2.6 The simplest three-phase winding that produces a rotating field. (a) A cross-sectional
surface of the machine and a schematic view of the main flux route at the observation instant t1 ,
(b) a developed view of the winding in a plane and (c) a three-dimensional view of the winding.
The figure illustrates how the winding penetrates the machine. The coil end at the rear end of the
machine is not illustrated as in reality, but the coil comes directly from a slot to another without
travelling along the rear end face of the stator. The ends of the phases U, V and W at the terminals
are denoted U1–U2, V1–V2 and W1–W2. (d) The three-phase currents at the observed time instant
t1 when i W = i V = −1/2i U , which means (iU + iV + iW = 0), (e) a voltage phasor diagram for the
given three-phase system, (f) the total phase voltage for individual phases. The voltage of the phase
U is created by summing the voltage of slot 1 and the negative voltage of slot 4, and therefore the
direction of the voltage phasor in slot 4 is taken opposite and denoted −4. We can see the sum of
voltages in both slots and the phase shift by 120◦ of the V- and W-phase voltages
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58 Design of Rotating Electrical Machines

4i z
ΘˆU1 = U Q
2
(a) zQiU/2 zQiU

0 π
zQiU/2
starting of study

slotted stator inner periphery

U1 U2 U1

slot 2 1 6 5 4 3 2 slot 2 1 6 5 4 3 2
Θ Θ
α α

O O O O O O
0 180 360 0 180 360
U V W U V W
i i

t1 t2
(b) (c)

Figure 2.7 Current linkages Θ created by a simple three-phase q = 1 winding. (a) Only the phase
U is fed by current and observed. A rectangular waveform of current linkage with its fundamental
component is shown to explicate the staircase profile of the current linkages below. If all three phases
are fed and observed in two different current situations (iU + iV + iW = 0) at two time instants
t1 and t2 , see (b) and (c), respectively. The figure also illustrates the fundamental of the staircase
current linkage curves. The stepped curves are obtained by applying Ampère’s law in the current-
carrying teeth zone of the electrical machine. Note that as time elapses from t1 to t2 , the three-phase
currents change and also the position of the fundamental component changes. This indicates clearly
the rotating-field nature of the winding. The angle α and the numbers of slots refer to the previous
figure, in which we see that the maximum flux density in the air gap lies between slots 6 and 5. This
coincides with the maximum current linkage shown in this figure. This is valid if no rotor currents
are present

Figure 2.6a. The polarity of instantaneous currents is shown at the instant when the current
of the phase U is at its positive maximum value flowing in slot 1, depicted as a cross (the
tail of an arrow) in U1 (current flowing away from the observer). Then, U2 is depicted
by a dot (the point of the arrow) in slot 4 (current flowing towards the observer). At the
same instant in V1 and W1, there are also dots, because the phases V and W are carrying
negative current values (see Figure 2.6d), and therefore V2 and W2 are positive, indicated
by crosses. In this way, a sequence of slots with inserted phases is as follows: U1, W2, V1,
U2, W1, V2, if q = 1.
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Windings of Electrical Machines 59

The cross-section of the stator winding in Figure 2.6a shows fictitious coils with current
directions resulting in the magnetic field represented by the force lines and arrows.
The phasor diagram in Figure 2.6e includes six phasors. To determine their number, the
largest common divider of Q and p denoted t has to be found. In this case, for Q = 6 and
p = 1, t = 1 and therefore the number of phasors is Q/t = 6. The angle between the voltage
phasors in the adjacent slots is given by the expression

360◦ p 360◦ · 1
αu = = = 60◦ ,
Q 6

which results in the numbering of the voltage phasors in slots as shown in Figure 2.6e.
Now the total phase voltage for individual phases has to be summed. The voltage of the
phase U is created by the positive voltage in slot 1 and the negative voltage in slot 4. The
direction of the voltage phasor in slot 4 is taken opposite and denoted −4. We can see
the sum of voltages in both slots of the phase U, and the phase shift of 120◦ of the V and
W phase voltages in Figure 2.6f.
The current linkage waveforms for this winding are illustrated in Figure 2.7b and c for
the time instants t1 and t2 , between which the waveforms proceed by 30◦ . The procedure of
drawing the figure can be described as follows. We start observation at α = 0. We assume
the same constant number of conductors zQ in all slots.
The current linkage value on the left in Figure 2.7b is changed stepwise at slot 2, where
the phase W is located and is carrying a current with a cross sign. This can be drawn as
a positive step of Θ with a certain value (Θ(t1 ) = iuW (t1 )zQ ). Now, the current linkage
curve remains constant until we reach slot 1, where the positive currents of the phase U
are located. The instantaneous current in slot 1 is the phase U peak current. The current
sum is again indicated with a cross sign. The step height is now twice the height in slot
2, because the peak current is twice the current flowing in slot 2. Then, in slot 6, there is
again a positive half step caused by the phase V. In slot 5, there is a current sum indicated
by a dot, which means a negative Θ step. This is repeated with all slots, and when the
whole circle has been closed, we get the current linkage waveform of Figure 2.7b. When
this procedure is repeated for one period of the current, we obtain a travelling wave for
the current linkage waveform. Figure 2.7c shows the current linkage waveform after 30◦ .
Here we can see that if the instantaneous value of a slot current is zero, the current linkage
does not change, and the current linkage remains constant; see slots 2 and 5. We can also
see that the Θ profiles in b and c are not similar, but the form is changed depending on the
time instant at which it is investigated.
Figure 2.7 shows that the current linkage produced with such a simple winding deviates
considerably from a sinusoidal waveform. Therefore, in electrical machines, more coil
sides are usually employed per pole and phase.

Example 2.3: Consider an integral slot winding, where p = 1 and q = 2, m = 3. Distribute

the phase winding into the slots, produce an illustration of the windings in the slots, draw
a phasor diagram and show the phase voltages of the individual phases. Create a waveform
of the current linkage for this winding and compare it with that in Figure 2.7.
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60 Design of Rotating Electrical Machines

U1
1 2
3
V2 12 W2
4
α
11 5 12 1 2 3 4 5 6 7 8 9 10 11 12 1
p=1
10 m=3 6
W1 9 V1
8 7

U2 U1 W2 V1 U2 W1 V2 U1
(a) (b)
12 1
11 2
12 1 2 3 4 5 6 7 8 9 12 1 2 3 4 5 6 7 8 9
3
yQ1 = 5 10 αu = 30o

9
5
U1 yQ = 6 U2 U1 yQ2 = 7 U2 8
7 6
(c) (d) (e)

-8 UphU
UphU -7

2 2
-7 -8

1 1

UphW
UphW

UphV
(f ) UphV (g)

Figure 2.8 Three-phase, two-pole winding with two slots per pole and phase: (a) a stator with 12
slots, the number of slots per pole and phase q = 2, (b) divided coil groups, (c) full-pitch coils of
the phase U, (d) average full-pitch coils of the phase U, (e) a phasor diagram with 12 phasors, one
for each slot, (f) the sum phase voltage of individual phases corresponding to figure (c), (g) the sum
phase voltage of individual phases corresponding to figure (d)

Solution: The number of slots needed for this winding is Q = 2pmq = 2 × 3 × 2 = 12.
The cross-sectional area of such a stator with 12 slots and embedded conductors of
individual phases is illustrated in Figure 2.8a. The distribution of the slots into the phases
is made in the same order as in Example 2.2, but now q = 2 slots per pole and phase.
Therefore, the sequence of the slots for the phases is as follows: U1, U1, W2, W2, V1, V1,
U2, U2, W1, W1, V2, V2. The direction of the current in the slots will be determined in
the same way as above in Example 2.2. The coils wound in individual phases are shown
in Figure 2.8b. The pole pitch expressed in number of slot pitches is

Q 12
yQ = = = 6.
2p 2
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Windings of Electrical Machines 61

Figure 2.8c shows how the phase U is wound to keep the full pitch equal to six slots. In
Figure 2.8d, the average pitch is also six, but the individual steps are yQ = 5 and 7, which
give the same average result for the value of induced voltage.
The phasor diagram has 12 phasors, because t = 1 again. The angle between two phasors
of adjacent slots is
360◦ p 360◦ · 1
αu = = = 30◦ .
Q 12
The phasors are numbered gradually around the circle. Based on this diagram, the phase
voltage of all phases can be found. Figures 2.8f and g show that the voltages are the same
independent of how the separate coil sides are connected in series. In comparison with
the previous example, the geometrical sum is now less than the algebraic sum. The phase
shifting between coil side voltages is caused by the distribution of the winding in more than
one slot, here in two slots for each pole. This reduction of the phase voltage is expressed
by means of a distribution winding factor; this will be derived later.
The waveform of the current linkage for this winding is given in Figure 2.9. We can see
that it is much closer to a sinusoidal waveform than in the previous example with q = 1.

Θ /A

200

100 Θˆs1

5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

Figure 2.9 Current linkage Θs = f (α) created by the winding on the surface of the stator bore of
Figure 2.8 at a time i W = i V = −1/2i U . The fundamental Θsl of Θs is given as a sinusoidal curve. The
numbering of the slots is also given

In undamped permanent magnet synchronous motors, such windings can also be employed,
the number of slots per pole and phase of which being clearly less than one, for instance
q = 0.4. In that case, a well-designed machine looks like a rotating-field machine when ob-
served at its terminals, but the current linkage produced by the stator winding deviates so
much from the fundamental that, because of excessive harmonic losses in the rotor, no other
rotor type comes into question.
When comparing Figure 2.9 (q = 2) with Figure 2.7 (q = 1), it is obvious that the higher
the term q (slots per pole and phase), the more sinusoidal the current linkage of the stator
winding.
As we can see in Figure 2.7a, the current linkage amplitude of the fundamental component
for one full-pitch coil is
4 z Q iˆU
Θ̂1U = . (2.6)
π 2
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62 Design of Rotating Electrical Machines

If the coil winding is distributed into more slots, and q > 1 and N = pqzQ /a, the winding
factor must be taken into account:
4 Nkw1 iˆU
Θ̂1U = . (2.7)
π 2
In a 2p-pole machine (2p > 2), the current linkage for one pole is

4 Nkw1 iˆU
Θ̂1U = . (2.8)
π 2p
This expression can be rearranged with the number of conductors in a slot. In one phase,
there are 2N conductors, and they are embedded in the slots belonging to one phase Q/m.
Therefore, the number of conductors in one slot will be
2N 2m N N
zQ = = = (2.9)
Q/m 2 pqm pq
and
N
= qz Q . (2.10)
p
Then N/p presented in Equation (2.8) and in the following can be introduced by qzQ :

4 Nkw1 iˆU 4 kw1 iˆU

Θ̂1U = = qz Q . (2.11)
π 2p π 2
Equation (2.8) can also be expressed by the effective value of sinusoidal phase current if there
is a symmetrical system of phase currents:
4 Nkw1 √
Θ̂1U = 2I. (2.12)
π 2p
For an m-phase rotating-field stator or rotor winding, the amplitude of current linkage is
m/2 times as high
m 4 Nkw1 √
Θ̂1 = 2I (2.13)
2 π 2p
and for a three-phase stator or rotor winding, the current linkage amplitude of the fundamental
component for one pole is
3 4 Nkw1 √ 3 Nkw1 √
Θ̂1 = 2I = 2I. (2.14)
2 π 2p π p

For a stator current linkage amplitude Θ̂sν of the harmonic ν of the current linkage of a
poly-phase (m > 1) rotating-field stator winding (or rotor winding), when the effective value
of the stator current is I s , we may write
m 4 kwv Ns 1 √ mkwv Ns ˆ
Θ̂sν = 2Is = i s. (2.15)
2 π pν 2 π pν
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Windings of Electrical Machines 63

Example 2.4: Calculate the amplitude of the fundamental component of stator current
linkage, if N s = 200, kw1 = 0.96, m =√3, p = 1 and i sU (t) = iˆ = 1 A, the effective value
for a sinusoidal current being Is = (1/ 2) A = 0.707 A.
Solution: For the fundamental, we obtain Θ̂s1 = 183.3 A, because:

3 4 Nkw1 √ 3 Nkw1 √ 3 200 · 0.96 √

Θ̂1 = 2Is = 2Is = · 2 · 0.707 A = 183.3 A.
2 π 2p π p π 1

2.4 Voltage Phasor Diagram and Winding Factor

Since the winding is spatially distributed in the slots on the stator surface, the flux (which is
proportional to the current linkage Θ) penetrating the winding does not intersect all windings
simultaneously, but with a certain phase shift. Therefore, the emf of the winding is not
calculated directly with the number of turns N s , but the winding factors kwν corresponding to
the harmonics are required. The emf of the fundamental induced in the turn is calculated with
the flux linkage Ψ by applying Faraday’s induction law e = −Nkw1 dΦ/dt = −dΨ /dt (see
Equations 1.3, 1.7 and 1.8). We can see that the winding factor correspondingly indicates
the characteristics of the winding to produce harmonics, and it has thus to be taken into
account when calculating the current linkage of the winding (Equation 2.15). The common
distribution of all the current linkages created by all the windings together produces a
flux density distribution in the air gap of the machine, which, when moving with respect
to the winding, induces voltages in the conductors of the winding. The phase shift of the
induced emf in different coil sides is investigated with a voltage phasor diagram. The
voltage phasor diagram is presented in electrical degrees. If the machine is for instance a
four-pole one, p = 2, the voltage vectors have to be distributed along two full circles in the
stator bore. Figure 2.10a illustrates the voltage phasor diagram of a two-pole winding of
Figure 2.8.
In Figure 2.10a, phasors 1 and 2 are positive and 7 and 8 are negative for the phase under
consideration. Hence, phasors 7 and 8 are turned by 180◦ to form a bunch of phasors. For
harmonic ν (excluding slot harmonics that have the same winding factor as the fundamental)
the directions of the phasors of the coil sides vary more than in the figure, because the slot
angles α u are replaced with the angles να u .
According to Figure 2.10b, when calculating the geometric sum of the voltage phasors for
a phase winding, the symmetry line for the bunch of phasors, where the negative phasors
have been turned opposite, must be found. The angles α ρ of the phasors with respect to this
symmetry line may be used in the calculation of the geometric sum. Each phasor contributes
to the sum with a component proportional to cos α ρ .
We can now write a general presentation for the winding factor kwv of a harmonic ν, by
employing the voltage phasor diagram

νπ
sin

Z
kwv = 2 cos αρ . (2.16)
Z ρ=1
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64 Design of Rotating Electrical Machines

αz ∑z U

1 2
–U 8 –U7 cosα
3 αρ
12
4
U2 U2 symmetry
11 line
5 α2
-U 8
10 –U7
positive
6 phasors
9
7 U1 –U8
8
–U7 U2
negative phasors
(a) (b) (c)

Figure 2.10 (a), (b) Fundamental voltage phasor diagram for the winding of Figure 2.8 Qs = 12,
p = 1, qs = 2. A maximum voltage is induced in the bars in slots 1 and 7 at the moment depicted in the
figure, when the rotor is rotating clockwise. The figure also illustrates the calculation of the voltage in
a single coil with the radii of the voltage phasor diagram. (c) General application of the voltage phasor
diagram in the determination of the winding factor (fractional slot winding since the number of phasors
is uneven). The phasors of negative coil sides are turned 180◦ , and then the summing of the resulting
bunch of phasors is calculated according to Equation (2.16). A symmetry line is drawn in the middle
of the bunch, and each phasor forms an angle α ρ with the symmetry line. The geometric sum of all the
phasors lies on the symmetry line

Here Z is the total number of positive and negative phasors of the phase in question, ρ is
the ordinal number of a single phasor, and ν is the ordinal number of the harmonic under
observation. The coefficient sin νπ/2 in the equation only influences the sign (of the factor).
The angle of a single phasor α ρ can be found from the voltage phasor diagram drawn for
the specific harmonic, and it is the angle between an individual phasor and the symmetry
line drawn for a specific harmonic (cf. Figure 2.10b). This voltage phasor diagram solution
is universal and may be used in all cases, but the numerical values of Equation (2.16) do not
always have to be calculated directly from this equation, or with the voltage phasor diagram
at all. In simple cases, we may apply equations introduced later. However, the voltage phasor
diagram forms the basis for the calculations, and therefore its utilization is discussed further
when analysing different types of windings.
If in Figure 2.10a we are considering a currentless stator of a synchronous machine, a
maximum voltage can be induced in the coil sides 1 and 7 at the middle of the pole shoe,
when the rotor is rotating at no load inside the stator bore (which corresponds to the peak value
of the flux density, but the zero value of the flux penetrating the coil), where the derivative of
the flux penetrating the coil reaches its peak value, the voltage induction being at its highest
at that moment. If the rotor rotates clockwise, a maximum voltage is induced in coil sides 2
and 8 in a short while, and so on. The voltage phasor diagram then describes the amplitudes
of voltages induced in different slots and their temporal phase shift.
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Windings of Electrical Machines 65

The series-connected coils of the phase U travel, for example, from slot 1 to slot 8 (coil 1)
and from slot 2 to slot 7 (coil 2; see Figure 2.8c). Thus a voltage, which is the difference of
the phasors U 1 and U 8 , is induced in coil 1. The total voltage of the phase is thus

U U = U 1 − U 8 + U 2 − U 7. (2.17)

The figure also indicates the possibility of connecting the coils in the order 1–7 and 2–8,
which gives the same voltage but a different end winding. The winding factor kw1 based on the
distribution of the winding for the fundamental is calculated here as a ratio of the geometric
sum and the sum of absolute values as follows:

geometric sum U −U +U −U
kw1 = =   1  8  2  7  = 0.966 ≤ 1. (2.18)
sum of absolute values U  + U  + U  + U 
1 8 2 7

Example 2.5: Equation (2.16) indicates that the winding factor for the harmonics may
also be calculated using the voltage phasor diagram. Derive the winding factor for the
seventh harmonic of the winding in Figure 2.8.
Solution: We now draw a new voltage phasor diagram based on Figure 2.10 for the seventh
harmonic, Figure 2.11.

τ p1
(a)

τ p7

10 11 12 1 2 3 4 5 6 7 8 9 10

1 8
(b) (c) –U U 7,2 –U 7,7
7,8

U 7,1
–U
α νu = να u 7,7
5π/12

U 7,2

7 –U 7,8
2

Figure 2.11 Deriving the harmonic winding factor: (a) the fundamental and the seventh harmonic
field in the air gap over the slots, (b) voltage phasors for the seventh harmonic of a full-pitch q = 2
winding (slot angle α u7 = 210◦ ) and (c) the symmetry line and the sum of the voltage phasors. The
phasor angles α ρ with respect to the symmetry line are α ρ = 5π/12 or −5π /12
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66 Design of Rotating Electrical Machines

Slots 1 and 2 belong to the positive zone of the phase U and slots 7 and 8 to the negative
zone measured by the fundamental. In Figure 2.11, we see that the pole pitch of the seventh
harmonic is one-seventh of the fundamental pole pitch. Deriving the phasor sum for the
seventh harmonic is started for instance with the voltage phasor of slot 1. This phasor
remains in its original position. Slot 2 is physically and by the fundamental located 30◦
clockwise from slot 1, but as we are now studying the seventh harmonic, the slot angle
measured in degrees for it is 7 × 30◦ = 210◦ , which can also be seen in the figure. The
phasor for slot 2 is, hence, located 210◦ clockwise from phasor 1. Slot 7 is located at
7 × 180◦ = 1260◦ from slot 1. Since 1260◦ = 3 × 360◦ + 180◦ phasor 7 remains opposite
to phasor 1. Phasor 8 is located 210◦ clockwise from phasor 7 and will find its place 30◦
clockwise from phasor 1. By turning the negative zone phasors by π and applying Equation
(2.17) we obtain
7π
sin

4
kw7 = 2 cos αρ
4 ρ=1
7π  
sin
= 2 cos −5π + cos +5π + cos −5π + cos +5π = −0.2588.
4 12 12 12 12

It is not necessary to apply the voltage phasor diagram, but also simple equations may be
derived to directly calculate the winding factor. In principle, we have three winding factors: a
distribution factor, a pitch factor and a skewing factor. The last may also be taken into account
by a leakage inductance. The winding factor derived from the shifted voltage phasors in the
case of a distributed winding is called the distribution factor, denoted by the subscript ‘d’.
This factor is always kd1 ≤ 1. The value kd1 = 1 can be reached when q = 1, in which case
the geometric sum equals the sum of absolute values, see Figure 2.6f. If q = 1, then kd1 < 1.
In fact, this means that the total phase voltage is reduced by this factor (see Example 2.6).
If each coil is wound as a full-pitch winding, the coil pitch is in principle the same as
the pole pitch. However, the voltage of the phase with full-pitch coils is reduced because
of the winding distribution with the factor kd . If the coil pitch is shorter than the pole pitch
and the winding is not a full-pitch winding, the winding is called a short-pitch winding, or a
chorded winding (see Figure 2.15). Note that the winding in Figure 2.8 is not a short-pitch
winding, even though the coil may be realized from slot 1 to slot 8 (shorter than pole pitch)
and not from slot 1 to slot 7 (equivalent to pole pitch). A real short pitching is obviously
employed in the two-layer windings. Short pitching is another reason why the voltage of the
phase winding may be reduced. The factor of such a reduction is called the pitch factor kp .
The total winding factor is given as

kw = kd · kp . (2.19)

Equations to calculate the distribution factor kd will now be derived; see Figure 2.12. The
equations are based on the geometric sum of the voltage phasors in a similar way as in Figures
2.10 and 2.11.
The distribution factor for the fundamental component is given as
geometric sum U1
kd1 = = . (2.20)
sum of absolute values qUcoil1
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Windings of Electrical Machines 67

Uv3 Uv4
U
B v2 3 B̂ 1
2 4 Uv5
Uv1 U1 αν=5 = 90o
D 5 B̂ 5
1
A C
qαu/2
αu τp5
r τp1
αν=1 = 18o

O
(a) (b)

Figure 2.12 (a) Determination of the distribution factor with a polygon with q = 5, (b) the pole pitch
for the fundamental and the fifth harmonic. The same physical angles for the fifth harmonic and the
fundamental are shown as an example. Voltages Uv1 − Uv5 represent corresponding coil voltages

According to Figure 2.12, we may write for the triangle ODC

U1
qαu qαu
sin = 2 ⇒ U1 = 2r sin , (2.21)
2 r 2
and for the triangle OAB
Uv1
αu αu
sin = 2 ⇒ Uv1 = 2r sin . (2.22)
2 r 2
We may now write for the distribution factor
qαu qαu
U1 2r sin sin
kd1 = = 2 2 .
qUv1 αu = αu (2.23)
q2r sin q sin
2 2
This is the basic expression for the distribution factor for the calculation of the fundamental
in a closed form. Since the harmonic components of the air-gap magnetic flux density are
present, the calculation of the distribution factor for the νth harmonic will be carried out
applying the angle να u ; see Figure 2.11b and 2.12b:
qαu
sin ν
kdν = 2 . (2.24)
αu
q sin ν
2

Example 2.6: Repeat Example 2.5 using Equation (2.24).

Solution for ν = 7:
qαu 2π 7π
sin ν
sin 7 6 sin
kdν = 2 = 2 = 6 = −0.2588.
αu 2 sin 7 π 7π
q sin ν 6·2 2 sin
2 12
The result is the same as above.
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68 Design of Rotating Electrical Machines

The expression for the fundamental may be rearranged as

Q 2π p π/2
sin sin
2 pm 2Q m .
kd1 = = (2.25)
2π p π/6
q sin q sin
2 · 2 pmq q

For three-phase machines, m = 3, the expression is as follows:

sin (π/6) 1
kd1 = = . (2.26)
π/6 π/6
q sin 2q sin
q q

This simple expression of the distribution factor for the fundamental is most often employed
for practical calculations.

Example 2.7: Calculate the phase voltage of a three-phase, four-pole synchronous ma-
chine with a stator bore diameter of 0.30 m, a length of 0.5 m and a speed of rotation
1500 min−1 . The excitation creates the air-gap fundamental flux density B̂δ1 = 0.8 T.
There are 36 slots, in which a one-layer winding with three conductors in each slot is
embedded.
Solution: According to the Lorentz law, an instantaneous value of the induced electric
field strength in a conductor is E = v × B0 . In one conductor embedded in a slot of an
AC machine, we may get the induced voltage by integrating, e1c = Bδl  v, where Bδ is the
local air-gap flux density value of the rotating magnetic field, l is the effective length of
the stator iron stack, and v is the speed at which the conductor travels in the magnetic field,
see Figure 2.13.

travelling direction

B̂ 1
B̂ 1

B av

l'
α

τ p1 τ p1 τ p1

=ˆ T

(a) (b)

Figure 2.13 (a) Flux density variation in the air gap. One flux density period travels two pole
pitches during one time period T. (b) The flux distribution over one pole and the conductors in slots
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Windings of Electrical Machines 69

During one period T, the magnetic flux density wave travels two pole pitches, as shown
in the figure above. The speed of the magnetic field moving in the air gap is

2τ p
ν= = 2τp f.
T

The effective value of the induced voltage in one conductor is

B̂δ
E 1c = √ l  2τp f.
2

Contrary to a transformer, where approximately the same value of magnetic flux density
penetrates all the winding turns, Figure 2.13 shows that in AC rotating-field machines, the
conductors are subject to the sinusoidal waveform of flux density, and each conductor has
a different value of magnetic flux density. Therefore, an average value of the magnetic
flux density is calculated to unify the value of the magnetic flux for all conductors. The
average value of the flux density equals the maximum value of the flux penetrating a
full-pitch winding:

Φ̂ = Bδ avl  τp .

Bδ is spread over the pole pitch τ p , and we get for the average value

2 π
Bδav = B̂δ ⇒ B̂δ = Bδav .
π 2

Now, the RMS value of the voltage induced in a conductor written by means of average
magnetic flux density is

π π
E c = √ Bδavl  2τp f = √ Φ̂ f.
2 2 2

The frequency f is found from the speed n

pn 2 · 1500
f = = = 50 Hz.
60 60

Information about three conductors in each slot can be used for calculating the number
of turns N in series. In one phase, there are 2N conductors, and they are embedded in the
slots belonging to one phase Q/m. Therefore, the number of conductors in one slot zQ will
be

2N 2Nm N
zQ = = = .
Q/m 2 pqm pq

In this case, the number of turns in series in one phase is N = 3 pq = 3 · 2 · 3 = 18, where
q = Q/2 pm = 36/4 × 3 = 3. The effective value of the induced voltage in one slot is
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70 Design of Rotating Electrical Machines

(N / pq)E c . The number of such slots is 2pq. The linear sum of the voltages of all conduc-
tors belonging to the same phase must be reduced by the winding factor to get the phase
voltage

N
E ph = E c q2 pkw .
pq

The final expression for the effective value of the induced voltage in the AC rotating
machine is
N π N √
E ph = E c q2 pkw1 = √ Φ̂ f q2 pkw1 = 2π f Φ̂Nkw1 .
pq 2 pq

In this example, there is a full-pitch one-layer winding, and therefore kp = 1, and only kd
must be calculated (see Equation (2.26)):

1 1
kw1 = kd1 = = = 0.96.
30◦ 30◦
2q sin 2 · 3 sin
q 3

The maximum value of the magnetic flux is

2 2
Φ̂ = B̂δ τpl  = 0.8 · 0.236 · 0.5 = 0.060 Wb
π π
where the pole pitch τ p is

πDs π · 0.3
τp = = = 0.236 m.
2p 4

An effective value of the phase induced voltage is

√ √
E ph = 2π f Φ̂Nkd = 2π · 50 · 0.060 · 18 · 0.96 = 230 V.

Example 2.8: The stator of a four-pole, three-phase induction motor has 36 slots, and it is
fed by 3 × 400/230 V, 50 Hz. The diameter of the stator bore is Ds = 15 cm and the length
lFe = 20 cm. A two-layer winding is embedded in the slots. Besides this, there is a one-
layer, full-pitch search coil embedded in two slots. In the no-load condition, a voltage of
11.3 V has been measured at its terminals. Calculate the air-gap flux density, if the voltage
drop on the impedance of the search coil can be neglected.
Solution: To be able to investigate the air-gap flux density, the data of the search coil
can be used. This coil is embedded in two electrically opposite slots, and therefore the
distribution factor kd = 1; because it is a full-pitch coil, also the pitch factor kp = 1, and
therefore kw = 1.
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Windings of Electrical Machines 71

Now, the maximum value of magnetic flux is

Uc 11.3
Φ̂ = √ =√ Wb = 0.0127 Wb.
2π f Nc kwc 2π · 50 · 4 · 1.0

The amplitude of the air-gap flux density is

π π Φ̂ π 0.0127
B̂δ = Bav = = T = 0.847 T.
2 2 πDs  2 π · 0.15
l 0.2
2p 4

2.5 Winding Analysis

The winding analysis starts with the analysis of a single-layer stator winding, in which the
number of coils is Qs /2. In the machine design, the following setup is advisable: the periphery
of the air gap of the stator bore (diameter Ds ) is distributed evenly in all poles, that is 2p
of equal parts, which yields the pole pitch τ p . Figure 2.14 illustrates the configuration of a
two-pole slot winding ( p = 1).
The pole pitch is evenly distributed in all stator phase windings, that is in ms equal parts.
Now we obtain a zone distribution τ sv . In Figure 2.14, the number of stator phases is ms = 3.
The number of zones thus becomes 2pms = 6. The number of stator slots in a single zone is

U1 Θ
2τp
τsv
+U
–V –W
U V α 0 U
W 0 –U α
+W +V
–U τp

U2

(a) (b)

Figure 2.14 (a) Three-phase stator diamond winding p = 1, qs = 3, Qs = 18. Only the coil end on the
side of observation is visible in the U-phase winding. The figure also illustrates the positive magnetic
axes of the phase windings U, V and W. The current linkage creates a flux in the direction of the magnetic
axis when the current is penetrating the winding at its positive terminal, for example U1. The current
directions of the figure depict a situation in which the current of the windings V and W is a negative half
of the current in the winding U. (b) The created current linkage distribution Θ s is shown at the moment
when its maximum is in the direction of the magnetic axis of the phase U. The small arrows in (a) at the
end winding indicate the current directions and the transitions from coil to coil. The same winding will
be observed in Figure 2.23
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72 Design of Rotating Electrical Machines

qs , which is the number of slots per pole and phase in the stator. By using stator values in the
general equation (2.5), we obtain

Qs
qs = . (2.27)
2 pm s

If qs is an integer, the winding is termed an integral slot winding, and if qs is a fraction, the
winding is called a fractional slot winding.
The phase zones are labelled symmetrically to the phase windings, and the directions of
currents are determined so that we obtain a number of ms magnetic axes at a distance of
360◦ /ms from each other. The phase zones are labelled as stated in Section 2.2. The positive
zone of the phase U, that is a zone where the current of the phase U is flowing away from
the observer, is set as an example (Figure 2.14). Now the negative zone of the phase U is
at a distance of 180 electrical degrees; in other words, electrically on the opposite side. The
conductors of respective zones are connected so that the current flows as desired. This can be
carried out for instance as illustrated in Figure 2.14. In the figure, it is assumed that there are
three slots in each zone, qs = 3. The figure shows that the magnetic axis of the phase winding
U is in the direction of the arrow drawn in the middle of the illustration. Because this is a
three-phase machine, the directions of the currents of the phases V and W have to be such that
the magnetic axes of the phases V and W are at a distance of 120◦ (electrical degrees) from
the magnetic axis of the phase U. This can be realized by setting the zones of the V and W
phases and the current directions according to Figure 2.14.
The way in which the conductors of different zones are connected produces different me-
chanical winding constructions, but the air gap remains similar irrespective of the mechani-
cal construction. However, the arrangement of connections has a significant influence on the
space requirements for the end windings, the amount of copper and the production costs of
the winding. The connections also have an effect on certain electrical properties, such as the
leakage flux of the end windings.
The poly-phase winding in the stator of a rotating-field machine creates a flux wave when a
symmetric poly-phase current flows in the winding. A flux wave is created for instance when
the current linkage of Figure 2.14 begins to propagate in the direction of the positive α-axis,
and the currents of the poly-phase winding are alternating sinusoidally as a function of time.
We have to note, however, that the propagation speeds of the harmonics created by the winding
are different from the speed of the fundamental (nsv = ± ns1 /ν), and therefore the shape of
the current linkage curve changes as a function of time. However, the fundamental propagates
in the air gap at a speed defined by the fundamental of the current and by the number of
pole pairs. Furthermore, the fundamental is usually dominating (when q ≥ 1), and thus the
operation of the machine can be analysed basically with the fundamental. For instance, in a
three-phase winding, time-varying sinusoidal currents with a 120◦ phase shift in time create a
temporally and positionally alternating flux in the windings that are distributed at distances of
120 electrical degrees. The flux distribution propagates as a wave on the stator surface. (See
e.g. Figure 7.7 illustrating the fundamental ν = 1 of a six-pole and a two-pole machine.)

2.6 Short Pitching

In a double-layer diamond winding, the slot is divided into an upper and a lower part, and
there is one coil side in each half slot. The coil side at the bottom of the slot belongs to
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Windings of Electrical Machines 73

12
11
10
+U

9
-V

8
7
+U

6
W
-V V -W -W

5
U

4
W

3
+W +W +V

2
top
-U

1
bottom +V

-U

(a) ( b)

Figure 2.15 (a) Three-phase, double-layer diamond winding Qs = 18, qs = 3, p = 1. One end winding
is shown to illustrate the coil span. The winding is created from the previous winding by dividing the
slots into upper and bottom layers and by shifting the bottom layers clockwise by a single slot pitch.
The magnetic axes of the new short-pitched winding are also shown. (b) A coil end of a double-layer
winding produced from preformed copper, with a coil span W or expressed as numbers of slot pitches y.
The coil ends start from the left at the bottom of the slot and continue to the right to the top of the slot

the bottom layer of the slot, and the coil side adjacent to the air gap belongs to the upper
layer. The number of coils is now the same as the number of slots Qs of the winding; see
Figure 2.15b.
A double-layer diamond winding is constructed like the single-layer winding. As illustrated
in Figure 2.15, there are two zone rings, the outer illustrating the bottom layer and the inner
the upper layer, Figure 2.15a. The distribution of zones does not have to be identical in the
upper and bottom layers. The zone distribution can be shifted by a multiple of the slot pitch.
In Figure 2.15a, a single zone shift equals a single slot pitch. Figure 2.15b illustrates one of
the coils of the phase U. By comparing the width of the coil with the coil span of the winding
in Figure 2.14, we can see that the coil is now one slot pitch narrower; the coil is said to
be short pitched. Because of short pitching, the coil end has become shorter, and the copper
consumption is thus reduced. On the other hand, the flux linking the coil decreases somewhat
because of short pitching, and therefore the number of coil turns at the same voltage has to be
higher than for a full-pitch winding. The short pitching of the coil end is of more significance
than the increased number of coil turns, and as a result the consumption of coil material
decreases.
Short pitching also influences the harmonics content of the flux density of the air gap.
A correctly short-pitched winding produces a more sinusoidal current linkage distribution
than a full-pitch winding. In a salient-pole synchronous generator, where the flux density
distribution is basically governed by the shape of pole shoes, a short-pitch winding produces
a more sinusoidal pole voltage than a full-pitch winding.
Figure 2.16 illustrates the basic difference of a short-pitch winding and a full-pitch
winding.
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74 Design of Rotating Electrical Machines

W = τp
W < τp

12 1 12 1
2 2
11 11 U1-6
U1 U1 3
3 y
10 10 yQ
U1-7
4  y 4
1− 
2  yQ
9 U7 9

5 U6 5
8 8
6 6
7 7

(a) (b)

Figure 2.16 Cross-sectional areas of two machines with 12 slots. The basic differences of (a) a two-
pole full-pitch winding and (b) a two-pole short-pitch winding. In the short-pitch winding, the width of
a single coil W is less than the pole pitch τ p or, expressed as the number of slots, the short pitch y is less
than a full pitch yQ . The coil voltage U 1–6 is lower than U 1–7 . The short-pitched coil is located on the
chord of the periphery, and therefore the winding type is also called a chorded winding. The coil without
short pitching is located on the diameter of the machine

The short-pitch construction is now investigated in more detail. Short pitching is commonly
created by winding step shortening (Figure 2.17b), coil side shift in a slot (Figure 2.17c) and
coil side transfer to another zone (Figure 2.17d). In Figure 2.17, the zone graphs illustrate
the configurations of a full-pitch winding and of the short-pitch windings constructed by the
above-mentioned methods. Of these methods, the step shortening can be considered to be
created from a full-pitch winding by shifting the upper layer left for a certain number of slot
pitches.
Coil side shift in a slot is generated by changing the coil sides of the upper and bottom
layers in certain slots of a short-pitch winding. For instance, if in Figure 2.17b the coil sides
of the bottom layer in slots 8 and 20 are removed to the upper layer, and in slots 12 and 24
the upper coil sides are shifted to the bottom layer, we get the winding of Figure 2.17c. Now,
the width of a coil is again W = τp , but because the magnetic voltage of the air gap does not
depend on the position of a single coil side, the magnetizing characteristics of the winding
remain unchanged. The windings with a coil side shift in a slot and winding step shortening
are equal in this respect. The average number of slots per pole and phase for windings with a
coil side shift in a slot is

Qs q1 + q2
qs = = ; q1 = q + j, q2 = q − j (2.28)
2 pm 2

where j is the difference of q (the numbers of slots per pole and phase) in different layers. In
Figure 2.17, j = 1.
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Windings of Electrical Machines 75

W=6 τ u = τp W

Full-pitch winding W= τ p

(a) 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

τ v =2 τ u
W=5 τ u x W
Winding step shortening W=(5/6) τ p

(b) 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

τ v =2 τ u
W=6 τ u W x Coil side shift W=τ p
in a slot

(c) 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

τ v1 =3 τ u τ v =τu
2
W=6 τ u Coil s. transfer
W= τ p
to another zone

(d) 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Figure 2.17 Different methods of short pitching for a double-layer winding: (a) full-pitch winding,
(b) winding step shortening, (c) coil side shift in a slot, (d) coil side transfer to another zone. τv , zone;
τu , slot pitch; W, coil span; x, coil span decrease. In the figure, a cross indicates one coil end of the
phase U, and the dot indicates the other coil end of the phase U. In the graph for a coil side transfer to
another zone, the grid indicates the parts of slots filled with the windings of the phase W

Coil side transfer to another zone (Figure 2.17d) can be considered to be created from the
full-pitch winding of Figure 2.17a by transferring the side of the upper layers of 2 and 14 to
a foreign zone W. There is no general rule for the transfer, but practicality and the purpose of
use decide the solution to be selected. The method may be adopted in order to cancel a certain
harmonic from the current linkage of the winding.
The above-described methods can also be employed simultaneously. For instance, if we
shift the upper layer of the coil with a coil side transfer of Figure 2.17d left for the distance of
one slot pitch, we receive a combination of a winding step shortening and a coil side transfer.
This kind of winding is double short pitched, and it can eliminate two harmonics. This kind of
short pitching is often employed in machines where the windings may be rearranged during
drive to form another pole number.
When different methods are compared, we have to bear in mind that when considering
the connection, a common winding step shortening is always the simplest to realize, and the
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76 Design of Rotating Electrical Machines

consumption of copper is often the lowest. A winding step shortening is an advisable method
down to W = 0.8τp without an increase in copper consumption. In short two-pole machines,
the ends are relatively long, and therefore it is advisable to use even shorter pitches to make the
end winding area shorter. Short pitchings down to W = 0.7τp are used in two-pole machines
with prefabricated coils. The most crucial issue concerning short pitching is, however, how
completely we wish to eliminate the harmonics. This is best investigated with winding factors.
The winding factor kwv has already been determined with Figure 2.10 and Equation (2.16).
When the winding is short pitched, and the coil ends are not at a distance of 180 electrical
degrees from each other, we can easily understand that short pitching reduces the winding
factor of the fundamental. This is described by a pitch factor kpv . Further, if the number of
slots per pole and phase is higher than one, we can see that in addition to the pitch factor
kpv , the distribution factor kdv is required as was discussed above. Thus, we can consider the
winding factor to consist of the pitch factor kpv and the distribution factor kdv and, in some
cases, of a skewing factor (cf. Equation 2.35).
The full pitch can be expressed in radians as π, as a pole pitch τ p , or as the number of slot
pitches yQ covering the pole pitch. The pitch expressed in the number of slots is y, and now the
relative shortening is y/yQ . Therefore, the angle of the short pitch is (y/yQ )π. A complement
to π, which is the sum of angles in a triangle, is

   
y y
π− π =π 1− .
yQ yQ

This value will be divided equally between the other two angles as in Figure 2.16b:

 
π y
1− .
2 yQ

Also the pitch factor is defined as the ratio of the geometric sum of phasors and the sum of
the absolute values of the voltage phasors, see Figure 2.16b. The pitch factor is

Utotal
kp = . (2.29)
2Uslot

When
  
π y
cos 1−
2 yQ

is expressed in the triangle being analysed, it will be found that it equals the pitch factor
defined by

   
π y Utotal 2 Utotal
cos 1− = = = kp . (2.30)
2 yQ Uslot 2Uslot
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Windings of Electrical Machines 77

On rearranging the final expression for the pitch factor will be obtained:
   
y π Wπ
kp = sin = sin . (2.31)
yQ 2 τp 2

In a full-pitch winding, the pitch is equal to the pole pitch, y = yQ , W = τ p and the pitch
factor is kp = 1. If the pitch is less than yQ , kp < 1.
In a general presentation, the distribution factor kd and the pitch factor kp have to be valid
also for the stator harmonics. We may write for the νth harmonic, the pitch factor kpν and the
distribution factor kdν
   
Wπ y π
kpν = sin ν = sin ν , (2.32)
τp 2 yQ 2
 π 
sin (νqαu /2) 2 sin ν
kdν = =  2m  . (2.33)
q sin (ναu /2) Q πp
sin ν
mp Q

Here αu is the slot angle, αu = p2π/Q.

The skewing factor will be developed in Chapter 4, but it is shown here as
 
s π
sin ν
τp 2
ksqν = s π (2.34)
ν
τp 2

Here the skew is measured as s/τ p (cf. Figure 4.16).

The winding factor is thus a product of these factors
 
 ν π s π
  2 sin sin ν
Wπ τp 2
kwν = kpν kdν ksqν = sin ν · m 2  · s π (2.35)
τp 2 Q p ν
sin νπ τp 2
mp Q

Example 2.9: Calculate a winding factor for the two-layer winding Q = 24, 2p = 4,
m = 3, y = 5 (see Figure 2.17b). There is no skewing, that is ksqν = 1.
Solution: The number of slots per phase per pole is
Q 24
q= = = 2.
2 pm 4·3
The distribution factor for the three-phase winding is
1 1
kd1 = = = 0.966.
30 30
2q sin 2 · 2 sin
q 2
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78 Design of Rotating Electrical Machines

The number of slots per pole, or in the other words the pole pitch expressed as the number
of slots, is

Q 24
yQ = = = 6.
2p 4

If the pitch is five slots, it means that it is a short pitch, and it is necessary to calculate the
pitch factor:
   
y π 5π
kp1 = sin = sin = 0.966.
yQ 2 62

The winding factor is

kw1 = kd1 kp1 ksq1 = 0.966 · 0.966 · 1 = 0.933.

Example 2.10: A two-pole alternator has on the stator a three-phase two-layer winding
embedded in 72 slots, two conductors in each slot, with a short pitch of 29/36. The di-
ameter of the stator bore is Ds = 0.85 m, the effective length of the stack is l = 1.75 m.
Calculate the fundamental component of the induced voltage in one phase of the stator
winding, if the amplitude of the fundamental component of the air gap flux density is
B̂δ1 = 0.92 T and the speed of rotation is 3000 min−1 .
Solution: The effective
√ value of the induced phase voltage will be calculated from the ex-
pression E 1ph = 2π f Φ̂1 Ns k1w at the frequency of f = pn/60 = 1 · 3000/60 = 50 Hz.
The pole pitch is τp = πDs /2 p = π · 0.85 m/2 = 1.335 m. The maximum value of the
magnetic flux is Φ̂1 = (2/π) B̂1δ τpl  = (2/π)0.92 T · 1.335 m · 1.75 m = 1.368 Wb. The
number of slots per pole and phase is qs = Q s /2 pm = 72/2 · 3 = 12. The number of turns
in series N s will be determined from the number of conductors in the slot z Q = N / pq =
2 ⇒ N = 2 pq = 2 · 1 · 12 = 24. There is a two-layer distributed short-pitch winding, and
therefore both the distribution and pitch factors must be calculated (cf. Equation 2.26):

1 1
kd1 = = = 0.955,
π/6 π/6
2qs sin 2 · 12 sin
q 12
 s   
y π 29 π
kp1 = sin = sin = 0.953,
yQ 2 36 2

because the full pitch is y Q = Q/2 p = 72/2 = 36. The winding factor yields kw1 =
k√d1 kp1 = 0.955 · 0.953
√ = 0.91 and the induced phase voltage of the stator is E ph =
2π f Φ̂1 Ns kw = 2π · 50 1s 1.368 V s · 24 · 0.91 = 6637 V.

On the other hand, as shown previously, the winding constructed with the coil side shift in a
slot in Figure 2.17c proved to have an identical current linkage as the winding step shortening
2.17b, and therefore also its winding factor has to be same. The distribution factor kdν is
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Windings of Electrical Machines 79

calculated with an average number of slots per pole and phase q = 2, and thus the pitch
factor kpν has to be the same as above, although no actual winding step shortening has been
performed. For coil side shift in a slot, Equation (2.32) is not valid as such for the calculation
of pitch factor (because sin(ν π/2) = 1).
When comparing magnetically equivalent windings of Figure 2.17 that apply winding step
shortening and coil side shift in a slot, it is shown that an equivalent reduction x of the coil
span for a winding with coil side shift is

1
x = τp − W = (q1 − q2 )τu . (2.36)
2

The substitution of slot pitch τ u = 2pτ p /Q in the equation yields

W p
= 1 − (q1 − q2 ). (2.37)
τp Q

In other words, if the number of slots per pole and phase of the different layers of coil side
shift are q1 and q2 , the winding corresponds to the winding step shortening in the ratio of
W/τ p . By substituting (2.37) in Equation (2.32) we obtain a pitch factor kpwν of the coil side
shift in a slot


p π
kpwν = sin ν 1 − (q1 − q2 ) . (2.38)
Q 2

In the case of the coil side shift of Figure 2.17c, q1 = 3 and q2 = 1. We may assume
the winding to be a four-pole construction as a whole ( p = 2, Qs = 24). In the figure, a
basic winding is constructed of the conductors of the first 12 slots (the complete winding may
comprise an undefined number of sets of 12-slot windings in series), and thus we obtain for
the fundamental winding factor

  
2 π 5π
kpw1 = sin 1 − (3 − 1) = sin = 0.966.
24 2 62

which is the same result as Equation (2.32) in the case of a winding step shortening of
Figure 2.17b.
Because we may often apply both the winding step shortening and coil side transfer in a
different zone in the same winding, the winding factor has to be rewritten as

kwν = kdν kpwν kpν . (2.39)

With this kind of doubly short-pitched winding, we may eliminate two harmonics, as stated
earlier. The elimination of harmonics implies that we select a double-short-pitched winding
for which, for instance, kpw5 = 0 and kp7 = 0. Now we can eliminate the undesirable fifth
and seventh harmonics. However, the fundamental winding factor will get smaller. The dis-
tribution factor kdv is now calculated with the average number of slots per pole and phase
q = (q1 + q2 )/2.
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80 Design of Rotating Electrical Machines

When analysing complicated short-pitch arrangements, it is often difficult to find a universal

equation for the winding factor. In that case, a voltage phasor diagram can be employed, as
mentioned earlier in the discussion of Figure 2.10. Next, the coil side transfer to another zone
of Figure 2.17 is discussed.
Figure 2.18a depicts the fundamental voltage phasor diagram of the winding with coil side
transfer to another zone in Figure 2.17, assuming that there are Q = 24 slots and 2p = 4 poles.
The slot angle is now α u = 30 electrical degrees, and thus the phase shift of the emf is 30◦ .
Figure 2.18b depicts the phasors of the phase U in a polygon according to Figure 2.17d. The
resultant voltage Uph and its ratio to the sum of the absolute values of the phasors is the fun-
damental winding factor. By also drawing the resultants of the windings V and W from point
0, we obtain an illustration of the symmetry of a three-phase machine. The other harmonics
(ordinal ν) are treated equally, but the phase shift angle of the phasors is now να u .

13 14 –22

1 2 –20
24 15
3 UphU
–19
12
23 4 16 –19

11 14 16

5
22 17 13
10 13
6
9 –8 –10
21 7 18
8
–7
20 19
–7

4
2

1
0

(a) (b)

Figure 2.18 Voltage phasor diagram of a four-pole winding with a coil side transfer (Figures 2.17d)
and (b) the sum of slot voltage phasors of a single phase. Note that the voltage phasor diagram for a four-
pole machine (p = 2) is doubled, because it is drawn in electrical degrees. The parts of the figure are in
different scales. In the voltage phasor diagram, there are in principle two layers (one for the bottom layer
and another for the top layer), but only one of them is illustrated here. Now two consequent phasors, for
example 2 and 14, when placed one after another, form a single radius of the voltage phasor diagram.
The winding factor is thus defined by the voltage phasor diagram by comparing the geometrical sum
with the sum of absolute values
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Windings of Electrical Machines 81

2.7 Current Linkage of a Slot Winding

The current linkage of a slot winding refers to a function Θ = f (α), created by the winding
and its currents in the equivalent air gap of the machine. The winding of Figure 2.8 and its
current linkage in the air gap are investigated at a time when iW = iV = −1/2 iU , Figure 2.9. The
curved function in the figure is drawn at time t = 0. The phasors of the phase currents rotate
at an angular speed ω, and thus after a time 2π/(3ω) = 1/(3f ) the current of the phase V has
reached its positive peak, and the function of current linkage has shifted three slot pitches to
the right. After a time 2/(3f ), the shift is six slot pitches, and so on. The curved function shifts
constantly in the direction +α. To be exact, the curved waveform is of the form presented
in the figure only at times t = c/(3f ), when the factor c has values c = 0, 1, 2, 3, . . . . As
time elapses, the waveform proceeds constantly. Fourier analysis of the waveform, however,
produces harmonics that remain constant.
Figure 2.19 illustrates the current linkage Θ(α) produced by a single coil. A flux that passes
through the air gap at an angle γ returns at an angle β = 2π − γ . In the case of a nonfull-
pitch winding, the current linkage is distributed in the ratio of the permeances of the paths.
This gives us a pair of equations

Θγ β
z Q i = Θγ + Θβ ; = (2.40)
Θβ γ

from which we obtain two constant values for the current linkage waveform Θ(α)

β γ
Θγ = z Q i; Θβ = z Q i. (2.41)
2π 2π

The Fourier series of the function Θ(α) of a single coil is

Θ (α) = Θ̂1 cos α + Θ̂3 cos 3α + Θ̂5 cos 5α + · · · + Θ̂ν cos να + · · · . (2.42)

Θγ
izQ
−π 0 +π
α
Θβ
zQ

β β γ
2π
(a) (b)

Figure 2.19 (a) Currents and schematic flux lines of a short-pitch coil in a two-pole system. (b) Two
wavelengths of the current linkage created by a single, narrow coil
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82 Design of Rotating Electrical Machines

The magnitude of the νth term of the series is obtained from the equation by substituting
the function of the current linkage waveform for a single coil

π  νγ 
2 2
Θ̂ν = Θ (α) cos (να) dα = z Q i sin . (2.43)
π νπ 2
0


As γ /W = 2π/2τp , and hence γ /2 = W/τp · (π/2), the last factor of Equation (2.43)

 νγ   
Wπ
sin = sin ν = kpν (2.44)
2 τp 2

is the pitch factor of the harmonic ν for the coil observed. For the fundamental ν = 1, we ob-
tain kp1 . We can thus see that the fundamental is just a special case of the general harmonic ν.
While the electrical angle of the fundamental is α, the corresponding angle for the harmonic ν
is always να. If now νγ /2 is a multiple of the angle 2π, the pitch factor becomes kpν = 0. Thus,
the winding does not produce such harmonics, neither are voltages induced in the winding by
the influence of possible flux components at this distribution. However, voltages are induced
in the coil sides, but over the whole coil these voltages compensate each other. Thus, with a
suitable short pitching, it is possible to eliminate harmful harmonics.
In Figure 2.20, there are several coils 1 . . . q in a single pole of a slot winding. The current
linkage of each coil is zQ i. The coil angle (in electrical degrees) for the harmonic ν of the
narrowest coil is νγ , the next being ν(γ + 2α u ) and the broadest ν(γ + 2(q − 1)α u ). For an
arbitrary coil g, the current linkage is, according to Equation (2.43),

2  γ 
Θνg = z Q i sin ν + (q − 1)αu . (2.45)
νπ 2

C' C
izQ

q
q iz Q
2
να u iz Q
νγ /2
1
ν (q-1) αu /2
α=0
νγ
ναu
2
r

B νγ /2
1
α=0
A

Figure 2.20 Concentric coils of a single pole; the calculation of the winding factor for a harmonic ν
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Windings of Electrical Machines 83

When all the harmonics of the same ordinal generated by all coils of one phase are summed,
we obtain per pole

q
2
q


Θνtot = Θνg = qz Q i kwν
νπ
g=1 g=1 (2.46)
2  νγ γ  γ 
1 1 1
= z Q i sin + sin ν + αu + · · · + sin ν + (q − 1) αu .
νπ 2 2 2

The sum kwν in braces can be calculated for instance with the geometrical figure of Figures
2.20 and 2.12. The line segment AC is written as

νqαu
AC = 2r sin . (2.47)
2

The arithmetical sum of unit segments is

ναu
q AB = q2r sin (2.48)
2

and we can find for the harmonic ν

νqαu
AC sin
= = 2
kdν
q AB ναu . (2.49)
q sin
2

This equals the distribution factor of Equation (2.33). Now, we see that the line segment
AC = qkdν AB . We use Figure 2.12a again. The angle BAC is obtained from Figure 2.12 as
the difference of angles OAB and OAC. It is ν(q − 1)α u /2. The projection AC  is thus

ν (γ + (q − 1) αu )
AC  = AC sin = ACkdν . (2.50)
2

Here we have a pitch factor influencing the harmonic ν, because in Figure 2.20, ν[γ +
(q − 1)α u ] is the average coil width angle. Equation (2.46) is now reduced to

2 kwν
Θνtot = qz Q i, (2.51)
π ν

where

kwν = kpν kdν . (2.52)

This is the winding factor of the harmonic ν. It is an important observation. The winding factor
was originally found for the calculation of the induced voltages. Now we understand that the
same distribution and pitch factors also affect the current linkage harmonic production. By
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84 Design of Rotating Electrical Machines

substituting the harmonic current linkage Θ ν in Equation (2.42) with the current linkage Θ νtot ,
we obtain the harmonic ν generated by the current linkage of q coils

Θν = Θνtot cos να. (2.53)

This is valid for a single-phase coil. The harmonic ν created by a poly-phase winding is
calculated by summing all the harmonics created by different phases. By its nature, the pitch
factor is zero if να u = ±c2π (since sin (νqαu /2) = sin (±cπq) = 0) (i.e. the coil sides are at
the same magnetic potential), when the factor c = 0, 1, 2, 3, 4. . . . It therefore allows only the
harmonics

2π
ν = c . (2.54)
αu

The slot angle and the phase number are interrelated

π
qαu = . (2.55)
m

The distribution factor is zero if ν = ±c2m. The winding thus produces harmonics

ν = +1 ± 2cm. (2.56)

Example 2.11: Calculate which ordinals of the harmonics can be created by a three-phase
winding.
Solution: A symmetrical three-phase winding may create harmonics calculated from
Equation (2.56), by inserting m = 3. These are listed in Table 2.2.

Table 2.2 Ordinals of the harmonics created by a three-phase winding (m = 3)

c 0 1 2 3 4 5 6 7. . .
ν +1 +7 +13 +19 +25 +31 +37 +43. . . Positive sequence
— −5 −11 −17 −23 −29 −35 −41. . . Negative sequence

We see that ν = −1, and all even harmonics and harmonics divisible by three are miss-
ing. In other words, a symmetrical poly-phase winding does not produce for instance a
harmonic propagating in the opposite direction at the fundamental frequency. Instead, a
single-phase winding m = 1 creates also a harmonic, the ordinal of which is ν = −1. This
is a particularly harmful harmonic, and it impedes the operation of single-phase machines.
For instance, a single-phase induction motor, because of the field rotating in the negative
direction, does not start without assistance because the positive and negative sequence
fields are equally strong.
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Windings of Electrical Machines 85

Example 2.12: Calculate the pitch and distribution factors for ν = 1, 5, 7 if a chorded
stator of an AC machine has 18 slots per pole and the first coil is embedded in slots 1 and
16. Calculate also the relative harmonic current linkages.

Solution: The full pitch would be yQ = 18 and a full-pitch coil should be embedded in
slots 1 and 19. If the coil is located in slots 1 and 16, the coil pitch is shorted to y = 15.
Therefore, the pitch factor for the fundamental will be

Wπ y π 15 π
kp1 = sin = sin = sin = 0.966
τp 2 yQ 2 18 2

and correspondingly for the fifth and seventh harmonics

   
y π 15 π
kp5 = sin ν = sin −5 = −0.259,
yQ 2 18 2
   
y π 15 π
kp7 = sin ν = sin 7 = 0.259.
yQ 2 18 2

The number of slots per pole and phase is q = 18/3 = 6 and the slot angle is α u = π/18.
Now, the distribution factor is

νqαu 1 · 6π/18 −5 · 6π/18

sin sin sin
= 2 2 2
kdν ναu , kd1 =
1π/18
= 0.956, kd−5 =
−5π/18
= −0.197,
q sin 6 sin 6 sin
2 2 2

7 · 6π/18
sin
kd7 = 2 = −0.145.
7π/18
6 sin
2

kw1 = kd1 kp1 = 0.956 · 0.966 = 0.923, kw−5 = kd−5 kp−5 = −0.197 · (−0.259) = 0.051,
kw7 = kd7 kp7 = −0.145 · 0.259 = −0.038.

The winding creates current linkages

2 kwν
Θνtot = qz Q i.
π ν

Calculating kwv /ν for the harmonics 1, −5, 7

kw1 kw−5 0.051 kw7 −0.038

= 0.923, = = 0.01, = = 0.0054.
1 −5 −5 7 7
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86 Design of Rotating Electrical Machines

Here we can see that because of the chorded winding, the current linkages of the fifth
and seventh harmonics will be reduced to 1.1 and 0.58% of the fundamental, as the funda-
mental is also reduced to 92.3% of the full sum of the absolute values of slot voltages.

Example 2.13: A rotating magnetic flux created by a three-phase 50 Hz, 600 min−1 alter-
nator has a spatial distribution of magnetic flux density given by the expression

B = B̂1 sin ϑ + B̂3 sin 3ϑ + B̂5 sin 5ϑ = 0.9 sin ϑ + 0.25 sin 3ϑ + 0.18 sin 5ϑ [T].

The alternator has 180 slots, the winding is wound with two layers, and each coil has three
turns with a span of 15 slots. The armature diameter is 135 cm and the effective length
of the iron core 0.50 m. Write an expression for the instantaneous value of the induced
voltage in one phase of the winding. Calculate the effective value of phase voltage and
also the line-to-line voltage of the machine.
Solution: The number of pole pairs is given by the speed and the frequency:

pn 60 f 60 · 50
f = ⇒p= = =5
60 n 600
and the number of poles is 10. The area of one pole is

πD  π1.35
τ pl  = l = 0.50 = 0.212 m2 .
2p 10

From the expression for the instantaneous value of the magnetic flux density, we may
derive B̂1 = 0.9 T, B̂3 = 0.25 T and B̂5 = 0.18 T. The fundamental of the magnetic flux
on the τ p is Φ̂1 = (2/π) B̂1 τpl  = (2/π) · 0.9 T · 0.212 m2 = 0.1214 V s. To be able to cal-
culate the induced voltage, it is necessary to make a preliminary calculation of some pa-
rameters:
Q 180
The number of slots per pole and phase is q = = = 6.
2 pm 10 · 3
p2π π
The angle between the voltages of adjacent slots is αu = = .
Q 18

The distribution and pitch factors for each harmonic is

 α   π  π
u
sin q sin 6 · sin 3 · 6 ·
 α2  = π36 = 0.956,  36
kd1 =
u
kd3 = π  = 0.643,
q sin 6 sin 6 sin 3 ·
2 36 36
 π
sin 5 · 6 ·
 36
kd5 = π  = 0.197.
6 sin 5 ·
36
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Windings of Electrical Machines 87

The number of slots per pole is Q p = 180/10 = 18, which would be a full pitch. The
coil span is 15 slots, which means the chorded pitch y = 15, and the pitch factors are
       
y π 15 π y π 15 π
kp1 = sin = sin = 0.966, kp3 = sin 3 = sin 3 · = −0.707,
yQ 2 18 2 yQ 2 18 2
   
y π 15 π
kp5 = sin 5 = sin 5 · = 0.259
yQ 2 18 2

which results in the following winding factors:

kw1 = kd1 · kp1 = 0.955 · 0.966 = 0.9234, kw3 = 0.643 · (−0.707) = −0.4546,
kw5 = 0.197 · 0.259 = 0.051.

Now it is possible to calculate the effective values of the induced voltages of the har-
monics. The phase number of turns is determined as follows: the total number of coils in
a 180-slot machine in a two-layer winding is 180. This means that the number of coils per
phase is 180/3 = 60, each coil has three turns, and therefore N = 60 × 3 = 180:
√ √
E 1 = 2π f Φ̂1 Nkw1 = 2π · 50/s · 0.1214 V s · 180 · 0.9234 = 4482 V.

The induced voltage of harmonics can be written similarly as follows:

√ √ 2 √ 2 τp1
Eν = 2π f ν Φ̂ν Nkwν = 2π f ν B̂ν τpν Nkwν = 2πν f 1 B̂ν Nkwν
π π ν
√ 2
= 2π f 1 B̂ν τp1 Nkwν .
π
The ratio of the νth harmonic and fundamental is
√ 2
Eν 2π f 1 B̂ν τp1 Nkwν B̂ν kwν
= √ π =
E1 2 B̂1 kw1
2π f 1 B̂1 τp1 Nkw1
π
and the results for Eν :

B̂3 kw3 0.25 · (−0.4546)

E3 = E1 = 4482 V = −612.9 V,
B̂1 kw1 0.9 · 0.9225
B̂5 kw5 0.18 · 0.051
E5 = E1 = 4482 V = 49.5 V.
B̂1 kw1 0.9 · 0.9225

Finally, the expression for the instantaneous value of the induced voltage is

e (t) = Ê 1 sin ωt + Ê 3 sin 3ωt + Ê 5 sin 5ωt

√ √ √
= 2E 1 sin ωt + 2E 3 sin 3ωt + 2E 5 sin 5ωt
√ √ √
e (t) = 2 · 4482 sin ωt − 2 · 612.9 sin 3ωt + 2 · 49.5 sin 5ωt
= 6338.5 sin ωt − 866.77 sin 3ωt + 70 sin 5ωt.
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88 Design of Rotating Electrical Machines

The total value of the effective phase voltage is

 
E ph = E 12 + E 32 + E 52 = 44822 + 612.92 + 49.52 V = 4524 V

and its line-to-line voltage is

√  √ 
E= 3 E 12 + E 52 = 3 44822 + 49.52 V = 7763.58 V.

The third harmonic component does not appear in the line-to-line voltage, which will be
demonstrated later on.

Example 2.14: Calculate the winding factors and per unit magnitudes of the current
linkage for ν = 1, 3, −5 if Q = 24, m = 3, q = 2, W/τp = y/yQ = 5/6.
Solution: The winding factor is used to derive the per unit magnitude of the current link-
age. In Figure 2.21, we have a current linkage distribution of the phase U of a short-pitch
winding (Q = 24, m = 3, q = 2, 2p = 4, W/τp = y/yQ = 5/6), as well as its fundamental
and the third harmonic at time t = 0, when i U = i. ˆ The total maximum height of the cur-
ˆ
rent linkage of a pole pair is at that moment qz Q i. Half of the magnetic circuit (involving
a single air gap) is influenced by half of this current linkage. The winding factors for the
fundamental and lowest harmonics and the amplitudes of the current linkages according
to Equations (2.51) and (2.52) and Example 2.13 are:

ν=1 kw1 = kp1 kd1 = 0.965 · 0.965 = 0.931 Θ̂1 = 1.185 Θ̂max
ν=3 kw3 = kp3 kd3 = −0.707 · 0.707 = −0.5 Θ̂3 = −0.212 Θmax
ν = −5 kw5 = kp−5 kd−5 = −0.258 · 0.258 = −0.067 Θ̂−5 = −0.017 Θmax

The minus signs for the third- and fifth-harmonic amplitudes mean that, if starting at
the same phase, the third and fifth harmonics will have a negative peak value as the funda-
mental is at its positive peak, see Figures 2.21 and 2.22.
For instance, the fundamental is calculated with (2.51); see also (2.15):

2 kwν 2 0.931
Θ̂1 = qz Q i = 2z Q i = 1.185z Q i.
π ν π 1
Only the fundamental and the third harmonic are illustrated in Figure 2.21.
The amplitude of harmonics is often expressed as a percentage of the fundamental. In
this case, the amplitude of the third harmonic is 17.8% (0.212/1.185) of the amplitude of
the fundamental. However, this is not necessarily harmful in a three-phase machine, be-
cause in the harmonic current linkage created by the windings together, the third harmonic
is compensated. The situation is illustrated in Figure 2.22, where the currents iU = 1 and
iV = iW = −1/2 flow in the winding of Figure 2.21. In salient-pole machines, the third
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Windings of Electrical Machines 89

+U –W +V –U +W –V +U

24 1 2 3 4 5 6 7 8 9 10 11 12 ...

2 Θ max
Θ max Θ (α)

0 π
α
Θ^1

Figure 2.21 Short-pitch winding (Qs = 24, p = 2, m = 3, qs = 2) and the analysis of its current
linkage distribution of the phase U. The distribution includes a notable amount of the third harmonic.
In the figure, the fundamental and third harmonic are illustrated by dotted lines

harmonic may, however, cause circulating currents in delta connection, and therefore star
connection in the armature is preferred.

In single- and two-phase machines, the number of slots is preferably selected higher than in
three-phase machines, because in these coils, at certain instants, only a single-phase coil alone
creates the whole current linkage of the winding. In such a case, the winding alone should
produce as sinusoidal a current linkage as possible. In single- and double-phase windings, it
is sometimes necessary to fit a different number of conductors in the slots to make the stepped
line Θ(α) approach sinusoidal form.
A poly-phase winding thus produces harmonics, the ordinals of which are calculated with
Equation (2.56). When the stator is fed at an angular frequency ωs , the angular speed of the
harmonic ν with respect to the stator is
ωs
ωνs = . (2.57)
ν
The situation is illustrated in Figure 2.23, which shows that the shape of the harmonic
current linkage changes as the harmonic propagates in the air gap. The deformation of the
harmonic indicates the fact that harmonic amplitudes propagate at different speeds and in
different directions. A harmonic according to Equation (2.57) induces the voltage of the fun-
damental frequency in the stator winding. The ordinal of the harmonic indicates how many
wavelengths of a harmonic are fitted in a distance 2τ p of a single pole pair of the fundamental.
This yields the number of pole pairs and the pole pitch of a harmonic

pν = νp, (2.58)
τp
τpν = . (2.59)
ν
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90 Design of Rotating Electrical Machines

+U –W +V –U +W –V +U

24 1 2 3 4 5 6 7 8 9 10 11 12 ...

Figure 2.22 Compensation of the third harmonic in a three-phase winding. There are currents iU =
−2iV = −2iW flowing in the winding. We see that when we sum the third harmonics of the phases V
and W with the harmonic of the phase U, the harmonics compensate each other

The amplitude of the νth harmonic is determined with the ordinal from the amplitude of
the current linkage of the fundamental, and it is calculated in relation to the winding factors

kwν
Θ̂ν = Θ̂1 . (2.60)
νkw1

The winding factor of the harmonic ν can be determined with Equations (2.32) and (2.33)
by multiplying the pitch factor kpν and the distribution factor kdν :

  
Wπ ν π
2 sin ν sin
τp 2 m2
kwν = kpν kdν =   . (2.61)
Q p
sin νπ
mp Q
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Windings of Electrical Machines 91

Θ
2 τp

U
–U +U τv

–V –W
β = ω t1 V
U
Θ 2τ p
W
+W +V
–U

β = ω t2 τp
Θ 2τ p

t1 t3 t5

iU

β = ω t3 iW

Θ iV
2τ p

t2 t4

β = ω t4

Θ 2τ p

β = ω t5

Figure 2.23 Propagation of a harmonic current linkage and the deformations caused by harmonics. If
there is a current flowing only in the stator winding, we are able to set the peak of the air-gap flux density
at β. The flux propagates but the magnetic axis of the winding U remains stable

Compared with the angular velocity ω1s of the fundamental component, a harmonic current
linkage wave propagates in the air gap at a fractional angular velocity ω1s /ν. The synchronous
speed of the harmonic ν is also at the same very angular speed ω1s /ν. If a motor is running
at about synchronous speed, the rotor is travelling much faster than the harmonic wave. If we
have an asynchronously running motor with a per unit slip s = (ωs − pΩr )/ωs (ωs is the stator
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92 Design of Rotating Electrical Machines

angular frequency and Ω r is the rotor mechanical angular rotating frequency), the slip of the
rotor with respect to the νth stator harmonic is given by

sν = 1 − ν (1 − s) . (2.62)

The angular frequency of the νth harmonic in the rotor is thus

ωνr = ωs (1 − ν (1 − s)) . (2.63)

If we have a synchronous machine running with slip s = 0, we immediately observe from

Equations (2.62) and (2.63) that the angular frequency created by the fundamental compo-
nent of the flux density of the stator winding is zero in the rotor co-ordinate. However, har-
monic current linkage waves pass the rotor at different speeds. If the shape of the pole shoe is
such that the rotor produces flux density harmonics, they propagate at the speed of the rotor
and thereby generate pulsating torques with the stator harmonics travelling at different speeds.
This is a particular problem in low-speed permanent magnet synchronous motors, in which
the rotor magnetization often produces a quadratic flux density and the number of slots in the
stator is small, for instance q = 1 or even lower, the amplitudes of the stator harmonics being
thus notably high.

2.8 Poly-Phase Fractional Slot Windings

If the number of slots per pole and phase q of a winding is a fraction, the winding is called a
fractional slot winding. Windings of this type are either concentric or diamond windings with
one or two layers. Some advantages of fractional slot windings when compared with integer
slot windings are:

r great freedom of choice with respect to the number of slots;

r opportunity to reach a suitable magnetic flux density with the given dimensions;
r multiple alternatives for short pitching;
r if the number of slots is predetermined, the fractional slot winding can be applied to a wider
range of numbers of poles than the integral slot winding;
r segment structures of large machines are better controlled by using fractional slot windings;
r opportunity to improve the voltage waveform of a generator by removing certain harmonics.

The greatest disadvantage of fractional slot windings is subharmonics, when the denomi-
nator of q (slots per pole and phase) is n = 2

Q z
q= = . (2.64)
2 pm n

Now, q is reduced so that the numerator and the denominator are the smallest possible in-
tegers, the numerator being z and the denominator n. If the denominator n is an odd number,
the winding is said to be a first-grade winding, and when n is an even number, the winding
is of the second grade. The most reliable fractional slot winding is constructed by selecting
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Windings of Electrical Machines 93

n = 2. An especially interesting winding of this type can be designed for fractional slot per-
manent magnet machines by selecting q = 1/2.
In integral slot windings, the base winding is of the length of two pole pitches (the distance
of the fundamental wavelength), whereas in the case of fractional slot windings, a distance
of several fundamental wavelengths has to be travelled before the phasor of a voltage phasor
diagram again meets the exact same point of the waveform. The difference between an integral
slot and fractional slot winding is illustrated in Figure 2.24.

B B

α α p' 2π
0 π 2π 0 π 2π

slot positions slot positions

...
Qs
Q s, 1... 5... =12 Q s, 1... 5... Q s'+1
p

base winding base winding

(a) (b)
B

1 2 3 4 5 1 p=5

0 α

slot positions and coil sides of phase U

Q s = 12

1 2 3 4 5 6 7 8 9 10 11 12 1

base winding
(c)

Figure 2.24 Basic differences of (a) an integral slot stator winding and (b) a fractional slot winding.
The number of stator slots is Qs . In an integral slot winding, the length of the base winding is Qs /p
slots ((a): 12 slots, qs = 2), but in a fractional slot winding, the division is not equal ((b): qs < 2).
In the observed integer slot winding, the base winding length Qs = 12 and, after that, the magnetic
conditions for the slots repeat themselves equally; observe slots 1 and 13. In the fractional slot winding,
the base winding is notably longer and contains Q s slots. Figure (c) illustrates an example of a fractional
slot winding with Qs = 12 and p = 5. Such a winding may be used in concentrated wound permanent
magnet fractional slot machines, where q = 0.4. In a two-layer system, each of the stator phases carries
four coils. The coil sides are located in slots 12–1, 1–2, 6–7 and 7–8. The air gap flux density is mainly
created by the rotor poles
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94 Design of Rotating Electrical Machines

In a fractional slot winding, we have to proceed a distance of p pole pairs before a coil
side of the same phase again meets exactly the peak value of the flux density. Then, we need
a number of Q s phasors of the voltage phasor diagram, pointing in different directions. Now,
we can write

Qs
Q s = p  , Q s < Q s , p > p . (2.65)
p

Here the voltage phasors Q s + 1, 2Q s + 1, 3Q s + 1 and (t − 1)Q s + 1 are in the same posi-
tion in the voltage phasor diagram as the voltage phasor of slot 1. In this position, the cycle of
the voltage phasor diagram is always started again. Either a new periphery is drawn, or more
slot numbers are added to the phasors of the initial diagram. In the numbering of a voltage
phasor diagram, each layer of the diagram has to be circled p times. Thus, t layers are created
in the voltage phasor diagram. In other words, in each electrical machine, there are t electri-
cally equal slot sequences, the slot number of which is Qs  = Qs /t and the number of pole
pairs p = p/t. To determine t, we have to find the smallest integers Q s and p · t is thus the
largest common divider of Qs and p. If Qs /(2pm) ∈ N (N is the set of integers, Neven the set of
even integers and Nodd the set of odd integers), we have an integral slot winding, and t = p,
Q s = Q s / p and p = p/p = 1. Table 2.3 shows some parameters of a voltage phasor diagram.
To generalize the representation, the subscript ‘s’ is left out of what follows.
If the number of radii in the voltage phasor diagram is Q = Q/t, the angle of adjacent radii,
that is the phasor angle α z , is written as

2π
αz = t. (2.66)
Q

The slot angle α u is correspondingly a multiple of the phasor angle α z

p
αu = αz = p  αz . (2.67)
t

When p = t, we obtain α u = α z , and the numbering of the voltage phasor diagram pro-
ceeds continuously. If p > t, α u > α z , a number of (p/t) − 1 phasors have to be skipped in
the numbering of slots. In that case, a single layer of a voltage phasor diagram has to be cir-
cled (p/t) times when numbering the slots. When considering the voltage phasor diagrams of
harmonics ν, we see that the slot angle of the νth harmonic is να u . Also the phasor angle is

Table 2.3 Parameters of voltage phasor diagrams

t the largest common divider of Q and p, the number of phasors of a single radius, the
number of layers of a voltage phasor diagram
Q = Q/t the number of radii, or the number of phasors of a single turn in a voltage phasor
diagram (the number of slots in a base winding)
p = p/t the number of revolutions around a single layer when numbering a voltage phasor
diagram
(p/t) − 1 the phasors skipped in the numbering of the voltage phasor diagram
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Windings of Electrical Machines 95

να z . The voltage phasor diagram of the νth harmonic differs from the voltage phasor diagram
of the fundamental with respect to the angles, which are ν-fold.

Example 2.15: Create voltage phasor diagrams for two different fractional slot windings:
(a) Q = 27 and p = 3, (b) Q = 30, p = 4.
Solution: (a) Q = 27, p = 3, Q/p = 9 ∈ N, qs = 1.5, t = p = 3, Q = 9, p = 1, α u =
α z = 40◦ .
There are, therefore, nine radii in the voltage phasor diagram, each having three phasors.
Because α u = α z , no phasors are skipped in the numbering, Figure 2.25a.
(b) Q = 30, p = 4, Q/p = 7.5 ∈ N, qs = 1.25, t = 2 = p, Q = 15, p = 2, Z = Q/t =
30/2 =15, α z = 360◦ /15 = 24◦ , α u = 2α z = 2 × 24◦ = 48◦ , (p/t) − 1 = 1.
In this case, there are 15 radii in the voltage phasor diagram, each having two phasors.
Because α u = 2α z , the number of phasors skipped will be (p/t) − 1 = 1. Both of the layers
of the voltage phasor diagram have to be circled twice in order to number all the phasors,
Figure 2.25b.

19 23 16
27 24
30
20
10 17
18
22 8 1
11 15 9
26
9 1 7
17 8 2 25
2
21 29 14 10
7 3 12
6 3
16
6
5
4 13 11 α u 18
25 21 5 12
13 4
15 26
14 22
28
24 19
α z= αu 20
27 αz
23

(a) (b)

Figure 2.25 Voltage phasor diagrams for two different fractional slot windings. On the left, the
numbering is continuous, whereas on the right, certain phasors are skipped. (a) Q = 27, p = 3, t = 3,
Q = 9, p = 1 α u = α z = 40◦ ; (b) Q = 30, p = 4, t = 2, Q = 15, p = 2, α u = 2α z = 48◦ ; α u is the
angle between voltages in the slots in electrical degrees and the angle α z is the angle between two
adjacent phasors in electrical degrees

2.9 Phase Systems and Zones of Windings

2.9.1 Phase Systems
Generally speaking, windings may involve single or multiple phases, the most common case
being a three-phase winding, which has been discussed here also. However, various other
winding constructions are possible, as illustrated in Table 2.4.
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96 Design of Rotating Electrical Machines

Table 2.4 Phase systems of the windings of electrical machines. The fourth column introduces
radially symmetric winding alternatives
Nonreduced winding Reduced system: loaded
systems have separate star point needs a neutral Normal system: nonloaded
Number of windings for positive and line unless radially star point and no neutral
phases m negative magnetic axes symmetric (e.g. m = 6) line, unless m = 1

1 —

m' = 2
2 —

m' = 4
3 —

m' = 6
4 —

m' = 8
5 —

m' = 10

6… —

m' = 12

12 —

m' = 24

Reading instructions for L1

Table 2.4 L1

L2
N L2 L3
loaded star point nonloaded star point
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Windings of Electrical Machines 97

On a single magnetic axis of an electrical machine, only one axis of a single-phase winding
may be located. If another phase winding is placed on the same axis, no genuine poly-phase
system is created, because both windings produce parallel fluxes. Therefore, each phase sys-
tem that involves an even number of phases is reduced to involving only half of the original
number of phases m as illustrated in Table 2.4. If the reduction produces a system with an
odd number of phases, we obtain a radially symmetric poly-phase system, also known as a
normal system.
If the reduction produces a system with an even number of phases, the result is called a
reduced system. In this sense, an ordinary two-phase system is a reduced to a four-phase
system, as illustrated in Table 2.4. For an m-phase normal system, the phase angle is

αph = 2π/m. (2.68)

Correspondingly, for a reduced system, the phase angle is

αph = π/m. (2.69)

For example, in a three-phase system α ph3 = 2π/3 and for a two-phase system α ph2 = π/2.
If there is even a single odd number as a multiplicand of the phase number in the reduced
system, a radially symmetric winding can be constructed again by turning the direction of the
suitable phasors by 180 electrical degrees in the system, as shown in Table 2.4 for a six-phase
system (6 = 2 × 3). With this kind of a system, a nonloaded star point is created exactly
as in a normal system. In a reduced system, the star point is normally loaded, and thus for
instance the star point of a reduced two-phase machine requires a conductor of its own, which
is not required in a normal system. Without a neutral conductor, a reduced two-phase system
becomes a single-phase system, because the windings cannot operate independently, but the
same current that produces the current linkage is always flowing in them, and together they
form only a single magnetic axis. An ordinary three-phase system also becomes a single-phase
system if the voltage supply of one phase ceases for some reason.
Of the winding systems in Table 2.4, the three-phase normal system is dominant in indus-
trial applications. Five- and seven-phase windings have been suggested for frequency con-
verter use to increase the system output power at a low voltage. Six-phase motors are used
in large synchronous motor drives. In some larger high-speed applications, six-phase wind-
ings are also useful. In practice, all phase systems divisible by three are practical in inverter
supplies. Each of the three-phase partial systems is supplied by its own three-phase frequency
converter having a temporal phase shift 2π/m , in a 12-phase system, for example π/12. For
example, a 12-phase system is supplied with four three-phase converters having a π/12 tem-
poral phase shift.
Single-phase windings may be used in single-phase synchronous generators and also in
small induction motors. In the case of a single-phase-supplied induction motor, however, the
motor needs starting assistance, which is often realized as an auxiliary winding with a phase
shift of π/2. In such a case, the winding arrangement starts to resemble the two-phase reduced
winding system, but since the windings are usually not similar, the machine is not purely a
two-phase machine.
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98 Design of Rotating Electrical Machines

–V +U +U –W –X

–V +U –V +Z +U
U U U V
V–W –V
+W +W –W V –W +Y Z W +V
W W Y X –Y
–U +V +W –U +X +W

+V
–U +V –U –Z

(a) (b) (c)

Figure 2.26 Zone formation of double-layer windings, m = 3, p = 1. (a) a normal-zone span, (b) a
double-zone span, (c) the zone distribution of a six-phase radially symmetric winding with a double-
zone span. The tails and heads of the arrows correspond to a situation in which there are currents
I U = −2I V = −2I W flowing in the windings. The winding in (a) corresponds to a single-layer wind-
ing, which is obtained by unifying the winding layers by removing the insulation layer between the
layers

2.9.2 Zones of Windings

In double-layer windings, both layers have separate zones: an upper-layer zone and a bottom-
layer zone, Figure 2.26. This double number of zones also means a double number of coil
groups when compared with single-layer windings. In double-layer windings, one coil side is
always located in the upper layer and the other in the bottom layer. In short-pitched double-
layer windings, the upper layer is shifted with respect to the bottom layer, as shown in Figures
2.15 and 2.17. The span of the zones can be varied between the upper and bottom layer,
as shown in Figure 2.17 (zone variation). With double-layer windings, we can easily apply
systems with a double-zone span, which usually occur only in machines where the windings
may be rearranged during the drive to produce another number of poles. In fractional slot
windings, zones of varying spans are possible. This kind of zone variation is called natural
zone variation.
In a single-layer winding, each coil requires two slots. For each slot, there is now half a
coil. In double-layer windings, there are two coil sides in each slot, and thus, in principle,
there is one coil per slot. The total number of coils zc is thus

Q
for single-layer windings: z c = , (2.70)
2
for double-layer windings: z c = Q. (2.71)

The single- and double-layer windings with double-width zones form m coil groups per
pole pair. Double-layer windings with a normal zone span from 2m coil groups per pole pair.
The total numbers of coil groups are thus pm and 2pm respectively. Table 2.5 lists some of the
core parameters of phase windings.
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Windings of Electrical Machines 99

Table 2.5 Phase winding parameters

Number of Number of Average zone Average zone
Winding coils zc groups of coil span angle α zav
Single-layer Q/2 pm τ p /m π/m
Double-layer, normal zone span Q 2pm τ p /m π/m
Double-layer, double-zone span Q pm 2τ p /m 2π/m

2.10 Symmetry Conditions

A winding is said to be symmetrical if, when fed from a symmetrical supply, it creates a
rotating magnetic field. Both of the following symmetry conditions must be fulfilled:

a) The first condition of symmetry: Normally, the number of coils per phase winding has to be
an integer:

Q
for single-layer windings: = pq ∈ N, (2.72)
2m
Q
for double-layer windings: = 2 pq ∈ N. (2.73)
m

The first condition is met easier by double-layer windings than by single-layer windings,
thanks to a wider range of alternative constructions.
b) The second condition of symmetry: In poly-phase machines, the angle α ph between the
phase windings has to be an integral multiple of the angle α z . Therefore for normal systems,
we can write
αph 2πQ Q
= = ∈ N, (2.74)
αz m2πt mt
and for reduced systems

αph πQ Q
= = ∈ N. (2.75)
αz m2πt 2mt

Let us now consider how the symmetry conditions are met with integral slot windings. The
first condition is always met, since p and q are integers. The number of slots in integral slot
windings is Q = 2pqm. Now the largest common divider t of Q and p is always p. When we
substitute p = t into the second symmetry condition, we can see that it is always met, since

Q Q
= = 2q ∈ N. (2.76)
mt mp

Integral slot windings are thus symmetrical. Because t = p, also α u = α z , and hence the
numbering of the voltage phasor diagram of the integral slot winding is always consecutive,
as can be seen for instance in Figures 2.10 and 2.18.
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100 Design of Rotating Electrical Machines

Symmetrical Fractional Slot Windings

Fractional slot windings are not necessarily symmetrical. A successful fulfilment of symmetry
requirements starts with the correct selection of the initial parameters of the winding. First,
we have to select q (slots per pole and phase) so that the fraction presenting the number
of slots per pole and phase

z
q= (2.77)
n

is indivisible. Here the denominator n is a quantity typical of fractional slot windings.

a) The first condition of symmetry: For single-layer windings (Equation 2.72), it is required
that in the equation

Q z p
= pq = p , ∈ N. (2.78)
2m n n

Here z and n constitute an indivisible fraction and thus p and n have to be evenly divisible.
We see that when designing a winding, with the pole pair number p usually as an initial
condition, we can select only certain integer values for n. Correspondingly, for double-layer
windings (Equation 2.73), the first condition of symmetry requires that in the equation

Q z 2p
= 2 pq = 2 p , ∈ N. (2.79)
m n n

On comparing Equation (2.78) with Equation (2.79), we can see that we achieve a wider
range of alternative solutions for fractional slot windings by applying a double-layer wind-
ing than a single-layer winding. For instance, for a two-pole machine p = 1, a single-layer
winding can be constructed only when n = 1, which leads to an integral slot winding. On
the other hand, a fractional slot winding, for which n = 2 and p = 1, can be constructed as
a double-layer winding.
b) The second condition of symmetry: To meet the second condition of symmetry (Equation
2.74), the largest common divider t of Q and p has to be defined. This divider can be
determined from the following equation:

p p
Q = 2 pqm = 2mz and p = n .
n n

According to Equation (2.78), p/n ∈ N, and thus this ratio is a divider of both Q and p.
Because z is indivisible by n, the other dividers of Q and p can be included only in the
figures 2m and n. These dividers are denoted generally by c and thus

p
t =c . (2.80)
n
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Windings of Electrical Machines 101

Now the second condition of symmetry can be rewritten for normal poly-phase windings
in a form that is in harmony with Equation (2.74):
p
Q 2mz 2z
= n = ∈ N. (2.81)
mt p c
mc
n
The divider c of n cannot be a divider of z. The only possible values for c are c = 1
or c = 2.

For normal poly-phase systems, m is an odd integer. For reduced poly-phase systems, ac-
cording to Equation (2.75), it is written as
p
2mz
Q
= n = z ∈ N. (2.82)
2mt p c
2mc
n
For c, this allows only the value c = 1.
As shown in Table 2.4, for normal poly-phase windings, the phase number m has to be an
odd integer. The divider c = 2 of 2m and n cannot be a divider of m. For reduced poly-phase
systems, m is an even integer, and thus the only possibility is c = 1. The second condition
of symmetry can now be written simply in the form: n and m cannot have a common divider
n/m ∈ / N. If m = 3, n cannot be divisible by three, and the second condition of symmetry reads
n
∈
/ N. (2.83)
3
Conditions (2.78) and (2.83) automatically determine that if p includes only the figure 3 as
its factor (p = 3, 9, 27, . . . ), a single-layer fractional slot winding cannot be constructed at all.
Table 2.6 lists the symmetry conditions of fractional slot windings.
As shown, it is not always possible to construct a symmetrical fractional slot winding for
certain numbers of pole pairs. However, if some of the slots are left without a winding, a
fractional slot winding can be carried out. In practice, only three-phase windings are realized
with empty slots.
Free slots Qo have to be distributed on the periphery of the machine so that the phase
windings become symmetrical. The number of free slots has thus to be divisible by three, and
the angle between the corresponding free slots has to be 120◦ . The first condition of symmetry

Table 2.6 Conditions of symmetry for fractional slot windings

Number of slots per pole and phase q = z/n, where z and n cannot be mutually
divisible
Type of winding, number of phases Condition of symmetry
Single-layer windings p/n ∈ N
Double-layer windings 2p/n ∈ N
Two-phase m = 2 n/m ∈ N → n/2 ∈ N
Three-phase m = 3 n/m ∈ N → n/3 ∈ N
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102 Design of Rotating Electrical Machines

is now written as
Q − Qo
∈ N. (2.84)
6

The second condition of symmetry is

Q
∈ N. (2.85)
3t

Furthermore, it is also required that

Qo
∈ Nodd . (2.86)
3

Usually, the number of free slots is selected to be three, because this enables the construc-
tion of a winding, but does not leave a considerable amount of the volume of the machine
without utilization. For normal zone width windings with free slots, the average number of
slots of a coil group is obtained from the equation

Q − Qo Q Qo Qo
Q av = = − =q− . (2.87)
2 pm 2 pm 2 pm 2 pm

2.11 Base Windings

It was shown previously that in fractional slot windings, a certain coil side of a phase winding
occurs at the same position with the air gap flux always after p = p/t pole pairs, if the largest
common divider t of Q and p is greater than one. In that case, there are t electrically equal
slot sequences containing Q slots in the armature, each of which includes a single layer of the
voltage phasor diagram. Now it is worth considering whether it is possible to connect a system
of t equal sequences of slots containing a winding as t equal independent winding sections.
This is possible when all the slots Q of the slot sequence of all t electrically equal slot groups
meet the first condition of symmetry. The second condition of symmetry does not have to
be met.
If Q /m is an even number, both a single-layer and a double-layer winding can be con-
structed in Q slots. If Q /m is an odd number, only a double-layer winding is possible in Q
slots. When constructing a single-layer winding, q has to be an integer. Thus, two slot pitches
of t with 2Q slots are all that is required for the smallest, independent, symmetrical single-
layer winding. The smallest independent symmetrical section of a winding is called a base
winding. When a winding consists of several base windings, the current and voltage of which
are due to geometrical reasons always of the same phase and magnitude, it is possible to con-
nect these basic windings in series and in parallel to form a complete winding. Depending
on the number of Q /m, that is whether it is an even or odd number, the windings are defined
either as first- or second-grade windings.
Table 2.7 lists some of the parameters of base windings.
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Windings of Electrical Machines 103

Table 2.7 Some parameters of fractional slot base windings

Base winding of
first grade Base winding of second grade
Parameter q q = z/n
Denominator n n ∈ Nodd n ∈ Neven

Q Q
Parameter Q  /m ∈ Neven ∈ Nodd
m m
Q Q
Parameter Q/tm ∈ Neven ∈ Nodd
tm tm
Divider t, the largest p 2p
common divider of Q t= t=
n n
and p
Slot angle α u expressed 2π n π
with voltage phasor αu = nαz = n t αu = αz = n t
Q 2 Q
angle α z

Single-layer windings
Type of winding double-layer windings Single-layer windings Double-layer windings

Number of slots Q* of a Q Q Q
Q∗ = Q∗ = 2 Q∗ =
base winding t t t
Number of pole pairs p* p p p n
p∗ = =n p∗ = 2 =n p∗ = =
of a base winding t t t 2
Number of layers t* in a
voltage phasor diagram t* = 1 t* = 2 t* = 1
for a base winding

The asterix * indicates the values of the base winding.

2.11.1 First-Grade Fractional Slot Base Windings

In first-grade base windings,

Q Q
= ∈ Neven . (2.88)
m mt

There are Q* slots in a first-grade base winding, and the following is valid for the parameters
of the winding:

Q p
Q∗ = , p∗ = = n, t ∗ = 1. (2.89)
t t

Both conditions of symmetry (2.72)–(2.75) are met under these conditions.

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104 Design of Rotating Electrical Machines

2.11.2 Second-Grade Fractional Slot Base Windings

A precondition of the second-grade base windings is that

Q Q
= ∈ Nodd . (2.90)
m mt
According to Equations (2.81) and (2.82), Equation (2.90) is valid for normal poly-phase
windings when c = 2 only for even values of n. Thus we obtain t = 2p/n and α u = nα z /2.
The first condition of symmetry is met with the base windings of the second grade only when
Q* = 2Q . Now we obtain

Q∗ Q Q
= = ∈ N. (2.91)
2m m mt
The second-grade single-layer base winding thus comprises two consequent tth parts of a
total winding. Their parameters are written as

Q p
Q∗ = 2 , p∗ = 2 = n, t ∗ = 2. (2.92)
t t
With these values, also the second condition of symmetry is met, since

Q∗ 2Q  Q
∗
= = ∈ N. (2.93)
mt 2m mt
The second-grade double-layer base winding meets the first condition of symmetry imme-
diately when the number of slots is Q* = Q . Hence

Q∗ Q Q
= = ∈ N. (2.94)
m m mt
The parameters are now

Q p n
Q∗ = , p∗ = = , t ∗ = 1. (2.95)
t t 2
The second condition of symmetry is now also met.

2.11.3 Integral Slot Base Windings

For integral slot windings, t = p. Hence, we obtain for normal poly-phase systems

Q Q
= = 2q ∈ Neven . (2.96)
mt mp

For a base winding of the first grade, we may write

Q p
Q∗ = , p∗ = = 1, t ∗ = 1. (2.97)
p p
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Windings of Electrical Machines 105

U V W U V W

–U +W –V +U –W +V –U +W –V +U –W +V

1 2 3 4 5 6 7 8 9 10 13 16 19 22 25 28 31 34 36

τp

Figure 2.27 Zone distribution for a single-layer winding. Q = 36, p = 2, m = 3, q = 3

Since also the integral slot windings of reduced poly-phase systems form the base wind-
ings of the first grade, we can see that all integral slot windings are of the first grade, and that
integral slot base windings comprise only a single pole pair. The design of integral slot wind-
ings is therefore fairly easy. As we can see in Figure 2.17, the winding construction is repeated
without change always after one pole pair. Thus, to create a complete integral slot winding, we
connect a sufficient number of base windings to a single pole pair either in series or in parallel.

Example 2.16: Create a voltage phasor diagram of a single-layer integral slot winding,
for which Q = 36, p = 2, m = 3.
Solution: The number of slots per pole and phase is

Q
q= = 3.
2 pm

A zone distribution, Figure 2.27, and a voltage phasor diagram, Figure 2.28, are con-
structed for the winding.

A double-layer integral slot winding is now easily constructed by selecting different phasors
of the voltage phasor diagram of Figure 2.28, for instance for the upper layer. This way, we can
immediately calculate the influence of different short pitchings. The voltage phasor diagram
of Figure 2.28 is applicable to the definition of the winding factors for the short-pitched coils
of Figure 2.15. Only the zones labelled in the figure will change place. Figure 2.28 is directly
applicable to the full-pitch winding of Figure 2.14.

2.12 Fractional Slot Windings

2.12.1 Single-Layer Fractional Slot Windings
Fractional slot windings with extremely small fractions are popular in brushless DC machines
and permanent magnet synchronous machines (PMSMs). Machines operating with sinusoidal
voltages and currents are regarded as synchronous machines even though their air-gap flux
density might be rectangular. Figure 2.29 depicts the differences between single-layer and
double-layer windings in a case where the permanent magnet rotor has four poles and q = 1/2 .
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106 Design of Rotating Electrical Machines

α z= α u
–U

36 19
20 α ph
35
21
+V 34 +W
18 1 2 22
17
16 3
33
15 4
23
5
14
32 6
13
12 7 24
31 11 8
10 9

–W 25
–V
30
26
29
28 27

+U

Figure 2.28 Complete voltage phasor diagram for a single-layer winding. p = 2, m = 3, Q = 36,
q = 3, t = 2, Q = 18, α z = α u = 20◦ . The second layer of the voltage phasor diagram repeats the first
layer and it may, therefore, be omitted. The base winding length is 18 slots

–W +U
+U

+W –U
–W –U
–V +V

+V –V
+W +V
–U +W

–V +U –W

Figure 2.29 Comparison of a single-layer and a double-layer fractional slot winding with concentrated
coils. Qs = 6, m = 3, p = 2, q = 1/2
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Windings of Electrical Machines 107

When the number of slots per pole and phase q of a fractional slot machine is greater than
one, the coil groups of the winding have to be of the desired slot number q on average. In
principle, the zone distribution of the single-layer fractional slot windings is carried out based
on either the voltage phasor diagram or the zone diagram. The use of a voltage phasor diagram
has often proved to lead to an uneconomical distribution of coil groups, and therefore it is
usually advisable to apply a zone diagram in the zone distribution. The average slot number
per pole and per phase of a fractional slot winding is hence q, which is a fraction that gives
the average number of slots per pole and phase qav . This kind of average number of slots can
naturally be realized only by varying the number of slots in different zones. The number of
slots in a single zone is denoted by qk . Now

qk = qav = q ∈
/ N. (2.98)

qav has thus to be an average of the different values of qk . Then we write

z
q =g+ , (2.99)
n

where g is an integer, and the quotient is indivisible so that z < n. Now we have an average
number of slots per pole and phase q = qav , when the width of z zones in n coil groups is set
to g + 1 and the width of n − z zones is g:

1
z  (g + 1) + n − z  g
n
z
qav = qk = = g + = q. (2.100)
n k=1 n n

The divergences from a totally symmetrical winding are smallest when the same num-
ber of slots per pole and phase occurs in consequent coil groups as seldom as possible.
The best fractional slot winding is found with n = 2, when the number of slots per pole
and phase varies constantly when travelling from one zone to another. To meet Equa-
tion (2.100), at least n groups of coil are required. Now we obtain the required number
of coils

Q∗
qav nm = qp ∗ m = . (2.101)
2

This number corresponds to the size of a single-layer base winding. Thus we have shown again
that a base winding is the smallest independent winding for single-layer windings. When
the second condition of symmetry for fractional slot windings is considered, it makes no
difference how the windings are distributed in the slots (n zones, qk coil sides in each), if only
the desired average qav is reached (e.g. 1 + 2 + 1 + 1 + 2 gives an average of 12/5). The nm
coil groups of a base winding have to be distributed in m phase windings so that each phase
gets n single values of qk (a local number of slots), in the same order in each phase. The coil
numbers of consequent coil groups run through the single values of qk n times in m equal
cycles. This way, a cycle of coil groups is generated.
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108 Design of Rotating Electrical Machines

Table 2.8 Order of coil groups for symmetrical single-layer fractional slot windings
Local
Number of coil number of
group. This slots per pole
column runs m and phase Phase cycle. Phases from 1
times from 1 to (equals local All the to m (for a
Cycle of coil n (the divider number of phases are three-phase
groups of the fraction slots per pole introduced system we Number of
1...m q = z/n) and phase qk ) once have U, V, W) coil group
1 1 Q1 1 U 1
1 2 Q2 1 V 2
1 3 Q3 1 W 3
1 | | 1 | |
1 K qk 1 m m
1 | | 2 U m+1
1 | | 2 V m+2
1 | | 2 W m+3
1 N qn 2 | |
2 n+1 Q1 2 | |
2 n+2 | 2 | |
2 | | | |
2 n+k qk | |
| | | |
Dn qn | |
d+1 dn + 1 Q1 c | |
| | c | |
| | C m Cm
dn + k qk c+1 U cm + 1
| | V |
| | W |
m (m − 1)n + k qk | |
m | | | |
m | | | |
m | | | |
m | | | |
m mn qn N m Nm

The first column of Table 2.8 shows m consequently numbered cycles of coil groups. The
second column consists of nm coil groups in running order. The third column lists n single val-
ues of qk m times in running order. Because the consequent coil groups belong to consequent
phases, we get a corresponding running phase cycle in the fourth column. During a single
cycle, the adjacent fifth column goes through all the phases U, V, W, . . . , m of the machine.
The sixth column repeats the numbers of coil groups.
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Windings of Electrical Machines 109

Example 2.17: Compare two single-layer windings, an integral slot winding and a frac-
tional slot winding having the same number of poles. The parameters for the integral slot
winding are Q = 36, p = 2, m = 3, q = 3 and for the single-layer fractional slot winding
Q = 30, p = 2, m = 3, q = 21/2.
Solution: For the fractional slot winding,

1
z  (g + 1) + n − z  g
n
z
qav = qk = = g + = q.
n k=1 n n

We see that in this case g = 2, z = 1, n = 2. Now, a group of coils with z = 1 is obtained,

in which there are q1 = g + 1 = 3 coils, and another n − z = 1 group of coils with q2 =
g = 2 coils. As p = p* = n = 2, we have here a base winding with three (m = 3) cycles of
coil groups of both the coil numbers q1 and q2 . They occur in n = 2 cycles of three phases.

Table 2.9 Example of Table 2.8 applied to Figure 2.30. For the fractional slot winding q = z/n =
5/2
Cycle of Number of Number of Number of
coil groups coil group coils qk Phase cycle Phase coil group
1 1 3 = q1 1 U 1
1 2 (= n) 2 = q2 1 V 2
2 2+1=3 3 1 W 3
2 2+2=4 2 2 U 4
3 (= m) (2 + 2) + 1 = 5 3 2 V 5
3 (= m) (2 + 2) + 2 = 6 = nm = 2·3 2 2 W 6 = nm

In Table 2.9, the example of Table 2.8 is applied to Figure 2.30. The above information
presented in Table 2.9 can be presented simply as:

qk 3 2 3 2 3 2
Phase U V W U V W

Each phase comprises a single coil group with two coils, and one coil group with three
coils. Figure 2.30 compares the above integral slot winding and a fractional slot winding.

Fractional slot windings create more harmonics than integral slot windings. By dividing the
ordinal number ν of the harmonics of a fractional slot winding by the number of pole pairs
p* , we obtain

ν
ν = . (2.102)
p∗
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110 Design of Rotating Electrical Machines

Θ subharmonic

0 τp 2τ p 3τp 4τ p

–U +W –V +U –W +V –U +W –V +U –W +V

Figure 2.30 Zone diagrams and current linkage distributions of two different windings (q = 3,
q = 2 1/2 ). The integral slot winding is fully symmetrical, but the current linkage distribution of the
fractional slot winding (dotted line) differs somewhat from the distribution of the integral slot winding
(solid line). The current linkage of the fractional slot winding clearly contains a subharmonic, which has
a double pole pitch compared with the fundamental

In integral slot windings, such relative ordinal numbers of the harmonics are the following
odd integers: ν  = 1, 3, 5, 7, 9, . . . . For fractional slot windings, when ν = 1, 2, 3, 4, 5, . . . ,
the relative ordinal number gets the values ν  = 1/p* , ν  = 2/p* , ν  = 3/p* , . . . ; in other
words, values for which ν  < 1, ν  ∈ N or ν  ∈ Neven . The lowest harmonic created by an
integral slot winding is the fundamental (ν  = 1), but a fractional slot winding can also produce
subharmonics (ν  < 1). Other harmonics also occur, the ordinal number of which is a fraction
or an even integer. These harmonics cause additional forces, unintended torques and losses.
These additional harmonics are the stronger, the greater is the zone variation; in other words,
the divergence of the current linkage distribution from the respective distribution of an integral
slot winding. In poly-phase windings, not all the integer harmonics are present. For instance,
in the spectrum of three-phase windings, those harmonics are absent, the ordinal number of
which is divisible by three, because α ph,ν = α ph,1 = ν 360◦ /m = ν 120◦ , and thus, because
of the displacement angle of the phase windings α ph = 120◦ , they do not create a voltage
between different phases.

Example 2.18: Design a single-layer fractional slot winding of the first grade, for which
Q = 168, p = 20, m = 3. What is the winding factor of the fundamental?
Solution: The number of slots per pole and phase is

168 2
q= =1 .
2 · 20 · 3 5
We have a fractional slot winding with n = 5 as a divider. The conditions of symmetry
(Table 2.6) p/n = 20/5 = 4 ∈ N and n/3 = 5/3 ∈ N are met. According to Table 2.7, when
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Windings of Electrical Machines 111

n is an odd number, n = 5 ∈ Nodd , a first-grade fractional slot winding is created. When

t = p/n = 4, its parameters are

Q ∗ = Q/t = 168/4 = 42, p ∗ = n = 5, t ∗ = 1.

The diagram of coil groups, according to Equation (2.101), qav nm = qp ∗ m = Q ∗ /2,

consists of p * m = nm = 5 × 3 = 15 groups of coils. The coil groups and the phase order
are selected according to Table 2.8:

qk 2 1 2 1 1 2 1 2 1 1 2 1 2 1 1
Phase U V W U V W U V W U V W U V W

m = 3 cycles of coil groups with n = 5 consequent numbers of coils qk yield a symmetrical

distribution of coil groups for single-phase coils.

qk q1 q2 q3 q4 q5 q1 q2 q3 q4 q5 q1 q2 q3 q4 q5

Phase U 2 1 1 1 2
Phase V 1 1 2 2 1
Phase W 2 2 1 1 1

In each phase, there is one group of coils qn . The average number of slots per pole and
phase qav of the coil group is written according to Equation (2.100) using the local qk value
order of phase U

1

5
1 2
qk = (2 + 1 + 1 + 1 + 2) = 1 = q.
5 k=1 5 5

We now obtain a coil group diagram according to Figure 2.31 and a winding phasor
diagram according to Figure 2.32.
q 2 1 2 1 1 2 1 2 1 1 2 1 2 1 1
k

phase U V W U V W U V W U V W U V W

1 5 7 11 15 19 21 25 29 33 35 39
3 4 9 10 13 14 17 18 23 24 27 28 31 32 37 38 41 42
2 6 8 12 16 20 22 26 30 34 36 40

Figure 2.31 Coil group diagram of a single-layer fractional slot winding. Q* = Q/t = 168/4 = 42,
p* = n = 5, t* = 1
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112 Design of Rotating Electrical Machines

–U

+V 9 26 1 18 35
34 10
17 27
42 2
25 19
8 36
33 11
16 28
41 3 +W
–W
24 20
7 37
32 12
15 29
40 4
23 21
6 38
31 13
14 39 22 5 30 –V
+U
(a) (b)

Figure 2.32 (a) Voltage phasor diagram of a first-grade, single-layer base winding. p* = 5, m = 3,
Q = Q* = 42, q = 12/5, t* = 1, α u = 5α z = 426/7◦ , α z = 8 47 ◦ . The phasors of the phase U are
illustrated with a solid line, (b) the phasors of phase U are turned to form a bunch of phasors for the
winding factor calculation and the symmetry line

When calculating the winding factor for this winding, the following parameters are
obtained for the voltage phasor diagram:

Number of layers in the voltage phasor t* = 1

diagram
Number of radii Q = Q* /t* = 42
Slot angle αu = 360◦ p ∗ /Q ∗ = 360◦ × 5/42 = 426/7◦
Phasor angle αz = 360◦ t ∗ /Q ∗ = 360◦ × 1/42 = 84/7◦
Number of phasors skipped in the numbering (p* /t* ) − 1 = 5 − 1 = 4
Number of phasors for one phase Z = Q /m = 42/3 = 14

The voltage phasor diagram is illustrated in Figure 2.32.

The winding factor may now be calculated using Equation (2.16):

νπ
sin

Z
kwv = 2 cos αρ .
Z ρ=1

The number of phasors Z = 14 for one phase and the angle between the phasors in the
bunch is αz = 84/7◦ . The fundamental winding factor is found after having determined the
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Windings of Electrical Machines 113

angles α ρ between the phasors and the symmetry line, hence

◦ ◦ ◦ ◦ 
cos 4 · 84/7 + cos 3 · 84/7 + 2 cos 2 · 84/7 + 2 cos 84/7 + 1 · 2
kw1 =
14
= 0.945.

As a result of the winding design based on the zone distribution given above, we have
a winding in which, according to the voltage phasor diagram, certain coil sides are trans-
ferred to the zone of the neighbouring phase. By exchanging the phasors 19–36, 5–22 and
8–33 we would also receive a functioning winding but there would be less similar coils
than in the winding construction presented above. This kind of winding would lead to a
technically inferior solution, in which undivided and divided coil groups would occur side
by side. Such winding solutions are favourable when the variation of coil arrangements is
kept to a minimum. This way, the best shape of the end winding is achieved.

Example 2.19: Is it possible to design a winding with (a) Q = 72, p = 5, m = 3,

(b) Q = 36, p = 7, m = 3, (c) Q = 42, p = 3, m = 3?
Solution: (a) Using Table 2.6, we check the conditions of symmetry for fractional slot
windings. The number of slots per pole and phase is q = z/n = 72/(2 × 5 × 3) = 22/5,
z = 12 and n = 5, which are not mutually divisible. As p/n = 5/5 = 1 ∈ N a single-layer
winding should be made and as n/m = 5/3 ∈ N the symmetry conditions are all right. And
as n ∈ Nodd we will consider a first-grade base winding as follows:
Q ∗ = 72, p ∗ = 5, m = 3, q = 22/5 .

That is, qav = 1

5
(3 + 2 + 2 + 2 + 3) = 2 25 = q. This is a feasible winding.

qk 3 2 2 2 3 3 2 2 2 3 3 2 2 2 3
Phase U V W U V W U V W U V W U V W

(b) The number of slots per pole and phase is q = z/n = 36/(2 · 7 · 3) = 6/7, z = 6 and
n = 7, which are not mutually divisible. As p/n = 7/7 = 1 ∈ N a single-layer winding can
be made, and as n/m = 7/3 ∈ N the symmetry conditions are all right. And as n ∈ Nodd
we will consider a first-grade base winding as follows:
Q ∗ = 36, p ∗ = 7, m = 3, q = 6/7 .

qk 1 1 1 0 1 1 1 1 1 1 0 1 1 1 1 1 1 0 1 1 1
Phase U V W U V W U V W U V W U V W U V W U V W

qav = 1
7
(1 + 1 + 1 + 0 + 1 + 1 + 1) = 67 .
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114 Design of Rotating Electrical Machines

The number of slots per pole and phase can thus also be less than one, q < 1. In such
a case, coil groups with no coils occur. These nonexistent coil groups are naturally evenly
distributed in all phases.
(c) The number of slots per pole and phase is q = z/n = 42/(2 · 3 · 3) = 2 13 , z = 7 and
n = 3, which are mutually divisible, the condition n/3 ∈ N is not met, and the winding
is not symmetric. If, despite the nonsymmetrical nature, we considered a first-grade base
winding, we should get a result as follows:

Q ∗ = 42, p ∗ = 3, m = 3, q = 21/3 .

qk 2 2 3 2 2 3 2 2 3
Phase U V W U V W U V W

We can see that all coil groups with three coils now belong to the phase W. Such a
winding is not functional.

Example 2.20: Create a winding with Q = 60, p = 8, m = 3.

Solution: The number of slots per pole and phase is q = 60/(2 · 8 · 3) = 1 14 . z = 5,
n = 4. The largest common divider of Q and p is t = 2p/n = 16/4 = 4. As t also in-
dicates the number of layers in the phasor diagram we get Q = Q/t = 60/4 = 15 which
is the number of radii in the phasor diagram in one layer. Q /m = 15/3 = 5 ∈ Nodd . The
conditions of symmetry p/n = 8/4 = 2 ∈ N and n/3 = 4/3 ∈ N are met. Because n = 4 ∈
Neven , we have according to the parameters in Table 2.7 a second-grade, single-layer frac-
tional slot winding. We get the base winding parameters

Q ∗ = 2Q/t = 2 · 60/4 = 30, p ∗ = n = 4, t ∗ = 2.

The second-grade, single-layer fractional slot windings are designed like the first-grade
windings. However, the voltage phasor diagram is now doubled. The coil group diagram
of the base winding comprises p* × m = n × m = 4 × 3 = 12 coil groups. The coil group
phase diagram is selected as follows:

qk 2 1 1 1 2 1 1 1 2 1 1 1
Phase U V W U V W U V W U V W

A coil group diagram for the base winding corresponding to this case is illustrated in
Figure 2.33.
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Windings of Electrical Machines 115

qk 2 1 1 1 2 1 1 1 2 1 1 1
ph as e U V W U V W U V W U V W U

1 5 11 15 21 25 31 35
slots 2 3 4 6 7 8 9 10 12 13 14 16 17 18 19 20 22 23 24 26 27 28 29 30 32 33 34 36 ...

base winding base winding

Figure 2.33 Coil group diagram of a base winding for a single-layer fractional slot winding p = 8,
m = 3, Q = 60, q = 11/4

A voltage phasor diagram for the base winding is illustrated in Figure 2.34:

Number of layers in the voltage phasor diagram t* = 2 (second-grade winding)

Number of radii Q = Q* /t* = 30/2 = 15
Slot angle α u = 360◦ p* /Q* = 360◦ × 4/30 = 48◦
Phasor angle α z = 360◦ t* /Q* = 360◦ × 2/30 = 24◦
Number of phasors skipped in the numbering (p* /t* ) − 1 = 4/2 − 1 = 1

The number of phasors Z = 10 for one phase and the angle between the phasors in the
bunch is α z = 24◦ . After having found the angles α ρ with respect to the symmetry line,
the fundamental winding factor may be calculated using Equation (2.16)

(2 cos (6◦ ) + 2 cos (6◦ + 12◦ ) + cos (6◦ + 24◦ )) · 2

kw1 = = 0.951.
10

2.12.2 Double-Layer Fractional Slot Windings

In double-layer windings, one of the coil sides of each coil is in the upper layer of the slot, and
the other coil side is in the bottom layer. The coils are all of equal span. Consequently, when
the positions of the left coil sides are defined, the right sides also will be defined. Here double-
layer fractional slot windings differ from single-layer windings. Let us now assume that the
left coil sides are positioned in the upper layer. For these coil sides of the upper layer, a voltage
phasor diagram of a double-layer winding is valid. Contrary to the voltage phasor diagram
illustrated in Figure 2.34, there is only one layer in the voltage phasor diagram of the double-
layer fractional slot winding. Therefore, the design of a symmetrical double-layer fractional
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116 Design of Rotating Electrical Machines

+V
–U
16
23
24
30
17
8 1
15 9
22
2 25
7
–W –W
10
14
29
3 18 +W
6
11
13
21 4
5 12
26

28
19
20 27
+U –V
(a) (b)

Figure 2.34 (a) Voltage phasor diagram of the base winding p* = 4, Q* = 30, t* = 2, Q = 15,
α u = 2α z = 48◦ of a single-layer fractional slot winding p = 12, m = 3, Q = 60, q = 1/4 . The phasors
belonging to the phase U are illustrated with a solid line. (b) The phasors of the phase U are turned for
calculating the winding factor and for illustrating a symmetrical bunch of phasors

slot winding is fairly straightforward with a voltage phasor diagram of a base winding. Now,
symmetrically distributed closed bunches of phasors are composed of the phasors of single
phases. This phasor order produces minimum divergence when compared with the current
linkage distribution of the integral slot winding.
First, we investigate first-grade, double-layer fractional slot windings. It is possible to di-
vide the phasors of such a winding into bunches of equal size; in other words, into zones of
equal width.

Example 2.21: Design the winding previously constructed as a single-layer winding Q =

168, p = 20, m = 3, q = 12/5 now as a double-layer winding.
Solution: We have a fractional slot winding for which the divider n = 5. The conditions
of symmetry (Table 2.6) p/n = 20/5 = 4 ∈ N and n/3 = 5/3 ∈ N are met. According
to Table 2.7, if n is an odd number n = 5 ∈ Nodd , a first-grade fractional slot winding is
created. The parameters of the voltage phasor diagram of such a winding are:

Number of layers in the voltage phasor diagram t* = 1

Number of pole pairs in the base winding p* = 5
Number of radii Q = Q* /t* = 42
Slot angle α u = 360◦ p* /Q* = 360◦ ×5/42 = 42 67 ◦
Phasor angle α z = 360◦ t* /Q* = 360◦ ×1/42 = 8 47 ◦
Number of phasors skipped in the numbering (p* /t* ) − 1 = 5 − 1 = 4
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Windings of Electrical Machines 117

–U
+V 9 26 1 18 35 1
34 10
17 27
42 2
αz
25 19
8 36 U1 U2
33 11
αu
16 28
41 3 +W U1–U5
–W
24 20 U2–U6
7 37
U6
32 12
15 29 U5
40 4
23 21
6 38
31
14 39 22 5 30 13 –V 5
+U

(a) (b)

Figure 2.35 (a) Voltage phasor diagram of a first-grade, double-layer base winding p* = 5, m = 3,
Q = Q* = 42, q ∗ = 12/5, t* = 1, α u = 5α z = 426 /7 ◦ , α z = 84 /7 ◦ . (b) A couple of examples of coil
voltages in the phase U

Since t* = 1, the number of radii Q is the same as the number of phasors Q* , and we
obtain Q* /m = 42/3 = 14 phasors for each phase, which are then divided into negative Z −
and positive Z + phasors. The number of phasors per phase in the first-grade base winding
is Q* /m = Q/mt ∈ Neven . In normal cases, there is no zone variation, and the phasors
are evenly divided into positive and negative phasors. In the example case, the number of
phasors of both types is seven, Z − = Z + = 7. By employing a normal zone order −U,
+W, −V, +U, −W, +V we are able to divide the voltage phasor diagram into zones with
seven phasors in each, Figure 2.35.
When the voltage phasor diagram is ready, the upper layer of the winding is set. The
positions of the coil sides in the bottom layer are defined when an appropriate coil span is
selected. For fractional slot windings, it is not possible to construct a full-pitch winding,
because q ∈ N. For the winding in question, the full-pitch coil span yQ of a full-pitch
winding would be y in slot pitches

2 1
y = yQ = mq = 3 · 1 =4 ∈/ N,
5 5

which is not possible in practice because the step has, of course, to be an integer number
of slot pitches.
Now the coil span may be decreased by yv = 1/5. The coil span thus becomes an integer,
which enables the construction of the winding:

2 1
y = mq − yv = 3 · 1 − = 4 ∈ N.
5 5
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118 Design of Rotating Electrical Machines

1 5 10 15 20 25 30 35 40 42 1

U2 ...U1

Figure 2.36 Base winding of a fractional slot winding. p = 20, m = 3, Q = 168, q = 12/5. The U1
end of the base winding is placed in slot 40

Double-layer fractional slot windings are thus short-pitched windings. When construct-
ing a two-layer fractional slot winding, there are two coil sides in each slot. Hence, we
have as many coils as slots in the winding. In this example, we first locate the U-phase
bottom coil side in slot 1. The other coil side is placed according to the coil span of y = 4
at a distance of four slots in the upper part of slot 5. Similarly, coils run from 2 to 6. The
coils to be formed are 1–5, 18–22, 35–39, 10–14, 27–31, 2–6 and 19–23. Starting from
the +U zone, we have coils 22–26, 39–1, 14–18, 31–35, 6–10, 23–27 and 40–2. Now, six
coil groups with one coil in each and four coil groups with two coils in each are created in
each phase. The average is

1 14 2
q= (6 · 1 + 4 · 2) = =1 .
10 10 5

A section of the base winding of the constructed winding is illustrated in Figure 2.36.
Next, the configuration of a second-grade, double-layer fractional slot winding is inves-
tigated. Because now Q /m = Q* /m = Q/mt ∈ Nodd , a division Z − = Z + is not possible.
In other words, all the zones of the voltage phasor diagram are not equal. The voltage
phasor diagram can nevertheless be constructed so that phasors of neighbouring zones are
not located inside each other’s zones.

Example 2.22: Create a second-grade, double-layer fractional slot winding with Q = 30,
p = 4, m = 3.
Solution: The number of slots per pole per phase is written as

30
q= = 21/2.
2·2·3

As n = 2 ∈ Neven , we have a second-grade, double-layer fractional slot winding. Because

t = 2p/n = 2, its parameters are

Q ∗ = Q/t = 30/2 = 15,

p ∗ = n/2 = 2/2 = 1,
t ∗ = 1.
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Windings of Electrical Machines 119

1
15 2

–U
14 +V 3

13 4

+W
–W
12 5

11 6

+U –V
10 7

9 8

Figure 2.37 Voltage phasor diagram of a second-grade, double-layer fractional slot winding. p* =
1, m = 3, q = 21/2, Q = Q* /t* = 15, α u = 360◦ p* /Q* = 360◦ /15 = 24◦ , α z = 360◦ t* /Q* = 360◦ /15
= 24◦ , (p* /t* ) − 1 = 0

This winding shows that the base winding of a second-grade, double-layer fractional
slot winding can only be the length of one pole pair. The parameters of the voltage phasor
diagram are:

Number of layers in the voltage phasor diagram t* = 1 = p*

Number of radii Q = Q* /t* = 15
Slot angle α u = 360◦ p* /Q* = 360◦ /15 = 24◦
Phasor angle α z = 360◦ t* /Q* = 360◦ /15 = 24◦
Number of phasors skipped in the numbering (p* /t* ) − 1 = 0

For each phase, we obtain Q /m = Q* /m = 15/3 = 5 phasors. This does not allow an
equal number of negative and positive phasors. If a natural zone variation is employed, we
have to set either Z + = Z − + 1 or Z + = Z − − 1. In the latter case, we obtain Z − = 3 and
Z + = 2. With the known zone variation, electrical zones are created in the voltage phasor
diagram, for which the number of phasors varies: Z − = 3 phasors in zone −U, Z + = 2
phasors in zone +W, Z − = 3 phasors in zone −V, and so on, Figure 2.37.
When the coil span is decreased by yv = 1/2, the coil span becomes an integer

y = mq − yv = 71/2 − 1/2 = 7.
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120 Design of Rotating Electrical Machines

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

U1 (a) U2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

U1 (b) U2

Figure 2.38 Winding diagram of a double-layer fractional slot winding. p = 2, m = 3, Q = 30,

q = 21/2. (a) Lap winding, (b) wave winding. To simplify the illustration, only a single phase is
shown

The winding diagram of Figure 2.38 shows that all the positive coil groups consist of
three coils, and all the negative coil groups consist of two coils, which yields an average
of q = 2 1/2 . Since all negative and all positive coil groups comprise an equal number of
coils, the winding can be constructed as a wave winding. A wave is created that passes
through the winding three times in one direction and two times in the opposite direction.
The waves are connected in series to create a complete phase winding.

Example 2.23: Create a fractional slot winding for a three-phase machine, where the
number of stator slots is 12, and the number of rotor poles is 10, Figure 2.39.
Solution: The number of slots per pole and phase is q = 12/(3 × 10) = 2/5 = z/n =
0.4. Hence, n = 5. We should thereby find a base winding of the first kind. According to
Table 2.6, p/n ∈ N. In this case 5/5 ∈ N. In a three-phase machine n/m ∈ N → n/3 ∈ N.
Now 5/3 ∈ N and the symmetry conditions are met. Let us next consider the parameters
in Table 2.7. The largest common divider of Q and p is t = p/n = 5/5 = 1, Q/tm =
12/(1 × 3) = 4 which is an even number. The slot angle in the voltage phasor diagram is
2π 2π 5π
αu = nαz = n t, αu = 5αz = 5 1= .
Q 12 6
The number slots in the base windings is Q* = Q/t = 12 and the number of pole pairs
in the base winding is p/t = n = 5. The winding may be realized as either a single- or
double-layer winding, and in this case a double-layer winding is found. In drawing the
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Windings of Electrical Machines 121

–U
–U 1 +V 1 top layer U8
8 6 12
+V 2 bottom layer
–V –U +U
o
+W
3 11
+V 11
–V +U
3 α = 30 U8 –U
–W –U 7
+V +W

–U9
+W 10 4 –W 10+W`+W –W –W 4 –U3
–W –V –U1 U2
9 9 +U +W 5
5
–V –W –U
+U
+V
–U +V
8 –V 6
o
2cos 30 + 2 U2
12 2 7 kw1= = 0.933
–V 7 +U 4
+U
–U
(a) (b) (c)

Figure 2.39 (a) Phasors of a 12-slot, 10-pole machine, (b) the double-layer winding of a 12-slot,
10-pole machine, (c) the phasors of the phase U for the calculation of the winding factor

voltage phasor diagram, the number of phasors skipped in the numbering is (p* /t* ) − 1=
((p/t)/t* ) − 1 = ((5/1)/1) − 1 = 4.
First, 12 phasors are drawn (a number of Q , when Q = Q* /t* ). Phasor 1 is positioned
to point straight upwards, and the next phasor, phasor 2, is located at an electrical angle
of 360 × p/Q from the first phasor, in this case 360 × 5/12 = 150◦ . Phasor 3 is, again,
located at an angle of 150◦ from phasor 2 and so on. The first coil 1–2 (−U, +U) will be
located on the top layer of slot 1 and on the bottom layer of slot 2. The other coil (+U,
−U) 2–3 will be located on the top layer of slot 2 and on the bottom layer of slot 3. The
phase coils are set in the order U, −V, W, −U, V, −W. In the example, a single-phase
zone comprises four slots, and thus a single winding zone includes two positive and two
negative slots.
Based on the voltage phasor diagram of Figure 2.39a and the winding construction of
Figure 2.39b, the fundamental winding factor of the machine can be solved, Figure 2.39c.
First, the polarity of the coils of phase U in Figure 2.39b is checked and the respective
phasors are drawn. In slots 1, 2 and 3, there are four coil sides of the phase U in total, and
the number of phasors will thus be four. Now the angles between the phasors and their
cosines are calculated. This yields a winding factor of 0.933.

Example 2.24: Create a fractional slot winding for a three-phase machine, in which the
number of slots is 21, and the number of rotor poles is 22, Figure 2.40.
Solution: The number of slots per pole and phase is thus only q = 21/66 = z/n = 7/22 =
0.318. As n ∈ Neven , we have a fractional slot winding of the second grade. Although a
winding of this kind meets the symmetry conditions, it is not an ideal construction, because
in the winding all the coils of a single phase are located on the same side of the machine.
Such a coil system may produce harmful unbalanced magnetic forces in the machine.
In Figure 2.40a, 21 phasors are drawn (a number of Q , when Q = Q* /t* ). Phasor 1 is
placed at the top and the next phasor at a distance of 360 × p/Q from it. In this example,
the distance is thus 360 × 11/21 = 188.6◦ . Phasor 2 is thus set at an angle of 188.6◦ from
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122 Design of Rotating Electrical Machines

+V –U –U
+U –U +U
+V 20 1 3 –U
+V –V –U –U
18 5 –U
+U +V
–V
+V
21 1 2
–U
+U
16 7
–V 20 3 +U
–W 14 +W
+V 19 4 9
+V –U –U
18 5
–V –V 17 –W 12 11 +W
6 +U +U
16 –W 10 13
+V +V 7 –U +W +W
15 8
–V –W 8 15
–V 14 9 –W –W –V
–W 13 12
11 10
+W 6 17 k w1 = 0.956
+V +W –W +W 4 19
–W +W +U 2 21 –V
+W –W
–W +W +U –V
+U –V

(a) (b) (c)

Figure 2.40 (a) Winding of a 21-slot, 22-pole machine, (b) the phasors of a 21-slot, 22-pole ma-
chine and (c) the phasors of the phase U for the calculation of the winding factor

phasor 1. The procedure is repeated with phasors 3, 4, . . . . The phase coils are set in the
order −W, U, −V, W, −U, V. Here a single phase consists of seven slots, and therefore we
cannot place an equal number of positive and negative coils in one phase. In one phase,
there are four positive and three negative slots. Note that we are now generating just the
top winding layer, and when the bottom winding is also inserted, we have an equal number
of positive and negative coils.
In Figure 2.40b, the coils are inserted in the bottom layer of the slots according to the
phasors of Figure 2.40a. Phasor 1 of Figure 2.40a is −U, and it is located in the top layer
of slot 1. Correspondingly, phasor 2, +U, is mounted in the top layer of slot 2. The bottom
winding of the machine repeats the order of the top winding. When the top coil sides
are transferred by a distance of one slot forward and the ± sign of each one is changed, a
suitable bottom layer is obtained. The first coil of the phase U will be located in the bottom
of slot 21 and on the surface of slot 1, and so on.

Table 2.10 contains some parameters of double-layer fractional slot windings, when the
number of slots q ≤ 0.5 (Salminen, 2004).

2.13 Single- and Two-Phase Windings

The above three-phase windings are the most common rotating-field windings employed in
poly-phase machines. Double- and single-phase windings, windings permitting a varying
number of poles, and naturally also commutator windings are common in machine construc-
tion. Of commutator AC machines, nowadays only single-phase-supplied, series-connected
commutator machines occur, for instance as motors of electric tools. Poly-phase commutator
AC machines will eventually disappear as the power electronics enables easy control of the
rotation speed of different motor types.
Since there is no two-phase supply network, two-phase windings occur mainly as auxiliary
and main windings of machines supplied from a single-phase network. In some special cases,
for instance small auxiliary automotive drives such as fan drives, two-phase motors are also
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Table 2.10 Winding factors kw1 of the fundamental and numbers of slots per pole and phase q for double-layer, three-phase fractional slot
concentrated windings (q ≤ 0.5). The boldface figures are the highest values in each column. Reproduced by permission of Pia Salminen
Number of poles 2p
Qs 4 6 8 10 12 14 16 20 22 24 26
November 25, 2008

Windings of Electrical Machines

6 kw1 0.866 —a 0.866 0.5 —a 0.5 0.866 0.866 0.5 —a 0.5

q 0.5 0.25 0.2 0.143 0.125 0.1 0.091 0.077
16:47

9 kw1 0.866 —b —b 0.866 0.617 0.328 0.328 0.617 0.866 0.945

q 0.5 0.375 0.3 0.25 0.214 0.188 0.15 0.136 0.125 0.115
12 kw1 0.866 0.933 —a 0.933 0.866 0.5 0.25 —a 0.25
q 0.5 0.4 0.286 0.25 0.2 0.182 0.154
15 kw1 0.866 —a —b —b 0.866 0.711 —a 0.39
q 0.5 0.357 0.313 0.25 0.227 0.192
18 kw1 0.866 0.902 0.945 0.945 0.902 0.866 0.74
q 0.5 0.429 0.375 0.3 0.273 0.25 0.231
21 kw1 0.866 0.89 —b —b —a 0.89
q 0.5 0.438 0.35 0.318 0.269
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24 kw1 0.866 0.933 0.949 —a 0.949

q 0.5 0.4 0.364 0.308
a
Not recommended, because the denominator n (q = z/n) is an integral multiple of the number of phases m.
b
Not recommended as single base winding because of unbalanced magnetic pull.
123
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124 Design of Rotating Electrical Machines

used in power electronic supply. A two-phase winding can also be constructed on the rotor of
low-power slip-ring asynchronous motors. As is known, a two-phase system is the simplest
possible winding that produces a rotating field, and it is therefore most applicable to rotating-
field machines. In a two-phase supply, however, there exist time instants when the current of
either of the windings is zero. This means that each of the windings should alone be capable of
creating as sinusoidal a supply as possible to achieve low harmonic content in the air gap and
low losses in the rotor. This makes the design of high-efficiency two-phase winding machines
more demanding than three-phase machines.
The design of a two-phase winding is based on the principles already discussed in the
design of three-phase windings. However, we must always bear in mind that in the case of a
reduced poly-phase system, when constructing the zone distribution, the signs of the zones
do not vary in the way that they do in a three-phase system, but the zone distribution will
be −U, −V, +U, +V. In a single-phase asynchronous machine, the number of coils of the
main winding is usually higher than the number of coils of the auxiliary winding.

Example 2.25: Create a 5/6 short-pitched, double-layer, two-phase winding of a small

electrical machine, Q = 12, p = 1, m = 2, q = 3.
Solution: The required winding is illustrated in Figure 2.41, where the rules mentioned
above are applied.

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4

U1 V1 U2 V2

Figure 2.41 Symmetrical 5/6 short-pitched double-layer, two-phase winding, Q = 12, p = 1,

m = 2, q = 3

When considering a single-phase winding, we must bear in mind that it does not, as a
stationary winding, produce a rotating field, but a pulsating field. A pulsating field can be
presented as a sum of two fields rotating in opposite directions. The armature reaction of
a single-phase machine thus has a field component rotating against the rotor. In synchronous
machines, this component can be damped with the damper windings of the rotor. However, the
damper winding copper losses are significant. In single-phase squirrel cage induction motors,
the rotor also creates extra losses when damping the negative-sequence field.
Also the magnetizing windings of the rotors of nonsalient-pole machines belong to
the group of single-phase windings, as exemplified at the beginning of the chapter. If a
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Windings of Electrical Machines 125

single-phase winding is installed on the rotating part of the machine it, of course, creates a
rotating field in the air gap of the machine contrary to the pulsating field of a single-phase
stator winding.
Large single-phase machines are rare, but for instance in Germany, single-phase syn-
chronous machines are used to feed the supply network of 16 23 Hz electric locomotives. Since
there is only one phase in such a machine, there are only two zones per pole pair, and the con-
struction of an integral slot winding is usually relatively simple. In these machines, damper
windings have to cancel the negative-sequence field. This, however, obviously is problematic
because lots of losses are generated in the damper.
The core principle also in designing single-phase windings is to aim at as sinusoidal a
distribution of the current linkage as possible. This is even more important in single-phase
windings than in three-phase windings, the current linkage distribution of which is by nature
closer to ideal. The current linkage distribution of a single-phase winding can be made to
resemble the current linkage distribution of a three-phase winding instantaneously in a po-
sition where a current of one phase of a three-phase winding is zero. At that instant, a third
of the slots of the machine are in principle currentless. The current linkage distribution of a
single-phase machine can best be made to approach a sinusoidal distribution when a third of
the slots are left without conductors, and a different number of turns of coil are inserted in
each slot. The magnetizing winding of the nonsalient-pole machine of Figure 2.3 is illustrated
as an example of such a winding.

Example 2.26: Create various kinds of zone distributions to approach a sinusoidal current
linkage distribution for a single-phase winding with m = 1, p = 1, Q = 24, q = 12.
Solution: Figure 2.42 depicts various methods to produce a current linkage waveform with
a single-phase winding.

current (a)
linkage (b)

(c)

–U +U –U

(a)

(b)

–U +W –V +U –W +V

(c)

Figure 2.42 Zone diagram of a single-phase winding p = 1, Q = 24, q = 12 and current linkage
distributions produced by different zone distributions. (a) A single-phase winding covering all slots.
(b) A two-thirds winding, with the zones of a corresponding three-phase winding. The three phase
zones +W and −W are left without conductors. The distribution of the current linkage is better
than in the case (a). (c) A two-thirds short-pitched winding, producing a current linkage distribution
closer to an ideal (dark stepped line)
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126 Design of Rotating Electrical Machines

2.14 Windings Permitting a Varying Number of Poles

Here, windings permitting a variable pole number refer to such single- or poly-phase windings
that can be connected via terminals to a varying number of poles. Windings of this type occur
typically in asynchronous machines, when the rotation speed of the machine has to be varied
in a certain ratio. The most common example of such machines is a two-speed motor. The
most common connection for this kind of arrangement is a Lindström–Dahlander connection
that enables alteration of the pole number of a three-phase machine in the proportion of 1 to 2.
Figure 2.43 illustrates the winding diagram of a single phase of a 24-slot machine. It can be
arranged as a double-layer diamond winding, which is a typical Dahlander winding. Now the

smaller number of pole pairs is denoted by p and the higher by p , where p = 2p . The
winding is divided into two sections U1–U2 and U3–U4, both of which consist of two coil
groups with the higher number of poles.

V
U4 V1

(a) (b) U0 V0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
U1 V4
U W
W4 W0 W1

U1 V W U3 U0 U2 U4

U4 V1

(c) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 (d) W V
U0 V0

U1 W0 V4

W4 U W1

U1 V U3 W U0 U2 U4

flux going flux coming

+W +U +V +W +U +V +W +U +V +W +U +V +W +U
(e) zone plan for p'' = 4

-V -W -U -V -W -U -V -W -U -V -W -U -V -W
+U -W +V -U +W -V +U -W +V -U +W -V
(f) zone plan for p' = 2

+V -U +W -V +U -W +V -U +W -V +U -W

Figure 2.43 Principle of a Dahlander winding. The upper connection (a) produces eight poles and
the lower (c) four poles. The number of poles is shown by the flux arrowheads and tails (b) and (d)
equivalent connections. When the number of coil turns of the phase varies inversely proportional to the
speed, the winding can be supplied with the same voltage at both speeds. Network connections are U, V
and W. The figure illustrates only a winding of one phase. In Figure 2.43d between U1 and U4 there is
the connection W, between W4 and W1 there is U and between V1 and V4 there is V to keep the same
direction of rotation; (e) and (f) zone plans for p = 4 and p = 2
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Windings of Electrical Machines 127

The Dahlander winding is normally realized for the higher pole pair number as a double-
layer, double-zone-width winding. The number of coil groups per phase is equal to p , which
is always an even number. Deriving a double-layer, integral slot, full-pitch Dahlander winding
(short-pitch or fractional slot Dahlander windings are not possible at all) starts by creating mp
negative zones with a double width. All the negative zones −U, −V, −W are located in the
top layer and all the positive zones in the bottom layers of slots.
The phase U is followed by the winding V at a distance of 120◦ . For a number of pole pairs

p = 4, the winding V has to be placed at a distance

Q 24
τu = τu = 2τu
3 p  3·4

from the winding U. The winding V thus starts from slot 3 in the same way as the winding
U starts from slot 1. The winding W starts then from slot 5. When considering the pole pair
number p = 2, we can see that the winding V is placed at a distance

Q 24
τu = τu = 4τu
3 p 3·2

from the winding U and thus starts from slot 5, and the winding W from slot 9. External
connections have to be arranged to meet these requirements. At its simplest, the shift of the
above-mentioned pole pair from one winding to another is carried out according to the right-
hand circuit diagrams. To keep the machine rotating in the same direction, the phases U, V
and W have to be connected according to the illustration.
There is also another method to create windings with two different pole numbers: pole
amplitude modulation (PAM) is a method with which ratios other than 1 : 2 may be found.
PAM is based on the following trigonometric equation:

1
sin pb α sin pm α = [cos ( pb − pm ) α − cos ( pb + pm ) α] . (2.103)
2

The current linkage is produced as a function of the angle α running over the perime-
ter of the air gap. A phase winding might be realized with a base pole pair number pb and
a modulating pole pair number pm . In practice, this means that if for instance pb = 4 and
pm = 1, the PAM method produces pole pairs 4 − 1 or 4 + 1. The winding must be created
so that one of the harmonics is damped and the other dominates.

2.15 Commutator Windings

A characteristic of poly-phase windings is that the phase windings are, in principle, galvani-
cally separated. The phase windings are connected via terminals to each other, in a star or in
a polygon. The armature winding of commutator machines does not start or end at terminals.
The winding comprises turns of conductor soldered as a continuum and wound in the slots of
the rotor so that the sum of induced voltages is always zero in the continuum. This is possible
if the sum of slot voltages is zero. All the coil sides of such a winding can be connected in
series to form a continuum without causing a current to flow in the closed ring as a result of
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128 Design of Rotating Electrical Machines

1 2 3 4

1 3
(a) 2 4

1 2 3

1 3 5 7 9
(b) 2 4 6 8

Figure 2.44 Two examples of commutator winding coil sides mounted in the slots. (a) Two coil sides
in a slot, one side in a layer, u = 1. (b) Four coil sides in a slot, two coil sides in a layer, u = 2. Even-
numbered coil sides are located at the bottom of the slots. There has to be a large enough number of
coils and commutator segments to keep the voltage between commutator segments small enough

the voltages in the coil sides. An external electric circuit is created by coupling the connection
points of the coils to the commutator segments. A current is fed to the winding via brushes
dragging along the commutator. The commutator switches the coils in turns to the brushes
thus acting as a mechanical inverter or rectifier depending on the operating mode of the ma-
chine. This is called commutating. In the design of a winding, the construction of a reliable
commutating arrangement is a demanding task.
Commutator windings are always double-layer windings. One coil side of each coil is al-
ways in the upper layer and the other in the bottom layer approximately at the distance of a
pole pair from each other. Because of problems in commutating, the voltage difference be-
tween the commutator segments must not be too high, and thus the number of segments and
coils has always to be high enough. On the other hand, the number of slots is restricted by
the minimum width of the teeth. Therefore, usually more than two coil sides are placed in
each slot. In the slot of the upper diagram of Figure 2.44, there are two coil sides, and in the
lower diagram the number of coil sides is four. The coil sides are often numbered so that the
sides of the bottom layer are even numbers, and the slots of the upper layer are odd numbers.
If the number of coils is zc , 2zc coil sides have to be mounted in Q slots, and thus there are
2u = 2zc /Q sides in a slot. The symbol u gives the number of coil sides in one layer. In each
side, there are N v conductors. The total number of conductors z in the armature is

z = Qz Q = 2u Nv Q = 2z c Nv . (2.104)

Here

Q is the number of slots,

zQ is the number of conductors in a slot,
u is the number of coil sides in a layer,
zc is the number of coils,
N v is the number of conductors in a coil side, 2uN v = zQ , because
z Q = z/Q = 2u Nv Q/Q = 2u Nv , see (2.104).
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Windings of Electrical Machines 129

q
25- 8
11 9 23-6 27- 10
8 7
13 10 21- 4 29- 12
12 6
N 6 5 4 5 S
15 14 7 3 4
19- 2 31- 14
8 2 2
3
17 16 d
9 Ο
1 17- 32 1-16
32 1
19 18 10 16
21
20 11 15 30 31 15- 30 3-18
22 12 13 14 28
24 26 29
23 13-2 8 5-20
25 27
11- 26 7-22 ω =Ω
9-24

(a) (b)

Figure 2.45 (a) Principle of a two-pole, double-layer commutator armature. The armature rotates at
an angular speed Ω clockwise generating an emf in the conductors in the slots. The emf tends to create
the current directions illustrated in the figure. (b) A coil voltage phasor diagram of the armature. It is a
full-pitch winding, which does not normally occur as a commutator winding. Nevertheless, a full-pitch
winding is given here as a clarifying example. Q = 16, u = 1 (one coil side per layer)

Commutator windings may be used both in AC and DC machines. Multi-phase commutator

AC machines are, however, becoming rare. DC machines, instead, are built and used also
in the present-day industry even though DC drives are gradually being replaced by power
electronic AC drives. Nevertheless, it is advisable to look briefly also at the DC windings.
The AC and DC commutator windings are in principle equal. For simplicity, the configura-
tion of the winding is investigated with the voltage phasor diagram of a DC machine. Here, it
suffices to investigate a two-pole machine, since the winding of machines with multiple poles
is repeated unchanged with each pole pair. The rotor of Figure 2.45, with Q = 16, u = 1, is
assumed to rotate clockwise at an angular speed Ω in a constant magnetic field between the
poles N and S.
The magnetic field rotates in the positive direction with respect to the conductors in the
slots, that is counterclockwise. Now, a coil voltage phasor diagram is constructed for a wind-
ing, in which we have already calculated the difference of the coil side voltages given by the
coil voltage phasor diagram. By applying the numbering system of Figure 2.44, we have in
slot 1 the coil sides 1 and 32, and in slot 9 the coil sides 16 and 17. With this system, the coil
voltage phasor diagram can be illustrated as in Figure 2.45b.
Figure 2.45 shows that if the induced emf decides the direction of the armature current, the
produced torque is opposite to the direction of rotation (counterclockwise in Figure 2.45), and
mechanical power has to be supplied to the machine, which is acting as a generator. Now, if
the armature current is forced to flow against the emf with the assistance of an external voltage
or current source, the torque is in the direction of rotation, and the machine acts as a motor.
There are zc = Qu = 16 × 1 = 16 coils in the winding, the ends of which should next be
connected to the commutator. Depending on the way they are connected, different kinds of
windings are produced. Each connection point of the coil ends is connected to the commutator.
There are two main types of commutator windings: lap windings and wave windings. A lap
winding has coils, creating loop-like patterns. The ends of the coils are connected to adjacent
commutator segments. A wave winding has a wavelike drawing pattern when presented in a
plane.
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130 Design of Rotating Electrical Machines

The number of commutator segments is given by

K = u Q, (2.105)

because each coil side begins and ends at the commutator segment. The number of com-
mutator segments, therefore, depends on the conductor arrangement in the slot, and eventu-
ally on the number of coil sides in one layer. Further important parameters of commutator
windings are:

yQ coil span expressed as the number of slots per pole (see Equation (2.111)).
y1 back-end connector pitch, which is a coil span expressed as the number of coil sides. For
the winding, the coil sides of which are numbered with odd figures in the top layer and
with even figures in the bottom layer, this is

y1 = 2uyQ ∓ 1, (2.106)

where the minus sign stands for the coil side numbering as seen in Figure 2.44, and the plus
sign for the numbering where in slot 1 there are coil sides 1, 2, in slot 2 there are coil sides
3, 4, and so on, if u = 1; or in the top layer of slot 1 there are coil sides 1, 3 and in the bottom
layer there are coil sides 2, 4, and so on, if u = 2.

y2 front-end connector pitch; it is a pitch expressed as the number of coil sides between the
right coil side of one coil and the left coil side of the next coil.
y total winding pitch expressed as the number of coil sides between two left coil sides of
two adjacent coils.
yc commutator pitch between the beginning and end of one coil expressed as the number of
commutator segments.

The equation for commutator pitch is a basic equation for winding design because this pitch
must be an integer

nK ± a
yc = , (2.107)
p

where a is the number of parallel paths per half armature in a commutator winding, which
means 2a parallel paths for the whole armature.
The windings that are most often employed are characterized on the basis of n:

1. If n = 0, it results in a lap winding. The commutator pitch will be yc = ±a/ p, which

means that a is an integer multiple of p to give an integer for the commutating pitch. For
a lap winding 2a = 2p, this means a = p, yc = ±1. Such a winding is called a paral-
lel one. The plus sign is for a progressive winding moving from left to right, and the
minus sign for a retrogressive winding moving from right to left. If a is a k-multiple of
the pole pair number, a = kp, then it is a k-multiplex parallel winding. For example, for
a = 2p, the commutator pitch is yc = ±2, and this winding is called a duplex parallel
winding.
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Windings of Electrical Machines 131

2. If n = 1, it results in a wave winding and a commutator pitch, that is

K ±a uQ ± a
yc = = (2.108)
p p

must be an integer. The plus sign is for progressive and the minus sign for retrogressive
winding. In the wave winding the number of parallel paths is always 2; there is only one
pair of parallel paths, irrespective of the number of poles: 2a = 2, a = 1.
Not all the combinations of K, a, p result in an integer. It is a designer’s task to choose a
proper number of slots, coil sides, number of poles and type of winding to ensure an integer
commutator pitch.

If the number of coils equals the number of commutator segments, then, if the coil sides are
numbered with odd figures in the top layer and even figures in the bottom layer, we can write

y = y1 + y2 = 2yc . (2.109)

Therefore, if the commutator pitch is determined, the total pitch expressed as a number of
coil sides is given by

y = 2yc (2.110)

and after y1 is determined from the numbers of slots per pole yQ and number of coil sides in a
layer u,

Q
yQ ∼
= , (2.111)
2p
y1 = 2u yQ ∓ 1. (2.112)

The front-end connector pitch can be determined as

y2 = y − y1 . (2.113)

2.15.1 Lap Winding Principles

The principles of the lap winding can best be explained by an example.

Example 2.27: Produce a layout of a lap winding for a two-pole DC machine with 16
slots and one coil side in a layer.
Solution: Given Q = 16, 2p = 2, u = 1, the number of commutator segments is K =
u Q = 1 · 16 = 16, and for a lap winding 2a = 2p = 2. The commutator pitch is yc =
±a/ p = ±1. We choose a progressive winding, which means that yc = +1 (the winding
proceeds from left to right), and the total pitch is y = 2yc = 2. The coil span yQ in number
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132 Design of Rotating Electrical Machines

of slots is given by the number of slots per pole:

Q 16
yQ = = = 8.
2p 2

The same pitch expressed in the number of coil sides is y1 = 2uyQ − 1 = 2 · 1 · 8 − 1 =

15. The front-end connector pitch is y2 = y − y1 = 2 − 15 = −13, which is illustrated in
Figure 2.46. The coils can be connected in series in the same order that they are inserted
in the slots of the rotor. The neighbouring coils are connected together, coil 1–16 to coil
3–18, and again to 5–20, and so on. This yields the winding diagram of Figure 2.46.

d q d
y1 = 15
y=2 y2 = −13

S N

25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13

H1 H2
10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11
I R

Figure 2.46 Diagram of a full-pitch lap winding. The winding is connected via brushes to an
external resistance R. The pole shoes are also illustrated above the winding. In reality, they are placed
above the coil sides. The laps illustrated with a thick line have been short-circuited via the brushes
during commutation. The direction of current changes during the commutation. The numbers of slots
(1–16) are given. The numbers of coil sides (1–32) in the slots are also given, the coil sides 1 and 32
are located in slot 1 and, for example, the coil sides 8 and 9 are located in slot 5. The commutator
segments are numbered (1–16) according to the slots. It is said that the brushes are on the quadrature
axis; this is nevertheless valid only magnetically. In this figure, the brushes are physically placed
close to the direct axes

When we follow the winding by starting from the coil side 1, we can see that it proceeds
by one step of span y1 = 15 coil sides. In slots 1 and 9, a coil with a large enough number
of winding turns is inserted. Finally, after the last coil turn the winding returns left by a
distance of one step of connection y2 = 2 − 15= −13 coil sides, to the upper coil side 3.
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Windings of Electrical Machines 133

We continue in this way until the complete winding has been gone through, and the coil
side 14 is connected to the upper coil side 1 through the commutator segment 1. The
winding has now been closed as a continuum. The winding proceeds in laps from left to
right; hence the name lap winding.

The pitches of a commutator winding are thus calculated by the number of coil sides, not
by the number of slots, because there can be more than two coil sides in one layer, for instance
four coil sides in a slot layer (u = 1, 2, 3, 4, . . . ).
In the lap winding of Figure 2.46, all the coil voltages are connected in series. The connec-
tion in series can be illustrated by constructing a polygon of the coil voltages, Figure 2.47.
This figure illustrates the phasors at time t = 0 in the coil voltage phasor diagram of Figure
2.45. When the rotor rotates at an angular speed Ω, the coil voltage phasor diagram also ro-
tates in a two-pole machine at an angular speed ω = Ω. Also the polygon rotates around its
centre at the same angular speed. The real instantaneous value of each coil voltage may be
found as a projection of the phasor on the real axis (see figure). According to the figure, the
sum of all coil voltages is zero. Therefore, no circulating currents occur in the continuum.
The highest value of the sum of the instantaneous values of coil voltages is equal to the
diameter H1–H2 parallel to the real axis. This value remains almost constant as the polygon
rotates, and thus the phasor H1–H2 represents a DC voltage without significant ripple. The
voltage approaches a constant value when the number of coils approaches infinity. A DC
voltage can be connected to an external electric circuit via the brushes that are in contact
with the commutator segments. At the moment t = 0, as illustrated, the brushes have to be in
contact with the commutator segment pairs 5–6 and 13–14 that are connected to coils 9–24
and 25–8. According to Figure 2.46, the magnetic south pole (S) is at slot 1 and magnetic
north pole (N) at slot 9. Further, the direction of the magnetic flux is towards the observer at
the south pole, and away from the observer at the north pole. As the winding moves left, a

1–16
31–14 3–18

29–12 5–20

27–10 7–22

u (t) Re
H1 19–2 A H2 9–24
25–8

11–26
23–6

13–28
21–4

19–2 15–30
17–32

Figure 2.47 Polygon of coil voltages of the winding in Figure 2.46. The sum of all the voltages is zero
and hence the coils may be connected in series. The instantaneous value of a coil voltage u(t) will be the
projection of the phasor on the real axis, for example u(t)19–2
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134 Design of Rotating Electrical Machines

positive emf is induced in the conductors under the south pole, and a negative emf under the
north pole, in the direction indicated by the arrows.
By following the laps from segment 14 to coil 27–10, we end up at the commutator
segment 15, then gradually at segments 16, 1, 2, 3, 4 and at last coil 7–22 is brought to
segment 5, touched by the brush H2. We have just described one parallel path created by coils
connected in series via commutator segments. An induced emf creates a current in the external
part of the electric circuit from the brush H2 to the brush H1, and thus in a generator drive,
H2 is a positive brush with the given direction of rotation. Half of the current I in the external
part of the circuit flows in the above-described path, and the other half via the coils 23–6 . . .
11–26, via commutator segments 12, 11, . . . 7, to the brush H2 and further to the external part
of the circuit. In other words, there are two parallel paths in the winding. In the windings
of large machines, there can be several pairs of paths in order to prevent the cross-sectional
area of the conductors from increasing impractically. Because the ends of different pairs of
paths touch the neighbouring commutator segments and have no other galvanic contact, the
brushes have to be made wider to keep each pair of paths always in contact with the external
circuit.
If for instance in the coil voltage phasor diagram of Figure 2.45 every other coil 1–16, 5–20,
9–24 . . . 29–12 is connected in series with the first pair of paths, the lap is closed after the last
turn of coil side 12 by connecting the coil to the first coil 1–16 (12 → 1, from 12 to 1). The
coils that remain free are connected in the order 3–18, 7–22 . . . 31–14 and the lap is closed at
the position 14 → 3. This way, a doubly-closed winding with two paths 2a = 2 is produced.
In the voltage polygon, there are two revolutions, and its diameter, that is the brush voltage,
is reduced to half the original polygon of one revolution illustrated in Figure 2.47. The output
power of the system remains the same, because the current can be doubled when the voltage
is cut in half. In general, the number of pairs of paths a always requires that a − 1 phasors
are left between the phasors of series-connected coils in a coil voltage phasor diagram. The
phasors may be similar. Because u is the number of coil sides per layer, each phasor of the coil
voltage phasor diagram represents u coil voltages. This makes it possible to skip completely
similar voltage phasors. This takes place for instance when u = 2.
The winding of Figure 2.46 is wound clockwise, because the voltages of the coil voltage
phasor diagram are connected in series clockwise starting from phasor 1–16. Were coil 1–16
connected via the commutator segment 16 to coil 31–14, the winding would have been wound
counterclockwise.
The number of brushes in a lap winding is always the same as the number of poles. Brushes
of the same sign are connected together. According to Figure 2.46, the brushes always short-
circuit those coils, the coil sides of which are located at the quadrature axis (in the middle,
between two stator poles) of the stator, where the magnetic flux density created by the pole
magnetization is zero. This situation is also described by stating that the brushes are located
at the quadrature axis of the stator independent of the real physical position of the brushes.

2.15.2 Wave Winding Principles

The winding of Figure 2.46 can be turned into a wave winding by bending the coil ends of the
commutator side according to the illustration in Figure 2.48, as a solution of Example 2.28
(see also Figure 2.49).
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Windings of Electrical Machines 135

y = 30
y2 = 15 y1= 15 y2 = 15

S N

2526 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 1112 1314 15 16 17 18 19 20 2122 2324 25 26 27 28

13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13

H1 H2
9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
I R

Figure 2.48 Full-pitch lap winding of Figure 2.46 turned into a wave winding. The currents of wave-
forms indicated with a thick line are commutating at the moment illustrated in the figure. The commu-
tator pitch is yc = 15, which means almost two pole pitches. For instance, the wave coil that starts at the
commutator segment 14 ends at segment 13, because 14 + yc = 14 + 15 = 29, but there are only 16
commutator segments, and therefore 29 − 16 = 13

Example 2.28: Produce a layout of a wave winding for a two-pole DC machine with 16
slots and one coil side in a layer.

Solution: Given that Q = 16, 2p = 2, u = 1. The number of commutator segments is

K = u Q = 1 · 16 = 16, and for a wave winding 2a = 2. The commutator pitch is

K ±a 16 ± 1
yc = = = 17 or 15.
p 1

We choose yc = +15 (winding proceeds from right to left), and the total winding pitch
is y = 2yc = 30. The coil span yQ in number of slots is given by the number of slots
per pole: yQ = Q/2 p = 16/2 = 8. The same pitch expressed as number of coil sides
is y1 = 2uy Q − 1 = 2 · 1 · 8 − 1 = 15. The front-end connector pitch is y2 = y − y1 =
30 − 15 = 15, which is shown in Figure 2.48.
In the above wave winding, the upper coil side 1 is connected to the commutator seg-
ment 10, and not to segment 1 as in the lap winding. From segment 10, the winding pro-
ceeds to the bottom side 18. The winding thus receives a waveform. In the figure, the
winding proceeds from right to left, and counterclockwise in the coil voltage phasor dia-
gram. The winding is thus rotated to the left. If the winding were turned to the right, the
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136 Design of Rotating Electrical Machines

commutator pitch would be yc = 17, y = 34, y1 = 15, y2 = 19. The coil from the bottom
side 16 would have to be bent to the right to segment 10, and further to the upper side 3,
because 16 + y2 = 16 + 19 = 35. But there are only 32 coil sides, and therefore the coil
will proceed to 35 − 32 = 3 or the third coil side. The commutator ends would in that case
be even longer, which would be of no use.

y1 = 11

y=2 y2 = –9

N S N S

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2

H1 H2 H3 H4
21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

(a)

+ –
y = 13 + 11 = 24
y2 = 13 y1 = 11

N S N S

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2

18 19
H1 H2 H3 H4
21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
y c = 12
(b)

Figure 2.49 (a) Four-pole, double-layer lap winding presented in a plane. The winding moves from
left to right and acts as a generator. The coils belonging to the commutator circuit are illustrated by a
thick line. This winding is not a full-pitch winding, unlike the previous ones. The illustrated winding
commutates better than a full-pitch winding. (b) The same winding developed into a wave winding. The
wave under commutation is drawn with a thicker line than the others
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Windings of Electrical Machines 137

The pitch of the winding for a wave winding follows the illustration

y = y1 + y2 . (2.114)

The position of brushes in a wave winding is solved in the same way as in a lap winding.
When comparing the lap and wave windings, we can see that the brushes short-circuit the
same coils in both cases. The differences between the windings are merely structural, and the
winding type is selected basically on these structural grounds. As written above, the pitch of
the winding for regular commutator windings, which equals the commutator pitch, is obtained
from
nK ± a nu Q ± a
yc = = , (2.115)
p p

where the plus sign in the equation is used for progressive winding (from left to right, i.e.
clockwise) and the minus is used for retrogressive winding (from right to left, i.e. counter-
clockwise); n is zero or a positive integer. If n is zero, it results in a lap winding; if n = 1, it
results in a wave winding. The commutator pitch yc must be an integer, otherwise the wind-
ing cannot be constructed. Not all combinations of K, p and a result in yc as an integer, and
therefore a designer must solve this problem in its complexity.

2.15.3 Commutator Winding Examples, Balancing Connectors

Nowadays, the conductors are typically inserted in slots that are on the surfaces of the arma-
ture. These windings are called drum armature windings. Drum-wound armature windings are
in practice always double-layer windings, in which there are two coil sides in the slot on top
of each other. Drum armature windings are constructed either as lap or wave windings. As
discussed previously, the term ‘lap winding’ describes a winding that is wound in laps along
the periphery of the armature, the ends of one coil being connected to adjacent segments,
Figure 2.49a.

Example 2.29: Produce a layout of the lap winding for a four-pole DC machine with 23
slots and one coil side in a layer.
Solution: Given that Q = 23, 2p = 4, u = 1, the number of commutator segment is
K = u Q = 1 · 23 = 23 and for a lap winding 2a = 2p = 4. The commutator pitch is
yc = ±a/ p = 2/2 = ±1. We choose a progressive winding, which means that yc = +1
(winding proceeds from left to right), and the total winding pitch is y = 2yc = 2. The
coil span yQ as the number of slots is given by the number of slots per pole: yQ =
Q/2 p = 23/4 = 5.75 ⇒ 6 slots. The same pitch expressed as the number of coil sides
is y1 = 2uy Q − 1 = 2 · 1 · 6 − 1 = 11. The minus sign is used because of the coil side
arrangement in the slots according to Figure 2.44a.
The front-end connector pitch is y2 = y − y1 = 2 − 11 = −9, which is shown in
Figure 2.49a.
In the winding of Figure 2.49a, there are 23 armature coils (46 coil sides, two in each
slot), with one turn in each, four brushes and a commutator with 23 segments. There
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138 Design of Rotating Electrical Machines

are four current paths in the winding (2a = 4), which thereby requires four brushes. By
following the winding starting from the first brush, we have to travel a fourth of the total
winding to reach the next brush of opposite sign.
From segment 1, the left coil side is put to the upper layer 1 in slot 1 (see Figure 2.44a).
Then, the right side is put to the bottom layer 1 + y1 = 1 + 11 = 12 in slot 7, from where
it is led to the segment number 1 + yc = 1 + 1 = 2, and then from segment 2 to the upper
layer 3 in slot 2, because 12 − 9 = 3. It proceeds to the bottom layer 14 in slot 8, because
3 + 11 = 14, and then to segment 3, and continues to the coil side 5 in slot 3 and via 16 in
slot 9 to segment 4, and so on.
In the figure, the brushes are broader than the segments of the commutator, the laps
illustrated with thick lines being short-circuited via the brushes. In DC machines, a proper
commutation requires that the brushes cover several segments. The coil sides of short-
circuited coils are approximately in the middle between the poles, where the flux density
is small. In these coils, the induced voltage is low, and the created short-circuit current is
thus insignificant.

Example 2.30: Produce a layout of a wave winding for a four-pole DC machine with 23
slots and one coil side in a layer.
Solution: Given that Q = 23, 2p = 4, u = 1. The number of commutator segments is
K = u Q = 1 · 23 = 23, and for a wave winding 2a = 2. The commutator pitch isyc =
K ±a
p
= 23±1
2
= 12, or 11.
We choose yc = +12 and the total winding pitch is y = 2yc = 24. The coil span yQ as the
number of slots is given by the number of slots per pole: yQ = Q/2 p = 23/4 = 5.75 ⇒ 6.
The same pitch expressed as the number of coil sides is y1 = 2uyQ − 1 = 2 · 1 · 6 − 1 =
11. The minus sign is used because of the coil side arrangement in the slots according to
Figure 2.44a.
The front-end connector pitch is y2 = y − y1 = 24 − 11 = 13, which is shown in Fig-
ure 2.49b. Figure 2.49b illustrates the same winding as in Figure 2.49a but developed for
a wave winding. In wave windings, there are only two current paths: 2a = 2 regardless
of the number of poles. A wave winding and a lap winding can also be combined as a
frog-leg winding.
We can see in Figure 2.49b that from the commutator segment 1 the coil left side is put
to the upper layer 13 in slot 7. Then the right side in the lower layer is put to 13 + y1 =
13 + 11 = 24 in slot 13, from where it is led to segment 1 + yc = 1 + 12 = 13, and then
from segment 13 to the upper layer 37 (slot 19), because 24 + y2 = 24 + 13 = 37. We
then proceed to the lower layer 2 in slot 2, because 37 + y1 = 37 + 11 = 48, which is
over the number coil sides of 46 in 23 slots; therefore, it is necessary to make a correction
48 − (2 × 23) = 50 − 46 = 2. From here we continue to segment 2, because 13 + yc =
13 + 12 = 25, after the correction 25 − 23 = 2, and so on.

When passing through a wave winding from one brush to another brush of the opposite
sign, half of the winding and half of the segments of the commutator are gone through. The
current thus has only two paths irrespective of the number of poles. As a matter of fact, in
a wave winding, only one pair of brushes is required, which is actually enough for small
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Windings of Electrical Machines 139

machines. Nevertheless, usually as many brushes are required as there are poles in the ma-
chine. This number is selected in order to reach a maximum brush area with the shortest
commutator possible. One coil of a wave winding is always connected to the commutator at
about a distance of two pole pitches.
A wave winding is a more common solution than a lap winding for small (<50 kW) ma-
chines, since it is usually more cost effective than a lap winding. In a machine designed for
a certain speed, a number of pole pairs and a flux, the wave winding requires less turns than
a lap winding, excluding a two-pole machine. Correspondingly, the cross-sectional area of
conductors in a wave winding has to be larger than the area of a lap winding. Therefore, in
a machine of a certain output, the copper consumption is the same irrespective of the type of
winding.
The previous windings are simple examples of various alternative constructions for commu-
tator windings. In particular, when numerous parallel paths are employed, we must ensure that
the voltages in the paths are equal, or else compensating currents will occur flowing through
the brushes. These currents create sparks and wear out the commutator and the brushes. The
commutator windings have to be symmetrical to avoid extra losses.
If the number of parallel pairs of paths is a, there are also a revolutions in the voltage poly-
gon. If the revolutions completely overlap the voltage polygon, the winding is symmetrical. In
addition to this condition, the diameter H1–H2 has to split the polygon into two equal halves
at all times. These conditions are usually met when both the number of slots Q and the num-
ber of poles 2p are evenly divisible by the number of parallel paths 2a. Figure 2.50 illustrates
the winding diagram of a four-pole machine. The number of slots is Q = 16, and the num-
ber of parallel paths is 2a = 4. Hence, the winding meets the above conditions of symmetry.
The coil voltage phasor diagram and the voltage polygon are depicted in Figure 2.51. Since
a = 2, there has to be one phasor a − 1 = 1 of the coil voltage phasor diagram between the
consequent phasors of the polygon. When starting with phasor 1–8, the next phasor in the
voltage polygon is 3–10. In between, there is phasor 17–24, which is of the same phase as
the previous one, and so on. The first circle around the voltage polygon ends up at the point of
phasor 15–22, in the winding diagram, at the commutator segment 9. However, the winding is
not yet closed at this point, but continues for a second, similar revolution formed by phasors
17–24 . . . 31–6. The winding is fully symmetrical, and the coils short-circuited by the brushes
placed on the quadrature axes.
The potential at different positions of the winding is now investigated with respect to an
arbitrary position, for instance a commutator segment 1. In the voltage polygon, this zero po-
tential is indicated by point A of the polygon. At t = 0, the instant depicted by the voltage
polygon, the potential of segment 2 amounts to the amplitude of phasor 1–8, otherwise it is
a projection on the straight line H1–H2. Respectively, the potential at all other points in the
polygon with respect to segment 1 is at every instant the phasor drawn from point A to this
point, projected on the straight line H1–H2. Since for instance phasors 3–10 and 19–26 have
a common point in the voltage polygon, the potential of the respective segments 3 and 11 of
the commutator is always the same, and the potential difference between them is zero at every
instant. Thus, these commutator segments can be connected with conductors. All those points
that correspond to the common points of the voltage polygon can be interconnected. Figure
2.50 also depicts three other balancing connectors. The purpose of these compensating com-
binations is to conduct currents that are created by the structural asymmetries of the machine,
such as the eccentricity of the rotor. Without balancing connectors, the compensating currents,
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140 Design of Rotating Electrical Machines

S N S

2526 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 26

13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13

- + - +
13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12

A
B
C
D
Ia Ia

Figure 2.50 Balancing connectors or equalizer bars (bars A, B, C and D) of a lap winding. For in-
stance, the coil sides 29 and 13 are located in similar magnetic positions if the machine is symmetric.
Hence, the commutator segments 15 and 7 may be connected together with a balancing connector

created for various reasons, would flow through the brushes, thus impeding the commutation.
There is an alternating current flowing in the compensating combinations, the resulting flux
of which tends to compensate the asymmetry of the magnetic flux caused by the eccentricity
of the rotor. From this we may conclude that compensating combinations are not required in
machines with two brushes.
The maximum number of compensating combinations is obtained from the number of
equipotential points. In the winding of Figures 2.50 and 2.51, we could thus assemble eight
combinations; however, usually only a part of the possible combinations is needed to improve
the operation of the machine. According to the illustrations, there are four possible combi-
nations: A, B, C and D. In machines that do not commutate easily, it may prove necessary
to employ all the possible compensating combinations. In small and medium machines, the
compensating combinations are placed behind the commutator. In large machines, ring rails
are placed at one end of the rotor, while the commutator is at the other end.

2.15.4 AC Commutator Windings

The equipotential points A, B, C and D of the winding in Figure 2.51 are connected with rails
at A, B, C and D in Figure 2.50. The voltages between the rails at time t = 0 are illustrated
by the respective voltages in the voltage polygon. When the machine is running, the voltage
polygon is rotating, and therefore the voltages between the rails form a symmetrical four-
phase system. The frequency of the voltages depends on the rotation speed of the machine.
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Windings of Electrical Machines 141

1–8
A 17–24
15–22 3–10
13–20 29–4 A: comm. segments
31–6 1 and 9 19–26
11–18 15–22
27–2 31–6 B
B: comm. segments
3 and 11
9–16 1–8 H1 H2
13–20 5–12
25–32 17–24
29–4 D: comm. segments 21–28
7–14 3–10 7 and 15
D
23–30 19–26
11–18 C: comm. segments 7–14
21–28 5–12
27–2 5 and 13
23–30
9–16 C
25–32

(a) (b)

Figure 2.51 (a) Coil voltage phasor diagram of the winding of Figure 2.50. (b) The coil voltage poly-
gon of the winding of Figure 2.50 and the connection points of the balancing connectors A, B, C and
D. There are two overlapping polygons in the illustrated voltage polygon. Phasor 1–8 is the first phasor
and 3–10 the next phasor of the polygon. Phasor 17–24 is equal to phasor 1–8 because both have their
positions in the middle of poles, but it is skipped when constructing the first polygon. The first polygon
is closed at the tip of phasor 15–22. The winding continues to form another similar polygon using pha-
sors 17–24 . . . 31–6. The winding is completely symmetrical, and its brush-short-circuited coils are on
the quadrature axes. Phasors 3–10 and 19–26 have a common tip point B in the polygons created by the
commutator segments 3 and 11, as shown in Figure 2.50 and in figure (b), and the points can thus be
connected by balancing connectors. The three other balancing connector points are A, C and D

The phase windings of this system, with two parallel paths in each, are connected in a square.
From the same principle, with tappings, we may create other poly-phase systems connected
in a polygon, Figure 2.52.
If zc coils are connected as a closed commutator winding with a parallel path pairs, the
system is transformed with tappings into an m-phase AC system connected in a polygon by
coupling the tappings at the distance of a step

zc
ym = (2.116)
ma

from each other. In a symmetrical poly-phase system, both ym and zc /a are integers. Windings
of this type have been employed for instance in rotary converters, the windings of which
have been connected both to the commutator and to the slip rings. They convert direct current
into alternating current and vice versa. Closed commutator windings cannot be turned into
star-connected windings, and only polygons are allowed.
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142 Design of Rotating Electrical Machines

Figure 2.52 Equipotential points A, B and C of the voltage polygon, which represents 12 coils of the
commutator winding, are connected as a triangle to form a poly-phase system. The respective voltages
are connected via slip rings and brushes to the terminals of the machine

2.15.5 Current Linkage of the Commutator Winding and Armature Reaction

The curved function of the current linkage created by the commutator winding is com-
puted in the way illustrated in Figure 2.9 for a three-phase winding. When defining the slot
current I u , the current of the short-circuited coils can be set to zero. In short-pitched coils,
there may be currents flowing in opposite directions in the different coil sides of a single
slot. If zb is the number of brushes, the armature current I a is divided into brush currents
I = I a /(zb /2). Each brush current in turn is divided into two paths as conductor currents
I s = I/2 = I a /2a, where a is the total number of path pairs of the winding. In a slot, there
are zQ conductors, and thus the sum current of a slot is

z Ia
Iu = z Q Is = , (2.117)
Q 2a

where z is the number of conductors in the complete winding. All the pole pairs of the armature
are alike, and therefore it suffices to investigate only one of them, namely a two-pole winding,
Figure 2.46. The curved function of the magnetic voltage therefore follows the illustration in
Figure 2.53.

S N
Θ
Θma Θma
Θ a =
2

slots 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1

Figure 2.53 Current linkage curve of the winding of Figure 2.46, when the commutation takes place
in the coils in slots 5 and 13
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Windings of Electrical Machines 143

The number of brushes in a commutator machine normally equals the number of poles. The
number of slots between the brushes is
Q
q= . (2.118)
2p
This corresponds to the number of slots per pole and phase of AC windings. The effective
number of slots per pole and phase is always somewhat lower, because a part of the coils is
always short-circuited. The distribution factor for an armature winding kda is obtained from
Equation (2.33). For a fundamental, and m = 1, it is rewritten in the form
2p
kda1 = pπ . (2.119)
Q sin
Q
Armature coils are often short pitched, and the pitch factor kpa is thus obtained from Equa-
tion (2.32). The fundamental winding factor of a commutator winding is thus
2
kwa1 = kda1 kpa1 ≈ . (2.120)
π
When the number of slots per pole increases, kda1 approaches the limit 2/π. This is the ratio
of the voltage circle (polygon) diameter to half of the circle perimeter. In ordinary machines,
the ratio of short pitching is W/τ p > 0.8, and therefore kpal > 0.95. As a result, the approxi-
mate value kwa1 = 2/π is an adequate starting point in the initial manual computation. More
thorough investigations have to be based on an analysis of the curved function of the current
linkage. In that case, the winding has to be observed in different positions of the brushes.
Figure 2.45 shows that at the right side of the quadrature axis q, the direction of each slot
current is towards the observer, and on the left, away from the observer. In other words, the
rotor becomes an electromagnet with its north pole at the bottom and its south pole at the top.
The pole pair current linkage of the rotor is
Q z Ia z
Θma = q Iu = = Ia = N a Ia . (2.121)
2 p Q 2a 4ap
The term
z
Na = (2.122)
4ap
in the equation is the number of coil turns per pole pair in a commutator armature in one
parallel path, that is turns connected in series, because z/2 is the number of all armature turns;
z/2(2a) is the number of turns in one parallel path, in other words connected in series, and
finally z/2(2a)p is the number of turns per pole pair. The current linkage calculated according
to Equation (2.121) is slightly higher than in reality, because the number of slots per pole and
phase includes also the slots with short-circuited coil sides. In calculation, we may employ
the linear current density
Q Iu 2p N a Ia
Aa = = N a Ia = . (2.123)
πD πD τp
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144 Design of Rotating Electrical Machines

The current linkage of the linear current density is divided into magnetic voltages of the air
gaps, the peak value of which is

τp
2
1 1 z Ia N a Ia Θma
Θ̂δa = Aa dx = Aa τp = = = , (2.124)
2 2 2 p 2a 2 2
0
1 1 z Ia 1 Θma
Θδa = Θma /2 = Aa τp = = N a Ia = = Θδa . (2.125)
2 2 2 p 2a 2 2

In the diagram, the peak value Θ̂δa is located at the brushes (in the middle of the poles), the
value varying linearly between the brushes, as illustrated with the dashed line in Figure 2.53.
Θ̂δa is the armature reaction acting along the quadrature axis under one tip of a pole shoe,
and it is the current linkage to be compensated. The armature current linkage also creates
commutation problems, which means that the brushes have to be shifted from the q-axis by
an angle ε to a new position as shown in Figure 2.54.
This figure also gives the positive directions of the current I and the respective current
linkage. The current linkage can be divided into two components:

Θma
Θmd = sin ε = Θδa sin ε, (2.126)
2
Θma
Θmq = cos ε = Θδa cos ε. (2.127)
2

The former is called a direct component and the latter a quadrature component. The direct
component magnetizes the machine either parallel or in the opposite direction to the actual
field winding of the main poles of the machine. There is a demagnetizing effect if the brushes

ε
Θ md
Θma q

Θ mq

Figure 2.54 Current linkage of a commutator armature and its components. To ensure better commu-
tation, the brushes are not placed on the q-axis
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Windings of Electrical Machines 145

are shifted in the direction of rotation in generator mode, or in the opposite direction of rota-
tion in motoring operation; the magnetizing effect, on the contrary, is in generating operation
opposite the direction of rotation, and in motoring mode in the direction of rotation. The
quadrature component distorts the magnetic field of the main poles, but neither magnetizes
nor demagnetizes it. This is not a phenomenon restricted to commutator machines – the reac-
tion is in fact present in all rotating machines.

2.16 Compensating Windings and Commutating Poles

As stated above, the armature current linkage (also called armature reaction) has some neg-
ative influence on DC machine operation. The armature reaction may create commutation
problems and must, therefore, be compensated. There are different methods to mitigate such
armature reaction problems: (1) shift the brushes from their geometrical neutral axis to the
new magnetically neutral axis; (2) increase the field current to compensate for the main flux
decrease caused by the armature reaction; (3) build commutating poles; and (4) build com-
pensating winding.
The purpose of compensating windings in DC machines is to compensate for harmful flux
components created by armature windings. Flux components are harmful, because they create
an unfavourable air-gap flux distribution in DC machines. The dimensioning of compensating
windings is based on the current linkage that has to be compensated by the compensating
winding. The conductors of a compensating winding have therefore to be placed close to the
surface of the armature, and the current flowing in them has to be opposite to the armature
current. In DC machines, the compensating winding is inserted in the slots of the pole shoes.
The compensating effect has to be created in the section αi τp of the pole pitch, as illustrated
in Figure 2.55. If z is the total number of conductors in the armature winding, and the current
flowing in them is I s , we obtain an armature linear current density

z Is
Aa = . (2.128)
Dπ

S i
ia f
commutating pole

commutating
pole T Nk- turns
armature
NS ia S N ia N S compensating winding

ia ia
compensating
winding ia Na- turns per
N if pole pair
field
ατi τ p
armature winding
winding τp
S

(a) (b)

Figure 2.55 (a) Location of the compensating windings and the commutating poles. (b) Definition of
the current linkage of a compensating winding
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146 Design of Rotating Electrical Machines

The total current linkage Θ  of the armature reaction and the compensating winding has
to be zero in the integration path. It is possible to calculate the required compensating current
linkage Θ k by evaluating the corresponding current linkage of the armature to be compen-
sated. The current linkage of the armature Θ a occurring under the compensating winding at
the distance α i τ p /2, as shown in Figure 2.55, is

α τ  αi τp αi τp Aa
i p
Θa = z Is = . (2.129)
2 2Dπ 2

Since there is an armature current I a flowing in the compensating winding, we obtain the
current linkage of the compensating winding accordingly

Θk = −Nk Ia , (2.130)

where N k is the number of turns of the compensating winding. Since the current linkage of the
armature winding has to be compensated in the integration path, the common current linkage
is written as

αi τp Aa
Θ = Θk + Θa = −Nk Ia + = 0, (2.131)
2

where

1 1 z Ia 1
Θa = αi Aa τp = αi = N a Ia . (2.132)
2 2 2 p 2a 2

Now, we obtain the number of turns of the compensating winding to be inserted in the
pole shoes producing demagnetizing magnetic flux in the q-axis compensating the armature
reaction flux:

αi τp Aa
Nk = . (2.133)
2Ia

Since N k has to be an integer, Equation (2.133) is only approximately feasible. To avoid large
pulsating flux components and noise, the slot pitch of the compensating winding is set to
diverge by 10–15% from the slot pitch of the armature.
Since a compensating winding cannot completely cover the surface of the armature, com-
mutating poles are also utilized to compensate for the armature reaction although their func-
tion is just to improve commutation. These commutating poles are located between the main
magnetizing poles of the machine. There is an armature current flowing in the commutating
poles. The number of turns on the poles is selected such that the effect of the compensat-
ing winding is strengthened appropriately. In small machines, commutating poles alone are
used to compensate for the armature reaction. If commutation problems still occur despite a
compensating winding and commutating poles, the position of the brush rocker of the DC
machine can be adjusted so that the brushes are placed on the real magnetic quadrature axis
of the machine.
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Windings of Electrical Machines 147

In principle, the dimensioning of a commutating pole winding is straightforward. Since

the compensating winding covers the section αi τp of the pole pitch and includes N k turns
that carry the armature current I a , the commutating pole winding should compensate for the
remaining current linkage of the armature (1 − αi ) τp . The number of turns in the commutating
pole N cp should be

1 − αi
Ncp = Nk . (2.134)
αi

When the same armature current I a flows both in the compensating winding and in the
commutating pole, the armature reaction will be fully compensated.
If there is no compensation winding, the commutating pole winding must be dimensioned
and the brushes positioned so that the flux in a commutating armature coil is at its maximum,
and no voltage is induced in the coil.

2.17 Rotor Windings of Asynchronous Machines

The simplest rotor of an induction machine is a solid iron body, turned and milled to the cor-
rect shape. In general, a solid rotor is applicable to high-speed machines and in certain cases
also to normal-speed drive. However, the computation of the electromagnetic characteristics
of a steel rotor is a demanding task, and it is not discussed here. A solid rotor is character-
ized by a high resistance and a high leakage inductance of the rotor. The phase angle of the
apparent power created by a waveform penetrating a linear material is 45◦ , but the saturation
of the steel rotor reduces the phase angle. A typical value for the phase angle of a solid rotor
varies between 30◦ and 45◦ , depending on the saturation. The characteristics of a solid-rotor
machine are discussed for instance in Pyrhönen (1991), Huppunen (2004) and Aho (2007).
The performance characteristics of a solid rotor can be improved by slotting the surface of the
rotor, Figure 2.56. Axial slots are used to control the flow of eddy currents in a direction that
is favourable to torque production. Radial slots increase the length of the paths of the eddy
currents created by certain high-frequency phenomena. This way, eddy currents are damped
and the efficiency of the machine is improved. The structure of the rotor is of great signifi-
cance in torque production, Figure 2.57. An advantage of common cage winding rotors is that
they produce the highest torque with small values of slip, whereas solid rotors yield a good
starting torque.
In small machines, a Ferraris rotor can be employed. It is constructed from a laminated
steel core covered with a thin layer of copper. The copper covering provides a suitable path
for eddy currents induced in it. The copper covering takes up a certain amount of space in
the air gap, the electric value of which increases notably because of the covering, since the
relative permeability of copper is µr = 0.999 992 6. As a diamagnetic material, copper is thus
even a somewhat weaker path for the magnetic flux than air.
The rotor of an induction machine can be produced as a normal slot winding by following
the principles discussed in the previous sections. A wound rotor has to be equipped with the
same number of pole pairs as the stator, and therefore it is not in practice suitable for machines
permitting a varying number of poles. The phase number of the rotor may differ from the phase
number of the stator. For instance, a two-phase rotor can be employed in slip-ring machines
with a three-phase stator. The rotor winding is connected to an external circuit via slip rings.
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148 Design of Rotating Electrical Machines

axial slots

radial slots

(a) (b) (c)

Figure 2.56 Different solid rotors. (a) A solid rotor with axial and radial slots (in this model, short-
circuit rings are required). They can be constructed either by leaving the part of the rotor that extends
from the stator without slots, or by equipping it with aluminium or copper rings. (b) A rotor equipped
with short-circuit rings in addition to slots. (c) A slotted and cage-wound rotor. A completely smooth
rotor can also be employed

The most common short-circuit winding is the cage winding, Figure 2.58. The rotor is
produced from electric steel sheets and provided with slots containing noninsulated bars, the
ends of which are connected either by welding or brazing to the end rings, that is to the short-
circuit rings. The short-circuit rings are often equipped with fins that together act as a cooling
fan as the rotor rotates. The cage winding of small machines is produced from pure aluminium
by simultaneously pressure casting the short-circuit rings, the cooling ribs and the bars of the
rotor.
Figure 2.59 illustrates a full-pitch winding of a two-pole machine observed from the rotor
end. Each coil of the rotor also constitutes a complete phase coil, since the number of slots in

T (a)
(d)

(c)

(b)

0
0 W

Figure 2.57 Torque curves of different induction rotors as a function of mechanical angular speed
Ω: (a) a normal double-cage winding rotor, (b) a smooth solid-rotor without short-circuit rings, (c) a
smooth solid rotor equipped with copper short-circuit rings, (d) an axially and radially slitted solid rotor
equipped with copper short-circuit rings
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Windings of Electrical Machines 149

bars

short-circuit rings

Figure 2.58 Simple cage winding. Cooling fans are not illustrated. Qr = 24

the rotor is Qr = 6. The star point 0 forms, based on symmetry, a neutral point. If there is only
one turn in each coil, the coils can be connected at this point. The magnetic voltage created
by the rotor depends only on the current flowing in the slot, and therefore the connection of
the windings at the star point is of no influence. However, the connection of the star point at
one end of the rotor turns the winding into a six-phase star connection with one bar, that is
half a turn, in each phase. The six-phase winding is then short-circuited also at the other end.
Since the shaft of the machine also takes up some room, the star point has to be created with a
short-circuit ring as illustrated in Figure 2.58. We can now see in Figure 2.59 a star-connected,

2 1

3 6

Nr = 1

4 5

Figure 2.59 Three-phase winding of a two-pole rotor. The number of turns in the phase coil is
N r = 1. If the winding is connected in star at point 0 and short-circuited at the other end, a six-phase,
short-circuited winding is created, for which the number of turns is Nr = 1/2, kwr = 1
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150 Design of Rotating Electrical Machines

short-circuited poly-phase winding, for which the number of phase coils is in a two-pole case
equal to the number of bars in the rotor: mr = Qr .
In machine design, it is often assumed that analysis of the fundamental ν = 1 alone gives
an adequate description of the characteristics of the machine. However, this is valid for cage
windings only if we consider also the conditions related to the number of bars. A cage winding
acts differently with respect to different harmonics ν. Therefore, a cage winding has to be
analysed with respect to the general harmonic ν. This is discussed in more detail in Chapter 7,
in which different types of machines are investigated separately.

2.18 Damper Windings

The damper windings of synchronous machines are usually short-circuit windings, which in
nonsalient-pole machines are contained in the same slots with magnetizing windings, and in
salient-pole machines in particular, in the slots at the surfaces of pole shoes. There are no
bars in the damper windings on the quadrature axes of salient-pole machines, and only the
short-circuit rings encircle the machine. The resistances and inductances of the damper wind-
ing of the rotor are thus quite different in the d- and q-directions. In a salient-pole machine
constructed of solid steel, the material of the rotor core itself may suffice as a damper wind-
ing. In that case, asynchronous operation resembles the operation of a solid-rotor induction
machine. Figure 2.60 illustrates the damper winding of a salient-pole synchronous machine.

damper bar
copper plate

q-axis

connector

copper plate d-axis

Figure 2.60 Structure of the damper winding of a six-pole salient-pole synchronous machine. The
copper end plates are connected with a suitable copper connector to form a ring for the damper currents.
Sometimes real rings also connect the damper bars
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Windings of Electrical Machines 151

Damper windings improve the performance characteristics of synchronous machines es-

pecially during transients. As in asynchronous machines, thanks to damper windings, syn-
chronous machines can in principle be started direct-on-line. Also a stationary asynchronous
drive is in some cases a possible choice. Especially in single-phase synchronous machines
and in the unbalanced load situations of three-phase machines, the function of damper wind-
ings is to damp the counter-rotating fields of the air gap which otherwise cause great losses.
In particular, the function of damper windings is to damp the fluctuation of the rotation
speed of a synchronous machine when rotating loads with pulsating torques, such as piston
compressors.
The effective mechanisms of damper windings are relatively complicated and diverse, and
therefore their mathematically accurate design is difficult. That is why damper windings are
usually constructed by drawing upon empirical knowledge. However, the inductances and
resistances of the selected winding can usually be evaluated with normal methods to define
the time constants of the winding.
When the damper windings of salient-pole machines are placed in the slots, the slot pitch
has to be selected to diverge by 10–15% from the slot pitch of the stator to avoid pulsation of
the flux and noise. If the slots are skewed (usually by the amount of a single stator slot pitch),
the same slot pitch can be selected both for the stator and the rotor. Damper winding comes
into effect only when the bars of the winding are connected with short-circuit rings. If the
pole shoes are solid, they may, similar to the solid rotor of a nonsalient-pole machine, act as a
damper winding as long as the ends of the pole shoes are connected with durable short-circuit
rings. In nonsalient-pole machines, an individual damper winding is seldom used; however,
conductors may be mounted under slot wedges, or the slot wedges themselves are used as the
bars of the damper winding.
In synchronous generators, the function of damper windings is for instance to damp
counter-rotating fields. To minimize losses, the resistance is kept to a minimum in damper
windings. The cross-sectional area of the damper bars is selected to be 20–30% of the cross-
sectional bar area of the armature winding. The windings are made of copper. In single-phase
generators, damper bar cross-sectional areas larger than 30% of the stator copper area are
employed. The frequency of the voltages induced by counter-rotating fields to the damper
bars is doubled when compared with the network frequency. Therefore, it has to be con-
sidered whether special actions are required with respect to the skin effect of the damper
windings (e.g. utilization of Roebel bars (braided conductors) to avoid the skin effect). The
cross-sectional area of the short-circuit rings is selected to be approximately 30–50% of the
cross-sectional area of the damper bars per pole.
The damper bars have to damp the fluctuations of the rotation speed caused by the pulsating
torque loads. They also have to guarantee a good starting torque when the machine is start-
ing as an asynchronous machine. Thus, brass bars or small-diameter copper damper bars are
employed to increase the rotor resistance. The cross-sectional area of copper bars is typically
only 10% of the cross-sectional area of the copper of the armature winding.
In PMSMs, in axial flux machines in particular, the damper winding may be easily con-
structed by placing a suitable copper or aluminium plate on the surface of the rotor, on top
of the magnets. However, achieving a total conducting surface in the range of 20–30% of the
stator copper surface may be somewhat difficult because the plate thickness easily increases
to become too large and limits the air-gap flux density created by the magnets.
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152 Design of Rotating Electrical Machines

Bibliography
Aho, T. (2007) Electromagnetic Design of a Solid Steel Rotor Motor for Demanding Operational Environments,
Dissertation. Acta Universitatis Lappeenrantaensis 134, Lappeenranta University of Technology. (https://
oa.doria.fi/)
Heikkilä, T. (2002) Permanent Magnet Synchronous Motor for Industrial Inverter Applications – Analysis and
Design, Dissertation. Acta Universitatis Lappeenrantaensis 134, Lappeenranta University of Technology. (https://
oa.doria.fi/)
Hindmarsh, J. (1988) Electrical Machines and Drives. Worked Examples, 2nd edn, Pergamon Press, Oxford.
Huppunen, J. (2004) High-Speed Solid-Rotor Induction Machine – Electromagnetic Calculation and Design, Disser-
tation. Acta Universitatis Lappeenrantaensis 197, Lappeenranta University of Technology. (https://oa.doria.fi/)
IEC 60050-411 (1996) International Electrotechnical Vocabulary (IEC). Rotating Machines. International Elec-
trotechnical Commission, Geneva.
Pyrhönen, J. (1991) The High-Speed Induction Motor: Calculating the Effects of Solid-Rotor Material on Machine
Characteristics, Dissertation, Acta Polytechnica Scandinavica, Electrical Engineering Series 68, Helsinki Uni-
versity of Technology (https://oa.doria.fi/)
Richter, R. (1954) Electrical Machines: Induction Machines (Elektrische Maschinen: Die Induktionsmaschinen),
Vol. IV, 2nd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1963) Electrical Machines: Synchronous Machines and Rotary Converters (Elektrische Maschinen: Syn-
chronmaschinen und Einankerumformer), Vol. II, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1967) Electrical Machines: General Calculation Elements. DC Machines (Elektrische Maschinen: Allge-
meine Berechnungselemente. Die Gleichstrommaschinen), Vol. I, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Salminen, P. (2004) Fractional Slot Permanent Magnet Synchronous Motors for Low Speed Applications, Disserta-
tion. Acta Universitatis Lappeenrantaensis 198, Lappeenranta University of Technology (https://oa.doria.fi).
Vogt, K. (1996) Design of Electrical Machines (Berechnung elektrischer Maschinen), Wiley-VCH Verlag GmbH,
Weinheim.
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3
Design of Magnetic Circuits

The magnetic circuit of an electrical machine generally consists of ferromagnetic materi-

als and air gaps. In an electrical machine, all the windings and possible permanent magnets
participate in the magnetizing of the machine. It must also be noted that in a multiple-pole
system, the magnetic circuit has several magnetic paths. Normally, an electrical machine has
as many magnetic paths as it has poles. In a two-pole system, the magnetic circuit is symmet-
rically divided into two paths. A possible magnetic asymmetry occurring in the geometry of
the magnetic circuit also influences the magnetic state of the machine. In the literature, a mag-
netic circuit belonging to one pole is usually analysed in the design of a complete magnetic
circuit. This method is employed here also. In other words, according to Equation (2.15), the
amplitude Θ̂s1 of the fundamental component of the current linkage is acting on half of the
magnetic path. A complete magnetic path requires two amplitudes; see Figure 2.9.
The design of a magnetic circuit is based on the analysis of the magnetic flux density B
and the magnetic field strength H in different parts of the machine. The design of a magnetic
circuit is governed by Ampère’s law. First, we select a suitable air-gap flux density Bδ to the
machine. Next, we calculate the corresponding field strength values H in different parts of the
machine. The mmf F m of the circuit equals the current linkage Θ of the circuit


Fm = H · dl = i = Θ. (3.1)

In a running electrical machine, the sum current linkage is produced by all the currents
and possible permanent magnet materials. In the basic design of a magnetic circuit, only the
winding, the main task of which is to magnetize the machine, is considered the source of
magnetizing current linkage; that is, the machine is observed when running at no load. In DC
machines and synchronous machines, the machine is magnetized by magnetizing windings
(field windings) or permanent magnets, and the armature winding is kept currentless. In a
synchronous machine, the armature winding may nevertheless take part in the determination
of the magnetic state of the machine also when the machine is running at no load, if the air-gap
flux created by the rotor magnetization does not induce a stator emf exactly equal to the stator
voltage. The influence of an armature winding, that is the armature reaction, is investigated
later in design, when the performance characteristics of the machine are being calculated. In

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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154 Design of Rotating Electrical Machines

an induction machine, the magnetizing winding and the armature winding are not separated,
and therefore the magnetizing of the machine is carried out by the stator winding. However,
according to the IEC, the induction machine stator is not regarded as an armature even though
it is similar to a synchronous machine armature.
Our objective now is to solve the magnetic potential differences


Um, i = Hi · dli (3.2)

 of the magnetic circuit and the required current linkage Θ corresponding

in different parts
to their sum Um,i . In traditional machines, this is a fairly straightforward task, since the
main parameters of the magnetic circuit have in principle been set quite early in the machine
design and the need for magnetizing current does not necessarily alter the dimensions of the
magnetic circuit.
In magnetic circuits with permanent magnets instead, the situation is somewhat more com-
plicated especially in machines where magnets are embedded inside the iron core. In that case,
the leakage flux of permanent magnets is high and the leakage flux saturates the iron bridges,
which enclose the magnets inside the iron core. The division of the flux created by permanent
magnets into the main flux and the leakage flux is difficult to carry out analytically. In practice,
the magnetic field has to be solved numerically using a finite element program for determining
the magnetic fields. To increase the air-gap flux density of a permanent magnet machine, we
can embed the magnets in V-form and have magnets wider than the pole pitch of the machine.
This way, it is possible to increase the air-gap flux density of a permanent magnet machine
even higher than the remanence flux density of the permanent magnet material.
In electrical machines, the term ‘magnetic circuit’ refers to those sections of the machine
through which the main flux of the machine is flowing. In stator and rotor yokes, the main flux
splits up into two paths. Now, an electrical machine actually includes as many magnetic paths
as there are magnetic poles, that is 2p pieces. Figure 3.1 illustrates, in addition to the cross-
section of a magnetic circuit of a six-pole induction machine and a four-pole synchronous
reluctance machine, a single magnetic path of the machine defined by the curves 1–2–3–4–1.
The same figure also depicts the direct (d) and quadrature (q) axes of the magnetic circuit.
Since we now have a rotating-field machine, the flux density wave created by the poly-phase
winding of the stator rotates along the inner surface of the stator, and the depicted d- and
q-axes rotate fixed to the peak value of the magnetic flux.
Rotor saliency makes the machine’s magnetic circuit unsymmetrical. Differences in reluc-
tance, and correspondingly in stator magnetizing inductance, may be found depending on the
rotor position with respect to the stator. In traditional machines, the d-axis is usually placed
so that when the magnetic flux joins the rotor d-axis, the minimum reluctance for the whole
magnetic system is found. Vice versa, the q-axis normally represents the maximum reluctance
of the magnetic circuit. In such a machine, the stator d-axis inductance is larger than the stator
q-axis inductance Ld > Lq . In synchronous machines, the field windings are wound around the
rotor d-axes. In permanent magnet machines, however, the permanent magnet material itself
belongs to the d-axis magnetic circuit, which makes the d-axis reluctance high. Depending on
the rotor construction, in permanent magnet machines, we may have ‘inverse saliency’, where
the d-axis reluctance is higher than the q-axis reluctance. Correspondingly, Ld < Lq .
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Design of Magnetic Circuits 155

d d
q 2 2
q

d 3

1 3 1
4 d
4

D ri hyr hdr D ri

D ryi δ δ
hys hys Dr
Dr
Ds hds Ds hds

Dsyi D syi

Dse Dse

(a) (b)

Figure 3.1 Main dimensions of the cross-section of an electrical machine, and the instantaneous posi-
tions of the magnetic axes and the magnetic circuit of (a) a six-pole poly-phase induction machine and
(b) a four-pole synchronous reluctance machine. The magnetic circuits can be considered to rotate with
the stator flux of the machine. The d-axis of the rotor of a synchronous machine remains stationary at
every instant, but in an induction machine, the d-axis is only virtual and turns with respect to the rotor
at the speed of slip

In some cases, for instance for control purposes, the d- and q-axes may also be defined for
magnetically symmetrical induction machines. From the machine design point of view, the
division to d- and q-axes in symmetrical machines is not as important as in unsymmetrical
machines.
In nonsalient synchronous machines, the division to d- and q-axes is natural, since despite
the fact that the reluctances and hence also the inductances are about equal, the rotor is un-
symmetrical because of the field winding wound around the rotor d-axis.
If the main flux of the machine is assumed to flow along the d-axis, the magnetic circuit
of the figure comprises half of the main flux, created by the current penetrating the magnetic
circuit in the area in question. When the machine is running under load, the magnetizing
current of an induction machine is the sum of the stator and rotor currents. When comput-
ing this sum, both the windings of the stator and the rotor have to be taken into account so
that in each conductor penetrating the area S (here the slots of the stator and the rotor), there
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156 Design of Rotating Electrical Machines

flows a current that is measurable at the stator and at the rotor. We now obtain according to
Ampère’s law a magnetizing resultant current linkage Θ, which, as a result of the occurrence
of flux, is divided into magnetic voltages U m,i in the different sections of the magnetic circuit.
Normally, a majority, 60–95% of the sum of the magnetic voltages, consists usually of the
magnetic voltages of the air gaps. In the design of a magnetic circuit, we start by magnetiz-
ing the machine with a single winding, for instance a magnetizing winding. Later, when the
performance characteristics of the machine are analysed, other windings and their effects are
considered. In the rotor of a synchronous reluctance machine, there is no winding, and thus
the torque production is based only on the saliency effects. Saliency is created in the depicted
machine by cutting suitable sections from the rotor plate.
A corresponding illustration of the magnetic circuit and the main dimensions of a six-pole
DC machine and an eight-pole salient-pole synchronous machine is given in Figure 3.2. A

d d
q
q 2 2

d
3
d 3

1
1
4
4

D ri hyr hdr D ri h yr h dr

D ryi δ D ryi
δ
h ys Ds hds h ys Ds hds
D syi D syi
D se D se

(a) (b)

Figure 3.2 Main dimensions of the cross-sections of a six-pole DC machine (or an outer pole syn-
chronous machine) and an eight-pole salient-pole synchronous machine, and the instantaneous positions
of one of the magnetic axes and the magnetic circuit. In a DC machine or a synchronous machine, the
position of the magnetic axes can be considered more easily than with an asynchronous machine, since
the magnetic axes d and q are defined by the position of the rotor. DC machines are usually constructed
as external (inward-projecting) pole machines, and the poles of the stator chiefly define the position of
the magnetic axes of the machine. The field windings of both machine types are placed around the poles
lying on the d-axis
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Design of Magnetic Circuits 157

synchronous machine can operate magnetized either with the direct current in the field wind-
ing or with permanent magnets, or completely without DC magnetizing as a synchronous
reluctance machine. However, in the rotor circuit of the reluctance machine, special attention
has to be paid to maximizing the ratio of the reluctances of q- and d-axes to reach maxi-
mum torque. Here, the torque is completely based on the difference of inductances between
the direct and quadrature axes. When the ratio of inductances Ld /Lq is about 7–10–16, ap-
proximately the same machine constants can be applied with a reluctance machine as with
induction motors.
Doubly salient reluctance machines (switched reluctance, SR machines) differ both struc-
turally and by their performance characteristics from traditional electrical machines. However,
there are also some similarities. Figure 3.3 illustrates two doubly salient reluctance machines
that differ from each other by their ratios of poles (8/6 and 6/4); in these machines, both the
stator and the rotor have salient poles. A crucial difference when compared with traditional
machines is that the stator and rotor have different numbers of magnetizing poles. Such a ma-
chine cannot operate without power electronics or other switches, and therefore it has to be
designed in accordance with the accompanying electronics.

A
A
B' D B' C'

C C'

B C B
D'
A'
A'

hdr δ hys

Ds Dr hds
Dsyi
Dse

(a) (b)

Figure 3.3 Basic types of an SR machine. (a) In an 8/6 machine, there are eight stator poles and six
rotor poles. Correspondingly, there are six stator poles and four rotor poles in a 6/4 motor (b). The pole
numbers of the stator and the rotor always differ from each other. The rotor of both machines turns
clockwise when the poles A and A are magnetized. The illustration of an eight-pole machine shows the
path of the main flux when the poles A and A are being magnetized
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158 Design of Rotating Electrical Machines

The definition of the current linkage is essential for the design of the magnetic circuit to
create the desired flux density and the respective magnetizing current. The current linkage
per pole pair is solved by applying Equation (1.10) and by calculating the line integral of the
field strength H along a suitable integration path, for instance along the route 1–2–3–4–1 of
Figure 3.2:

 
Fm = Ûm,tot = H · dl = J · dS = I = Θ̂tot . (3.3)
l S S

In rotating-field machines, the peak value of the magnetic voltage Ûm,tot is usually cal-
culated by following the flux line at the peak value of the air-gap flux density around the
magnetic circuit. l is the unit vector parallel to the integration path, S is the unit vector of the
surface of the cross-section of the electrical machine (in practice, e.g. either the teeth area of
an induction machine or the teeth area of the stator of a synchronous machine, and the pole
bodies of the rotor are observed), and finally, J is the density of the current penetrating the
magnetic circuit. The task is simplified by calculating the sum of all the currents I penetrating
the magnetic circuit. The sum of all currents is called current linkage and denoted Θ̂  tot . Equa-
tion (3.3) describes how the current linkage of the machine has to equal the mmf l H · dl of
the machine.
When computing the peak magnetic voltage Ûm,tot over a single magnetic circuit of the
machine, the task can be divided so that each section of the magnetic circuit is analysed for
instance at the peak value of the flux density. Now, the total magnetic voltage over a complete
pole pair is written as

 
Ûm,tot = Hi · dli = Ûm,i . (3.4)
i i

To be able to calculate the current linkage required by the iron parts of the magnetic circuit,
the magnetizing curve of the material in question has to be known. The magnetizing curve
illustrates the flux density reached in the material as a function of the magnetic field strength
B = f (H). First, the magnetic flux density Bi in each section of the magnetic circuit of the
machine is calculated with the selected air-gap flux density. Next, the field strength Hi is
checked from the BH curve of the material in question. Finally, in simple cases, the result
is multiplied by the length of the section parallel to the magnetic path li , which yields the
magnetic voltage of the section in question Ûm,i = li Hi . In the appendices, BH curves are
given for some typical electric sheets measured with DC magnetization.
Since Equation (2.15) gives the height of the amplitude of the current linkage wave of a
rotating-field winding, and such an amplitude magnetizes half of a single magnetic circuit,
we usually treat only half of a single magnetic circuit in the computation of magnetic volt-
ages. For instance, the stator of an asynchronous machine has to produce the amplitude Θ̂s1
of the fundamental current linkage. Correspondingly, on the rotor pole of a nonsalient-pole
synchronous machine, there has to be a current producing a similar current linkage

Θ̂s1 = Ûm,δe + Ûm,ds + Ûm,dr + 1/2Ûm,ys + 1/2Ûm,yr . (3.5a)

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Design of Magnetic Circuits 159

Ûm,δe denotes the magnetic voltage of a single air gap, Ûm,d the magnetic voltages of the
teeth, and Ûm,ys + Ûm,yr the magnetic voltages of the stator and rotor yokes. The subscripts s
and r denote the stator and the rotor. Equation (3.5a) represents only one pole of the magnetic
circuit. Two current linkage amplitudes Ûm,tot = 2Θ̂s1 are thus acting on the total magnetic
path.
In an internal salient-pole machine (e.g. an ordinary synchronous machine), the correlation
of the magnetic voltage and a single pole is

Θ̂pr = Ûm,δe + Ûm,ds + Ûm,pr + 1/2Ûm,ys + 1/2Ûm,yr . (3.5b)

Ûm,pr is the magnetic voltage of the salient pole of the rotor. In an external salient-pole ma-
chine (e.g. an ordinary DC machine or an external pole synchronous machine) the current
linkage of a single pole can be written correspondingly as

Θ̂ps = Ûm,δe + Ûm,ps + Ûm,dr + 1/2Ûm,ys + 1/2Ûm,yr . (3.5c)

The magnetizing of doubly salient reluctance machines (SR machines) depends on the con-
stantly changing shape of the magnetic circuit in question. The torque calculation of SR ma-
chines is carried out for instance based on the principle of virtual work. The machine is always
seeking the maximum inductance of the magnetic circuit, which is reached when the poles of
the rotor have turned to the position of the magnetic poles of the stator.

3.1 Air Gap and its Magnetic Voltage

The air gap of an electrical machine has a significant influence on the mmf of the magnetic
circuit. Nonsalient-pole machines and salient-pole machines have different types of air gaps
that greatly influence machine performance.

3.1.1 Air Gap and Carter Factor

To be able to calculate the magnetic voltage manually over an air gap, the geometry of the air
gap has to be simplified. Often in an electrical machine, the surfaces of both the stator and the
rotor are split with slots. The flux density always decreases at the slot opening (Figure 3.4),
and therefore it is not easy to define the average flux density of the slot pitch between the
stator and the rotor.
However, in 1901 F.W. Carter provided a solution to the problem of manual calculation
(Carter, 1901). On average, according to Carter’s principle, the air gap seems to be longer
than its physical measure. The length of the physical air gap δ increases with the Carter factor
kC . The first correction is carried out by assuming the rotor to be smooth. We obtain

δes = kCs δ. (3.6)

The Carter factor kCs is based on the dimensions in Figure 3.5. When determining the
Carter factor, the real flux density curve is replaced with a rectangular function so that the
flux remains constant under the teeth and is zero at the slot opening; in other words, the shaded
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160 Design of Rotating Electrical Machines

B
δ

τu τu
slot pitch
(a) (b)

Figure 3.4 (a) Flux diagram under a stator slot along one slot pitch, and (b) the behaviour of the air-
gap flux density Bδ along a slot pitch. At the slot opening, there is a local minimum of flux density. The
flux density on the right side of the slot is slightly higher than on the left side, since a small current is
flowing in the slot towards the observer

B(α)
be
B av

S1 S1

1.0

2B0 /Bav

B av
B max
B av kC =
Bav

S2
Bmin /Bav
α
0 2
δ Qs
0 0.5
–0.5
b1

τu

Figure 3.5 Distribution of air-gap flux density Bδ (α) in a distance of one slot pitch τ u . α is the angle
revolving around the periphery of the machine. be is the equivalent slot opening
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Design of Magnetic Circuits 161

areas S1 + S1 in Figure 3.5 are equal to S2 . The equivalent slot opening be , in which the flux
density is zero, is

be = κb1 , (3.7a)
where
   b1

2
2 b1 2δ b1  δ
κ= arctan − ln 1 + ≈ . (3.7b)
π 2δ b1 2δ b1
5+
δ
The Carter factor is
τu τu
kC = = . (3.8)
τu − be τu − κb1
The Carter factor is also the ratio of the maximum flux density Bmax to the average flux
density Bav
Bmax
kC = . (3.9)
Bav
The variation of the flux density assuming no eddy currents damping the flux variation is

B0 (Bmax − Bmin ) 1 + u 2 − 2u
β= = = , (3.10a)
Bmax 2Bmax 2(1 + u 2 )
Bmin 2u
= , (3.10b)
Bmax 1 + u2


2
b1 b1
u= + 1+ . (3.10c)
2δ 2δ

When both the stator and rotor surfaces are provided with slots, we calculate kCs first by
assuming the rotor surface to be smooth. The calculations are repeated by applying the cal-
culated air gap δ es and the slot pitch of the rotor τ r , and by assuming the stator surface to be
smooth. We then obtain kCr . Finally, the total factor is

kC,tot ≈ kCs · kCr , (3.11)

which gives us the equivalent air gap δ e

δe ≈ kC,tot δ ≈ kCr δes . (3.12)

The influence of slots in the average permeance of the air gap is taken into account by
replacing the real air gap by a longer equivalent air gap δ e . The result obtained by applying
the above equations is not quite accurate, yet usually sufficient in practice. The most accurate
result is obtained by solving the field diagram of the air gap with the finite element method.
In this method, a dense element network is employed, and an accurate field solution is found
as illustrated in Figure 3.4. If the rotor surface lets eddy currents run, the slot-opening-caused
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162 Design of Rotating Electrical Machines

flux density dips are damped by the values suggested by the Carter factor. In such a case, eddy
currents may create remarkable amounts of losses on the rotor surfaces.

Example 3.1: An induction motor has an air gap δ = 0.8 mm. The stator slot opening
is b1 = 3 mm, the rotor slots are closed and the stator slot pitch is 10 mm. The rotor
magnetic circuit is manufactured from high-quality electrical steel with low eddy current
losses. Calculate the Carter-factor-corrected air gap of the machine. How deep is the flux
density dip at a slot opening if the rotor eddy currents do not affect the dip (note that the
possible squirrel cage is designed so that the slot harmonic may not create large opposing
eddy currents)? How much three-phase stator current is needed to magnetize the air gap to
0.9 T fundamental peak flux density? The number of stator turns in series is N s = 100, the
number of pole pairs is p = 2, and the number of slots per pole and phase is q = 3. The
winding is a full-pitch one.
Solution:

b1 /δ 3/0.8
κ≈ = = 0.429,
5 + b1 /δ 5 + 3/0.8
be = κb1 = 0.429 · 3 = 1.29,
τu 10
kCs = = = 1.148,
τu − be 10 − 1.29
 

2
2
b1 b1 3 3
u= + 1+ = + 1+ = 3.984,
2δ 2δ 2 · 0.8 2 · 0.8
1 + u 2 − 2u
β= = 0.179.
2(1 + u 2 )

The depth of the flux density dip on the rotor surface is 2B0 :

2B0 = 2β Bmax = 2βkC Bav = 2 · 0.179 · 1.148Bav = 0.41Bav .

The equivalent air gap is δe ≈ kCs δ = 1.148 · 0.8 mm = 0.918 mm.

At 0.9 T the peak value of the air gap field strength is
0.9 T
Ĥδ = = 716 kA/m.
4π · 10−7 V s/A m
The magnetic voltage of the air gap is

Ûm,δe = Ĥδ δe = 716 kA/m · 0.000 918 m = 657 A.

According to Equation (2.15), the amplitude of the stator current linkage is

m 4 kws1 Ns √ mkws1 Ns √
Θ̂s1 = 2Ism = 2Ism .
2 π 2p πp
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Design of Magnetic Circuits 163

To calculate the amplitude, we need the fundamental winding factor for a machine with
q = 3. For a full-pitch winding with q = 3, we have the electrical slot angle

360◦ 360◦
αu = = = 20◦ .
2mq 2·3·3

We have six voltage phasors per pole pair: three positive and three negative phasors. When
the phasors of negative coil sides are turned 180◦ , we have two phasors at an angle of −20◦ ,
two phasors at an angle of 0◦ and two phasors at +20◦ . The fundamental winding factor
will hence be
2 cos (−20◦ ) + 2 cos (0◦ ) + 2 cos (+20◦ )
kws1 = = 0.960.
6
Since this is a full-pitch winding the same result is found by calculating the distribution
factor according to Equation (2.23)

αus 20
sin qs sin 3
kds1 = kws1 = 2 2 = 0.960.
αus = 20
qs sin 3 sin
2 2
We may now calculate the stator current needed to magnetize the air gap

Θ̂s1 π p 657 · π · 2
Ism = √ = √ A = 10.1 A.
mkws1 Ns 2 3 · 0.960 · 100 2

If an analytic equation is required to describe the flux distribution in case of an air gap
slotted on only one side, an equivalent approximation introduced by Heller and Hamata (1977)
can be employed. This equation yields a flux density distribution in the case of a smooth rotor
in a distance of one slot. If the origin is set at the centre of the stator slot, the Heller and
Hamata equations are written for a stator (see Figure 3.5)

π
B (α) = 1 − β − β cos α Bmax , when 0 < α < 0.8α0
0.8α0

and

B (α) = Bmax elsewhere, when 0.8α0 < α < αd . (3.13)

Here α0 = 2b1 /D and αd = 2π/Q s = 2τu /D.

Drops in the flux density caused by stator slots create losses on the rotor surface. Corre-
spondingly, the rotor slots have the same effect on the stator surface. These losses can be
reduced by partially or completely closing the slots, by reshaping the slot edges so that the
drop in the flux density is eliminated, or by using a semi-magnetic slot wedge, Figure 3.6.
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164 Design of Rotating Electrical Machines

special slot opening

B
semi-magnetic
slot wedge
semi-magnetic
no w edge stator slot
slot wedge

Rotor surface along

a stator slot pitch rotor

(a) (b) (c)

Figure 3.6 (a) Slot opening of a semi-closed stator slot of Figure 3.4 has been filled with a semi-
magnetic filling (µr = 5). The flux drop on the rotor surface, caused by the slot, is remarkably reduced
when the machine is running with a small current at no load. (b) Simultaneously, the losses on the
rotor surface are reduced and the efficiency is improved. The edges of the stator slot can also be shaped
according to (c), which yields the best flux density distribution. (b) The curve at the top

3.1.2 Air Gaps of a Salient-Pole Machine

Next, three different air gaps of a salient-pole machine are investigated. The importance of
these air gaps lies in the following: the first air gap is employed in the calculation when the
machine is magnetized with a rotor field winding; the second is required for the calculation
of the direct-axis armature reaction, and thereby the armature direct-axis inductance; and
finally, the third air gap gives the armature quadrature-axis reaction and the quadrature-axis
inductance. The air gaps met by the rotor field winding magnetizing are shaped with pole
shoes such that as sinusoidal a flux density distribution as possible is obtained in the air gap
of the machine.
The air-gap flux density created by the rotor field winding magnetizing of a salient-pole
machine can be investigated with an orthogonal field diagram. The field diagram has to be
constructed in an air gap of accurate shape. Figure 3.7 depicts the air gap of a salient-pole
machine, into which the field winding wound around the salient-pole body creates a mag-
netic flux. The path of the flux can be solved with a magnetic scalar potential. The magnetic
field refracts on the iron surface. However, in the manual calculation of the air gaps of a syn-
chronous machine, the permeability of iron is assumed to be so high that the flux lines leave
the equipotential iron surface perpendicularly.
If the proportion Θ δ of the current linkage Θ f of the rotor acts upon the air gap, each duct
in the air gap takes, with the notation in Figure 3.7, a flux

x
Φδ = µ0 Θδ l = Θδ Rm , (3.14)
nδ
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Design of Magnetic Circuits 165

τp
main flux
main
flux

leakage flux

leakage flux

Figure 3.7 Field diagram of the rotor pole of an internal salient-pole synchronous machine with DC
magnetizing in an area of half a pole pitch τ p /2. The figure also indicates that the amount of leakage
flux in this case is about 15%, which is a typical number for pole leakage. Typically, a designer should
be prepared for about 20% leakage flux when designing the field winding

where l is the axial length of the pole shoe and n the number of square elements in the radial
direction. If the origin of the reference frame is fixed to the middle of the pole shoe, we may
write in the cosine form
Φδ µ0 Θδ
= = B̂δ cos θ. (3.15)
lx nδ

In the field diagram consisting of small squares, the side of a square equals the average
width x. The magnetic flux density of the stator surface can thus be calculated by the average
width of squares touching the surface. On the other hand, nδ is the length of the flux line
from the pole shoe surface to the stator surface:

µ0 Θδ δ0e
nδ = = , (3.16)
B̂δ cos θ cos θ

where δ 0e is the air gap in the middle of the pole, corrected with the Carter factor. Now the
pole shoe has to be shaped such that the length of the flux density line of the field diagram is
inversely proportional to the cosine of the electrical angle θ. A pole shoe shaped in this way
creates a cosinusoidal magnetic flux density in the air gap, the peak value of which is B̂δ . The
maximum value of flux penetrating thorough a full-pitch winding coil is called the peak value
of flux, although it is not a question of amplitude here. The peak value of the flux is obtained
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166 Design of Rotating Electrical Machines

by calculating a surface integral over the pole pitch and the length of the machine. In practice,
the flux of a single pole is calculated. Now, the peak value is denoted Φ̂m
τp
l   2

x
Φ̂m = B̂δ cos π dxdl  , (3.17)
τp
τ
0 − 2p

where l is the equivalent core length l ≈ l + 2δ in a machine without ventilating ducts (see
Section 3.2), τ p is the pole pitch, τ p = π D/(2p), x is the coordinate, the origin of which is in
the middle of the pole, and θ = xπ/τp .
When the flux density is cosinusoidally distributed, we obtain by integration for the air-gap
flux
2
Φ̂m = B̂δ τpl  . (3.18)
π
By reformulating the previous equation, we obtain

Dl  Dl 
Φ̂m = B̂δ = µ0 Θ̂δ . (3.19)
p pδ0e

Next, the air gap experienced by the stator winding current linkage is investigated. The
stator winding is constructed such that its current linkage is distributed fairly cosinusoidally
on the stator surface. The stator current linkage creates an armature reaction in the magnetiz-
ing inductances. As a result of the armature reaction, this cosinusoidally distributed current
linkage creates a flux of its own in the air gap. Because the air gap is shaped so that the flux
density created by the rotor pole is cosinusoidal, it is obvious that the flux density created by
the stator is not cosinusoidal, see Figure 3.8. When the peak value of the fundamental current
linkage of the stator is on the d-axis, we may write

Θs1 (θ ) = Θd (θ ) = Θ̂d cos θ. (3.20)

The amplitude of the current linkage is calculated by Equation (2.15). The permeance dΛ
of the duct at the position θ is

dS Dl dθ cos θ
dΛ = µ0 = µ0 . (3.21)
nδ 2 p δ0e

The magnetic flux density at the position θ is

dΦ µ0 
Bd (θ) = = Θ̂ cos2 θ. (3.22)
dS δ0e d

The distribution of the air-gap flux density created by the stator current is proportional to
the square of the cosine when the current linkage of the stator is on the d-axis. To be able
to calculate the inductance of the fundamental, this density function has to be replaced by a
cosine function with an equal flux. Thus, we calculate the factor of the fundamental of the
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Design of Magnetic Circuits 167

Bd (q )
Θs1(q ) Θ s1 (q )

B̂1d B̂ 1q

τp q Bq (q )
τp
d d
δ0 d
q q

(a) (b)

Figure 3.8 (a) Cosine-squared flux density Bd (θ), created in the shaped air gap by a cosinusoidal stator
current linkage Θ s1 occurring on a direct axis of the stator, where the peak value of the fundamental
component of Bd (θ ) is B̂1d . (b) The cosinusoidal current linkage distribution on the quadrature axis
creates a flux density curve Bq (θ ). The peak value of the fundamental component of Bq (θ) is B̂1q

Fourier series. The condition for keeping the flux unchanged is


+π/2 
+π/2
µ0 
Θ̂ cos θ dθ = B̂1d
2
cos θ dθ . (3.23)
δ0e d
−π/2 −π/2

The amplitude of the corresponding cosine function is thus

π µ0  µ0 
B̂1d = Θ̂d = Θ̂ . (3.24)
4 δ0e δde d
In the latter presentation of Equation (3.24), the air gap δ de is an equivalent d-axis air gap
experiencing the current linkage of the stator. Its theoretical value is
4δ0e
δde = . (3.25)
π
Figure 3.8a depicts this situation. In reality, the distance from the stator to the rotor on the
edge of the pole cannot be extended infinitely, and therefore the theoretical value of Equa-
tion (3.25) is not realized as such (it is only an approximation). However, the error is only
marginal, because when the peak value of the cosinusoidal current linkage distribution is at
the direct axis, the current linkage close to the quadrature axis is very small. Equation (3.25)
gives an interesting result: the current linkage of the stator has to be higher than the current
linkage of the rotor, if the same peak value of the fundamental component of the flux density
is desired with either the stator or rotor magnetization.
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168 Design of Rotating Electrical Machines

Figure 3.8b illustrates the definition of the quadrature air gap. The peak value of the stator
current linkage distribution is assumed to be on the quadrature axis of the machine. Next, the
flux density curve is plotted on the quadrature axis, and the flux Φ q is calculated similarly as
in Equation (3.19). The flux density amplitude of the fundamental component corresponding
to this flux is written as
pΦq µ0 
B̂1q = = Θ̂ , (3.26)
Dl δqe q

where δ qe is the equivalent quadrature air gap. The current linkages are set equal: Θ̂f = Θ̂d =
Θ̂q , the equivalent air gaps behaving inversely proportional to the flux density amplitudes

1 1 1
B̂δ : B̂1d : B̂1q = : : . (3.27)
δ0e δde δqe

Direct and quadrature equivalent air gaps are calculated from this (inverse) proportion. A
direct-axis air gap is thus approximately 4δ 0e /π . A quadrature-axis air gap is more problem-
atic to solve without numerical methods, but it varies typically between (1.5–2–3) × δ de .
According to Schuisky (1950), in salient-pole synchronous machines, a quadrature air gap is
typically 2.4-fold when compared with a direct air gap in salient-pole machines.
The physical air gap on the centre line of the magnetic pole is set to δ 0 . The slots in the
stator create an apparent lengthening of the air gap when compared with a completely smooth
stator. This lengthening is evaluated with the Carter factor. On the d-axis of the rotor pole, the
length of an equivalent air gap is now δ 0e in respect of the pole magnetization. In this single
air gap, the pole magnetization has to create a flux density B̂δ . The required current linkage
of a single pole is

δ0e B̂δ
Θf = . (3.28)
µ0
The value for current linkage on a single rotor pole is Θ f = N f I f , when the DC field wind-
ing current on the pole is I f and the number of turns in the coil is N f . The flux linkage and
the inductance of the rotor can now be easily calculated. When the pole shoes are shaped
according to the above principles, the flux of the phase windings varies at no load as a si-
nusoidal function of time, Φm (t) = Φ̂m sin ωt, when the rotor rotates at an electric angular
frequency ω. By applying Faraday’s induction law as presented in Equation (1.8), we can cal-
culate the induced voltage. The applied form of the induction law, which takes the geometry
of the machine into account, is written with the flux linkage Ψ as

dΨ (t) dΦm (t)

e1 (t) = − = −kw1 N , (3.29)
dt dt
and the fundamental component of the voltage induced in a single pole pair of the stator is
written as

e1p (t) = −Np kw1 ωΦ̂m cos ωt. (3.30)

Here N p is the number of turns of one pole pair of the phase winding. The winding factor
kw1 of the fundamental component takes the spatial distribution of the winding into account.
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Design of Magnetic Circuits 169

The winding factor indicates that the peak value of the main flux Φ̂m does not penetrate all
the coils simultaneously, and thus the main flux linkage of a pole pair is Ψ̂m = Np kw1 ωΦ̂m .
By applying Equation (3.18) we obtain for the voltage of a pole pair

2
e1p (t) = −Np kw1 ω B̂δ τpl  cos ωt, (3.31)
π
the effective value of which is
1 2 1
E 1p = √ ωNp kw1 B̂δ τpl  = √ ωΨ̂mp . (3.32)
2 π 2

The maximum value of the air-gap flux linkage Ψ̂mp of a pole pair is found at instants when
the main flux best links the phase winding observed. In other words, the magnetic axis of the
winding is parallel to the main flux in the air gap.
The voltage of the stator winding is found by connecting an appropriate amount of pole
pair voltages in series and in parallel according to the winding construction.
Previously, the air gaps δ de and δ qe were determined for the calculation of the direct and
quadrature stator inductances. For the calculation of the inductance, we have also to define the
current linkage required by the iron. The influence of the iron can easily be taken into account
by correspondingly increasing the length of the air gap, δdef = (Ûm,δde /(Ûm,δde + Ûm,Fe ))δde .
We now obtain the effective air gaps δ def and δ qef . With these air gaps, the main inductances
of the stator can be calculated in the direct and quadrature directions

2 Dδ l  2 2 Dδ l  2
L pd = µ0 kw1 Np , L pq = µ0 kw1 Np . (3.33)
π pδdef π pδqef

N p is the number of turns (N s /p) of a pole pair. The main inductance is the inductance of a
single stator phase. To obtain the single-phase equivalent circuit magnetizing inductance, for
instance for a three-phase machine, the main inductance has to be multiplied by 3/2 to take the
effects of all three windings into account. When deriving the equations, Equation (2.15) for
the current linkage of a stator is required, and also the equation for a flux linkage of a single
pole pair of the stator

2
Ψmp = −kw1 Np B̂δ τpl 
π
which is included in the previous voltage equations. The peak value for the air-gap flux density
is calculated with an equivalent air gap and a stator current linkage, which leads to Equation
(3.33). The inductances will be discussed in detail later in Section 3.9 and also in Chapter 7.

3.1.3 Air Gap of Nonsalient-Pole Machine

In nonsalient-pole machines, unlike in salient-pole machines, the shape of the air-gap flux
density cannot be adjusted by shaping the air gaps. The rotor of a salient-pole machine is a
steel cylinder provided with slots. The magnetizing winding is inserted in these slots. The air
gap of such a machine is in principle equal at all positions, and thus, to create a sinusoidal flux
density distribution, the magnitude of the current linkage acting upon different positions of
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170 Design of Rotating Electrical Machines

rotor current linkage

If
q d q d
zQ

(a) (b)

Figure 3.9 (a) Magnetizing winding of a nonsalient-pole rotor and (b) the distribution of the current
linkage on the surface of the rotor cylinder, when the number of conductors is equal in all slots. The
form of the current linkage can be improved by selecting the number of turns in the slots or the slot
positions better than in the above example

the air gap has to be varied. To get a correct result,the conductors of the magnetizing winding
have to be divided accordingly among the slots of the rotor, Figure 3.9.
The air gap of the nonsalient-pole machine is equal in all directions. The current linkage of
the stator meets the same air gap as the current linkage of the rotor, and thus, with the notation
in Equation (3.27), we obtain
δ0e ≈ δde ≈ δqe . (3.34)
Because both the stator and rotor are slotted, the Carter factor is applied twice. The main
inductance of a salient-pole machine can be calculated from Equation (3.33) by employing
an effective air gap δ ef , which takes also the effect of the iron into account and increases δ 0e
with the proportion of the iron. A nonsalient-pole machine has only a single main inductance,
because all the air gaps are equal. In practice, the slots in the rotor make the inductance of the
quadrature axis slightly smaller than the inductance of the direct axis in these machines.
Asynchronous machines are usually symmetrical, and therefore only a single equivalent
air-gap length is defined for them, similarly as for nonsalient-pole machines. The main induc-
tance is calculated from Equation (3.33). Usually, DC machines are external pole, salient-pole
machines, and therefore their air gaps have to be determined by a method similar to the solu-
tion presented previously for a salient-pole machine. The above determination of the air gaps
for a salient-pole machine is valid also for a synchronous salient-pole reluctance machine.
With respect to an SR machine, the concept of an air gap has to be redefined, since the whole
operation of the machine is based on the deformations of the magnetic circuit. The air gap
is changing constantly when the machine rotates. The difference in the direct and quadrature
inductances defines the average torque produced by the machine.
The magnetic voltage over the air gap is usually calculated with the smallest air gap and at
the peak value of the flux density. If the equivalent air gap in the middle of the pole is δ e , we
obtain
B̂δ
Ûm,δe = δe . (3.35)
µ0
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Design of Magnetic Circuits 171

3.2 Equivalent Core Length

At an end of the machine, and at possible radial ventilating ducts, the effects of field fringings
that may occur have to be taken into account. This is done by investigating the field diagrams
of the ventilating ducts and of the ends of the machine. Figure 3.10 illustrates the influence of
the edge field at the machine end on the equivalent length l of the machine.
The flux density of the machine changes in the direction of the shaft as a function of the
z-coordinate B = B(z). The flux density remains approximately constant over a distance of
the sheet core and decreases gradually to zero along the shaft of the machine as an effect
of the edge field. This edge field is included in the main flux of the machine, and thus it
participates also in torque production. In manual calculations, the lengthening of the machine
caused by the edge field can be approximated by the equation

l  ≈ l + 2δ. (3.36)

This correction is of no great significance, and therefore, when desired, the real length l is
accurate enough in the calculations. In large machines, however, there are ventilating ducts
that reduce the equivalent length of the machine, see Figure 3.11.
Here, we can estimate the length of the machine by applying the Carter factor again. By
applying Equations (3.7a) and (3.7b) and by substituting the width of the slot opening b with
the width of the ventilating duct bv we obtain

bve = κbv . (3.37)

l'

B(z)

B
l
δ

Figure 3.10 Orthogonal field diagram for the determination of the edge field at the end of the machine
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172 Design of Rotating Electrical Machines

bv
bve
ventilating duct
stator
B

δ bv

l
δ
rotor

Figure 3.11 Influence of radial ventilating ducts on the equivalent length of the machine and the be-
haviour of the flux density in the vicinity of the ventilating duct

The number of ventilating ducts being nv in the machine (in Figure 3.11, nv = 3), the
equivalent length of the machine is approximated by

l  ≈ l − n v bve + 2δ. (3.38)

If there are radial ventilating ducts both in the rotor and in the stator, as depicted in Figure
3.12, the above method of calculation can in principle be employed. In that case, the flux
density curve has to be squared, as was done previously, and the equivalent width of the

stator

δ δ

bv bv
rotor

bve

B bve
B

(a) (b)

Figure 3.12 (a) In the stator and the rotor, the ventilating ducts are axially at the same positions. (b)
The ventilating ducts are at different positions in the stator and in the rotor
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Design of Magnetic Circuits 173

duct bve , Equation (3.7a), is substituted in Equation (3.38). In the case of Figure 3.12a, the
number of rotor ventilating ducts is equal to the number of ventilating ducts of the stator and
the sum of the width of the stator and rotor ventilation ducts has to be substituted for b in
Equation (3.7b). In the case of Figure 3.12b, the number of ducts nv has to be the total number
of ducts.

Example 3.2: A synchronous machine has a stator core 990 mm long. There are 25 sub-
stacks of laminations 30 mm long and a 10 mm cooling duct after each stack (24 cooling
ducts all together). The air-gap length is 3 mm. Calculate the effective stator core length
of the machine when (a) the rotor surface is smooth, (b) there are 24 cooling ducts in the
rotor opposite the stator ducts and (c) there are 25 cooling ducts in the rotor opposite the
stator substacks.
Solution:
bv 10
(a) κ = δ
5+ bδv
= 3
5+ 10
= 0.40, bve = κbv = 0.40 · 10 mm = 4.0 mm,
3

l  ≈ l − n v bve + 2δ = 990 − 24 · 4.0 + 2 · 3 mm = 900 mm.

bvs +bvr 10+10
(b) κ = δ
5+ bvs +b vr = 3
5+ 10+10
= 0.571, bve = κbv = 0.571 · 10 mm = 5.71 mm,
δ 3

l  ≈ l − n v bve + 2δ = 990 − 24 · 5.71 + 2 · 3 mm = 859 mm.

(c) As in (a), κ = 0.40, bve = 4.0 mm for the stator and rotor ducts,

l  ≈ l − n vs bves − n vr bver + 2δ = 990 − 24 · 4.0 − 25 · 4.0 + 2 · 3 mm = 800 mm.

3.3 Magnetic Voltage of a Tooth and a Salient Pole

3.3.1 Magnetic Voltage of a Tooth
When there are Qs slots in the stator, we obtain the slot pitch of the stator by dividing the
air-gap periphery by the number of slots

πD
τu = . (3.39)
Qs

Figure 3.13a illustrates the flux density distribution in an air gap, the other surface of which
is smooth, and Figure 3.13b illustrates a tooth and a slot pitch.
The magnetic voltage of a tooth is calculated at a peak of the air-gap fundamental flux
density. When a tooth occurs at a peak value of the air-gap flux density, an apparent tooth flux
passes the slot pitch

Φ̂d = l  τu B̂δ . (3.40)

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174 Design of Rotating Electrical Machines

τu

B (θ )
B1

hd

bd

(a) (b)

Figure 3.13 (a) Semi-closed slots and the flux density in the air gap. (b) The dimensions of a tooth and
a slot: the height hd of the tooth and the slot, slot pitch τ u , and the width of the tooth bd

If the teeth of the machine are not saturated, almost the complete flux of the slot pitch flows
along the teeth, and there is no flux in the slots and the slot insulations. Neglecting the slot
opening and taking into account the space factor kFe of iron, we obtain for a tooth with a
uniform diameter and cross-sectional area Sd

Sd = kFe (l − n v bv ) bd . (3.41)

Here nv and bv are the number of ventilating ducts and their width (see Figure 3.12), and
l is the total length of the machine stack. Punching influences the crystal structure of iron,
and therefore the permeability on the cutting edges of the tooth is low. Thus, in the calcula-
tion of the flux density in a tooth, 0.1 mm has to be subtracted from the tooth width, that is
bd = breal − 0.1 mm in Equation (3.41) and the following equations. During the running of
the motor, a relaxation phenomenon occurs, and the magnetic properties recover year by year.
The space factor of iron kFe depends on the relative thickness of the insulation of the electric
sheet and on the press fit of the stack. The insulators are relatively thin, their typical thickness
being about 0.002 mm, and consequently the space factor of iron can in practice be as high as
98%. A space factor varies typically between 0.9 and 0.97. Assuming that the complete flux
is flowing in the tooth, we obtain its apparent flux density

Φ̂d l  τu
B̂d = = B̂δ . (3.42)
Sd kFe (l − n v bv ) bd

In practice, a part of the flux is always flowing through the slot along an area Su . Denoting
this flux by Φ̂u , we may write for a flux in the tooth iron

Φ̂d = Φ̂d − Φ̂u = Φ̂d − Su B̂u . (3.43)

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Design of Magnetic Circuits 175

By dividing the result by the area of the tooth iron Sd we obtain the real flux density of the
tooth iron

Su Su l  τu
B̂d = B̂d − B̂u , where = − 1. (3.44)
Sd Sd kFe (l − n v bv ) bd

The apparent flux density of the tooth iron B̂d can be calculated when the peak value B̂δ
of the fundamental air-gap flux density is known. To calculate the flux density in the slot, the
magnetic field strength in the tooth is required. Since the tangential component of the field
strength is continuous at the interface of the iron and the air, that is Hd = Hu , the flux density
of the slot is

B̂u = µ0 Ĥd . (3.45)

The real flux density in the tooth is thus

Su
B̂d = B̂d − µ0 Ĥd . (3.46)
Sd

Now, we have to find a point that satisfies Equation (3.46) on the BH curve of the electric
sheet in question. The easiest way is to solve the problem graphically as illustrated in Figure
3.14. The magnetic voltage Ûm,d in the tooth is then approximately Ĥd h d .
When a slot and a tooth are not of equal width, the flux density is not constant, and therefore
the magnetic voltage of the tooth has to be integrated or calculated in sections:

h d
Ûm,d = Hd · dl.
0

B
B̂d'

Su
Bˆ d = Bˆ d' – µ Hˆ
Sd 0 d
B̂d

Hˆd H

Figure 3.14 Definition of the flux density B̂d of the tooth with the BH curve of the electrical sheet and
the dimensions of the tooth
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176 Design of Rotating Electrical Machines

Example 3.3: The stator teeth of a synchronous machine are 70 mm high and 14 mm
wide. Further, the slot pitch τ u = 30 mm, the stator core length l = 1 m, there are no
ventilation ducts, the space factor of the core kFe = 0.98, the core material is Surahammars
Bruk electrical sheet M400-65A (Figure Example 3.3), the air gap δ = 2 mm and the
fundamental flux density of the air gap B̂d = 0.85 T. Calculate the magnetic voltage over
the stator tooth.

2.0

1.8
B/T
1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0.0
0 2 4 6 8 10 12 14 16 18
Hˆ d =13 .3kA /m H/kA/m

Figure Example 3.3 BH curve of the material used in Example 3.3 and its solution

Solution: The effective core length l = 1000 + 2 · 2 mm = 1004 mm. The apparent flux
density of the tooth Equation (3.42) is

1004 · 30
B̂d = 0.85 T = 1.88 T.
0.98 · 1000 · (14 − 0.1)
The intersection of the BH curve of the electrical sheet M400-65A and the line (3.46) gives

1004 · 30
B̂δ = 1.88 − − 1 4 · π · 10−7 Ĥd .
0.98 · 1000 · (14 − 0.1)

The figure above gives the field strength of the teeth Ĥd = 13.3 kA/m and the magnetic
voltage

h d
Ûm,d = Hd · dl = 13 300 · 0.07 A = 931 A.
0
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Design of Magnetic Circuits 177

3.3.2 Magnetic Voltage of a Salient Pole

The calculation of the magnetic voltage of a salient pole is in principle quite similar to the
procedure introduced for a tooth. However, there are certain particularities: for instance, the
magnetic flux density of the pole shoe is often so small that the magnetic voltage required by
it can be neglected, in which case only the magnetic voltage required by the pole body has to
be defined. When determining the magnetic voltage of the pole body, special attention has to
be paid to the leakage flux of the pole body. Figure 3.7 shows that a considerable amount of the
flux of the pole body is leaking. The leakage flux comprises 10–30% of the main flux. Because
of the leakage flux, the flux density B̂p at the foot of a uniform pole body of cross-sectional
area Sp is thus written with the main flux Φ̂m as
Φ̂m
B̂p = (1.1 . . . 1.3) . (3.47)
Sp
The calculation of the peak value of the flux Φ̂m will be discussed later at the end of the
chapter. Because of the variation of the flux density, the magnetic voltage Ûm,p of the pole
body has to be integrated:
h dr
Ûm,p = H · dl.
0

3.4 Magnetic Voltage of Stator and Rotor Yokes

Figure 3.15 depicts the flux distribution of a two-pole asynchronous machine when the ma-
chine is running at no load. The flux penetrating the air gap and the teeth section is divided
into two equal parts at the stator and rotor yokes. At the peak of the air-gap flux density on
the d-axis, the flux densities in the yokes are zero. The maximum flux densities for the yokes
occur on the q-axis, on which the air-gap flux density is zero. The maximum value for the flux

Figure 3.15 Flux diagram for a two-pole induction motor running at no load. The shaft of the machine
is far more reluctive than the rotor sheet, and therefore, at the plotted lines, no flux seems to penetrate
the rotor shaft. Furthermore, the shaft is often jagged at the rotor bundle, and thus in practice there are
air bridges between the rotor iron and the shaft
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178 Design of Rotating Electrical Machines

density of the stator yoke can be calculated on the q-axis without difficulty, since half of the
main flux is flowing there:

Φ̂m Φ̂m
B̂ys = = . (3.48)
2Sys 2kFe (l − n v bv ) h ys
Here Sys is the cross-sectional area of the stator yoke, kFe is the space factor of iron and hys is
the height of the yoke, see Figure 3.16. Respectively, the maximum flux density at the rotor
yoke is

Φ̂m Φ̂m
B̂yr = = . (3.49)
2Syr 2kFe (l − n v bv ) h yr

The calculation of the magnetic voltage of the yoke is complicated, since the flux density
at the yoke changes constantly over the pole pitch, and the behaviour of the field strength is
highly nonlinear, see Figure 3.16b.
Magnetic potential difference Ûm,ys over the whole yoke has to be determined by cal-
culating the line integral of the magnetic field strength between the two poles of the yoke
d-axis

real
integration path Ĥ ys
ideal
integration path

Hys
B̂ys

Bys
τp /2

q-axis Dryi

Dr
q-axis

d-axis
d-axis

Φ ys /2
Ds τp
D se

hys h yr

(a) (b)

Figure 3.16 (a) Flux of the stator yoke in an electrical machine, and the integration path of the mag-
netic voltage. (b) The behaviour of the flux density of the stator yoke, and the strongly nonlinear be-
haviour of the field strength H ys , which explain the difficulties in the definition of the magnetic voltage
of the yoke. The ideal integration path is indicated by the thick black dotted line and the real integration
path by any flux line, for example the thick grey dotted line
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Design of Magnetic Circuits 179

integration path

q
Ûm,ys = H · dl. (3.50)
d

The field diagram has to be known in order to be able to define the integral. Precise calculation
is possible only with numerical methods. In manual calculations, the magnetic voltages of the
stator and rotor yoke can be calculated from the equations

Ûm,ys = c Ĥys τys , (3.51)

Ûm,yr = c Ĥyr τyr . (3.52)

Here Ĥys and Ĥyr are the field strengths corresponding to the highest flux density, and τ ys
and τ yr are the lengths of the pole pitch in the middle of the yoke (Figures 3.1 and 3.16):

π (Dse − h ys )
τys = , (3.53a)
2p
π (Dryi − h yr )
τyr = . (3.53b)
2p

The coefficient c takes into account the fact that the field strength is strongly nonlinear in
the yoke, and that the nonlinearity is the stronger, the more saturated the yoke is at the q-axis.
For most places in the yokes, the field strength is notably lower than Ĥys or Ĥyr , see Figure
3.16. The coefficient is defined by the shape of the air-gap flux density curve, by the saturation
of the machine and by the dimensions of the machine. However, the most decisive factor is the
maximum flux density in the yoke of the machine. If there is a slot winding in the machine,
the magnetic voltage of the yoke can be estimated by the curve illustrated in Figure 3.17.
Figure 3.16 shows clearly that as the peak flux density in the q-axis approaches the iron
saturation flux density, the field strength H reaches very high peak values in the yoke. Since the

0.8
c
0.6

0.4

0.2

0
0 0.5 1.0 1.5 2.0
Bˆyr, Bˆys /T

Figure 3.17 Influence of the maximum flux density of the stator or rotor yoke in the definition of the
coefficient c, applied in the determination of magnetic voltage
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180 Design of Rotating Electrical Machines

peak H value is possible only on the q-axis, the average value of H decreases and consequently
so does the coefficient c.
In the case of a salient-pole stator or rotor, a value of c = 1 can be applied for the yoke on
the salient-pole side of the machine.

Example 3.4: In a four-pole machine, the outer diameter Dse = 0.5 m, the stator air gap
diameter is Ds = 0.3 m, the machine stator core length is 0.3 m and the air gap is 1 mm.
The peak value of the fundamental air-gap flux density is 0.9 T. The stator yoke height
hys = 0.05 m. Calculate the stator yoke magnetic voltage when the material is M400-50A.
Solution: Assuming a sinusoidal flux density distribution in the air gap according to Equa-
tion (3.18), the peak value of the air gap flux is

2 2 π · 0.3 m
Φ̂m = B̂δ τpl  = · 0.9 T · · (0.3 m + 0.002 m) = 0.0408 V s.
π π 2·2
This flux is divided into two halves in the stator yoke. The yoke flux density is therefore

Φ̂m Φ̂m 0.0408 V s

B̂ys = = = = 1.39 T.
2Sys 2kFe (l − n v bv ) h ys 2 · 0.98 · 0.3 m · 0.05 m

At this flux density, the maximum field strength in the yoke is about 400 A/m, see Ap-
pendix A. The stator yoke length is

π(Dse − h ys ) π (0.5 m − 0.05 m)

τys = = = 0.353 m.
2p 2·2

According to Figure 3.17, the coefficient c = 0.26, and hence we get for the stator yoke
magnetic voltage

Ûm,ys = c Ĥys τys = 0.26 · 400 A/m · 0.353 m = 37 A.

3.5 No-Load Curve, Equivalent Air Gap and Magnetizing Current

of the Machine
In the determination of the current linkage required by the magnetic circuit, magnetic voltages
corresponding to a certain peak value B̂δ of the magnetic flux density of the air gap of the
machine have been calculated for all parts of the machine in turn. By selecting several values
for B̂δ and by repeating the above calculations, we may plot the curves for the magnetic
voltages required by the different parts of the machine, and, as their sum, we obtain the current
linkage required by the magnetic circuit of the complete machine:

Ûm,ys Ûm,yr
Θ̂m = Ûmδ + Ûm,ds + Ûm,dr + + . (3.54)
2 2
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Design of Magnetic Circuits 181

B̂
Uˆ m, ds
Uˆ m, dr (Uˆ m, ys )
+ Uˆ m, yr /2
Û m, e

Û m, e Uˆ m, Fe /2 Θ̂m

Figure 3.18 No-load curve of the machine (thick line) and its composition of the influences of the
stator teeth ds, the air gap δe, the rotor teeth dr and the halves of stator and rotor yokes 1/2(ys, yr). In
some cases, the whole magnetic circuit is replaced with equivalent air gaps; consequently, the magnetiz-
ing curve can be replaced at an operation point by a straight line (dotted line). Note that the proportion
of the magnetic voltage of the iron is strongly exaggerated. In well-designed machines, the proportion
of the current linkage required by the iron is only a fraction of the current linkage required by the air
gaps. The total current linkage required by half a magnetic circuit is denoted Θ̂m . The current linkage
needed in the whole magnetic circuit is 2Θ̂m

As we can see, the equation sums the magnetic voltages of one air gap, one stator tooth, one
rotor tooth and halves of the stator and rotor yokes. This is illustrated in Figure 3.18. The
curve corresponds to the no-load curve defined in the no-load test of the machine, in which
the flux density axis is replaced by the voltage, and the current linkage axis is replaced by the
magnetizing current.
According to Figure 3.18, the magnetic voltage required by half of the iron in the complete
magnetic circuit is

Ûm,Fe
= Θ̂m − Ûm,δe . (3.55)
2

If the circuit has to be linearized (the dotted line in Figure 3.18), the air gap lengthened
with the Carter factor is replaced by the effective air gap δ ef , which also takes the reluctance
of the iron into account. This air gap can be defined by a proportion

Θ̂m δef
= . (3.56)
Ûm,δe δe

When the amplitude Θ̂m of the current linkage corresponding to the operating point of the
machine has been defined, we are able to calculate the magnetizing current required by the
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182 Design of Rotating Electrical Machines

machine. So far, no distinction has been made here between a machine that is magnetized with
the alternating current of the rotating-field winding (cf. asynchronous machines) and a ma-
chine magnetized with the direct current of the field winding (cf. synchronous machines). In
the case of a salient-pole machine (a synchronous machine or a DC machine), the magnetizing
field winding direct current I fDC required for one pole is

Θ̂m
IfDC = . (3.57)
Nf

Here N f is the total number of turns on the magnetizing pole of the machine. Pole windings
can in turn be suitably connected in series and in parallel to reach a desired voltage level and
current.
On the rotor of a nonsalient-pole synchronous machine, there has to be an equal number of
coil turns per pole as in a salient-pole machine, that is a number of N f . These turns are divided
to the poles in the same way as in a salient-pole machine. The winding is now inserted in slots
as illustrated in Figure 3.9.
In all rotating-field machines (induction machines, various synchronous machines) the sta-
tor winding currents have a significant effect on the magnetic state of the machine. However,
only induction machines and synchronous reluctance machines are magnetized with the mag-
netizing current component of the stator current alone. In the cases of separately magnetized
machines and permanent magnet machines, the magnitude of the armature reaction is es-
timated by investigating the stator magnetization. For rotating-field machines, the required
effective value of the alternating current I sm is calculated with Equation (2.15). For the sake
of convenience, Equation (2.15) is repeated here for the fundamental:

m 4 kws1 Ns √ mkws1 Ns √
Θ̂s1 = 2Ism = 2Ism . (3.58)
2 π 2p πp

Θ̂s1 is the amplitude of the fundamental of the current linkage of the stator winding. kws1
denotes the winding factor of the fundamental of the machine. N s /2p is the number of turns
per pole, when N s is the number of series-connected turns of the stator (parallel branches
being neglected). m is the phase number. A single such amplitude magnetizes half of one
magnetic circuit. If the magnetic voltage is defined for half a magnetic circuit as shown in
Figure 3.18, and thus includes only one air gap and half of the iron circuit, the magnetizing
current of the whole pole pair is calculated with this equation.
Pole pairs in rotating-field machines can also be connected both in series and in paral-
lel, depending on the winding of the machine. In integral slot windings, the base winding
is of the length of a pole pair. Thus, in a four-pole machine for instance, the pole pairs of
the stator can be connected either in series or in parallel to create a functional construction.
In the case of fractional slot windings, a base winding of the length of several pole pairs
may be required. These base windings can in turn be connected in series and in parallel as
required. The magnetizing current measured at the poles of the machine thus depends on
the connection of the pole pairs. The effective value of the magnetizing current for a single
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Design of Magnetic Circuits 183

pole pair I sm,p is

Θ̂mp
Ism,p = √ , (3.59)
m 4 kw1 Ns
2
2 π 2p
Θ̂mp π p
Ism,p = √ . (3.60)
2mkw1 Ns

In a complete magnetic circuit, there are two amplitude peaks, but the same current pro-
duces both a positive and a negative amplitude of the current linkage and, hence, 2Θ̂s1 alto-
gether magnetizes the whole magnetic circuit. The current linkage produced by the magnetiz-
ing current I sm,p for the complete pole pair is

mkws1 Ns √ 2Θ̂s1 Θ̂s1 π p

2Θ̂s1 = 2 2Ism,p ⇔ Ism,p = mk N √ = √ .
πp 2 πws1p s 2 2mkws1 Ns

As we can see, the result is, in practice, the same when we know that 2Θ̂s1 must equal 2Θ̂mp .

Example 3.5: The sum of magnetic voltages in half of the magnetic circuit of a four-
pole induction motor is 1500 A. There are 100 turns in series per stator winding, and the
fundamental winding factor is kw1 = 0.925. Calculate the no-load stator current.
Solution: The current linkage amplitude produced by a stator winding is, according to
Equation (2.15),

m 4 kws1 Ns √ mkws1 Ns √
Θ̂s1 = 2Ism = 2Ism .
2 π 2p πp

Rearranging, we get for the RMS value of the stator magnetizing current

Θ̂s1 π p 1500 A · π · 2
Ism = √ = √ = 24 A.
mkws1 Ns 2 3 · 0.925 · 100 2

3.6 Magnetic Materials of a Rotating Machine

Ferromagnetic materials and permanent magnets are the most significant magnetic materials
used in machine construction. In these materials, there are elementary magnets, known as
Weiss domains. These Weiss domains are separated from each other by Bloch walls, which
are transition regions at the boundaries between magnetic domains. The width of a Bloch wall
varies between a few hundred and a thousand atomic spacings, Figure 3.19.
The increase in the magnetic momentum of a body under the influence of an external field
strength is a result of two independent processes. First, in a weak external field, those Weiss
domains that are already positioned in the direction of the field increase at the expense of
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184 Design of Rotating Electrical Machines

Wei
ss do
main
Bloc
h wa
ll
Wei
ss d
oma
in

Figure 3.19 Bloch wall separating Weiss domains. For instance, the width of the transition region
(Bloch wall) is 300 grid constants (about 0.1 mm)

the domains positioned in the opposite direction, see Figure 3.20. Second, in a strong mag-
netic field, the Weiss domains that are in the normal direction turn into the direction of the
field.
Turning elementary magnets requires a relatively high field strength. In magnetically soft
materials, the Bloch wall displacement processes are almost completed before the Weiss do-
mains begin to turn in the direction of the external field.
Without an external field strength, the Bloch walls are at rest. In practice, the walls are
usually positioned at impurities and crystal defects in materials. If the body experiences only

(a) (c)

H=0
H

(b) (d)

H H

Figure 3.20 In a weak external field, the walls of the Weiss domains are in reversible motion so that
the magnetic momentum of the whole body increases. (a) The external field strength is zero. For (b) and
(c), as the field strength increases, those Weiss domains which were not originally in the direction of the
external field decrease in size. (d) The domain originally in the normal direction has started to turn in
the direction of the external field
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Design of Magnetic Circuits 185

a weak external field strength, the Bloch walls are only slightly displaced from rest. If the
field strength is removed, the Bloch walls return to their original positions. This process can
be observed even with a high-precision microscope.
If we let the field strength increase abruptly, the Bloch walls leave their position at rest
and do not return to their original positions even if the field strength is removed. These wall
displacements are called Barkhausen jumps, and they result from ferromagnetic hysteresis
and Barkhausen noise. It is possible that a Weiss domain takes over one of its neighbouring
domains in a single Barkhausen jump, particularly if the material includes a few, large crystal
defects.
If a magnetic field strength that is high enough begins to act on a Bloch wall, it moves from
its original position towards the next local energy maximum. If the magnetic field strength is
low, the wall does not cross the first energy peak, and as the action of the force ceases, the
wall returns to its original position. However, if the field strength is greater than the above, the
wall passes the first local energy maximum and cannot return to its original position, unless
an opposite field strength is acting upon it.
The displacement of Bloch walls in different materials takes place over a wide range of field
strengths. In ferromagnetic materials, some of the walls are displaced at low field strengths,
while some walls require a high field strength. The largest Barkhausen jumps occur at medium
field strengths. In some cases, all the walls jump at the same field strength so that saturation
magnetization is reached at once. Usually, the magnetization takes place in three separate
phases.
Figure 3.21 illustrates the magnetizing curve of a ferromagnetic material, with three dis-
tinctive phases. In the first phase, the changes are reversible; in the second phase, Barkhausen
jumps occur; and in the third phase, orientation of the Weiss domains takes place and all the
domains turn in the direction determined by the external field strength. Next, the saturation
magnetization and the respective saturation polarization J s are reached.
Figure 3.22 helps to comprehend the formation of Weiss domains. The sections of the figure
illustrate a ferromagnetic crystal divided into different Weiss domains.
In Figure 3.22a, the crystal comprises only a single Weiss domain that looks like a perma-
nent magnet with N and S poles. In this kind of system, the magnetic energy, 1/2 B H dV ,
is high. The energy density corresponding to case (a) in Figure 3.22 is for iron of magnitude
µ0 Ms2 = 23 kJ/m3 .
In Figure 3.22b, the magnetic energy has decreased by half when the crystal has been
divided into two Weiss domains. In Figure 3.22c, it is assumed that the number of domains is
N, and consequently the magnetic energy is reduced to 1/Nth part of case (a).
If the domains are settled as in cases (d) and (e), there is no magnetic field outside the
body, and the magnetic energy of the crystal structure is zero. Here the triangular areas
are at an angle of 45◦ with the square areas. No external magnetic field is involved as in
Figures 3.22a, b and c. The magnetic flux is closed inside the crystal. In reality, Weiss
domains are far more complicated than the cases exemplified here. However, the domains
are created inside the body so that the magnetic energy of the body seeks the minimum
value.
In the design of electromechanical applications, some of the most valuable information
about the magnetizing of a material is obtained from the BH curve of the material in ques-
tion. Figure 3.23 depicts a technical magnetizing curve of a ferromagnetic material. In the
illustration, the flux density B is given as a function of field strength H.
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186 Design of Rotating Electrical Machines

M, J, B

c B=M+B0

M, J

a B0 = µ0 H

Figure 3.21 Magnetizing curve of a ferromagnetic material; in area a, only reversible Bloch wall dis-
placements take place; in area b, irreversible Barkhausen jumps occur; and in area c, the material satu-
rates when all Weiss domains are settled in parallel positions. Magnetization M saturates completely in
area c. The polarization curve (JH) of the material is equal to the magnetizing curve. A BH curve differs
from these curves for the amount of the addition caused by the permeability of a vacuum. As is known,
the BH curve does not actually saturate at a horizontal plane in area c, but continues upwards with a
slope defined by µ0 as the field strength increases

(a) (b) (c) (d) (e)

Figure 3.22 Division of a ferromagnetic crystal into Weiss domains in such a way that the energy
minimum is realized
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Design of Magnetic Circuits 187

B, J
B = µ0 H
Bs
B
Br Js

J
–H cJ

–H cB Hs H

Figure 3.23 Technical magnetizing curve and a corresponding polarization curve of a ferromagnetic
material, that is a hysteresis loop. The coercivity related to the flux density −H cB is the field strength
required to restore the magnetic field density B from remanence flux density Br to zero. The remanence
flux density Br is reached when the external magnetic field strength is restored to zero from a very high
value. The saturation flux density Bs corresponds the saturation polarization J s (Bs = J s + µ0 H s )

3.6.1 Characteristics of Ferromagnetic Materials

The resistivity of pure ferromagnetic metals is usually of a few microohm centimetres
(10−8  m), as shown in Table 3.1.
Since laminated structures are applied mainly to prevent the harmful effects of eddy cur-
rents, it is advisable to select a sheet with maximum resistivity. The different elements al-
loyed with iron have different effects on the electromagnetic properties of iron. In alloys, the

Table 3.1 Physical characteristics of certain ferromagnetic materials (pure ferromagnetic materials at
room temperature are iron, nickel and cobalt). Adapted from Heck (1974)
Material Composition Density/kg/m3 Resistivity/µ cm Melting point/◦ C
Iron 100% Fe — 9.6 —
99.0% Fe 7874 9.71 1539
99.8% Fe 7880 9.9 1539
Ferrosilicon 4% Si 7650 60 1450
Aluminium–iron 16% Al, iron for 6500 145 —
the rest
Aluminium–ferrosilicon 9.5% Si, 5.5% 8800 81 —
Al, iron for
the rest
Nickel 99.6% Ni 8890 8.7 —
Cobalt 99% Co 8840 9 1495
99.95% Co 8850 6.3 —
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188 Design of Rotating Electrical Machines

ρ /µ Ωcm
80

70
Si
60
Al
50

40

30
Ni
20
Co
10
Cu
0
0 1 2 3 4 5 6 7 8
compounding agent, % per weight

Figure 3.24 Effect of silicon, aluminium, nickel, cobalt and copper alloying on the resistivity of iron.
Adapted from Heck (1974)

resistivity ρ tends to increase when compared with pure elements. This is an interesting char-
acteristic that has to be taken into account if we wish to reduce the amount of eddy currents
in magnetic materials. Figure 3.24 illustrates the increase in resistivity for iron, when a small
amount of an other element is alloyed with it. Copper, cobalt and nickel increase the resistiv-
ity of iron only marginally, whereas aluminium and silicon give a considerable increase in the
resistivity.
Consequently, materials suitable for electric sheets are silicon–iron and aluminium–iron.
A silicon-rich alloy makes the material brittle, and thus in practice the amount of silicon is
reduced to a few per cent in the alloy. Electric sheets have been developed with a silicon
content of 6%. An aluminium-rich alloy makes the material very hard (the Vickers hardness
HV is about 250 for a material with an aluminium content of 16% by weight), which may have
an influence on the usability of the material. However, the resistivity of the material is so high
that it proves a very interesting alternative for certain special applications. In the literature
(Heck, 1974), an equation is introduced for the resistivity ρ of AlFe alloy as a function of
aluminium content pAl (percentage by weight):

ρ = (9.9 + 11 pAl ) µ cm. (3.61)

This is valid at a temperature of +20 ◦ C, where the aluminium content is ≤4% by weight. The
temperature coefficient of resistivity decreases sharply when the aluminium content increases,
and it is 350 × 10−6 /K when the aluminium content of the alloy is 10% by weight. When
the alloying is in the range where the occurrence of Fe3 Al is possible, for instance if the
aluminium content is 12–14%, the resistivity of the material depends on the cooling method.
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Design of Magnetic Circuits 189

ρ/ µΩ cm
160

140
cooling in water
120

100

80
Fe3 Al
60
cooling 30 K/h
40

20

0
0 2 4 6 8 10 12 14 16
compounding agent % per weight

Figure 3.25 Resistivity of aluminium–iron alloy as a function of the proportion of admixing material.
The resistivity is also partly dependent on the cooling rate of the material. Fe3 Al compound is created
when the cooling takes place slowly, about 30 K/h. Adapted from Heck (1974)

As shown in Figure 3.25, the resistivity of a material cooled rapidly from 700 ◦ C is notably
higher than for a material that is cooled more slowly (30 K/h).
The resistivity reaches a value of 167 µ cm when the proportion of aluminium is 17%
by weight, but above this content the alloy becomes paramagnetic. Aluminium–iron alloys
have been investigated from the beginning of the twentieth century, when it was discovered
that the addition of aluminium to iron had very similar effects as the addition of silicon. With
small aluminium contents, the coercivity of the AlFe alloys, hysteresis losses and saturation
flux density do not differ significantly from the respective properties of SiFe alloys. As the
aluminium content increases, the resistivity increases, whereas coercitivity, hysteresis losses
and saturation flux density decrease.
Heck (1974) gives an equation for the saturation flux density of AlFe alloys as a function
of aluminium content pAl (% by weight):

Bs = (2.164 − 0.057 pAl ) V s/m2 . (3.62)

According to Heck (1974), the density ρ of the alloy may be written as

ρ = (7.865 − 0.117 pAl ) kg/m3 . (3.63)

Figure 3.26 illustrates half of the hysteresis loop of an AlFe alloy, the proportion of alu-
minium being 16 atomic per cent. The figure shows that the saturation flux density Bs =
1.685 T given by Equation (3.62) is sufficiently accurate.
Iron–aluminium alloys can be employed for instance as laminating materials to reduce the
harmful effects of eddy currents in solid parts. Due to its hardness, the alloy has been used in
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190 Design of Rotating Electrical Machines

B/T

2.0
10

1.0

0 50 100 H/A/cm

Figure 3.26 Half of a hysteresis loop of an AlFe alloy, the proportion of aluminium being 16 atomic
per cent (8.4% by weight). The resistivity of the material is about 84 µ cm at a temperature of +20 ◦ C,
and the temperature coefficient of the resistivity is very low, of magnitude 350 ppm (parts per million).
On the above curve, the field strength values have to be multiplied by 10

tape recorder magnetic heads, for instance. Aluminium can also be employed together with
silicon as an alloying material of iron, but the commercial electric sheets are usually silicon
alloys. The alloying of both aluminium and silicon reduces the saturation flux density of iron,
but the decrease is not very rapid when compared for instance with carbon, which, already
with a content of 0.5%, makes iron unfit for a magnetic circuit.
The magnetic properties of a material depend on the orientation of the crystals of the ma-
terial. The crystals may be in random directions, and therefore anisotropy is not discernible
in the macroscopic magnetizing curve of the material. However, the crystals may also be
positioned so that the anisotropy is discernible at a macroscopic scale. In that case, the mag-
netizing curve is different depending on the direction of magnetization. The material is then
anisotropic, and it is said to have a magnetic texture.
The selection of the most favoured crystal orientations is based on several factors. For
instance, internal stresses, crystal defects and impurities may ease the orientation when the
material is rolled or heat treated in a magnetic field. Finally, all the most favoured directions
of the crystals are more or less parallel. In that case, the material is said to have a crystal
structure or a crystal texture.
This kind of crystal texture is technically important, because the whole body can be treated
as a single crystal. There are two significant cases that enable mass production of crystal
orientation: one is the Goss texture, common mainly in silicon–irons; and the other is a cubic
texture, common in 50% NiFe alloys. It is also possible to produce silicon-containing irons
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Design of Magnetic Circuits 191

(a) (b)

Figure 3.27 (a) Cubic texture and (b) Goss texture. The arrow points in the rolling direction of the
sheet. The cubic texture produces nonoriented materials and the Goss texture produces oriented materi-
als. The oriented materials have different magnetic properties in different directions

with a cubic crystal texture. Figure 3.27 depicts the orientation of crystals in these textures
with respect to rolling direction.
In a crystal lattice with a Goss texture, only one corner of the cube is parallel to the rolling
direction, which is also the main magnetizing direction in technical applications. In a crystal
lattice with a cubic texture, the whole side of the cube is parallel to the rolling plane, and
thus a favoured crystal orientation occurs also in the normal direction. For both textures, a
rectangular magnetizing curve is typical, since the saturation flux density is reached without
rotation of the Weiss domains. Also, a relatively high coercive force is typical of both tex-
tures, since the spontaneous magnetizing of the crystals remains easily in the direction of the
external magnetic field.
In electrical machine construction, both oriented and nonoriented silicon–iron electric
sheets are important materials. Oriented electric sheets are very anisotropic, and their perme-
ability perpendicular to the rolling direction is notably lower than in the longitudinal direction.
Oriented sheets can be employed mainly in transformers, in which the direction of the flux
has always to be same. In large electrical machines also, an oriented sheet is used, since, due
to the large dimensions of the machine, the sheet can be produced from elements in which the
direction of flux remains unchanged regardless of the rotation of the flux.
Oriented sheet material can be employed also in small machines, as long as it is ensured
during machine construction that the sheets are assembled at random so that the permeance
of the machine does not vary in different directions. However, the magnetic properties of an
oriented sheet in the direction deviating by 45–90◦ from the rolling direction are so poor that
using an oriented sheet is not necessarily advantageous in rotating electrical machines. Figure
3.28 illustrates the influence of the rolling direction in the iron losses and the permeability of
the material.
The main principle in machine construction is that those elements of rotating machines,
which experience a rotating field, are produced from nonoriented electric sheets, the prop-
erties of which are constant irrespective of the rolling direction. Figure 3.29 depicts the
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192 Design of Rotating Electrical Machines

2.0 4.0

B5 /T P15 /W/kg
P15

B5
1.0 2.0

0 0
o o o o o o o o o
0o 10 20 30 40 50 60 70 80 90

deviation from rolling direction

Figure 3.28 Iron losses P15 of a transformer sheet M6 at a flux density of 1.5 T, a frequency of 50 Hz
and a flux density B5 with an alternating current, when the effective value of the field strength is 5 A/m.
Reproduced by permission of Surahammars Bruk AB

2.5
M800-65A
M400-65A 100 H
B /T 2.0
10 H
1.5

1.0

0.5

0
0 0.5 1 1.5 2 2.5 3
H /A/cm
Figure 3.29 DC magnetizing curves of nonoriented electrical sheets, produced by Surahammars Bruk.
The silicon content of M400-65A is 2.7% and of M800-65A about 1%. The resistivity of M400-65A is
46 µ cm, and of M700-65A 25 µ cm. As defined in the European Standard EN 10106, the standard
grade of the material expresses the iron losses of the sheet at a peak flux density of 1.5 T and a frequency
of 50 Hz, and also the thickness of the material. Thus, the grade M800-65A means that the dissipation
power is 8 W/kg and the thickness of the sheet is 0.65 mm. Reproduced by permission of Surahammars
Bruk AB
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Design of Magnetic Circuits 193

DC magnetizing curves of two nonoriented electric sheets, produced by Surahammars

Bruk AB.

3.6.2 Losses in Iron Circuits

In rotating machines, the machine parts are influenced by an alternating flux in different ways.
For instance, in an asynchronous machine, all the parts of the machine experience an alternat-
ing flux. The frequency of the stator is the frequency f s fed by the network or an inverter. The
frequency f r of the rotor depends on the slip s and is

fr = s · fs . (3.64)

The outer surface of the rotor and the inner surface of the stator experience high harmonic
frequencies caused by the slots. Also, the discrete distribution of the windings in the slots
creates flux components of different frequencies both in the stator and in the rotor. The varia-
tion of the flux in the rotor surface of an asynchronous machine can be restricted with certain
measures to a slow variation of the main flux. In that case, the rotor in some constructions can
be produced from solid steel.
In different synchronous machines (synchronous reluctance machines, separately magne-
tized machines, permanent magnet machines), the base frequency f s of the armature core
(usually stator) is the frequency of the network (50 Hz in Europe) or the frequency of the
supplying frequency converter, and the frequency of the rotor is zero in the stationary state.
However, the rotor surface experiences high-frequency alternating flux components because
of a changing permeance caused by the stator slots. During different transients, the rotor of
a synchronous motor is also influenced by an alternating flux. The rotor of a synchronous
machine can be produced from solid steel since, in normal use, harmonic frequencies occur
only on the surface of the rotor. The amplitudes of these frequencies are quite low because of
the large air gaps that are common especially in nonsalient-pole machines.
In DC machines, the frequency of the stator is zero, and the flux varies only during tran-
sients, if we neglect the high-frequency flux variation caused by the permeance harmonics on
the surface of the pole shoe. DC-magnetized machine parts can be produced from cast steel or
thick steel sheet (1–2 mm). However, the armature core experiences a frequency that depends
on the rotation speed and the number of pole pairs. In a modification of a DC series-connected
machine, an AC commutator machine, all the parts of the machine are influenced by an al-
ternating flux, and therefore the entire iron circuit of the machine has to be produced from
thin electric sheet. In a doubly salient reluctance machine, all the machine parts experience
pulsating flux components of varying frequencies, and thus in this case also the parts have to
be made of thin electric sheet.
The most common thicknesses of electric sheet are 0.2, 0.35, 0.5, 0.65 and 1 mm. There
are also notably thinner sheets available for high-frequency purposes. Common nonoriented
electric sheets are available at least with a thickness of 0.1 mm. Amorphous iron strips are
available with a thickness of 0.05 mm in various widths.
Losses in an iron circuit are of two different types, namely hysteresis losses and eddy cur-
rent losses. The curves in Figure 3.30 illustrate half of a hysteresis loop for a magnetic ma-
terial. Hysteresis in a material causes losses in an alternating field. First, a power loss caused
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194 Design of Rotating Electrical Machines

B Bmax B Bmax B Bmax

4 2 4 2 4 2

3, + Br w1 3, + B r w2

Hmax

H H H

w Hy
1,−B r 1, −B r

(a) (b) (c)

Figure 3.30 Determination of hysteresis loss: (a) entire hysteresis curve, (b) w1 , magnetic energy per
volume stored when moving from 1 to 2, (c) w2 , magnetic energy per volume returned when moving
from 2 to 3

by the hysteresis will be investigated in iron, see Figure 3.30. When H increases from zero at
point 1 to H max at point 2, an energy per volume w absorbed in a unit volume is
Bmax
w1 = H dB. (3.65)
−Br

Correspondingly, when H → 0, the dissipated energy is

Br
w2 = H dB. (3.66)
Bmax

The total hysteresis energy is calculated as a line integral, when the volume of the object
is V


WHy = V H dB. (3.67)

The hysteresis energy of Equation (3.67) is obtained by travelling around the hysteresis loop.
With an alternating current, the loop is circulated constantly, and therefore the hysteresis dis-
sipation power PHy depends on the frequency f . When the area of the curve describes the
hysteresis energy per volume why , we obtain for the hysteresis power loss in volume V

PHy = f V wHy . (3.68)

Empirical equations yield an approximation for the hysteresis loss

PHy = ηV f Bmax
n
, (3.69)

where the exponent n varies typically over [1.5, 2.5], η being an empirical constant.
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Design of Magnetic Circuits 195

B/T M800-65A
M400-65A
1

0.5

–0.5

–1

–4 –3 –2 –1 0 1 2 3 4 H /A/cm

Figure 3.31 Approximate hysteresis curves of electrical sheets produced by Surahammars Bruk AB.
M400-65A contains more silicon than M800-65A, which is a common material in small motors. Repro-
duced by permission of Surahammars Bruk AB

In the case of an alternating flux in the iron core, the alternation of the flux induces voltages
in the conductive core material. As a result, eddy currents occur in the core. These currents
tend to resist changes in the flux. In solid objects, the eddy currents become massive and effec-
tively restrict the flux from penetrating the material. The effect of eddy currents is limited by
using laminations or high-resistivity compounds instead of solid ferromagnetic metal cores.
Figure 3.31 depicts the hysteresis curves of two different electric sheets used in laminations,
produced by Surahammars Bruk AB.
Although magnetic cores are made of sheet, a thin sheet also enables eddy currents to occur
when the flux alternates. The case of Figure 3.32, in which an alternating flux penetrates the
core laminate, will now be investigated.
If a maximum flux density B̂m passes through the region 12341, the peak value for the flux
of a parallelogram (broken line) is obtained with the notation in Figure 3.32

Φ̂ = 2hx B̂m . (3.70)

Since d h, the effective value of the voltage induced in this path is, according to the
induction law,

ω B̂m
E = √ 2hx. (3.71)
2

The resistance of the path in question depends on the specific resistivity ρ, the length of the
path l and the area S. The lamination is thin compared with its other dimensions. Hence, we
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196 Design of Rotating Electrical Machines

h
4 1
path of eddy
current,
length l
x

B dx

3 d 2

–d/2 0 d/2

Figure 3.32 Eddy currents in a sheet material. The magnetic flux density B is varying in the directions
given by the arrows and the corresponding eddy currents circulate around the magnetic flux. The eddy
currents try, according to Lenz’s law, to prohibit the flux from penetrating the laminations. The broken
line is for electrical sheet M400-65A and the solid line for electrical sheet M800-65A produced by
Surahammars Bruk AB

may simply write for the resistance of the path l

ρl 2hρ
R= ≈ . (3.72)
S w dx

The flux density in the lamination creates a flux Φ = xhB. The alternating flux creates a
voltage −dΦ/dt in the area observed. The induced voltage creates a current

2π f · B̂m
√ 2xh
E 2 2π f · B̂m wx dx
dI = = = √ , (3.73)
R 2hρ 2·ρ
w dx

the differential power loss being respectively

(2π f · B̂m )2 whx 2 dx

dPFe,Ft = E dI = . (3.74)
ρ
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Design of Magnetic Circuits 197

The eddy current loss in the whole sheet is thus

d/2 2 d/2
2π f B̂m wh
PFe,Ft = dPFe,Ft = · x 2 dx. (3.75)
ρ
0 0

Since whd = V, the volume of the laminate, the eddy current loss is

whπ 2 f 2 d 3 B̂m2 V · π 2 f 2 d 2 B̂m2

PFe,Ft = = . (3.76)
6ρ 6ρ

Here we can see the radical influence of the sheet thickness d (PFe ∼ = d3 ), the peak value
of the flux density B̂m and the frequency f on eddy current losses. Also, the resistivity ρ is of
great significance. The measurements for silicon steel show that the eddy current loss is about
50% higher than the result given by Equation (3.76).
The reason for this difference lies in the large crystal size of silicon steel. In general, we
may state that as the crystal size increases, the eddy current losses in the material increase as
well. Equation (3.76) can nevertheless be used as a guide when estimating eddy current losses
for instance in the surroundings of a given operating point. Manufacturers usually give the
losses of their materials per mass unit at a certain peak value of flux density and frequency,
for instance P15 = 4 W/kg, 1.5 T, 50 Hz or P10 = 1.75 W/kg, 1.0 T, 50 Hz.
Figure 3.33 illustrates the iron losses in two electric sheets of equal thickness and different
resistivity. The sheets are produced from the same materials as in the previous examples. The
thickness of the sheets is 0.65 mm. The manufacturers usually give combined iron losses; in
other words, eddy current losses and hysteresis losses are not separated.

14
P Fe W M800-65A
12
m kg
10

8
M400-65A
6

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

B/ T

Figure 3.33 Iron losses of two different electrical sheets at an alternating flux of 50 Hz as a function of
the maximum value of the flux density. The curves include both the hysteresis loss and the eddy current
loss
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198 Design of Rotating Electrical Machines

In manual calculations, the iron losses are found by dividing the magnetic circuit of the
machine into n sections, in which the flux density is approximately constant. Once the masses
mFe,n of the different areas n have been calculated, the losses PFe,n of the different parts of the
machine can be approximated as follows:
 2  2
B̂n B̂n
PFe,n = P10 m Fe,n or PFe,n = P15 m Fe,n . (3.77)
1T 1.5 T

Total losses can be calculated by summing the losses of different sections n. A problem
occurring in the calculation of losses in rotating machines is that the loss values P15 and
P10 are valid only for a sinusoidally varying flux density. In rotating machines, however,
pure sinusoidal flux variation never occurs alone in any parts of the machine, but there are
always rotating fields that have somewhat different losses compared with varying field losses.
Also, field harmonics are present, and thus the losses, in practice, are higher than the results
calculated above indicate. Furthermore, the stresses created in the punching of the sheet and
also the burrs increase the loss index. In manual calculations, these phenomena are empirically
taken into account and the iron losses can be solved by taking into account the empirical
correction coefficients kFe,n defined for different sections n, Table 3.2:
 2  2
 B̂n  B̂n
PFe = kFe,n P10 m Fe,n or PFe = kFe,n P15 m Fe,n . (3.78)
n
1T n
1.5 T

The iron losses discussed above are calculated only for a time-varying flux density required
by the fundamental of the main flux. In addition to these losses, there are other iron losses of
different origin in rotating machines. The most significant of these losses are as follows:

r End losses, which occur when the leakage flux of the machine end penetrates the solid struc-
tures of the machine, such as the end shields, creating eddy currents. Calculation of these
losses is rather difficult, and in manual calculations it suffices to apply empirical correction
coefficients in Equation (3.78) to take the influence of the losses into account.
r Additional losses in the teeth are caused by permeance harmonics that occur when the stator
and rotor teeth pass each other rapidly. To be able to calculate the losses, it is necessary to
solve the frequency and the amplitude of the harmonic experienced by a tooth. The losses
are calculated similarly as before. These losses are also included in the correction coefficient
kFe,n .

Table 3.2 Correction coefficients kFe,n for the definition of iron losses in different sections of different
machine types taking the above-mentioned anomalies into account. (Coefficients are valid for AC
machines with a sinusoidal supply and for DC machines.)
Machine type Teeth Yoke
Synchronous machine 2.0 1.5–1.7
Asynchronous machine 1.8 1.5–1.7
DC machine 2.5 1.6–2.0
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Design of Magnetic Circuits 199

τu
2

Figure 3.34 Paths of eddy currents in a solid pole shoe. The pattern is repeated at intervals of half a
slot pitch

r In machines with solid parts, for instance on the surface of pole shoes, harmonics created by
slots (cf. Figures 3.5 and 3.6) generate eddy currents that cause surface losses, Figure 3.34.
Richter (1967) introduced empirical equations for solving these losses. An accurate analysis
of the phenomenon is extremely difficult and requires the solution of the field equations in
solid material.

Usually, loss calculations are carried out assuming fundamental flux variation only. Table
3.2 roughly takes into account the harmonic behaviour in different parts of the machine by
simply multiplying the values calculated by the fundamental. If a more detailed analysis is
possible, the eddy current loss in the stator yoke, for instance, may be determined by calcu-
lating the tangential and radial flux density components at different frequencies. The eddy
current loss in a lamination of thickness d, mass mFe , conductivity σ Fe and density ρ Fe is
calculated from

∞
π 2 σFe 2 2 2 
PFe,EC = f d m Fe n 2 Btan,n + Bnorm,n
2
6 ρFe n=1

π 2 σFe 2 2 2 
= f d m Fe Btan,1 + Bnorm,1
2
kd (3.79)
6 ρFe
 ∞ 2 
Btan,n + Bnorm,n
2
kd = 1 + 2 . (3.80)
n=2
Btan,1 + Bnorm,1
2

These equations require an accurate flux density solution that may be divided into the compo-
nents of different harmonics.
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200 Design of Rotating Electrical Machines

For the hysteresis losses, there is a similar approach:

∞
f 2  f 2 
PFe,Hy = cHy m Fe n 2 Btan,n + Bnorm,n
2
= cHy m Fe Btan,1 + Bnorm,1
2
kd . (3.81)
100 n=1
100

The hysteresis coefficient cHy = 1.2–2 [A m4 /V s kg] for anisotropic laminations with 4% of
silicon and 4.4–4.8 [A m4 /V s kg] for isotropic laminations with 2% of silicon.
Even Equations (3.79–3.81), however, give too low values for the iron losses, and additional
core losses have to be taken into account by suitable loss coefficients. For instance, the values
of Table 3.2 may be used.
Motors also face the problem of a pulse-width-modulated (PWM) supply. In a PWM supply,
the losses of the motor increase in many ways. Also the iron losses increase, especially on the
rotor surface. Depending on the PWM switching frequency, the overall efficiency of the motor
is typically 1–2% lower in a PWM supply than in a sinusoidal supply.

3.7 Permanent Magnets in Rotating Machines

Next, permanent magnet materials and their properties are discussed. Magnetically soft mate-
rials are employed to facilitate the magnetizing processes, such as the displacement of Bloch
walls and the orientation of Weiss domains; see Figure 3.19. With permanent magnets, the
requirements are the opposite. The displacement of a permanent magnet from the initial state
is difficult. When the Weiss domains have been aligned in parallel orientations with a high
external field strength, the material becomes permanently magnetized.
The objective can be met by the following means. The displacement of Bloch walls is
prevented by inhomogeneities and the extremely fine structure of the material. The best way
to completely prevent the displacement of Bloch walls is to select so fine a structure that each
particle of the material comprises only a single Weiss domain in order to create an energy
minimum.
In addition, the orientation of Weiss domains has to be impeded. Now, anisotropy is uti-
lized. Both a high crystal anisotropy of the material and a high anisotropy of the shape of
the crystals (rod-shaped crystals are selected) significantly impede the orientation of Weiss
domains. This leads to an increase of magnetic hardness and coercivity H cJ . With rare-earth
permanent magnets, a high crystal anisotropy is reached mainly by employing rare-earth met-
als as base materials. With hard ferrites, the crystal anisotropy is reached chiefly by orientating
the particles under pressure in a magnetic field.

3.7.1 History and Characteristics of Permanent Magnets

Excluding the natural magnet, magnetite (Fe3 O4 ), the development and manufacture of per-
manent magnet materials began in the early twentieth century with the production of carbon,
cobalt and wolfram steels. These permanent magnet materials, the magnetic properties of
which were rather poor, remained the only permanent magnet materials for decades. A re-
markable improvement in the field was due to the discovery of AlNi and especially AlNiCo
materials. The next significant step forward was taken in the 1960s, when the compounds of
rare-earth metals and cobalt were invented. The most important materials were SmCo5 and
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Design of Magnetic Circuits 201

400 Neorem
BHmax/kJ/m 3
8

300
7
6
200
5

4
100 3
2
1
0

1900 1920 1940 1960 1980 2000 year

Figure 3.35 Development of the energy product of permanent magnet materials in the twentieth
century: 1, cobalt steel; 2, FeCoV; 3, AlNiCo; 4, AlNiCo; 5, SmCo5 ; 6, Sm(Co, Cu,Fe,Zr)17; 7, NdFeB;
8, NdFeB; 9, NdFeB. Neorem refers to a commercial material NEOREM 503 i (produced by Ne-
orem Magnets), the energy product of which is about 370 kJ/m3 . Adapted from Vacuumschmelze (2003).
http://www.vacuumschmelze.de/dynamic/docroot/medialib/documents/broschueren/dmbrosch/PD002e.
pdf

Sm2 Co17 . Later, better and more complicated variations of these two were discovered, such
as Sm2 (Co, Cu, Fe, Zr)17 . After the discovery of these materials, the next significant invention
was the neodymium–iron–boron permanent magnets, which nowadays yield the highest en-
ergy product. An advantage of these materials is that the rare samarium and cobalt have been
replaced by the far more common neodymium and iron. The basic type of these materials
is Nd15 Fe77 B8 . Figure 3.35 illustrates the development of the energy product of permanent
magnets from the beginning of the twentieth century (Vacuumschmelze, 2003).
The remanence flux density of commonly used SmCo5 is 1.05 T at maximum, and its
energy product is 210 kJ/m3 . The maximum values for neodymium–iron–boron are 1.5 T
and 450 kJ/m3 . In practice, motor-grade materials still remain below an energy product of
400 kJ/m3 .
Previously, a serious problem with permanent magnet materials was the easy demagneti-
zation of the materials. The best permanent magnet materials are quite insensitive to external
field strengths and the influence of an air gap. Only short-circuit currents in hot machines may
constitute a risk of demagnetization in certain structures.
The most significant permanent magnetic materials in commercial production are the fol-
lowing:

r AlNiCo magnets are metallic compounds of iron and several other metals. The most impor-
tant alloying metals are aluminium, nickel and cobalt.
r Ferrite magnets are made of sintered oxides, barium and strontium hexa-ferrite.
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202 Design of Rotating Electrical Machines

r RECo magnets (rare-earth cobalt magnets) are produced by a powder metallurgy technique,
and comprise rare-earth metals (mainly samarium) and cobalt in the ratios of 1 : 5 and 2 : 17.
The latter also includes iron, zirconium and copper.
r Neodymium magnets are neodymium–iron–boron magnets, produced by a powder metal-
lurgy technique.

Neodymium magnets were invented in 1983. They are produced by a powder metallurgy
process developed by Sumimoto, or by a ‘melt-spinning’ process developed by General Mo-
tors. These materials typically comprise about 65% iron, 33% neodymium and 1.2% boron,
with small amounts of aluminium and niobium. In some cases, dysprosium and cobalt are also
employed.
Neodymium magnets are sensitive to changes in temperature. The intrinsic coercive force
drops notably when the temperature rises. However, by employing other rare-earth metals as
alloying elements for neodymium, the operating temperature can be raised to 180 ◦ C. Due to
their properties, neodymium magnets can be employed in electromagnetic hoists, magneti-
cally suspended trains, generators, magnetic separation devices and in various motors.
The energy product of SmCo (1 : 5) magnets (invented in 1969) is 175 kJ/m3 at maximum,
and SmCo (2 : 17) magnets (invented in the 1980s) typically reach 200 kJ/m3 (255 kJ/m3 max-
imum). The heat resistance of SmCo magnet is excellent when compared with neodymium
magnets, and they can be used at temperatures up to 250 ◦ C. Furthermore, the corrosion resis-
tance of SmCo magnets is better than that of neodymium magnets, but they are more brittle
than neodymium magnets. SmCo magnets are common in applications in which the amount
of material, that is the lightness, and the heat resistance are decisive factors, while the price
is of little significance. Typical applications are for small stepper motors, cathode-ray tube
(CRT) positioning systems, electromechanical actuators, earphones, loudspeakers, etc.
As a single-phase alloy, SmCo5 is rather easily saturated. As shown in Figure 3.36, about
200 kA/m suffices for the saturation of SmCo5 , since the Bloch walls are easily displaced in
the crystals. Also the coercivity in this case is rather small (H cJ ≈ 150 kA/m). The coercive
force changes only when the external field strength H mag increases so high that all the grains
have become magnetized against the inner leakage fields of the material. At complete satura-
tion, there are no longer any Bloch walls in the crystals. Figure 3.36 illustrates the change in
the coercive force of SmCo5 , when the field strength H mag used for the magnetization of the
material is increased.
A second basic material Sm2 Co17 behaves completely differently in magnetizing; see Fig-
ure 3.37. Here, at low field strengths (<H cJ ), the material is not magnetized even close to
saturation, but a double or triple field strength is required when compared with the coercive
force to reach a high remanence. This is because the Bloch walls are oriented along the crystal
domain boundaries, and their orientation and displacement are particularly difficult.
Ferrites were first introduced in the 1950s, and because of their low price, they are still
dominant on the market. There are two commercial alternatives of ferrites available, based on
either strontium (18%) or barium (21%) carbonate processed into hexa-ferrites. Both isotropic
and anisotropic qualities are produced by powder metallurgy methods.
AlNiCo magnets were invented in the 1930s, and their utilization was at its height in the
1960s. Nowadays they are employed at temperatures of 300 ◦ C and above. AlNiCo magnets
are produced either by casting or by sintering. Their typical composition is 50% Fe, 25%
Co, 14% Ni, 8% Al, 3% Cu/Nd/Si. Impurities of C, Cr, Mn and P have to be avoided. The
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Design of Magnetic Circuits 203

J [T]

1.2

1.0
Hmag = 2500 kA/m
1400 kA/m
1000 kA/m 0.8
VACOMAX 170

0.6
800 kA/m

0.4

600 kA/m
0.2
400 kA/m 200 kA/m
H [kA/m]

–1200 –1000 –800 –600 – 400 –200 0 200 400 600 800

Figure 3.36 Increase in the coercive force of the SmCo5 -type VACOMAX 170; the increase is due to
the increase in the magnetizing field strength, H mag , as a parameter. The behaviour of neodymium mag-
nets in magnetizing is similar to the behaviour of the SmCo5 . Adapted from Vacuumschmelze (2003).
http://www.vacuumschmelze.de/dynamic/docroot/medialib/documents/broschueren/dmbrosch/PD002e.
pdf

J [T]

1. 2
Hmag= 2000 kA/m

1.0
1240 kA/m

VACOMAX 240 HR
0.8
880 kA/m

0.6
750 kA/m

0.4

670 kA/m
0.2
560 kA/m

300 kA/m H [kA/m]

–1200 –800 –400 0 400 800 1200 1600 2000 2400 2800 3200

Figure 3.37 Increase in the coercive force of the Sm2 Co17 -type VACOMAX 240 HR caused by an
increase in the magnetizing field strength H mag . Different qualities may require notably higher mag-
netizing field strengths, for example up to 4000 kA/m. Adapted from Vacuumschmelze (2003). http://
www.vacuumschmelze.de/dynamic/docroot/medialib/documents/broschueren/dmbrosch/PD002e.pdf
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204 Design of Rotating Electrical Machines

cast qualities yield a 25% better magnetic performance than the sintered qualities. AlNiCo
magnets are resistant to high temperatures, and do not corrode easily. The energy products are
typically 10–80 kJ/m3 .
At the moment, the most rapidly growing field is polymer-bonded permanent magnets. All
the basic types can be produced as polymer-bonded types. Both isotropic and anisotropic
qualities are commercially available. Polymer-bonded magnets are well machinable, and they
can be used in complicated structures. Their heat resistance depends on the bonding agent and
varies between 100 and 150 ◦ C. They are common in small stepper and DC motors, tachome-
ters, motors of diskette drives, toys, quartz watches and phones.
In general, we may state that the decisive requirements for good permanent magnet ma-
terials are a high saturation polarization, a high Curie temperature, and either a high crystal
anisotropy as a material property, or the possibility to shape the anisotropy significantly. As
with magnetically soft materials, the hysteresis loop is now an important characteristic curve.
Usually, only the section in the second quadrant of the hysteresis loop is given. In the con-
struction of magnetic circuits with permanent magnets, the geometry of the magnetic circuit is
selected in such a way that a typical maximum energy product is reached for each permanent
magnet material, Figure 3.38.
The dependence of the B and J curves is written as J = B − µ0 H , and therefore either
one of the curves may be applied alone to describe the characteristics of a permanent magnet.
At the remanence Br , the curves are united, since H = 0. The intersection points on the H-
axis are different for the flux density curve and the polarization curve, and the corresponding
coercivities are denoted H cB and H cJ respectively. J s describes the saturation polarization
of the material. The quantities related to magnetizing are illustrated in Figure 3.39, which
describes a typical hysteresis curve of a neodymium magnet for both the flux density and the
polarization.

B B

Br

(BH ) PMmax

–HcB H (BH) PM

Figure 3.38 Second quarter of the hysteresis curve of a general permanent magnet and the correspond-
ing behaviour of (BH)PM product
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Design of Magnetic Circuits 205

B, J / T B, J / T
Br Js Js B

1.0 1.0
B
HcJ 0.5 0.5

H, kA/m H, kA/m
–1500 –500 +500 + 1500 –1500 –500
J HcB –0.5 J –0.5

(a) (b)

Figure 3.39 (a) Typical hysteresis curve of a neodymium magnet illustrated with the flux density B and
the polarization J. (b) The behaviour of the polarization and demagnetization curves under increasing
temperature T. Typically, the polarization of a neodymium magnet decreases by about 10% when the
temperature increases by 100 K

The characteristics of permanent magnets are chiefly described by the following quantities:
r remanence Br ;
r coercivity H cJ (or H cB );
r the second quarter of the hysteresis loop;
r energy product (BH)PMmax ;
r temperature coefficients of Br and H cJ , reversible and irreversible portions separated;
r resistivity ρ;
r mechanical characteristics;
r chemical characteristics.

A comparison of the characteristics of neodymium magnets and SmCo magnets is presented

in Table 3.3.

3.7.2 Operating Point of a Permanent Magnet Circuit

Let us consider the permanent magnet ring in Figure 3.40. First, it is assumed that the ring of
Figure 3.40 is complete, ‘closed’ and magnetized until saturation so that the saturation polar-
ization of the permanent magnet material is reached, after which the magnetizing equipment
is removed. Although the external field strength is removed, there remains a remanence flux
density Br in the ring. Next, a section is cut out of the ring; the magnet is ‘opened’ with an
air gap δ. In the created air
gap, we may measure field strength H δ . Since there is no current
flowing through the ring ( i = 0), we obtain from Ampère’s law


H dl = HPM h PM + Hδ δ = 0. (3.82)
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206 Design of Rotating Electrical Machines

Table 3.3 Comparison of the characteristics of neodymium magnets and SmCo magnets. Adapted
from TDK (2005) www.tdk.co.jp/tefe02/e331.pdf
Neodymium magnets SmCo magnets
Composition Nd, Fe, B, etc. Sm, Co, Fe, Cu, etc.
Production Sintering Sintering
Energy product 199–310 kJ/m3 255 kJ/m3
Remanence 1.03–1.3 T 0.82–1.16 T
Intrinsic coercive force, H cJ 875 kA/m to 1.99 MA/m 493 kA/m to 1.59 MA/m
Relative permeability 1.05 1.05
Reversible temperature coefficient of −0.11 to −0.13%/K −0.03 to −0.04%/K
remanence
Reversible temperature coefficient of −0.55 to −0.65%/K −0.15 to −0.30%/K
coercive H cJ
Curie temperature 320 ◦ C 800 ◦ C
Density 7300–7500 kg/m3 8200–8400 kg/m3
Coefficient of thermal expansion in 5.2 × 10−6 /K 5.2 × 10−6 /K
magnetizing direction
Coefficient of thermal expansion −0.8 × 10−6 /K 11 × 10−6 /K
normal to magnetizing direction
Bending strength 250 N/mm2 150 N/mm2
Compression strength 1100 N/mm2 800 N/mm2
Tensile strength 75 N/mm2 35 N/mm2
Vickers hardness 550–650 500–550
Resistivity 110–170 × 10−8  m 86 × 10−8  m
Conductivity 590 000–900 000 S/m 1160 000 S/m

Thus, we obtain for the field strength of the magnet

δ
HPM = − Hδ where h PM is the ‘height’ of the permanent magnet. (3.83)
h PM
We have now defined the field strength H PM caused by the atomic magnets of the ring
material. Equation (3.83) shows that the influence of an air gap corresponds to the situation

SPM
δ, Hδ

hPM, HPM

Figure 3.40 Definition of the field strength of an opened permanent magnet ring
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Design of Magnetic Circuits 207

–(BH ) PM, max

B, J
–(BH) PM

Br
A opt B'A
J PM T B PM

H'c Hc J H cB HA HAopt HPM 0 H

Figure 3.41 Characteristic demagnetization curve (H cB –A–Br ), an operation line segment (A–B A ),
an operating point (T) and the optimum operating point (Aopt ) of a permanent magnet system. The
energy product of the material is indicated by −(BH)PM . The polarization curve J PM shows that at higher
demagnetizing field strengths, the permanent magnet material loses its polarization. This magnet is in
too high a demagnetizing field when the point A is reached. Part of the polarization J is lost. The new
remanence is BA . For the best utilization of the magnet material, the demagnetizing field strength should
not go much beyond H Aopt

in which an unopened permanent magnet ring is magnetized in a negative direction with the
field strength H PM . On the characteristic curve of the ring material (Figure 3.41), the operating
point has moved from Br to the point A (called a base point), where the field strength H A =
H PM Equation (3.83).
If we now shorten the air gap, the operating point moves along the reversible magnetizing
line ABA , called an operation line segment. The reversible magnetizing curve is not exactly a
straight line but very close to it, and thus in our calculations we can use a straight line instead
of a curve. If we close the ring again, the new remanence flux density will be BA , which is
lower than the original remanence flux density Br before opening the ring. The closing of the
magnet may take place for instance either with the same permanent magnet material or with
ideal iron, in which no field strength is needed to produce the flux density BA .
Permanent magnets are usually hard to machine and expensive, and therefore soft iron is
used with them as part of the magnetic circuit, as shown in Figure 3.42. Let us assume that
the characteristics of the permanent magnet material in Figure 3.42 are as shown in Figure
3.41 and the operation line is ABA . If the height of the permanent magnet is hPM and the
cross-sectional area SPM , the flux of the magnet is

ΦPM = SPM BPM = (1 + σ ) Sδ Bδ = (1 + σ ) Sδ µ0 Hδ (3.84)

where σ is the leakage factor, that is the ratio of the leakage flux to the main flux σ = Φ σ /Φ δ ,
and Sδ the area of the air gap. From Equation (3.84), we obtain

Sδ h PM h PM
BPM = − (1 + σ ) µ0 HPM = − (1 + σ ) Λδ HPM (3.85)
δ SPM SPM
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208 Design of Rotating Electrical Machines

hPM Φ PM Φσ Φδ δ

Figure 3.42 Permanent magnet as a part of a magnetic circuit consisting of iron and an air gap. The
magnet creates a flux Φ PM , which is divided into an air-gap flux Φ δ and leakage flux Φ σ

where Λδ is the permeance of the air gap. Equation (3.85) describes a line passing through the
origin. This line meets the curve Hc ABA at the point T (Figure 3.41), which is the operating
point of the magnet system.
From the product of Equations (3.83) and (3.84), we may solve

1 |− (HB)PM | · VPM
Hδ = (3.86)
δ (1 + σ ) · Λδ

where V PM = SPM hPM is the volume of the permanent magnet. A permanent magnet of a
certain size thus yields a higher field in the air gap, the higher the energy product BPM H PM of
the magnet material. Figures 3.38 and 3.41 depict diagrams of this product, which show that
it has a maximum value. The magnet material is optimally utilized when the operating point
is as close as possible to the point Aopt . The maximum of the energy product is reached at this
point. If we wish to have a higher flux density than occurs at the optimum point Aopt , we have
to use more permanent magnet material and the operating point moves toward the remanence
flux density BA . However, the remanence flux density may not be exceeded in the magnet.
A permanent magnet keeps its operation line segment once selected, if its circuit is not
opened more than the base point A allows. If we wish to keep the respective polarization
and the remanence flux density BA , a permanent magnet may not be demagnetized with a
higher field strength than H A . In practice, because of their low relative permeability (µr =
1.05), samarium–cobalt and neodymium magnets form an air gap themselves (cf. Equation
(3.83), and physically opening the magnet circuit does not have any significant effect on the
operation of the magnet. The characteristic curve of samarium–cobalt and neodymium mag-
nets in the second quadrant is practically a straight line, and the operation line segment joins
the characteristic curve. In this case, the magnet is utilized best when the flux density of the
magnet is Br /2.
The situation is different with permanent magnet steel. It has a high relative permeability,
and therefore opening such a magnet has a remarkable influence on the operating point of
the magnet. Neodymium and samarium–cobalt magnets tolerate well possible demagnetizing
fields, and the operation line of the magnet may remain unchanged unless the polarization
of the magnet is lost under a very high demagnetizing field strength. Opening the material
with an air gap is not sufficient to demagnetize the magnets, but a negative armature reaction
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Design of Magnetic Circuits 209

at a high temperature might cause loss of polarization in samarium–cobalt and neodymium

magnets, for instance in the case of a stator short circuit.
The capability of tolerating negative field strength is a very important property of perma-
nent magnet materials used in electrical machines. Old high-permeability magnet materials
allow only a small opening of the magnetic circuit, and a demagnetizing armature reaction
is forbidden. Rare-earth magnets, however, can tolerate the opening of the magnet (air gap)
and also a demagnetizing armature reaction. In a permanent magnet machine, this means that
we may have a negative stator d-axis current in the rotor coordinate system. This allows the
possibility of a high power factor in permanent magnet machines.
The continuation of the operation line segment meets the field strength axis at the point Hc
(Figure 3.41), which is called the calculatory coercive force. If the magnet is opened more than
at the point A, the magnet is further demagnetized and the absolute value of the calculatory
coercive force decreases. The product of Hc and the length of the permanent magnet hPM
yields the current linkage of the permanent magnet

BA
ΘPM = Hc h PM = h PM . (3.87)
µ0 µr

µr is the relative permeability of the permanent magnet material.

The equation for the magnetic flux of a permanent magnet circuit can be written as

BA
Φ = Λtot Hc h PM = Λtot h PM , (3.88)
µ0 µr

where the permeance of the whole circuit, including the permanent magnet itself, is

ΛPM Λext
Λtot = . (3.89)
ΛPM + Λext

Here Λext is the permeance of the external part of the permanent magnet circuit (iron, air gap
and leakage) and ΛPM is the permeance of the permanent magnet.
From the study above we may note that, in practice, a permanent magnet material normally
operates at a flux density lower than the remanence flux density of the material BPM < Br . If
we use some rare-earth magnet material, the operation line joins the demagnetizing curve of
the material. Such a permanent magnet can create a flux density equal to its remanence flux
density Br in an infinitesimal air gap. In practical cases, the air gap is finite and also the iron
circuit creates a magnetic voltage. Hence, BPM < Br if the armature reaction is not affecting
in the same direction as the permanent magnet, which is not usually the case.
If a high air-gap flux density is sought and the permanent magnet material operates above
its optimal point (Aopt in Figure 3.41), the utilization of the magnet is inefficient, and an
excessive amount of the magnet is required. If, however, there is a possibility to arrange a
wide permanent magnet, wider than the air gap, the air-gap flux density may be higher than
the remanence of the magnet. This is illustrated in Figure 3.43.
The resistivity of a permanent magnet is a significant factor in the design of an electrical
machine. Permanent magnets are often exposed to the permeance and time harmonics of elec-
trical machines, and if the resistivity of the magnet is low, eddy currents and losses are also
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210 Design of Rotating Electrical Machines

Fe Fe
Φ PM1 w Φ PM2 w

BPM B = BPM < Br BPM B > BPM

PM PM

wPM1 w PM2

(a) (b)

Figure 3.43 Air-gap flux density Bδ compared with the permanent magnet material remanence Br
when using (a) narrow or (b) wide magnets. wPM , the width of the permanent magnet; w, the width
of the air gap. Φ PM2 > Φ PM1 . This makes it possible that the air-gap flux density Bδ may be even larger
than the remanence Br of the magnet material

created. The resistivity of sintered neodymium magnets is about 110−170 × 10−8  m. This
is 5–10-fold when compared with steel, and these magnets are thus clearly conductive and
produce losses under alternating fields.
As the resistivity of sintered NdFeB magnets is only a few times larger than that of steel,
eddy current losses in such magnets may not be omitted in machine design. Especially, the
slot harmonics and frequency converter switching harmonics should be taken into account
in machines with rotor surface magnets. The slot harmonics may be negligible only in very
low-speed machines. Exact calculation of the losses in permanent magnets is, however, very
difficult and the method presented here for the losses caused by slotting may be regarded as
an indicative method for the loss calculation.
The frequency f u on a rotor surface magnet caused by slotting in a machine rotating at
speed n [1/s] is

f u = Q s n. (3.90)

As the magnets are often long compared with the slot pitch τ u of the machine, the calcu-
lation is simplified assuming that only an axial (z-direction) eddy current travels in the per-
manent magnets similar to Figure 3.34. According to Gieras, Wang and Kamper (2008), eddy
current losses in permanent magnets may be estimated by using a simplified linear theory for
the eddy currents in the magnets. In such a case, the magnetic vector potential A (defined as
∇ × A = B and ∇ · A = 0) in the magnets may be described by the following two-dimensional
scalar equation:

∂ 2 Amzν ∂ 2 Amzν (1 + j)
+ = αν Amzν = (1 + j) kν Amzν = Amzν , (3.91)
∂x2 ∂ y2 δPMν

where the depth of penetration in the permanent magnet is


2 1
δPMν = = . (3.92)
ων µPM σPM kν
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Design of Magnetic Circuits 211

A general solution for (3.91) may for instance be written as

∞
  π  
Amz = sin ων t + βν x − A1ν e−κν y + A1ν eκν y (3.93)
ν=1
2

where
π ων ων
βν = ν = = , (3.94)
τp ν π Dn

κν = αν2 + βν2 = (α Rν + β Rν ) kν , (3.95)


4
2
1  βν βν
a Rν = √ 4+ + , (3.96)
2 kν kν


4
2
1  βν βν
aXν = √ 4+ − . (3.97)
2 kν kν

Adapting the details given by Gieras, Wang and Kamper (2008), it may be deduced that, by
using the Carter factor calculation for a fictive air-gap length measured from the stator inner
surface to the middle of a rotor surface permanent magnet, an estimate can be found for the
permanent magnet eddy current losses caused by stator slotting. When the following air gap
is used

h PM
δPMec = δ + , (3.98)
2µrPM

we get a suitable flux density variation for the evaluation of the permanent magnet eddy cur-
rent losses

B0 = β Bmax = βkC Bav . (3.99)

Now, the eddy current losses in permanent magnets may be calculated as


2
1 τu  |αν |2 B0 kν
PPM ec = a Rν 1 + SPM . (3.100)
2 2l βν2 µ0 µrPM σPM

The total surface of the permanent magnets is

SPM ≈ π Dr αPMl. (3.101)

Equation (3.100) can also be used to estimate reactive losses in permanent magnets by
replacing aRν by aXν .
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212 Design of Rotating Electrical Machines

Example 3.6: Calculate the eddy current losses in large sintered neodymium magnets
attached to the rotor surface in a 500 min−1 permanent magnet motor having a rotor di-
ameter of 200 mm and 60 stator slots. The rotor length is 200 mm and the relative width
of the permanent magnets is α PM = 0.7. The slot openings are b1 = 3 mm and the physi-
cal air gap is 0.8 mm. The magnets are 6 mm thick and the air-gap flux density under the
stator teeth is Bmax = 0.9 T. The conductivity of the permanent magnet material is about
670 000 S/m.
Solution: We assume that no hysteresis losses take place in permanent magnet materials,
and hence all the losses are eddy current losses. The frequency of the flux density variation
is (500/60) × 60 Hz = 500 Hz.
The fictive air gap is

h PM 6 mm
δPM ec = δ + = 0.8 mm + = 3.68 mm,
2µrPM 2 · 1.04
b/δ 3/3.68
κ ≈ = = 0.14,
5 + b/δ 5 + 3/3.68
be = κb1 = 0.14 · 3 mm = 0.42 mm,
τu 10
kC = = = 1.043,
τu − κb1 10 − 0.42
 

2
2
b1 b1 3 3
u = + 1+ = + 1+ = 1.487,
2δ 2δ 2 · 3.68 2 · 3.68

1 + u 2 − 2u 1 + 1.4872 − 2 · 1.487
β= = = 0.037,
2(1 + u )
2 2 · (1 + 1.4872 )

B0 = β Bmax = 0.037 · 0.9 T = 0.033 T,



ων µPM σPM 500 · 2π · 1.04 · 4π · 10−7 V s/A m · 670 000 S/m
kν = = = 37.1/m,
2 2

ων 2π · 60 · 60
500
2 · 60
βν = = s
= = 600,
π Dn π0.2 · 60 s
500 0.2
 

4
2 

1  βν βν 1  600 4 600 2

a Rν = √ 4+ + =√ 4+ + = 16.2,
2 kν kν 2 37.1 37.1

2
1 τu  |αν |2 B0 kν
PPM ec = a Rν 1 + SPM
2 2l βν 2 µ0 µrPM σPM


2
1 0.01 m |(1 + j) · 37.1|2 0.033 T
= 16.2 · 1 + · ·
2 2 · 0.2 m 6002 1.04 · 4π · 10−7 V s/A m
37.3
· SPM
670 000
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Design of Magnetic Circuits 213

√ 2
2 · 37.1
2
0.033 T 37.1
= 8.1 · 1.02 · · · SPM
6002 1.04 · 4π · 10−7 V s/Am 670 000
W W
≈ 2200 2
SPM = 2200 2 · 0.088 m2 ≈ 190 W.
m m

To reduce the losses, the magnets should have smaller dimensions, especially in the axial
direction.
There are also plastic-bonded magnets available. In these products, the best properties of
rare-earth and ferrite permanent magnet materials and suitable resins are combined. The resin
acts as a bonding material for permanent magnet powder. Because of the resin film between
the magnet particles, the conductivity of plastic-bonded magnets is extremely low, and thus
eddy current losses occur only inside the particles. Losses are in most cases insignificant.
The problem with the plastic-bonded magnets is that the magnetic properties are remarkably
weaker than in sintered products. The remanence flux density of plastic-bonded materials is
about half of that of sintered ones.
The mechanical properties of magnetic materials are weak. Sintered magnets are resistant
to pressure, but their tensile strength is low.
The chemical properties of neodymium magnets are also weak. With different coatings, it is
possible to make neodymium magnets relatively moisture resistant. Oxygen and moisture cor-
rode an unprotected neodymium magnet, and the material is reduced to light-coloured powder.

3.7.3 Application of Permanent Magnets in Electrical Machines

Permanent magnets are applied in a wide range of small electrical machines. They are utilized
for instance in the excitation of DC machines and synchronous machines, and in hybrid step-
per motors. Permanent magnets are increasingly occurring in large machines too. There are
already permanent magnet synchronous machines of several megawatts in for instance direct-
driven wind-power generators. Permanent magnets can in some cases be employed as magnet
bearings. In that case, the repulsive reaction between two permanent magnets is utilized. In
the design of a magnetic circuit with a permanent magnet material, more iteration is required
than in the design of magnetic circuits of ordinary machines. Since the permeability of a per-
manent magnet material roughly equals the permeance of a vacuum, the permanent magnet
material has a very strong influence on the reluctance of the magnetic circuit, and thus also on
the inductances of the armature winding of the rotating-field machine.

Example 3.7: Simple magnetic circuits with a small air gap are investigated (Figure 3.44).
One of the circuits is magnetized with a winding N 2 . The device is either a reactor with
two coils, or a transformer, but the arrangement can also be easily employed to illustrate
a rotating machine magnetized with a single magnetizing winding. The other winding
corresponds to the armature winding. One of the circuits is magnetized with a permanent
magnet material, the coercive force of which is 800 kA/m, and the relative permeability is
1.05. Calculate the properties of the magnetic systems.
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214 Design of Rotating Electrical Machines

Solution: It is first simply assumed that the iron parts of the magnetic circuits take 5% of
the current linkage required for magnetizing the physical air gap. Further, it is assumed
that no flux leakage occurs, and the whole magnetic flux flows in the circuit l. Now, we
aim for a flux density of 1 T in the air gap. First, a circuit magnetized with winding N 2
is investigated. We may assume that an effective air gap, including the influence of the
magnetic voltage of the iron, is δ ef = 1.05 mm.
For a flux density of 1 T in air, a field strength of

Hδ = Bδ /µ0 = 1/(4π · 10−7 ) A/m = 796 kA/m

is required. Because the entire magnetic circuit is replaced by a single air gap δ ef =
1.05 mm, the required current linkage

Θ = Hδ δef = 796 · 1.05 A = 836 A

is obtained, the proportion of the iron being 0.05 × 836 A = 42 A. There are 100 turns in
the winding, and hence the current flowing in the circuit has to be I 2 = 8.36 A.
The flux of the magnetic circuit is of magnitude

Φ = S Bδ = 0.01 · 1 V s = 0.01 V s.

Respectively, the flux linkage of the winding N 2 is

Ψ2 = Φ N2 = 0.01 · 100 V s = 1 V s.

Since there is a current I 2 = 8.36 A flowing in the coil, and it creates a flux linkage of
1 V s, the self-inductance of the coil is approximately

L 22 = ψ2 /I2 = 1/8.36 H = 120 mH.

The flux linkage of the coil N 1 is respectively

Ψ12 = Φ N1 = 0.01 · 50 V s = 0.5 V s.

There is no current flowing in the winding, because the flux Φ is created by the coil
N 2 alone. The self-inductance of the coil N 1 could be calculated accordingly. Instead, we
apply the reluctance of the magnetic circuit in the calculation, and thus

RmFe+δ = δef /µS = 0.00105/(4π · 10−7 · 0.01) A/V s = 83.6 kA/V s.

The self-inductance is thus

L 11 = N12 /RmFe+δ = 502 /83.6 mH = 30 mH.

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Design of Magnetic Circuits 215

Correspondingly, the mutual inductance between the windings can be written for an
ideal flux connection in the form

L 12 = L 21 = N1 N2 /RmFe+δ = 50 · 100/83.6 mH = 60 mH.

Next, the characteristics of a magnetic circuit with a permanent magnet are investigated.
A permanent magnet produces a strong current linkage:

ΘPM = h PM Hc = 8000 A.

This current linkage is very high when compared with the current linkage of the winding
N 2 of the previous magnetic circuit; however, most of the current linkage of the permanent
magnet is consumed in the reluctance created by the magnet itself. The reluctance of the
permanent magnet is

RPM = h PM /µ0 S = 0.01 · /(1.05 · 4π · 10−7 · 0.01) A/V s = 757.9 kA/V s.

The reluctances of the physical air gap and the iron are the same as above, RmFe+δ =
83.6 kA/V s. The reluctance of the entire magnetic circuit is approximately Rm,tot = RPM
+ RmFe+δ = 841.5 kA/V s. For such a reluctance, a flux of

ΦPM = ΘPM /Rm,tot = 8000/ 841.5 · 103 V s = 0.0095 V s

is created by the permanent magnet. The flux density of the permanent magnet is

BPM = ΦPM /S = 0.0095/0.01 V s/m2 = 0.95 T.

Thus, despite the large permanent magnet and its strong current linkage, the flux density
remains lower than in the previous case. We can see that with present permanent magnet
materials, it is difficult to create flux densities of 1 T in the air gap without a large amount
of magnetic material. Increasing the thickness of the magnet alone does not suffice, but
the magnets have to be connected in parallel in the magnetic circuit. This can be done for
instance by embedding two magnets per pole in a V-shape in the rotor structure.
The inductance of the winding is now

L 11 = N12 /Rm,tot = 502 /841.5 mH = 2.97 mH.

A permanent magnet in the iron circuit considerably increases the reluctance of the
magnetic circuit and reduces the inductances of the circuit. These phenomena are common
also in rotating machines with permanent magnets. The current linkage required by the
iron is yet to be investigated. It is now assumed that the iron is from M400-65A sheet,
which requires about 1.1 A/cm for 1 T. The length of the magnetic circuit is 35 cm, and
thus a current of 1.1 × 35 A = 38.5 A is required, which is sufficiently equal to the initial
assumption.
Now, the magnetic circuits of Figure 3.44 are investigated further. The left-hand mag-
netic circuit constitutes a transformer with an air gap, the transformation ratio of which is
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216 Design of Rotating Electrical Machines

l l
N1 = 50
N1 = 50
S δ = 0.001 m S δ = 0.001 m
h PM = 0.01 m
N2 = 100
PM

(a) (b)

Figure 3.44 Simple magnetic circuits with single main flux magnetic paths. The length of the
circuit is l = 0.35 m. There is an air gap δ of 1 mm in both circuits. The area of the circuit is S =
0.01 m2 . The left-hand circuit (a) is magnetized with the winding N 2 . The right-hand circuit (b) is
magnetized with an NdFeB permanent magnet. Both the cores have a winding N 1 , the inductance of
which has to be determined

K = N 1 /N 2 = 1 : 2. A magnetic circuit of this kind has the equivalent circuit illustrated in

Figure 3.45. The leakage inductances are included in the primary and secondary winding,
although they have not yet been taken into account in the previous discussion. It is now
assumed that 95% of the flux in both windings penetrates all the turns of the other wind-
ing, the connecting factor being k = 0.95. Thus, a part of the self-inductance is leakage
inductance

L 1σ = (1 − k) L 11 , L 2σ = (1 − k) L 22 .

The mutual inductance is now reduced to some extent, since it is determined from the
flux linkage created by the magnetizing winding to the other winding. The mutual induc-
tance L12 is therefore determined by the flux linkage Ψ 12 created in the winding N 1 by the
current I 2 in the winding N 2 :

L 12 = Ψ12 /I2 .

L1σ L12 L2σ L1σ L'2 σ

L11 L22 Lm

50:100
(a) (b)

Figure 3.45 (a) Equivalent circuit of a transformer with two windings, illustrated in Figure 3.44,
and (b) an equivalent circuit referred to the voltage level of the primary winding. L1σ and L2σ are
the leakage inductances of the primary and secondary windings. In the reduction, the square of the
transformation ratio K, L 2σ = K 2 L 2σ , is required. The magnetizing inductance Lm is proportional
to the mutual inductance of the primary and secondary windings, Lm = KL12
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Design of Magnetic Circuits 217

If now Ψ 12 is only 95% of its theoretical maximum value, we can see that also the
mutual inductance is reduced correspondingly. The current I 2 = 8.36 A of the previous
example creates a flux linkage of 100 × 0.01 V s = 1.0 V s in the winding N 2 , and a flux
linkage

Ψ12 = 0.95Φ N1 = 0.95 · 0.01 · 50 V s = 0.475 V s

in the winding N 1 . Next, the mutual inductance

L 12 = L 21 = Ψ12 /I2 = 0.475 V s/8.36 A = 56.8 mH

can be calculated.
If the connection between the windings is ideal, we obtain

L 12 = L 11 L 22 .

Since now only 95% of the flux of winding 1 penetrates winding 2, we obtain a con-
necting factor

k = L 12 / L 11 L 22 = 0.95,

which in practice is always less than one. The magnetizing inductance for Figure 3.45
becomes

L m = L 12 K = 56.8 · 0.5 mH = 28.4 mH.

The leakage inductance of the primary winding is thus L1σ = L11 − Lm = 30 − 28.4 mH
= 1.6 mH. Correspondingly, the leakage inductance of the secondary winding referred to
the primary winding is

L 2σ = L 22 K 2 − L m = 120 · 0.52 − 28.4 mH = 1.6 mH.

Now, the equivalent circuits are illustrated referred to the primary winding. They are, in
this example, magnetized by a direct current, either the direct current of the winding N 2 or
the virtual direct current of the permanent magnet


IPM = ΨPM /L m = 0.475 V s/2.97 mH = 160 A.

Here Ψ PM is the permanent magnet flux linkage linking the turns of the primary winding:
Ψ PM = Φ PM N 1 = 0.0095 × 50 V s = 0.475 V s. Since there is no current flowing in the
primary winding to create Ψ PM , no leakage of this flux takes place and Lm is applied to
calculate the virtual permanent magnet current. Although it is not conventional to discuss a
transformer with DC magnetization, in this case we may assume such ‘transformers’ to be
applied for instance as DC chokes that emulate the behaviour of a synchronous machine
in the rotor reference frame. This simplification is a good basis for the analysis of the
magnetic circuits of rotating machines, since the equivalent circuits of Figure 3.46 are,
in principle, equivalent to the equivalent circuits of electrical machines. The device and
the frame of reference in question decide whether the equivalent circuits function with
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218 Design of Rotating Electrical Machines

0. 025 V s

L1 σ L' 2 σ

0.475 V s
L m = 28.5 mH I 'mag = 16.7 A
0.5 V s

(a)
L1
σ

0.475 V s
L m = 2.97 mH I 'PM = 160 A

(b)

Figure 3.46 Direct current of the winding magnetizes the magnetic circuits of Figure 3.44. (a) The
equivalent circuit for the two winding choke, (b) the equivalent circuit for the choke with permanent
magnet excitation

a direct or an alternating current. Often the equivalent circuits of rotating electrical ma-
chines are also constructed in such a reference frame where a direct current is flowing in
the equivalent circuits in a stationary state. The magnetic circuits of electrical machines
differ from the examples presented above only with respect to their geometric complexity.
Naturally, in rotating-field machines, at least a two-phase winding is required to produce a
rotating magnetic flux that was not present in the simple connections of Figures 3.44–3.46.
The equivalent circuit of Figure 3.45 works, with certain preconditions, with transformers
and induction machines with an alternating current. Because of the direct currents in the
secondary winding of Figure 3.46, the equivalent circuits are suitable with certain supple-
mentary additions for the analysis of synchronous machines.
The currents are referred to the primary winding. The virtual direct current of the per-
manent magnet is calculated by dividing the flux linkage of the magnetizing winding
(0.475 V s) by the magnetizing inductance Lm = 2.97 mH (see the equation above where

IPM = 160 A). The virtual magnetizing current of the permanent magnet is high, since the
reluctance of this magnetic circuit is also relatively high when compared with the mag-
netic circuit magnetized by the winding N 2 . The direct current of the winding N 2 creates
a total flux linkage of 0.5 V s, which is divided into an air-gap flux linkage and a leakage
flux linkage. In the case of a permanent magnet, the leakage flux of the permanent magnet
is not discussed here. In reality, only a part of the current linkage of the permanent magnet
magnetizes the air gap. A small amount of the current linkage directly becomes a leakage
flux of the permanent magnet. Its flux leakage cannot be illustrated with a winding, since
no ‘permanent magnet winding’ exists (see Figure 3.46):

Imag = I2 /K = 8.36 A · 2/1 = 16.7 A.
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Design of Magnetic Circuits 219

Since the permeability of the best materials is about one, such materials have a significant
influence on the effective air gap δ ef of the magnetic circuit to which they belong. The relative
permeability of neodymium magnets is µrPM = 1.05, and hence the permanent magnet ma-
terial itself produces an apparent air gap of δ = hPM /1.05, which almost equals the thickness
of the magnet itself. Hence, the magnetic air gap of a machine carrying permanent magnets
is extremely large, especially if the magnets are fixed on the rotor surface. The magnet it-
self forms the largest magnetic reluctance of the magnetic circuit and therefore needs a large
magnetic voltage itself.
When considering the armature reaction, we can see that the synchronous inductance of a
rotor surface permanent magnet machine is low. In some cases, this impedes the application
of a voltage source inverter as a supply to these machines, since the current change speeds
are high because of the low inductances. Power electronic switches are nevertheless so fast
that permanent magnet rotor machines of low inductance can be fed with a voltage source
inverter.
Permanent magnets are particularly useful in low-speed machines, since in the rotating-field
machines the magnetizing inductance is inversely proportional to the square of the number of
pole pairs p (Lm ∼ = p−2 , see Section 3.9). A multiple-pole rotating-field machine will have a
low magnetizing inductance, and therefore it is generally not very advantageous to construct a
low-speed motor with a high number of pole pairs as an asynchronous motor. Such a machine
will have a relatively low power factor.
Instead, in the case of a permanent magnet machine, the effect of the low magnetizing in-
ductance is not harmful, since most of the current linkage of the magnetic circuit originates
from the permanent magnet. In a permanent magnet machine, the equivalent air gap δ e is
strongly dependent on the positioning of the permanent magnet material and on the thickness
of the material. Permanent magnets assembled on the surface of the rotor always produce the
lowest inductance, since in practice the thickness of the magnet directly increases the equiva-
lent air gap. A low magnetizing inductance increases the ability of a synchronous machine to
produce torque.
When using rare-earth permanent magnets in electrical machines, the relatively large con-
ductivity of neodymium and SmCo magnets is problematic. When the speed of the motor
increases, the air-gap harmonics create remarkable losses in the magnets. As neodymium
magnets are particularly sensitive to temperature, a very effective cooling for the magnets
has to be assured in the machine design. Ferrite magnets have a poor energy product, but are
cheap and have a very low conductivity, and hence the eddy current losses in ferrites remain
low compared with neodymium and SmCo magnets.

3.8 Assembly of Iron Stacks

The assembly of the parts of a magnetic circuit of an electrical machine has a significant
influence on the final quality of the machine. Punching of the sheet material is carried out in
a single punching action, or by first producing a suitable disc of the plate material, which is
then rotated in an indexing head, and the slots are punched in the disc one by one. A high
precision is required to produce stacks of even quality. The ready sheets of both the stator
and the rotor have to be rotated with respect to each other to avoid virtual saliency caused by
the anisotropy of the sheet. Also, the physical thickness of a sheet varies so much that it is
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220 Design of Rotating Electrical Machines

advisable to rotate the sheets in the assembly. This way it is possible to construct a stack of
even length.
In the assembly of the sheet stack, the stack is straightened with a suitable tool in order to
get the slots in the desired position. Here, guides can be employed either at the slot opening
or at the bottom of the slot. Next, the stack is pressed into its final length and clamped with a
suitable method. The best way to avoid losses is to press the stack straight to the stator frame
and to use seger rings, for instance, as clamps.
In serial production, welding the outer surface of the stator stack has become more and
more popular. In this method, small cuts are made in the outer surface of each sheet. When
the stack is assembled, these cuts comprise a continuous slot in the stack. The stack is welded
at these slots, and a welding bead covers the complete length of the stack. The insulation
between the sheets is damaged in the welding process. However, the damage is restricted to a
rather small region. Consequently, the iron losses of a welded stack are a few per cent higher
than the losses of a key-fitted stack.
Key fitting is also a common method of assembly. When a stator is punched, dovetail slots
are made on the outer surface of the stator. As the stack is pressed into shape, a key is placed
into the dovetail slots. The key bar is somewhat longer than the final length of the stack. The
ends of the key are bent 90◦ , and the stack is thereby clamped. The method is advantageous
for the minimization of losses. On the other hand, the key bars impede heat transfer from the
stator stack to the frame of the machine, which is a drawback of the key-fitting method.
Sometimes holes are cut in the outer edge of the stack for riveting. In principle, the method
is simple and mechanically suitable, but causes extra iron losses in the machine. There remains
a narrow bridge of stator yoke between the bar and the stator frame. This bridge provides a
path for the flux, which induces a voltage in the rivet. Since the rivet is galvanically connected
to the frame, a current flows in the loop formed by the rivet and the frame. This current creates
losses in the machine. In principle, the rivets should be insulated from the stack, which is not
an easy task.
The stator stack is usually equipped with straight slots to ease automatic winding. Some-
times, skewing is also required in the stator. Therefore, in automatic production, the stator
is first insulated and wound, and then it is skewed before clamping the stack and the resin
impregnation of the winding.
Rotor stacks are produced in large numbers for induction machines. If there is a cast alu-
minium cage winding in the machine, the winding is employed to clamp the whole stack. The
desired skew is created, and the stack is brought to a die-casting machine. The machine casts
aluminium into the slots at high pressure, and simultaneously produces short-circuit rings at
the ends of the rotor. The aluminium sets in a few seconds and ties the complete stack.
If the rotor is wound with a round wire or a shaped bar, the stack has to be tied before
winding. Now, rivets penetrating through the stack can be easily employed in the rotor yoke.
The stacks wound with a round wire or preformed copper are set in their final positions after
the resin impregnation of the winding. The vacuum pressure impregnation (VPI) in particular
glues all the sheets firmly together.
If the stack has to be divided into sections for cooling, and a suitable key material is re-
quired between the stack sections, the material has to be selected carefully to avoid unneces-
sary losses. Nonmagnetic stainless steels are appropriate for this purpose. Suitable insulation
materials can also be employed, if their mechanical strength is adequate.
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Design of Magnetic Circuits 221

3.9 Magnetizing Inductance

The winding, the dimensions of the magnetic circuit and the selected materials define the most
important inductance of the machine, namely the magnetizing inductance. Next, a magnetiz-
ing inductance of a poly-phase winding is calculated for an unsaturated machine. On the rotor
surface, there is for instance a sinusoidal flux density distribution over the pole pitch τ p and
the length of the machine l , from which we may integrate the flux of the machine. Figure 3.47
illustrates this behaviour of the flux density distribution (only the fundamental is shown).
The peak value of the air-gap flux of the machine is the surface integral of the flux density
B over one pole surface S. For a sinusoidally distributed flux density, we get


2
Φ̂m = B · dS = τp · l  · B̂m . (3.102)
S π

The expression ‘peak value of the air-gap flux’ describes the maximal flux Φ̂m that pene-
trates a diagonal coil and hence produces the maximum flux linkage of a phase winding Ψ̂m .
The expression may be somewhat misleading, but it is used here since it allows us to write
the time function Ψm (t) = Ψ̂m sin ωt. The flux linkage of a single phase is obtained from the
air-gap flux maximum value by multiplying Φ̂m by the effective turns of winding

2
Ψ̂m = kws1 Ns Φ̂m = kws1 Ns · τp · l  · B̂m . (3.103)
π

On the other hand, the magnetic flux density of an air gap can be determined by applying
the current linkage of the phase; in other words, the current linkage Θ̂s of the stator creates a

stator

Bm
l'

air gap δ
rotor τp

Figure 3.47 Distribution of fundamental flux density over a pole pitch and the length of the machine.
The flux of the machine is calculated from this distribution. In practice, the air-gap flux is distorted be-
cause of the slotting and the current linkage harmonics. However, the fundamental value of the waveform
has to be found in any case
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222 Design of Rotating Electrical Machines

flux in a direct-axis air gap

µ0 · Θ̂s
B̂m = , (3.104)
δef

where δ ef is the effective air gap met by the current linkage of the stator winding. Here, the
influence of the air gap is included (cf. Equation (3.25)) together with the influence of the iron
in the direct-axis direction. The equation is now substituted in Equation (3.103) for Ψ̂m , and
we obtain for a flux linkage of a single phase

2 µ0 · Θ̂s 
Ψ̂m = kws1 Ns τpl . (3.105)
π δef

The current linkage of a single phase winding is

4 kws1 Ns √
Θ̂s = 2Is . (3.106)
π 2p

Substitution yields for the flux linkage

2 µ0 4 kw1 Ns  √
Ψ̂m = kws1 Ns τpl 2Is , (3.107)
π δef π 2 p
2 1 4 τp  √
Ψ̂m = µ0 l (kws1 Ns )2 2Is . (3.108)
π 2 p π δef

By dividing the result by the peak value of the current, which in this case is magnetizing
current, we obtain the magnetizing (main) inductance Lmph of a single-phase winding

2 1 4 τp  4µ0 τp 
L mph = µ0 l (kws1 Ns )2 = 2 l (kws1 Ns )2 . (3.109)
π 2 p π δef π pδef

This magnetizing main inductance is the inductance of a single-phase winding. In a multi-

phase winding, the flux is contributed by all the phases of the winding. The magnetizing
inductance of an m-phase machine can be calculated by multiplying the main inductance
by m/2

m2 1 4 τp  2mτp m Dδ
Lm = µ0 l (kws1 Ns )2 = 2 µ0l  (kws1 Ns )2 = µ0l  (kws1 Ns )2 .
2 π 2 p π δef π pδef π p 2 δef
(3.110)

The magnetizing inductance Lm thus depends on the phase number m, the effective turns of
winding kw1 Ns and the length of the machine l , the number of pole pairs p, and the effective
air gap δ ef . The factor m/2 may, in the case of a three-phase machine (m = 3), be explained in
a simple manner, as follows. Let us, again, consider a time instant when the currents are iU =
+1, iV = iW = − 12 . According to Figure 3.48, the current linkage sum of three phases at this
instant is 3/2 = m/2.
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Design of Magnetic Circuits 223

ΘW

ΘU Θ sum
U

ΘV

Figure 3.48 Sum of the current linkages of three-phase windings at the time instant when iU = +1,
i V = i W = −1/2

An effective air gap δ ef includes an air gap lengthened with the Carter factor and the effect
of iron, which also increases the apparent air gap. The influence of iron varies typically from
a few per cent even up to tens of per cent. In such a case, the iron circuit is strongly saturated.
Figure 3.18 illustrates a case in which the magnetic voltage over the iron circuit is higher
than the voltage over the air gap. Such a situation is possible mainly in tightly dimensioned
induction machines. On the other hand, in permanent magnet synchronous machines, in which
the equivalent air gap includes in the d-direction the length of the permanent magnets, the
proportion of iron remains very low.
Magnetizing inductance is not constant but changes as a function of voltage and torque. The
voltage dependence can be easily explained. Increasing the voltage increases the flux density,
which may saturate the iron parts. The torque dependence can be explained by Faraday’s
principles. When the torque increases, the tension of the flux lines increases. The lines travel
along more saturated paths, and the machine requires more magnetizing current than before.
Figure 3.49 illustrates the saturation of the magnetizing inductance of a typical 30 kW, totally
enclosed, four-pole induction machine as a function of torque.

1.0
magnetizing inductance, p.u.

0.95

0.9

0.85

0.8

0.75
0 1 2 3 4
torque, p.u.

Figure 3.49 Saturation of the magnetizing inductance of an induction machine as a function of torque
in a 30 kW, four-pole, 400 V induction machine. The inductance is already reduced by a few per cent
by the rated torque of the machine itself. When the machine is overloaded, the decrease in inductance is
notable
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224 Design of Rotating Electrical Machines

Figure 3.50 Flux diagrams of an induction machine as a function of torque (0.3T n , 2.9T n ). Reproduced
by permission of Janne Nerg

Figure 3.50 depicts the paths of the flux with a small load and with an overload. The figure
indicates clearly how the
 flux selects different routes in each case. It is also easy to understand
why the line integral H · dl gets larger values in the latter case, thus indicating a higher
magnetizing current and a lower inductance.

Bibliography
Carter, F.W. (1901) Air-gap induction. Electrical World and Engineering, XXXVIII (22), 884–8.
European Standard EN 10106 (1996) Cold Rolled Non-Oriented Electrical Steel Sheet and Strip Delivered in the
Fully Processed State, CENELEC, Brussels.
Gieras, J.F., Wang, R.J. and Kamper, M.J. (2008) Axial Flux Permanent Magnet Brushless Machines, 2nd edn, Kluwer
Academic, Dordrecht.
Heck, C. (1974) Magnetic Materials and their Applications, Butterworth, London.
Heller, B. and Hamata, V. (1977) Harmonic Field Effects in Induction Machines, Elsevier Scientific, Amsterdam.
Jokinen, T. (1979) Design of a rotating electrical machine (Pyörivän sähkökoneen suunnitteleminen), Lecture notes.
Helsinki University of Technology, Laboratory of Electromechanics.
Miller, T.J.E. (1993) Switched Reluctance Motors and Their Controls, Magna Physics Publishing and Clarendon
Press, Hillsboro, OH and Oxford.
Nerg, J., Pyrhönen, J., Partanen, J. and Ritchie, A.E. (2004) Induction motor magnetizing inductance modeling as
a function of torque, in Proceedings ICEM 2004, XVI International Conference on Electrical Machines, 5–8
September 2004, Cracow, Poland. Paper 200.
Richter, R. (1967) Electrical Machines: General Calculation Elements. DC Machines (Elektrische Maschinen: Allge-
meine Berechnungselemente. Die Gleichstrommaschinen), Vol. I, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
TDK (2005) Neodymium-Iron-Boron Magnets NEOREC Series. [online]. Available from http://www.tdk.co.jp/
tefe02/e331.pdf (accessed 31 August 2007).
Vacuumschmelze (2003) Rare-Earth Permanent Magnets VACODYM · VACOMAX PD 002. 2003 Edition. [online].
Available from http://www.vacuumschmelze.de/dynamic/docroot/medialib/documents/broschueren/dmbrosch/
PD002e.pdf (accessed 1 December 2006).
Vogt, K. (1996) Design of Electrical Machines (Berechnung elektrischer Maschinen), Wiley-VCH Verlag GmbH,
Weinheim.
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4
Flux Leakage

In rotating electrical machines, the total flux does not participate in electromagnetic energy
conversion as a whole: the proportion of the flux that participates in energy conversion is
called the main flux (air-gap flux) Φ m of the machine, and the flux components not acting
in this process are defined as the leakage flux Φ σ . The main flux has to cross the air gap of
rotating machines, an important function of the main flux therefore being to connect electro-
magnetically both the stator and the rotor. In this sense, an air-gap flux Φ m creates an air-gap
flux linkage Ψ m in the investigated winding, and consequently connects different parts of the
machine. The leakage fluxes of the stator and rotor do not generally cross the air gap. They
contribute to the generation of the total flux linkage of the winding by producing a leakage
flux linkage Ψ σ component to it. Flux leakage occurs in both the stator and the rotor winding.
The corresponding leakage flux linkages are the flux leakage Ψ sσ of the stator and the flux
leakage Ψ rσ of the rotor. A leakage flux also occurs in the permanent magnet materials of
the machine. Because of the flux leakage, more magnetic material, or correspondingly more
magnetizing current, is required than in the case without flux leakage.
Flux leakage is often considered a negative phenomenon. However, flux leakage in some
cases has a positive role also. For instance, the transient inductance L
s of an asynchronous
machine L
s = L sσ + L rσ L m / (L rσ + L m ) consists mainly of the sum of the stator and rotor
flux leakage L
s ≈ L sσ + L rσ . For instance, if the target is to filter the motor current of a
pulse-width-modulated (PWM) AC inverter drive, the stator flux leakage of the machine can
be increased intentionally. Without a flux leakage, a PWM supply cannot be employed to
feed induction machines, for example. Now, a flux leakage is clearly a positive factor. Often,
flux leakage is assumed to contribute to the losses in a machine. However, no direct line can
be drawn between flux leakage and losses. Flux leakage may cause some extra losses in for
instance the frame of the machine. Furthermore, the slot leakage flux increases the skin effect
of the conductors in the slots causing more copper losses in the stator. Nevertheless, always
linking the flux leakage directly to losses is incorrect.
In rotating-field machines, at least one of the main components of the machine has a dis-
tributed winding that has been designed to participate in energy conversion only with the
fundamental component of the air-gap flux. The harmonic components of the air-gap flux
are considered harmful. In this sense, the harmonic components of the air-gap flux belong to

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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226 Design of Rotating Electrical Machines

the leakage flux, although they do cross the air gap. The fundamental is called the main flux
that creates the main flux linkage in a winding under observation. Depending on the winding
assembly, part of the winding may not be connected to the main flux, and flux components
resembling a leakage flux are created. These components cross the air gap.
Leakage fluxes thus comprise:

r all the flux components that do not cross the air gap; and
r those components crossing the air gap that do not participate in the formation of the main
flux linkage.

An inductance of a winding or a winding section is obtained by calculating the flux linkage

Ψ = kw NΦ caused by the current I, bearing in mind that Ψ = LI. We also have to remember
that L = N 2 Λ. Furthermore, we may utilize the analogy according to which a voltage drop
is created over a reactance U = XI. In some cases, the energy of a magnetic field can be
employed to determine inductances and reactances. According to Equations (1.90) and (1.91),
the energy stored in a magnetic circuit is



1
WΦ = 1/2 HB dV = B 2 dV. (4.1)
V 2µ V

The energy equation is valid irrespective of the way the flux density has been created. The
flux density can be created by one or several winding currents. First, a simple example is
investigated, in which two currents I 1 and I 2 create a flux density B = B1 + B2 in a linear
magnetic circuit. The energy equation is written in the form



1 1  
WΦ = (B1 + B2 ) dV =
2
B12 + 2B1 B2 + B22 dV. (4.2)
2µ V 2µ V

In electromechanical devices having two winding arrangements with a mutual inductance

M, the energy of a magnetic field is stored in the inductances, and thus the energy equation
can be rewritten applying self- and mutual inductances L1 , L2 and M

WΦ = 1/2 L 1 I12 + 1/2 MI 1 I2 + 1/2 L 2 I22 . (4.3)

When Equations (4.2) and (4.3) are set equal, the corresponding terms of both sides are
equal. The equation can be divided into three separate terms, the outermost terms now being
of equal form. The self-inductance of the winding becomes


1
L= B 2 dV. (4.4)
µI 2 V

Since the middle terms in Equations (4.2) and (4.3) are equal, we obtain the mutual induc-
tance


2
M= B1 B2 dV. (4.5)
µI1 I2 V
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Flux Leakage 227

When employing these equations, the volume can be divided into sections and the com-
ponents of inductance can be calculated. For instance, when calculating self-inductance, it is
advisable to divide the volume V into sections of the main and the leakage flux, and to calcu-
late the respective inductances. Next, we analyse the calculation of leakage fluxes and leakage
flux linkages.

4.1 Division of Leakage Flux Components

The calculation of leakage inductances from the structural dimensions of the machine is a
rather demanding task. Some of the leakage inductances are real ones created by a real leak-
age flux. Imaginary leakage inductances are employed to correct inaccuracies resulting from
simplifications made in the calculation. There is often also a physical explanation to imag-
inary leakage inductances. Next, we discuss the division of leakage fluxes into components
crossing and not crossing the air gap.

4.1.1 Leakage Fluxes Not Crossing an Air Gap

The flux components that do not cross the air gap self-evidently belong to the leakage flux.
Among these components we have:

r slot leakage flux (u);

r tooth tip leakage flux (d);
r end winding leakage flux (w);
r pole leakage flux (p).

Figures 4.1–4.3 illustrate the principles of the main paths of these leakage fluxes.
To determine the leakage flux, we have to define the magnetic field strength on a leakage
flux path, or the current linkage and the permeance of the path. Based on the current linkage
Θ σ creating a leakage flux, we may write

Φσ = Λσ Θσ . (4.6)

(a) (b)

Figure 4.1 (a) Paths of pole leakage fluxes of a salient-pole magnetizing and (b) paths of pole and slot
leakage of a nonsalient-pole magnetizing; see also Figure 4.15
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228 Design of Rotating Electrical Machines

Figure 4.2 Path of the slot leakage flux of a slot winding

Analytic calculation of leakage fluxes may be difficult, since the geometries are often quite
complicated. A three-dimensional geometry of the end windings is particularly difficult to
handle in the calculation of leakage fluxes. Therefore, some assisting empirical methods are
utilized in the calculation.

4.1.2 Leakage Fluxes Crossing an Air Gap

Leakage fluxes that cross the air gap are included in the air-gap flux. An air-gap flux does not
completely link the windings of the machine to each other. The reasons for incomplete linking
are: short pitching, skewing and the spatial distribution of the windings. A weakening of the
linking between the stator and rotor windings, caused by short pitching or skewing, is not
usually regarded as leakage, but it is taken into account with the pitch winding factor kp and
the skewing factor ksq , Figure 4.4. The spatial distribution of the windings causes an air-gap
(or harmonic) flux leakage. These leakage flux components crossing the air gap are included
in the air-gap flux Φ m , and they do not separately influence the magnetic potential difference
of the path of the main flux, calculated with the air-gap flux.
To analyse the harmonic flux leakage, the simple example in Figure 4.5 is investigated.
First, it is assumed that the windings are full-pitch windings (no short pitching) and there is
no skewing. Further, it is assumed that no flux leakage occurs in the slots, teeth tips or end
windings.

stator
stator
} tooth tip leakage flux end winding

}
leakage flux

slot leakage flux

rotor

rotor yoke main flux

(a) (b)

Figure 4.3 Leakage flux components of a coil winding contained in slots and end winding leakage
flux, (a) an axial cut-away view of a slot, (b) a side cut-away view of the end winding area
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Flux Leakage 229

τp W
τp

skewed winding turn short-pitched winding turn

(a) (b)

Figure 4.4 As a result of skewing in (a), the coil span W is the same as the pole pitch τ p but the slots
are skewed. As a result of short pitching in (b), the coil span W is smaller than the pole pitch τ p , and
in both cases a part of the air-gap flux remains unlinked to some of the windings of a pole pitch. Short
pitching is, however, not regarded as a leakage, but it is taken into account by the winding factor. It also
has an effect on the harmonics, and consequently on the air-gap inductance

stator stator

rotor rotor

Θs Θs
stator stator

Θr Θr

rotor
Θ sum Θ sum

(a) (b)

Figure 4.5 Occurrence of an air-gap flux leakage as a result of the spatial distribution of stator and
rotor windings in different positions (a) and (b). When the current-carrying parts of the windings are in
an aligned position, the resulting sum current linkage is zero, otherwise it deviates from zero
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230 Design of Rotating Electrical Machines

In Figure 4.5a, the current linkage of the stator winding is fully compensated, because a
corresponding current flows at an aligned position in the rotor winding. In the latter section
(Figure 4.5b) instead, the rotor has – as a result rotation – moved to a new position and the
current has been divided into two bars. Now, no full compensation takes place, but a small
leakage flux penetrates the air gap. When the rotor is rotated further, a position with full
compensation is again reached. In practice, in those machines in which the windings are not
concentrated but the slot number per pole and phase q is higher than one, there is always
some air-gap flux leakage. The importance of the air-gap leakage is highest in machines with
a relatively small air gap, particularly in induction machines.
In basic machine design, only the fundamental component of the main flux linkage is usu-
ally employed. In that case, all the harmonic components are included in the harmonic flux
linkage. Since the harmonic fields result from the spatial distribution of the winding, a har-
monic flux leakage component occurs instead of the average air-gap leakage. The term ‘air-
gap flux leakage’ is often employed, and therefore the air-gap inductance Lδ is introduced. It
is important to note that the harmonic fields induce voltages of the fundamental frequency in
the windings that produce these harmonic fields.

4.2 Calculation of Flux Leakage

Based on the discussion above, the leakage inductance Lσ of a machine can be calculated as
the sum of different leakage inductances. Nowadays, when an electrical machine is more and
more seldom fed with sinusoidal voltage, to be precise, the term ‘leakage inductance’ should
be applied instead of ‘leakage reactance’. According to the electrical motor design tradition,
leakage inductance Lσ can be divided into the following partial leakage inductances:

r air-gap leakage inductance Lδ ,

r slot leakage inductance Lu ,
r tooth tip leakage inductance Ld ,
r end winding leakage inductance Lw ,
r skew leakage inductance Lsq .

The leakage inductance of the machine is the sum of these leakage inductances

L σ = L δ + L u + L d + L w + L sq . (4.7)

4.2.1 Air-Gap Leakage Inductance

According to Faraday’s induction law, the air-gap back emf of an electrical machine is induced
in the magnetizing inductance Lm of the machine as a result of a propagating fundamental
component of air-gap flux density. Because of a spatial slotting, the permeance harmonics
induce emf components in the fundamental frequency of the winding. The air-gap leakage
inductance (i.e. the harmonic leakage inductance components) takes this into account.
The emf Eν induced by the harmonic ν of the flux density per phase is obtained by applying
Faraday’s induction law and by taking the geometry of the machine into account

1
E ν = √ ωN kwν Φ̂ν . (4.8)
2
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Flux Leakage 231

B̂ ν

l'
τν

z
x

Figure 4.6 Flux distribution created by a harmonic ν over a pole pitch τ ν corresponding to the har-
monic. The maximum flux value is calculated as an integral over the pole

Next, a sinusoidal harmonic ν is investigated. For this kind of flux, a maximum flux value
penetrating the coil is obtained according to Figure 4.6

2
Φ̂ν = B̂δν τν l
. (4.9)
π

The pole pitch of the harmonic ν is

πD
τν = . (4.10)
2 pν

Substituting Equations (4.9) and (4.10) into Equation (4.8) we obtain

ω N kwν
E ν = √ Dl
B̂δν . (4.11)
2 p ν

In a machine with m phases, the magnetizing current I m flowing in the windings creates a
peak flux density in the air gap

µ0 m kwν N √
B̂δν = 2Im . (4.12)
π δ ν p

By substituting this into Equation (4.11) we obtain

 2  2
µ0 m
N kwν
Eν = ω Dl Im . (4.13)
π δ p ν
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232 Design of Rotating Electrical Machines

The sum of the emfs induced by all the harmonics, the fundamental included, is

ν=+∞

E= Eν . (4.14)
ν=−∞

The inductance E/ωI m is the sum of the magnetizing inductance and the air-gap inductance

 2 ν=+∞
  2
E µ0 m
N kwν
= Lm + Lδ = Dl . (4.15)
ωIm π δ p ν=−∞
ν

The term ν = 1 in the sum equation represents the fundamental component, and thus the
magnetizing inductance Lm of the machine. The remainder of the equation represents the air-
gap inductance

 2 ν=+∞
  kwν 2
µ0 m
N
Lδ = Dl . (4.16)
π δ p ν=−∞
ν
ν=1

The air-gap or the harmonic inductance can also be written in the form

L δ = σδ L m . (4.17)

Here we have the leakage factor σ δ of the air-gap inductance, defined as

ν=+∞
  2
kwν
σδ = . (4.18)
ν=−∞
νkw1
ν=1

Naturally, in the sum equation, only the harmonics created by the winding occur as addends.
The value of the air-gap inductance depends on the winding factors kwν of the harmonics
and thus on the winding assembly. Figure 4.7 illustrates the leakage factor of a three-phase
winding as a function of short pitching, with the number of slots per pole and phase q as a
parameter. With three-phase windings, the leakage factor is at its minimum when the short
pitching is W/τ p ≈ 5/6, which is generally an advantageous short pitching when designing
windings of three-phase machines.
Equation (4.17) is valid for a stator winding. When calculating the magnetizing inductance
on the rotor side, we obtain it by referring it to the stator L
mr = L m . Thus, the air-gap induc-
tance of a rotor circuit referred to the stator may be written applying a rotor leakage factor

L
δr = σδr L m . (4.19)

Section 7.1.2 discusses the characteristics of a cage winding and shows that the rotor har-
monic n of a cage winding reacts only to those harmonics ν of the air-gap flux density, the
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Flux Leakage 233

0.1 0.1
q=1

0.09 0.09

0.08 0.08
q=2
0.07 0.07

σδ 0.06 σδ 0.06

0.05 0.05

0.04 0.04 q=3

+ +
0.03 0.03
q=2 q=4
q=6
0.02 0.02
q=3 q=5
0.01 q=4 0.01

8
q=6
q=5
8

0 0
0.7 0.8 0.9 1 0.7 0.8 0.9 1
W/τp W/τp
m =3 m=2

Figure 4.7 Leakage factors σ δ of three-phase (m = 3) and two-phase (m = 2) windings with a param-
eter q (slots per pole and phase), as a function of coil span. It is shown that an increase in q considerably
improves the characteristics of the winding. A three-phase winding is notably better with respect to har-
monics than a two-phase winding. For m = 2 and q = 1, σ δ = 0.234; it is left out of the figure because
of its large value

ordinal numbers of which meet the condition (7.63)

n cQ r
= + ν, c = 0, ±1, ±2, ±3 . . . . (4.20)
p p

When only the fundamental component of the rotor current n = 1 is taken into account for
the rotor current, the leakage factor of the rotor is

  2   2
1 p 1 π2 p
σδr =  2 ≈ = . (4.21)
Qr c2 3 Qr
c cQ r
p
+1 c
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234 Design of Rotating Electrical Machines

Usually, an air-gap leakage inductance is of significance only in machines with a small air
gap. This is particularly the case with asynchronous machines. In asynchronous machines with
a cage winding, however, the cage damps harmonics, and consequently the air-gap inductance
becomes less significant. This can be estimated empirically by multiplying the inductance
obtained from Equation (4.16) by a damping factor, usually of magnitude 0.8.

Example 4.1: Calculate the per unit air-gap leakage inductance of a three-phase winding
with p = 2 and Q = 36 for a machine with Lm,pu = 3. Short pitching by one slot is applied.
Compare the result with a similar machine having 24 slots and no short pitching.
Solution: The number of slots per pole and phase is q = Q/(2pm) = 3. A full-pitch winding
should have W/τ p = 9/9. As we now make a short-pitched winding, where the transfer is
one slot pitch, we get W/τ p = 8/9. The leakage factor σ δ of the winding may be seen in
Figure 4.7. The value of the factor is σ δ = 0.011. If the per unit magnetizing inductance
of an induction motor is Lm,pu = 3, we get for the leakage inductance per unit value

L δ,pu = σδ L m,pu = 0.011 · 3 = 0.033.

In such a machine, the per unit air-gap leakage inductance is thus 3.3%.
For the 24-slot machine q = 2 and the leakage factor is σ δ = 0.028. In this case, the per
unit leakage inductance is 8.4%, which is a relatively large leakage value.

4.2.2 Slot Leakage Inductance

Slot leakage inductance is an inductance created by a real leakage flux. The total current in
a slot is determined by the number of conductors zQ in the slot and by the current flowing in
them. The total current of a slot is thus zQ I. Next, the leakage flux of a slot is investigated with
Figure 4.8.
A flux carried by a duct of a height dh is analysed. First, it is assumed that the current
flowing in the slot is evenly distributed in the hatched area. When travelling from the bottom
of the conductor to a height h, a current linkage Θ = IzQ h/h4 is accumulated. At height h,
there is thus a leakage flux density flowing across an area dS = dhl
of the duct

z Q I hh4
B (h) = µ0 H (h) = µ0 . (4.22)
b4

In Figure 4.8, this function is illustrated with a solid line. By substituting B(h) and the volume
element dV = l
b4 dh in Equation (4.4), we obtain, using the energy stored in the field, the
inductance

h 4
l
b4 h4
L u1 = B 2 (h) dh = µ0l
z Q2 = z Q2 Λ. (4.23)
µ0 I 2 3b4
0
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Flux Leakage 235

h
b1
h1

bc

dh
Bσ(h)

h zQ I h4
0

Φ 0 B
u b4

Figure 4.8 Leakage flux of a current-carrying slot of an electrical machine and the density of a leakage
flux. Left, conductors in the slot. The current-carrying area is depicted by the current sum zQ I as a
hatched area. Right, the slot leakage flux density Bσ distribution as a function of position h; the solid
line depicts the situation with no skin effect in the winding, and the dotted line indicates the instant when
the skin effect occurs

Here

h4
Λ = µ0l
(4.24)
3b4

is the magnetic permeance of the slot for the slot leakage. Next, a permeance factor l 4 defined
as magnetic permeance Λ divided by the slot length l
and permeability µ0 is introduced.
Now

h4
l4 = . (4.25)
3b4

B(h) is constant in the area h1 , since the current sum influencing the area does not in-
crease any further, because the current-carrying area has already been passed: B = µ0 zQ I/b1 .
Therefore, we obtain for this region

h1
l1 = . (4.26)
b1

The total magnetic energy stored in the slot is

WΦu = 1/2 L u1 I 2 = WΦ1 + WΦ4 = 1/2µ0l
z Q2 I 2 (l1 + l4 ) . (4.27)

The sum (l 1 + l 4 ) = l u thus defines the leakage inductance Lu1 of one slot. The slot induc-
tance of a phase winding is obtained as follows.
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236 Design of Rotating Electrical Machines

Slot inductances of individual slots

Lu1 Lu1 Lu1 Lu1

a parallel paths

Q
am slots in series

Total slot inductance

Figure 4.9 Determination of the total slot inductance with the slot inductances of single slots

If the parallel symmetrical path in the winding is a (Figure 4.9), the number of slots in
series in a phase winding is Q/(am) and the total slot inductance of a phase winding is

Q 1 Q  z Q 2
Lu = L u1 = µ0l
lu . (4.28)
am a m a
Since the number of conductors in a slot is zQ , the number of conductors in series in a
phase winding is zQ Q/(am). We need two conductors to form a turn; so the number of series-
connected turns N in a phase winding is

Q
N= zQ. (4.29)
2am
Substituting zQ from Equation (4.29) into Equation (4.28), the slot inductance takes the form

4m
Lu = µ0l
N 2 lu . (4.30)
Q

Example 4.2: Calculate the slot leakage inductance of a three-phase winding with
p = 3, Q = 36 and zQ = 20. The slot shape is according to Figure 4.8: b1 = 0.003 m,
h1 = 0.002 m, b4 = 0.008 m and h4 = 0.02 m, l
= 0.25 m. There is no short pitching and
no parallel paths.
Solution: The permeance factor of the wound part of the slot is

h4 0.02
l4 = = = 0.833
3b4 3 · 0.008

and the permeance factor of the slot opening is

h1 0.002
l1 = = = 0.667.
b1 0.003
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Flux Leakage 237

The permeance factor of the whole slot is lu = l1 + l4 = 0.667 + 0.833 = 1.5. The slot
inductance is
Q  z Q 2 36
L u = µ0l
lu = 4π · 10−7 · 0.25 · · 202 · 1.5 H = 2.26 mH.
m a 3

The slot permeance factor depends on the geometry of the slot. With the method presented
above, we may derive slot permeance factors for slots of varying cross-section. Slot permeance
factors can be found in the literature (see e.g. Richter, 1967; Vogt, 1996) calculated for the
most common slot types. Figure 4.10 illustrates the different slot shapes and dimensions of
single-layer windings.
The following values are obtained for the permeance factors of the single-layer windings
of Figure 4.10. For slot types a, b, c, d and e, the equation

h4 h3 h1 h2 b4
lu = + + + ln (4.31)
3b4 b4 b1 b4 − b1 b1

is valid, in which

h2 b4
ln = lu3 .
b4 − b1 b1

The factor l u3 can also be taken from Figure 4.11.

Figure 4.10 Dimensioning of different slot types for the definition of the slot permeance factor
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238 Design of Rotating Electrical Machines

1.8
b1
1.6
α = 45 o

1.4
α = 30 o
1.2
α = 22.5 o

λu3 1.0 α
0.8 α = 18 o

0.6
α = 0o
0.4

0.2

0.0 b4
0 2 4 6 8 10 12 14 16 18
b1 b4

Figure 4.11 Slot permeance factor l u3 as a function of the ratio of the slot width and the slot opening
width. Adapted from Richter (1967)

In the case of Figure 4.10a, b3 has to be substituted for b4 in the last term of Equation
(4.31). Correspondingly, for slot types f, g and h, we obtain

h4 h1
lu = + + 0.66. (4.32)
3b4 b1

The last term (0.66) is again l u3 , and, according to Richter 1967, it can be calculated for the
upper round section of the slot also from the equation

b4
lu3 = 0.41 + 0.76 log . (4.33)
b1

For a slot in Figure 4.10f, Richter gives an alternative equation

h4 h1
lu = + + 0.685, (4.34)
3b4 b1

and for a round slot in Figure 4.10g, the equation

b4 h1
lu = 0.47 + 0.066 + . (4.35)
b1 b1

In the rotors of induction motors, closed rotor slots are often employed. In that case, the
inductance of the slot is highly dependent on the saturation of the bridge closing the slot, and
therefore no explicit permeance factor can be solved for the slot. Richter (1954) determines
a slot permeance factor for closed rotor slots, but since the selected materials have a strong
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Flux Leakage 239

h1

Jο h 42

h'

Ju h 41
0
0 B

b4

Figure 4.12 Dimensions of a slot of a double-layer winding and the principal behaviour of the flux
density if no skin effect occurs. In the figure, the current densities J o and J u are equal in both current-
carrying areas. However, in double-layer windings, there are also slots with coils belonging to two
different phases when the current densities are different

influence on the factor, the inductance of closed slots has to be estimated numerically as a
function of current in the slot.
The slot leakage of a double-layer winding is investigated with Figure 4.12.
The permeance factor for a double-layer winding is determined by calculating the energy
of the leakage magnetic field in the slot, Equation (4.2). In the calculation, we have to bear in
mind that there are coil sides of different phases in some of the slots.
The current linkages of the bottom (subscript ‘u’ (under)) and upper (subscript ‘o’ (over))
layers increase in proportion to the height (h):

h
Θu (h) = Θu , (4.36)
h 41
h
Θo (h) = Θu + Θo , (4.37)
h 42

where Θ u and Θ o are the total current linkages of the bottom and upper layers, respectively.
The height h is measured separately from the bottom of the each coil.
The energy of the leakage magnetic field in a slot is, according to Equations (4.2) and
(4.22),

k

h 41  
h

h 42  
1
1 h 2 h 2
WΦ = µ0 l Θu
2 2
dh+Θu dh + Θu + Θo dh+ (Θu + Θo ) 2
dh .
2 b4 0 h 41 0 0 h 42 0

(4.38)
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240 Design of Rotating Electrical Machines

After the integration Equation (4.38) reduces to

     
1 1 h 41 h 42
WΦ = µ0l
Θu2 + h
+ h 42 + h 1 + Θo2 + h 1 + Θu Θo (h 42 + 2h 1 ) .
2 b4 3 3
(4.39)

The current linkages Θ u and Θ o are equal to half of the total current linkage of the slot Θ

Θ
Θu = Θo = . (4.40)
2

A winding can also have slots in which the coil sides belong to different phases. If the phase
shift between the currents of the bottom and upper coils is γ , the current linkage product
Θ u Θ o has to be multiplied by cos γ . The product term Θ u Θ o represents the mutual influence
of the bottom and upper currents. Because the phase shift can vary from slot to slot, the
average value g over 2q coil sides has to be built

1 
2q
g= cos γn , (4.41)
2q n=1

and the current linkage product takes the form

 2
Θ g 2
Θu Θo = g = Θ . (4.42)
2 4

Substituting (4.40) and (4.42) into Equation (4.39) gives

    
1 1 Θ2 h 41 h 42
WΦ = µ0l


+ h + h 42 + h 1 + + h 1 + g (h 42 + 2h 1 ) . (4.43)
2 b4 4 3 3

In two-layer windings, the height of the coil sides is equal:

h4 − h

h 41 = h 42 = , (4.44)
2

with which Equation (4.43) is reduced to

 
1 5 + 3g h 4 − h
1 + g h1 h

WΦ = µ0 l
Θ 2 + + . (4.45)
2 8 3b4 2 b4 4b4

The term in square brackets is the permeance factor l u for a double-layer winding

h4 − h
h1 h

lu = k1 + k2 + , (4.46)
3b4 b4 4b4
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Flux Leakage 241

where

5 + 3g
k1 = (4.47)
8

and

1+g
k2 = . (4.48)
2

Correspondingly, the permeance factor for slot types from a to e in Figure 4.10 is
 
h4 − h
h3 h1 h2 b4 h

lu = k1 + k2 + + ln + (4.49)
3b4 b4 b1 b4 − b1 b1 4b4

and for slots types from f to g in Figure 4.10

 
h4 − h
h1 h

lu = k 1 + k2 + 0.66 + . (4.50)
3b4 h1 4b4

Equations (4.49) and (4.50) are valid also for a single-layer winding. In that case, h
= 0
and k1 = k2 = 1.
The factors k1 and k2 can also be calculated with the aid of the amount of short pitching ε
given by

W
ε =1− . (4.51)
τp

Within a zone, there are q = τ p /m slots (Figure 4.13), of which ετ p slots in the upper and
bottom coil sides belong to different phases and in the remaining (τ p /m − ετ p ) slots, the coil
sides belong to the same phase. In a three-phase winding (m = 3), the phase shift of the upper
and bottom coil currents is 180◦ − 120◦ = 60◦ in the slots, where the coil sides belong to
different phases; so cos γ = 0.5 in these slots. In the slots where the coil sides belong to the

q = τ p /m

ετ p ετ p

W = (1-ε)τ p
τp

Figure 4.13 Short-pitched winding with q = 5, m = 3 and W/τ p = 13/15

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242 Design of Rotating Electrical Machines

same phase, cos γ = 1. For three-phase windings, Equation (4.41) takes the form

1  1 τ  
2q
p 3
g= cos γ = τp 2ετp · 0.5 + 2 − ετp · 1 = 1 − ε. (4.52)
2q γ =1 23 3 2

Substituting (4.52) into Equations (4.47) and (4.48), the factors k1 and k2 take the form for a
three-phase winding

9 3
k1 = 1 − ε and k2 = 1 − ε. (4.53)
16 4

For a two-phase winding, the factors k1 and k2 are

3
k1 = 1 − ε and k2 = 1 − ε. (4.54)
4

Example 4.3: Calculate the slot leakage inductance of a double-layer winding with p = 2,
Q = 24, W/τ p = 5/6 and N = 40 (cf. Figure 2.17b). The pole pairs are connected in
parallel, a = 2. The slot shape is according to Figures 4.10b and 4.12: b1 = 0.003 m, h1 =
0.002 m, h2 = 0.001 m, h3 = 0.001, h
= 0.001 m, b4 = 0.008 m and h41 = h42 = 0.009 m
(h4 = 0.019 m), l
= 0.25 m. Compare the result with the slot leakage of a corresponding
double-layer full-pitch winding.
Solution: The short pitching ε = 1/6 and k1 = 1 − 9/(16 × 6) = 0.906, k2 = 1 − 3/(4 ×
6) = 0.875. The permeance factor is, according to Equation (4.49),
 
h4 − h
h3 h1 h2 b4 h

lu = k1 + k2 + + ln +
3b4 b4 b1 b4 − b1 b1 4b4
 
0.018 0.001 0.002 0.001 0.008 0.001
= 0.906 · + 0.875 + + ln +
3 · 0.008 0.008 0.008 0.008 − 0.003 0.003 4 · 0.008
= 1.211

and the slot leakage inductance is, according to Equation (4.30),

4m 4·3
Lu = µ0 l
N 2 lu = 4π · 10−7 · 0.25 · 402 · 1.211 H = 0.2513 · 1.211 mH
Q 24
= 0.304 mH.

For a full-pitch double-layer winding k1 = k2 = 1 and Equation (4.49) yields

 
0.018 0.001 0.002 0.001 0.008 0.001
lu = + + + ln + = 1.352.
3 · 0.008 0.008 0.008 0.008 − 0.003 0.003 4 · 0.008

The slot leakage inductance is now Lu = 0.2513 × 1.352 mH = 0.340 mH.

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Flux Leakage 243

As we can see, the phase shift of the different phase coil sides in the double-layer wind-
ing causes a smaller slot leakage inductance for the short-pitched winding compared with
the full-pitch winding. The slot leakage inductance in this case is about 10% smaller for
the short-pitched winding.

If the height of a conductor is considerable or a single homogeneous bar forms the winding
of a slot (as is the case in the rotor of an induction motor), a skin effect occurs in the conductors
with alternating current. The skin effect may be high even at moderate frequencies. It has a
strong influence on the rotor resistance during the start-up of a squirrel cage motor. In that
case, at the bottom of slot of Figure 4.8, the conductor elements dh are surrounded by a
larger flux than the conductor elements in the upper layer of the slot. The inductance of the
conductor elements of the upper layer is lower than the inductance of the conductor elements
at the bottom, and therefore a time-varying current is distributed so that the current density
in the upper section of the slot is higher than the current density at the bottom. The density
function of the leakage flux corresponds to the dotted line of Figure 4.8. Thus, the skin effect
increases the resistance of the bar and reduces the slot inductance. This will be discussed in
more detail in Chapter 5.
Now, the permeance factor (4.25) of the area with height h4 (or h41 and h42 ) is rewritten in
the form

h4
l4,ec = kL , (4.55)
3b4

where kL is the skin effect factor for the permeance as well as for the inductance (4.23),
representing the decrease in the slot inductance caused by the skin effect. l 4,ec has to be
applied in Equations (4.31), (4.32), (4.49) and (4.50) instead of the first term. To define the
permeance factor, the reduced conductor height ξ is determined as

bc
ξ = h 4 ωµ0 σ , (4.56)
2b4

where bc is the width of a conductor in a slot (see Figure 4.8), ω is the angular frequency of
the current investigated, and σ is the specific conductivity of the conductor. For instance, in
induction motors the slip s defines the rotor angular frequency ω = sωs .
The skin effect factor kL of the permeance can be obtained from the equation

1
z t2 − 1

kL = φ (ξ ) + ψ (ξ ) , (4.57)
z t2 z t2

where
 
3 sinh 2ξ − sin 2ξ
φ
(ξ ) = · , (4.58)
2ξ cosh 2ξ − cos 2ξ
 
1 sinh ξ + sin ξ
ψ
(ξ ) = (4.59)
ξ cosh ξ + cos ξ
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244 Design of Rotating Electrical Machines

and zt is the number of conductors on top of each other. For a squirrel cage winding zt = 1, as
depicted in Figure 4.8, and the skin effect factor is

kL = φ
(ξ ) . (4.60)

Usually, in squirrel cage rotors, h4 > 2 cm and for copper bars Equation (4.56) gives
ξ > 2, in which case sinh 2ξ  sin 2ξ , cosh 2ξ  cos 2ξ and sinh2ξ ≈ cosh2ξ , and hence

3
kL ≈ . (4.61)
2ξ

Example 4.4: Repeat Example 4.2 for an aluminium squirrel cage bar at cold start in a
50 Hz supply.
Solution: The slot shape is, according to Figure 4.8, b1 = 0.003 m, h1 = 0.002 m,
b4 = 0.008 m and h4 = 0.02 m, l
= 0.25 m and the slot at height h4 is fully filled with
aluminium bars. The conductivity of aluminium at 20 ◦ C is σ Al = 37 MS/m.
The permeance factor of the wound part of the slot without skin effect is

h4 0.02
l4 = = = 0.833.
3b4 3 · 0.008

The permeance factor of the slot opening is

h1 0.002
l1 = = = 0.667.
b1 0.003

The reduced height ξ of the conductor is

 
bc 0.008
ξ = h4 ωµ0 σ = 0.02 2π · 50 · 4π · 10−7 · 37 · 106 = 1.71
2b4 2 · 0.008

which is a dimensionless number

1
z2 − 1 1−1

kL = 2
φ (ξ ) + t 2 ψ
(ξ ) = φ
(ξ ) + ψ (ξ ) = φ
(ξ )
zt zt 1
   
3 sinh 2ξ − sin 2ξ 3 sinh 3.42 − sin 3.42
= · = · = 0.838.
2ξ cosh 2ξ − cos 2ξ 3.42 cosh 3.42 − cos 3.42
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Flux Leakage 245

The permeance factor of the slot under skin effect is lu,ec = l1 + kL l4 = 0.667 +
0.838 · 0.833 = 1.37. This is somewhat less than in Example 4.2. The slot leakage in-
ductance of a squirrel cage bar is

L u,bar = µ0l
z Q2 lu = 4π · 10−7 · 0.25 · 12 · 1.37 H = 0.43 µH.

4.2.3 Tooth Tip Leakage Inductance

The tooth tip leakage inductance is determined by the magnitude of leakage flux flowing in
the air gap outside the slot opening. This flux leakage is illustrated in Figure 4.14. The current
linkage in the slot causes a potential difference between the teeth on opposite sides of the slot
opening, and as a result part of the current linkage will be used to produce the leakage flux of
the tooth tip.
The tooth tip leakage inductance can be determined by applying a permeance factor
 
δ
5
b1
ld = k2  , (4.62)
δ
5+4
b1

where k2 = (1 + g)/2 is calculated from Equation (4.48).

The tooth tip leakage inductance of the whole phase winding is obtained by substituting l d
in Equation (4.30):

4m
Ld = µ0l
ld N 2 . (4.63)
Q

b1

Figure 4.14 Flux leakage creating a tooth tip leakage inductance around a slot opening
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246 Design of Rotating Electrical Machines

In salient-pole machines, we have to substitute the air gap in Equation (4.62) by the air
gap at the middle of the pole, where the air gap is at its smallest. If we select the air gap to be
infinite, we obtain a limit value of l d = 1.25, which is the highest value for l d . If δ is small, as
is the case in asynchronous machines in particular, the influence of tooth leakage inductance
is insignificant.
Equations (4.62)–(4.63) are no longer valid for the main poles of DC machines. The calcu-
lations in the case of DC machines are analysed for instance by Richter (1967).

Example 4.5: Calculate the toot tip leakage of the machine in Example 4.3. The machine
is now equipped with rotor surface permanent magnets. The magnets are neodymium
iron boron magnets 8 mm thick, and there is a 2 mm physical air gap, p = 2, Q = 24,
W/τ p = 5/6 and N = 40 (cf. Figure 2.17b). The pole pairs are connected in parallel,
a = 2. Compare the result with the slot leakage of Example 4.3.
Solution: As the permanent magnets represent, in practice, air (µrPM = 1.05), we may
assume that the air gap in the calculation of the tooth tip leakage is 2 + 8/1.05 mm =
9.62 mm. The factor k2 = 1 − 3ε/4 = 1 − 3/(4 · 6) = 0.875. We now obtain for the perme-
ance coefficient
   
δ 0.00 962
5 5
b1 0.003
ld = k2   = 0.875   = 0.787.
δ 0.00 962
5+4 5+4
b1 0.003

The tooth tip inductance is, according to Equation (4.63),

4m 4·3
Ld = µ0 l
ld N 2 = 4π · 10−7 · 0.25 · 0.787 · 402 H = 0.198 mH.
Q 24

In Example 4.3, the slot leakage of the same machine was 0.340 mH. As the air gap in
a rotor surface magnet machine is long, the tooth tip leakage has a significant value, about
70% of the slot leakage.

4.2.4 End Winding Leakage Inductance

End winding leakage flux results from all the currents flowing in the end windings. The
geometry of the end windings is usually difficult to analyse, and, further, all the phases of
poly-phase machines influence the occurrence of a leakage flux. Therefore, the accurate de-
termination of an end winding leakage inductance is a challenging task, which would require
a three-dimensional numerical solution. Since the end windings are relatively far from the
iron parts, the end winding inductances are not very high, and therefore it suffices to employ
empirically determined permeance factors l lew and l w . In machines with an alternating cur-
rent flowing in both the stator and the rotor, measuring always yields a sum of the leakage
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Flux Leakage 247

zQ zQ
q=2

leW

WeW

Figure 4.15 Leakage flux and dimensions of an end winding

inductance of the primary winding and the leakage inductance of the secondary winding re-
ferred to the primary winding. In a stationary state, there is a direct current flowing in the rotor
of a synchronous machine, and thus the end winding inductance of a synchronous machine is
determined only by the stator side.
When calculating the slot leakage inductance, the proportion of each slot can be calculated
separately. The number of conductors in a slot is zQ (in a two-layer winding zQ = 2zcs ) and
the conductors are surrounded by iron. The flux in the end windings is a result of the influence
of all the coil turns belonging to a coil group. According to Figure 4.15, the number of coil
turns is qzQ , which has to replace zQ in the inductance equation (4.23). The average length
lw of the end winding (see Figure 4.15) has to be substituted for the length l
of the stack in
Equation (4.23). The number of coil groups in series in a phase winding is Q/amq, and the
number of parallel current paths is a. The equation for end winding leakage inductance can
now be written as

Q 1 2 Q  z Q 2 4m
Lw = qz Q µ0lw lw = q µ0lw lw = q N 2 µ0lw lw . (4.64)
amq a m a Q

The average length lw of the end winding and the product lw l w can be written in the form

lw = 2lew + Wew , (4.65)

lw lw = 2lew llew + Wew lW , (4.66)

where lew is the axial length of the end winding measured from the end of the stack, and W ew is
the coil span according to Figure 4.15. l lew and l w are the corresponding permeance factors,
see Tables 4.1 and 4.2.
A permeance factor depends on the structure of the winding (e.g. a single-phase, or a two-
plane, three-phase, or a three-plane, three-phase, or a diamond winding constructed of coils
of equal shapes), the organization of the planes of the end winding, the ratio of the length of
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248 Design of Rotating Electrical Machines

Table 4.1 End winding leakage permeance factors of an asynchronous machine for various stator and
rotor combinations
Type of stator winding Type of rotor winding l lew lw
Three-phase, three-plane Three-phase, three-plane 0.40 0.30
Three-phase, three-plane Cylindrical three-phase diamond 0.34 0.34
winding
Three-phase, three-plane Cage winding 0.34 0.24
Three-phase, two-plane Three-phase, two-plane 0.55 0.35
Three-phase two-plane Cylindrical three-phase diamond 0.55 0.25
winding
Three-phase, two-plane Cage winding 0.50 0.20
Cylindrical three-phase diamond Cylindrical three-phase diamond 0.26 0.36
winding winding
Cylindrical three-phase diamond Cage winding 0.50 0.20
winding
Single-phase Cage winding 0.23 0.13

an average coil end to the pole pitch lw /τ p , and the rotor type (a nonsalient-pole machine, a
salient-pole machine, an armature winding of a DC machine, a cage winding, a three-phase
winding). Richter (1967: 279; 1963: 91) and (1954:161) presents in detail some calculated
values for permeance factors that are valid for different machine types.
Based on the literature, the following tables can be compiled for the definition of the end
winding leakage permeance factors for asynchronous and synchronous machines. With these
permeance factors, Equation (4.64) gives the sum of the stator end winding leakage inductance
and the rotor to the stator referred end winding leakage inductance. The major part of the sum
belongs to the stator (60–80%).

Table 4.2 Permeance factors of the end windings of a synchronous machine

Nonsalient-pole machine Salient-pole machine

Cross-section of
end winding l lew lw l lew lw

0.342 0.413 0.297 0.232

0.380 0.130 0.324 0.215

0.371 0.166 0.324 0.243

0.493 0.074 0.440 0.170

0.571 0.073 0.477 0.187

0.605 0.028 0.518 0.138

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Flux Leakage 249

Example 4.6: The air-gap diameter of the machine in Example 4.3 is 130 mm and the
total height of the slots is 22 mm. Calculate the end winding leakage inductance for a
three-phase surface-mounted, permanent magnet synchronous machine with Q = 24,
q = 2, N = 40, p = 2 and lw = 0.24 m. The third end winding arrangement in Table 4.2
is valid for the machine under consideration.
Solution: Let us assume that the average diameter of the end winding is 130 + 22 mm =
152 mm. The perimeter of this diameter is about 480 mm. The pole pitch at this diameter is
τp
= 480 mm/4 = 120 mm. From this we may assume that the width of the end winding is
about the pole pitch subtracted by one slot pitch, Wew = τp
− τu
= (0.12 − 0.48/24) m =
0.14 m and lew = 0.5(lw − Wew ) = 0.05 m.
The surface magnet machine may be regarded as a salient-pole machine, Hence, in
calculating end winding leakage the permeance factors are l lew = 0.324 and l w = 0.243:
lw lw = 2lew llew + Wew lW = 2 · 0.05 m · 0.324 + 0.14 m · 0.243 = 0.0664 m
4m 4·3
Lw = q N 2 µ0lw lw = 2 · 402 · 4π · 10−7 · 0.0664 H = 0.134 mH.
Q 24
The slot leakage of the 5/6 short-pitched winding in Example 4.3 was Lu = 0.340 mH,
the tooth tip leakage of the PMSM was Ld = 0.198 mH, and the end winding leakage was
Lw = 0.134 mH. The slot leakage is usually the most important leakage flux component as
these results may indicate. The air-gap leakage is dependent on the magnetizing inductance
and cannot now be compared with these other leakages.

For the leakage inductance of a short-circuit ring of a cage winding in an induction machine
or in a damper winding, Levi (1984) introduces the equation
 
Qr 1 

 πDr

L rwσ = µ0 l bar − l s + v , (4.67)
m s p2 3 2p
where lbar is the length of the rotor bar, ls
is the equivalent length of the stator and Dr
is the
average diameter of the short-circuit ring. The factor v = 0.36 when p = 1, and v = 0.18 when
p > 1. Calculation of the total impedance of a cage winding is discussed in Section 7.12.

Example 4.7: Calculate the rotor short-circuit ring leakage for a four-pole, three-phase
induction motor with Qr = 34, lbar = 0.12 m, ls
= 0.1216 m, Dr
= 0.11 m, δ = 0.008 m.
Solution: Inserting l
= l + 2δ = 0.1216 m in (4.67) gives
 
Qr 1 

 πDr

L rwσ = µ0 l bar − l s + v
m s p2 3 2p
 
V s 34 1 π · 0.1
= 4π · 10−7 (0.12 − 0.1216) + 0.18 m
A m 3 · 22 3 2·2
= 0.015 µH.

This value must be referred to the stator to get the single-phase equivalent-circuit leakage
inductance. This is studied in Chapter 7.
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250 Design of Rotating Electrical Machines

4.2.5 Skewing Factor and Skew Leakage Inductance

In rotating-field machines, especially in squirrel cage induction motors, the stator and rotor
slots are often assembled in a skew position with respect to each other in order to reduce the
influences of permeance harmonics caused by slots. Usually the slots of a stator stack are
straight and the slots of the rotor are skewed, as shown in Figure 4.16. However, it is of course
possible to skew the stator slots instead. In Figure 4.16, the orientation of the rotor slots forms
an angle α with the shaft. This angle is of the same magnitude as one stator slot angle. For
the same reason, in synchronous machines, the axial sides of the pole shoes can be similarly
skewed. In that case, the damping bars fitted to the rotor surface will also be skewed like the
cage winding. In low-speed permanent magnet machines with a low number of slots per pole
and phase, either the stator or the permanent magnets are often skewed.
The objective of skewing is to reduce the ability of certain air-gap harmonics, created by the
stator, to induce respective voltages in the rotor bars. Correspondingly, the induction effect of a
rotor bar on the stator field is weaker than in the case of a straight bar. Both of these effects can
be taken into account as follows: the emf calculated for straight slots and induced in the rotor
is multiplied by the skewing factor of the rotor, or alternatively, the magnetic voltage created
by the rotor current in the air gap is reduced by the same factor ksqν . The skewing factor thus
belongs to the winding factors, and can be taken into account as such in the calculations. The
value of the skewing factor is derived with Equation (2.24) of the distribution factor kdν

sin (νqαu /2)

kdν = . (4.68)
q sin (ναu /2)

A skewed bar is considered to be composed of a large number of short, straight bars. The
number of these bars is

l α
zl = = . (4.69)
l α

l
l

α
α
α

Figure 4.16 Determination of the skew of a rotor slot

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Flux Leakage 251

The slot angle between these bars is α. This is also the phase shift angle between the emfs
of the bars. The emf of a skewed bar can be calculated in the same way as the emf of a coil
group divided into q slots. The value α/α is substituted in Equation (4.68) as a value of q,
and a limit value is calculated when α approaches zero. We now obtain a skewing factor for
the νth harmonic
 
α α
sin ν
α 2 sin (να/2) sin (να/2)
ksqν = lim  = = (4.70)
α→0 α α α α να/2
sin ν ν
α 2 α 2
 
s π
sin ν
τp 2
ksqν = s π . (4.71)
ν
τp 2

Here s is the skewing (Figure 4.16) measured as an arc length, given by α = sπ/τp . The
skewing factor is applied similar to a winding factor. For instance, when referring the rotor
quantities to the stator, the number of coil turns in a rotor has to be multiplied by the winding
factor of the rotor and with the skewing factor.
To eliminate the slot harmonics, the factor ksqν should be zero. The orders of the slot har-
monics are (±2mqc + 1), c being an integer 1, 2, 3, . . . . The numerator of Equation (4.71)
should be zero:

ν sπ (±2mqc + 1) sπ
sin = sin = 0. (4.72)
2τp 2τp

This will be true if the argument of the sine function is kπ:

(±2mqc + 1) sπ
= kπ, (4.73)
2τp
(±2mqc + 1) s
= k, (4.74)
2τp
s 2 1
=k ≈ ±k . (4.75)
τp ±2mqc + 1 mqc

This means that for c = k = 1

s ∼ 1 1 τp
= = ⇒s= = τu . (4.76)
τp mq Q/2 p Q/2 p

Hence, the skewing factor will be effective in cancelling the slot harmonics if the skewing
is made by one slot pitch.
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252 Design of Rotating Electrical Machines

In the case s = τ u the skewing factor is

   
s π π 1
sin ν sin ν
τp 2 2 mq
ksqν = s π = . (4.77)
ν π 1
τp 2 ν
2 mq

When a winding is assembled and skewed with respect to another winding, the magnetic
connection between the windings is weakened. Now, a part of the flux created by the stator
winding does not penetrate a skewed rotor winding, although it passes through the air gap.
Thus, this part belongs to the leakage flux and can be described by the skew inductance Lsq .
The magnetizing inductance of an electrical machine is proportional to the square of the
effective number of turns (kw1 N)2 . The magnetizing inductance (3.110) of a machine with
straight slots is written as

L m ∼ kw1
2
. (4.78)

Since the skewing factor acts like a winding factor in calculations, the magnetizing inductance
of the same machine, now with skewed slots, is
 2
L
m ∼ ksq kw1 ∼ ksq
2
L m < L m. (4.79)

The difference L m − L
m = L sq represents the skew inductance

 
L sq = L m − L
m = 1 − ksq
2
L m = σsq L m . (4.80)

The leakage factor caused by skewing is thus

 
σsq = 1 − ksq
2
. (4.81)

In practice, skewing is typically small, about the amount of a single slot pitch. Therefore,
an approximation for a leakage factor can be generated by calculating a series development of
the numerator of the skewing factor (4.71), and by then employing the first two terms of the
series. For a fundamental, we thus obtain a skewing factor
   
s π s π 1 s π 3
sin −  
τp 2 τp 2 6 τp 2 1 s π 2
ksq1 = s π ≈ s π =1− (4.82)
6 τp 2
τp 2 τp 2

and a leakage factor

 2
2  2
  1 s π 1 s π
σsq = 1 − 2
ksq ≈1− 1− ≈ . (4.83)
6 τp 2 3 τp 2
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Flux Leakage 253

By substituting the pole pitch of the rotor

Q r τur
τp = , (4.84)
2p

where τ ur is the rotor slot pitch on the surface of the air gap, we obtain another equation for
the leakage factor
 2
1 πsp
σsq ≈ . (4.85)
3 τur Q r

The accuracy of the approximations is sufficient, when the calculated skew leakage inductance
factor meets the condition σsq < 0.03.

Example 4.8: Calculate the skewing factors for the first stator harmonics in a four-pole
squirrel cage motor, where the stator has 36 slots and the rotor 34 slots, and the rotor bars
are skewed by one stator slot pitch.
Solution: The stator slot electrical angle α u = 2 × 2π/36 = 0.349 rad (20◦ ). The slot
harmonics are (±2mqc + 1) = ± 2 × 3 × 3 × 1 + 1 = −17, 19, −35, 37, when c = 1, 2.

The skewing factor was defined as

sin (να/2)
ksqν = .
να/2

ν 1 −5 7 −11 13 −17 19 −23 25 −29 31 −35 37

ksqν 0.995 0.878 0.769 0.490 0.338 0.06 −0.05 −0.19 −0.22 −0.19 −0.14 −0.03 −0.03

As we can see, especially the slot harmonics −17, 19, −35 and 37 have small skew factors,
and thereby their effects are eliminated to a great degree. The fundamental is reduced only by
0.5%.

Bibliography
Levi, E. (1984) Polyphase Motors: A Direct Approach to Their Design, John Wiley & Sons, Inc., New York.
Richter, R. (1954) Electrical Machines: Induction Machines (Elektrische Maschinen: Die Induktionsmaschinen),
Vol. IV, 2nd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1963) Electrical Machines: Synchronous Machines and Rotary Converters (Elektrische Maschinen: Syn-
chronmaschinen und Einankerumforme.), Vol. II, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1967) Electrical Machines: General Calculation Elements. DC Machines (Elektrische Maschinen: Allge-
meine Berechnungselemente. Die Gleichstrommaschinen), Vol. I, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Vogt, K. (1996) Design of Electrical Machines (Berechnung elektrischer Maschinen), Wiley-VCH Verlag GmbH,
Weinheim.
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5
Resistances

Together with inductances, resistances define the characteristics of an electrical machine.

From an efficiency point of view, resistances are important electrical machine parameters.
In many cases, the resistive losses form dominant loss components in a machine. In electrical
machines, the conductors are usually surrounded by a ferromagnetic material, which encour-
ages flux components to travel through the windings. This, again, may cause large skin effect
problems if the windings are not correctly designed.

5.1 DC Resistance
The resistance of a winding can first be defined as a DC resistance. According to Ohm’s law,
the resistance RDC depends on the total length of a conductor in a coil lc , the number of parallel
paths a in windings without a commutator, per phase, or 2a in windings with a commutator,
the cross-sectional area of the conductor Sc and the conductivity of the conductor material σ c

lc
RDC = . (5.1)
σc aSc

Resistance is highly dependent on the running temperature of the machine, and therefore
a designer should be well aware of the warming-up characteristics of the machine before
defining the resistances. Usually, we may first investigate the resistances of the machine at the
design temperature or at the highest allowable temperature for the selected winding type.
Windings are usually made of copper. The specific conductivity of pure copper at room
temperature (+20 ◦ C) is σCu = 58 × 106 S/m and the conductivity of commercial copper wire
σCu = 57 × 106 S/m. The temperature coefficient of resistivity for copper is α Cu = 3.81 ×
10−3 /K. The respective parameters for aluminium are: conductivity σ Al = 37 × 106 S/m and
the temperature coefficient of resistivity α Al = 3.7 × 10−3 /K.
An accurate definition of the winding length in an electrical machine is a fairly difficult task.
Salient-pole machines are a relatively simple case: the conductor length can be defined fairly
easily when the shape of the pole body and the number of coil turns are known. Instead, the
winding length of slot windings is difficult, especially if coils of different length are employed

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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256 Design of Rotating Electrical Machines

in the machine. Preliminary calculations can be made by applying the following empirical
equations.
The average length lav of a coil turn of a slot winding of low-voltage machines with round
enamelled wires is given approximately as

lav ≈ 2l + 2.4W + 0.1 m. (5.2)

Here l is the length of the stator stack of the machine and W is the average coil span, both
expressed in metres. For large machines with prefabricated windings, the following approxi-
mation is valid:

lav ≈ 2l + 2.8W + 0.4 m, (5.3)

and

lav ≈ 2l + 2.9W + 0.3 m, when U = 6 . . . 11 kV, (5.4)

Using the length of the winding, the DC resistance may be calculated according to Equation
(5.1) by taking all the turns and parallel paths into account.

5.2 Influence of Skin Effect on Resistance

Alternating current creates an alternating flux in the conductor material and causes a skin
effect. In electrical machines, the skin effect occurs chiefly in the area of the slots, but it is
also present to a lesser extent in end windings.

5.2.1 Analytical Calculation of Resistance Factor

Let us consider a solid conductor in a slot surrounded on three sides by ferromagnetic mate-
rial, the permeability of the material being infinity, Figure 5.1. The current i creates a magnetic
field strength H and leakage flux across the slot and conductor. The leakage flux surrounding
the bottom part of the conductor is greater than the flux surrounding the upper part of the
conductor, whereupon the impedance of the conductor decreases from the bottom up. Corre-
spondingly, the current density J increases from the bottom up as shown in Figure 5.1.
Since the permeability of iron is assumed infinite, the leakage flux lines cross the slot rec-
tilinearly. The vectors of the current density J and electric field strength E in the conductor
have only a z-component. The magnetic field strength H and the flux density B have only
an x-component across the conductor. Applying Ampère’s law (Equation 1.4) to the route
1–2–3–4–1 having the area b dy we obtain

 
∂H
H · dl = H b − H + dy b = Jbc dy (5.5)
∂y
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Resistances 257

E + dE

H + dH E

H
6 y
H
y
dy 8
4 3 l
hc
1 5 2

i x
J z
J

Integration paths

bc

Figure 5.1 Definition of the skin effect in a conductor. The current i creates a leakage flux across the
conductor resulting in an uneven distribution of current density J in the conductor

from which

∂H bc
− = J. (5.6)
∂y b

Applying Faraday’s induction law (Equation 1.7) to the route 5–6–7–8–5 in Figure 5.1, we
obtain

 
∂E ∂B
E · dl = − El + E + dy l = − l dy (5.7)
∂y ∂t

from which

∂E ∂B ∂H
=− = −µ0 . (5.8)
∂y ∂t ∂t

The third equation needed in the calculations is Ohm’s law

J = σc E. (5.9)
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258 Design of Rotating Electrical Machines

Applying Equation (5.9) to Equation (5.8) yields

∂J ∂H
= −µ0 σc . (5.10)
∂y ∂t

With sinusoidally varying quantities, Equations (5.6), (5.8) and (5.10) change to complex
form:
∂H bc
− = J, (5.11)
∂y b
∂E
= −jωµ0 H , (5.12)
∂y
∂J
= −jωµ0 σc H . (5.13)
∂y

Differentiating Equation (5.13) with respect to y and using Equation (5.11) we obtain

∂2 J ∂H bc
= −jωµ0 σc = jωµ0 σc J (5.14)
∂y 2 ∂y b
∂ J
2
bc
− jωµ0 σc J = 0. (5.15)
∂ y2 b

Equation (5.15) has a solution in the form

J = C1 e(1+j)αy + C2 e−(1+j)αy , (5.16)

where

1 bc
α= ωµ0 σc . (5.17)
2 b

The inverse of α is called the depth of penetration. Usually, α is used in defining a dimen-
sionless number ξ

1 bc
ξ = αh c = h c ωµ0 σc , (5.18)
2 b

which is called reduced conductor height (the units of α are 1/m and so ξ is a dimensionless
number, while hc is the real conductor height in metres).
The integration constants C1 and C2 are determined by the following boundary conditions:

on the boundary y = 0 the magnetic field strength H = H0 = 0, √

on the boundary y = hc the magnetic field strength H = H c = −i
b
= 2 bI ,

where I is the effective value of the total current flowing in the conductor.
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Resistances 259

Differentiating the solution in Equation (5.16), substituting it into Equation (5.13) and using
the boundary conditions, we obtain for the integration constants

jωµ0 σc
C1 = C2 =  . (5.19)
(1 + j) bα e(1+j)αh c − e−(1+j)αh c

Now we know J = f(y) and we can calculate the power losses in the conductor. The current
in an element dy is Jbc dy and the resistive losses are

h c h c
l bcl
PAC = (J bc dy)2
= J 2 dy. (5.20)
σc bc dy σc
0 0

In complex form, we can write Equation (5.20) as

h c
bcl
PAC = J J ∗ dy, (5.21)
σc
0

   
where J ∗ is the complex conjugate of J , and  J ∗  and  J  are the effective values.
When a direct current having the same effective value I as the alternating current is flowing
in the conductor, the losses are

l
PDC = RDC I 2 = I 2. (5.22)
σc bc h c

The factor by which the DC resistive losses have to be multiplied to get the AC resistive
losses is the resistance factor kR . It is also the ratio of the AC and DC resistances of the
conductor. According to Equations (5.20), (5.21) and (5.22), the resistance factor is

h c h c
RAC PAC b2 b2
kR = = = c2 J dy = c2
2
J J ∗ dy. (5.23)
RDC PDC I I
0 0

The integration in (5.23) is laborious but not very difficult. Here, it is passed over because
there are solutions and applications readily available in the literature, for instance in Lipo
(2007), Richter (1967), Stoll (1974), Vogt (1996) and Küpfmüller (1959). Some of them are
given below.
Let us consider the case shown in Figure 5.2, where several conductors are placed in a slot.
All the conductors are series connected. The height of the subconductors is hc0 and the width
bc0 . There are zt conductors on top of each other and za adjacent conductors.
The reduced conductor height ξ is calculated using Equation (5.18) by substituting for
bc = za bc0 and for the conductor height, the height of an individual conductor hc0 , that is

1 bc0
ξ = αh c0 = h c0 ωµ0 σc . (5.24)
2 b
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260 Design of Rotating Electrical Machines

zt
.
.
.
.
.
hc0 2
k=1
bc0
1.... ...........z a
b

Figure 5.2 Determination of the reduced conductor height and the resistance factor of a winding with
several conductors in the width and height directions of a slot with a uniform width in the conductor
area. All the conductors are connected in series. The height and the width of the subconductors are hc0
and bc0 . There are zt conductors on top of each other and za adjacent conductors

Here we can see that dividing the conductor into adjacent subconductors does not affect the
reduced conductor height.
The resistance factor of the kth layer is

kRk = ϕ(ξ ) + k(k − 1)ψ(ξ ), (5.25)

where the functions ϕ(ξ ) and ψ(ξ ) are

sinh 2ξ + sin 2ξ
ϕ(ξ ) = ξ (5.26)
cosh 2ξ − cos 2ξ

and

sinh ξ − sin ξ
ψ(ξ ) = 2ξ . (5.27)
cosh ξ + cos ξ

Equation (5.25) shows that the resistance factor is smallest on the bottom layer and largest
on the top layer. This means that in the case of series-connected conductors, the bottommost
conductors contribute less to the resistive losses than the topmost conductors. The average
resistance factor over the slot is

z t2 − 1
kR = ϕ(ξ ) + ψ(ξ ), (5.28)
3

where zt is the number of conductor layers (Figure 5.2).

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Resistances 261

If 0 ≤ ξ ≤ 1, a good approximation for the resistance factor is

z t2 − 0.2 4
kR ≈ 1 + ξ . (5.29)
9
The equations above are valid for rectangular conductors. The eddy current losses of round
wires are 0.59 times the losses of rectangular wires, and therefore, for round wires, the ap-
proximate Equation (5.29) takes the form
z t2 − 0.2 4
kR ≈ 1 + 0.59 ξ . (5.30)
9
According to Equations (5.29) and (5.30), the reduced conductor height ξ as well as the
conductor height hc0 itself (Equation 5.18) strongly affect the resistance factor. With high
conductors, the resistance factor is also high. Despite the fact that the resistance factor is pro-
portional to the square of the number of conductors on top of each other, zt , to reduce the
resistance factor and eddy current losses in conductors, the conductors are divided into sub-
conductors, which are connected together only at the beginning and at the end of the wind-
ing. To get the full benefit of dividing the conductors, circulating currents in the conductors
must be prevented. To prevent such circulating currents flowing through the connections at
the beginning and at the end of the winding, every parallel-connected subconductor has to be
surrounded exactly by the same amount of slot leakage flux. This is put into effect by transpos-
ing the subconductors. If the number of subconductors is zp , the transposition has to be done
zp − 1 times. For instance, if a winding consists of six coils and the conductors are divided
into three subconductors, the transposition has to be done twice, which can be done at the end
winding area after every two coils, Figure 5.3.
To clarify the meaning of transposition, let us consider Figure 5.4, where two conductors
are connected in series and six conductors in parallel. If the subconductors were located in
similar positions from slot to slot, in other words there should be no transposition of the
conductors, the conductor height hc to be substituted in Equation (5.18) is hc = zp hc0 , where
zp is the number of parallel-connected conductors (in Figure 5.4 zp = 6) and hc0 the height of
the subconductor. This means that dividing a conductor into subconductors but not transposing
them equates to a solid conductor. As the skin effect is remarkably smaller in the end winding
area, dividing the conductors also helps slightly without transposing. The number of layers
zt in Equation (5.28) is, without transposition, the number of series-connected conductors (in

1st and 2 nd coil 3rd and 4 th coil 5 th and 6 th coil

1st transposition 2nd transposition

Figure 5.3 Transposition of three parallel-connected conductors is done twice in the end winding area
after every two coils in a winding having six coils
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262 Design of Rotating Electrical Machines

zp
.
.
.
.
h0 .
1
bc
b

Figure 5.4 Two series-connected conductors with six parallel subconductors on top of each other in a
slot zp = 6. (1) No transposition: hc = zp hc0 and zt = 2. (2) Full transposition: hc = hc0 and zt = 12

Figure 5.4, zt = 2). If the transposition is done so that every subconductor is located at an equal
length in every position of the slot, that is in Figure 5.4 at every six positions, the conductor
height in Equation (5.18) is hc = hc0 and the number of layers zt in Equation (5.28) is the total
number of conductors in the slot (in Figure 5.4, zt = 12).

Example 5.1: Calculate the reduced conductor height ξ and the resistance factor kR for
the winding of Figure 5.4 for hc0 = 2 mm, bc = 10 mm, b = 14 mm, zp = 6 and the total
number of conductors in the slot is 12, when (a) the winding is not transposed and (b) the
winding is fully transposed. The frequency is 50 Hz and the conductor temperature 20 ◦ C.
Solution: The specific conductivity of copper at 20 ◦ C is 57 MS/m:

a) hc = zp hc0 = 6 × 2 mm = 12 mm and zt = 2. According to Equations (5.18), (5.26),

(5.27) and (5.28):
 
1 bc −3 1 10
ξ = hc ωµ0 σc = 6 · 2 · 10 2π · 50 · 4π · 10−7 · 57 · 106 = 1.076
2 b 2 14
sinh 2ξ + sin 2ξ sinh(2 · 1.076) + sin(2 · 1.076)
ϕ(ξ ) = ξ = 1.076
cosh 2ξ − cos 2ξ cosh(2 · 1.076) − cos(2 · 1.076)
4.241 + 0.836
= 1.076 = 1.113
4.357 + 0.549
sinh ξ − sin ξ sinh 1.076 − sin 1.076 1.296 − 0.880
ψ(ξ ) = 2ξ = 2 · 1.076 = 2.152
cosh ξ + cos ξ cosh 1.076 + cos 1.076 1.637 + 0.475
= 0.423
z2 − 1 22 − 1
kR = ϕ(ξ ) + t ψ(ξ ) = 1.113 + 0.423 = 1.54.
3 3
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Resistances 263

b) hc = hc0 = 2 mm and zt = 12:


−3 1 10
ξ = 2 · 10 2π · 50 · 4π · 10−7 · 57 · 106 = 0.179
2 14
sinh(2 · 0.179) + sin(2 · 0.179) 0.366 + 0.351
ϕ(ξ ) = 0.179 = 0.179 = 0.995
cosh(2 · 0.179) − cos(2 · 0.179) 1.065 − 0.936
sinh 0.179 − sin 0.179 0.180 − 0.178
ψ(ξ ) = 2 · 0.179 = 0.359 = 0.000345
cosh 0.179 + cos 0.179 1.016 + 0.984
z2 − 1 122 − 1
kR = ϕ(ξ ) + t ψ(ξ ) = 0.995 + 0.000345 = 1.01.
3 3

We can see that transposition is a very effective way to reduce the skin effect; in the exam-
ple, the reduction is from 1.54 to 1.01.

Example 5.2: Calculate the reduced conductor height when the temperature of a copper
winding is 50 ◦ C and the frequency is 50 Hz.
Solution: The specific conductivity of copper at 50 ◦ C is 50 MS/m and, according to Equa-
tion (5.17),
  
1 bc 1 −7
bc bc 1
α= ωµ0 σc = 2π · 50 · 4π · 10 · 50 · 10 6 ≈ 1.0 .
2 b 2 b b cm

According to Equation (5.18),


hc bc
ξ = αh c ≈ . (5.31)
[cm] b

Example 5.3: Derive an equation for the resistance factor of a squirrel cage winding in the
locked rotor state when the frequency is 50 Hz and the temperature of the winding 50 ◦ C.
Solution: The number of conductors zt = 1, the ratio bc /b = 1 and the reduced conductor
height ξ according to Example 5.2 is ξ ≈ hc /cm. According to Equation (5.28), when
zt = 1

z t2 − 1 sinh 2ξ + sin 2ξ
kR = ϕ(ξ ) + ψ(ξ ) = ϕ(ξ ) = ξ .
3 cosh 2ξ − cos 2ξ

Usually, hc > 2 cm, and therefore ξ > 2, in which case sinh 2ξ  sin 2ξ , cosh 2ξ 
cos 2ξ and sinh 2ξ ≈ cosh 2ξ , and hence

kR = ϕ(ξ ) ≈ ξ ≈ h c /cm.
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264 Design of Rotating Electrical Machines

Example 5.4: Calculate the resistance factor for a rectangular squirrel cage bar with height
hc = 50 mm. The temperature of the bar is 50 ◦ C and the frequency 50 Hz.
Solution: According to Example 5.3,

kR ≈ h c /cm = 5.0.

More precisely,

sinh 2ξ + sin 2ξ sinh 10 + sin 10

kR = ϕ(ξ ) = ξ = 5.0 = 5.0
cosh 2ξ − cos 2ξ cosh 10 − cos 10

so the approximate equation kR ≈ hc /cm gives as good a result as the accurate equation
when the temperature is 50 ◦ C, the frequency 50 Hz and the conductor is high.

The skin effect of the end windings is usually negligible. If the end windings are arranged
as in Figure 5.5, the reduced conductor height ξ is again obtained from Equation (5.18) by
substituting bc = za bc0 and b = bc + 1.2h. Richter (1967) gives the following equation for the
resistance factor of an end winding:
z t2 − 0.8 4
kRw ≈ 1 + ξ . (5.32)
36

If the skin effect changes along a conductor, the conductor has to be divided into different
sections for detailed analysis. For instance, the skin effect in slots is notably higher than in
the end windings. If the resistance factor in the slots is kRu and in the end winding kRw , the
resistance factor of a total winding is

kRu RuDC + kRw RwDC RuDC RwDC

kR = = kRu + kRw , (5.33)
RuDC + RwDC RuDC + RwDC RuDC + RwDC

zt

.
h
.
2

hc0 1

bc0
za bco= b c

Figure 5.5 An imaginary arrangement of an end winding for the calculation of the reduced conductor
height and the resistance factor
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Resistances 265

where RuDC and RwDC are the DC resistances of the slot part and winding end part of the
winding, respectively.
Assuming the temperature to be the same everywhere in the conductor, the resistances are
proportional to the conductor lengths. Denoting the average length of the coil turn as lav and

the equivalent length of the iron core as l , the resistance factor is

2l  lav − 2l 
kR = kRu + kRw . (5.34)
lav lav
Usually, the skin effect in the end windings is negligible, thus kRw = 1 and

2l 
kR = 1 + (kRu − 1) . (5.35)
lav

5.2.2 Critical Conductor Height

If the conductor height hc in Figure 5.1 increases and the width bc remains constant, the
DC resistance of the conductor decreases in inverse proportion to the height. The reduced
conductor height ξ (Equation 5.18) increases linearly in proportion to the conductor height hc ,
and the second term of the resistance factor (5.29) increases with the fourth power of the con-
ductor height. If the conductor height is high, the resistance factor may have a very high value
and AC resistive losses will be multiple compared with the DC resistive losses of the winding.
In the area 0 ≤ ξ ≤ 1, the AC resistance is, according to Equation (5.29),

RAC ≈ (1 + kξ 4 )RDC , (5.36)

where k is a constant and RAC and RDC the AC and DC resistances. Equation (5.36) and
its components are presented in Figure 5.6. According to the figure, there is a measure

RAC =(1 + k ξ ( RDC

4

4
k ξ RDC

RDC

hc,cr hc

Figure 5.6 AC resistance RAC has its minimum at the critical conductor height hc,cr
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266 Design of Rotating Electrical Machines

hc = hc,cr , with which the AC resistance has a minimum. Above this critical conductor height,
the resistive losses increase with increasing conductor height. The resistance factor corre-
sponding to the critical conductor height for copper and 50 Hz is

kRcr ≈ 1.33. (5.37)

5.2.3 Methods to Limit the Skin Effect

The skin effect can be limited with the following methods:

1. The most effective method is to divide the conductors into subconductors and transpose
them as shown in Section 5.2.1.
2. Instead of dividing the bulky conductors into subconductors, we can use parallel paths, that
is parallel-connected poles and groups of poles. If the number of parallel paths is a, the
series-connected turns must be a-fold in order to keep the air-gap flux density constant.
This means that the conductor height is reduced in the ratio of 1/a.
3. Using multi-thread, twisted conductors with perfect conductor transposition is also a very
effective way to limit the skin effect. An example of such an arrangement is the Roebel bar
shown in Figure 5.7. Litz wire may also be used in special applications.

In a Roebel bar, a constant shift takes place between the layers. This way, the sums of
partial fluxes of the integration paths causing eddy currents are removed. The skin effect is
thus effectively minimized. However, some skin effect occurs in the subconductors. One way
to diminish this skin effect is to employ subconductors with as small a cross-sectional area
as possible. Roebel bars are common in applications in which there is only a single effective

Stator core length

(a)

(b) Roebel bar from top (c) Roebel bar from one side

Figure 5.7 A Roebel bar. (a) Simplified presentation of two adjacent subconductors. (b), (c) Pho-
tographs illustrating the construction of a Roebel bar. A Roebel bar has minimal skin effect in a slot
because of its perfect conductor transposition
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Resistances 267

turn per coil. Usually, the subconductors of a Roebel bar are connected together at the end
winding areas, where the skin effect is remarkably lower than in the slots.

5.2.4 Inductance Factor

The skin effect depends on the leakage flux of a conductor, which also changes the leakage
inductance Lσ of the conductor. The change in the leakage inductance is notable, for instance
at the beginning of starting up squirrel cage motors. A one-sided skin effect takes place in
the rotor bars, and the current density increases towards the slot opening. The leakage flux in
the conductor area crowds towards the slot opening, which in turn leads to a reduced leakage
flux linkage, and thus to a reduced slot leakage inductance Lσ , as given in Section 4.2.2. If
we denote the leakage inductance with direct current L σDC , we may write for the inductance
factor

Lσ
kL = . (5.38)
L σDC

The inductance factor can be calculated from Equations (4.56)–(4.59).

5.2.5 Calculation of Skin Effect Using Circuit Analysis

Besides the method presented in Section 5.2.1, the skin effect can be analysed by applying
circuit theory. This method is very suitable for rotor bars of arbitrary cross-sectional shape, for
example for double-cage rotors. In this method, a solid conductor is divided into n imaginary
layers or real subconductors as depicted in Figure 5.8. The height of the conductor is hc and
the height of the kth subconductors is hk . The width of the slot varies over b1 to bn , and also
the conductor width may vary. This usually happens when the skin effect of a squirrel cage
die-cast bar is evaluated. The length of the iron core is l. The conductor is assumed to be

bn

In In
I hk
Ik hc Ik Φ k
I
Iγ
I1 I1

b1

Figure 5.8 Division of solid conductors into several layers or subconductors in order to define the skin
effect. The current of a conductor is positioned in the middle of imaginary subconductors, arrows 1 to n.
The width of the slot varies from b1 to bn . The length of the iron core is l
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268 Design of Rotating Electrical Machines

of infinite length, and thus the division of the conductor does not have any influence on the
shape of the current density distribution. Further, it is assumed that no skin effect occurs inside
a subconductor.
The currents in subconductors k and k + 1 are Ik and Ik+1 . In the steady state, the voltage
equation is

E k = −jωΦ k = Rk I k − Rk+1 I k+1 , (5.39)

where Φ k is the leakage flux flowing between the kth and (k + 1)th subconductors.
The flux density Bk in the subconductor k depends on the current linkage Θ k calculated
from the bottom of the slot to the subconductor k

1
k
Θk
Bk = µ0 = µ0 iγ , (5.40)
bk bk γ =1

where bk is the width of the slot at the position of the kth subconductor. The partial flux Φ k
is

lh k
k
Θk
Φk = Bk lh k = µ0 lh k = µ0 iγ . (5.41)
bk bk γ =1

By substituting (5.41) into (5.39), and by employing phasors, we obtain

lh k
k
E k = −jωµ0 I = Rk I k − Rk+1 I k+1 . (5.42)
bk γ =1 γ

Next, the current is solved:

jωµ0 lh k ωL k
k k
Rk Rk
I k+1 = Ik + Iγ = Ik + j I . (5.43)
Rk+1 Rk+1 bk γ =1 Rk+1 Rk+1 γ =1 γ

The flux linkage of the subconductor forms an inductance Lk determined by

lh k
L k = µ0 . (5.44)
bk

If an initial value for the current I 1 is known, we obtain from Equation (5.43) the current
of the next subconductor I 2

R1 ωL 1
I2 = I +j I . (5.45)
R2 1 R2 1

If the initial value for the current I1 is not known, we can choose an arbitrary value for it, for
instance 1 A.
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Resistances 269

The current of the next subconductor I 3 is obtained:

R2 ωL 2  
I3 = I +j I1 + I2 (5.46)
R3 2 R3

and generally

Rk ωL k  
I k+1 = Ik + j I1 + I2 + ··· + Ik . (5.47)
Rk+1 Rk+1

This way, all the subcurrents of the bar are determined current by current. Now, the total
current of the bar is obtained:

n
I = Iγ. (5.48)
γ =1

Normally, a total current I of a bar is given, and thus the subcurrents have to be iterated until
the sum of the currents is equal to the total current of the bar.
If the width of the slot is constant and the height of each subconductor is selected equal,
hk , all the resistances Rk of the subconductors are equal as well as the inductances Lk . In that
case, in Equation (5.43), the ratio of resistances Rk /Rk+1 = 1, and correspondingly the ratio
ωLk /Rk+1 = c = constant, and we may write
 
I k+1 = I k + jc I 1 + I 2 + · · · + I k . (5.49)

Example 5.5: Consider a rectangular copper armature conductor of width bc = 15 mm in

a rectangular slot of width b = 19 mm. The height of the conductor is divided into seven
subconductors with height hk, = 4 mm. The length of the stator stack is 700 mm and the
frequency of the machine is 75 Hz. The temperature of the copper is 100 ◦ C. Calculate the
skin effect in the subconductors and draw a phasor diagram of the currents and voltages
when 1200 A is flowing in the bar.
Solution: At room temperature (20 ◦ C) ρ Cu = 1/(57 × 106 S/m) = 1.75 × 10−8 m. The
temperature coefficient of resistivity for copper is α Cu = 3.81 × 10−3 /K. At 100 ◦ C the
resistivity of copper is
 
ρCu, 100◦ C = ρCu, 20◦ C (1 + T αCu ) = 1.75 · 10−8 m 1 + 80 K · 3.81 · 10−3 /K
= 2.28 · 10−8 m.

All the resistances Rk of the subconductors and the inductances Lk are now equal. The
DC resistance of a subconductor is

ρl 2.28 · 10−8 m 0.7 m

RDC,k = = = 0.266 m .
Sc 0.015 m · 0.004 m
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270 Design of Rotating Electrical Machines

The inductance of a subconductor is

lh k V s 0.7 m · 0.004 m
L k = µ0 = 4π · 10−7 = 0.185 µH.
b Am 0.019 m
The ratio of all resistances Rk /Rk+1 = 1, and the ratio
ωL k 2π · 75/s · 0.185 µH
c= = = 0.327.
Rk 0.266 m
We are now ready to utilize Equation (5.49) to calculate the currents in the seven sub-
conductors. If we fix the phase angle of the lowest bar to zero, we get the following division
for the currents:

Current, I/A Per unit current Phase angle/◦ Current density J/A/mm2

Conductor 1 78.33 0.066 0 1.30

Conductor 2 82.41 0.069 18.1 1.37
Conductor 3 103.91 0.087 47.6 1.73
Conductor 4 155.28 0.130 76.4 2.58
Conductor 5 241.46 0.202 101.0 4.02
Conductor 6 370.80 0.310 123.9 6.17
Conductor 7 561.74 0.470 146.3 9.37
Whole bar 1200 1.0 112.4 Average 2.86

Figure 5.9 illustrates the sum of current phasors corresponding to Equation (5.49) for the
bar of Example 5.5. The figure shows clearly how the phase angle of the current changes

I7

I 6 = 370.8 A
no skin effect, DC
123.9˚
I tot = 1200 A 7
6 t, AC
effec
I5 5 skin
4
3
I 4 = 155.28 A
2
1
I3 A
0 1 2 3 4 5 6 7 8 9 J,
I 1 I2 mm 2

(a) (b) (c)

Figure 5.9 Skin effect according to Example 5.5: (a) phasor diagram of the currents of a conductor
divided into seven subconductors (4 mm × 15 mm) with c = 0.327, (b) the bar with seven subcon-
ductors, (c) current density. With a direct current, no skin effect occurs, and the current density J is
evenly distributed in the cross-sectional area of a conductor. With an alternating current at 75 Hz,
the skin effect causes a large increase in the current density when approaching the slot opening
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Resistances 271

radically and how most of the current crowds in those parts of the bar which are located
close to the slot opening. Since the skin effect constantly increases when approaching the
slot opening, the situation is called a single-sided skin effect. A current solution reached
with RMS values does not give exact information about the flux density distribution, since
it should be defined by the instantaneous values of the current. The RMS values are, how-
ever, suitable for solving the loss distribution in the slot.

We will now further examine the voltage behaviour of the subconductors in a slot. The
resistive voltage drop of the kth subconductor is

U rk = Rk I k . (5.50)

The voltage drop of the (k + 1)th subconductor is calculated accordingly. The result is
substituted in Equation (5.42), and we obtain

lh k
k
U rk − U r(k+1) = −jωµ0 I , (5.51)
bu,k γ =1 γ

which leads to

k
U r(k+1) = U rk + jωL k I γ = Rk+1 I k+1 . (5.52)
γ =1

On the surface of the conductor, we may write for the AC impedance of the bar
U AC = U r n + jωL n I . (5.53)
For a rectangular slot with similar rectangular subconductors, the inductance Ln is
L n = L k /2. (5.54)
The voltage over the topmost bar consists of the resistive voltage drop over the bar and the
inductive voltage drop caused by all the currents of the subconductors

n
U AC = Rn I n + jωL n Iγ. (5.55)
γ =1

The voltage UAC is the same over the last subconductor on the top of the bar as the whole
conductor: U AC = Rn I n + jωL n I tot . The total current Itot meets the total effective resistance
RAC and inductance L AC : U AC = (RAC + jωL AC ) I tot . Therefore, a comparison of the equa-
tions
 enables us toget the AC resistance with respect to the skin effect: (RAC + jωL AC ) I tot =
Rn I n + jωL n I tot , from which we obtain
In
(RAC + jωL AC ) = Rn + jωL n . (5.56)
I tot
Then the total effective AC resistance of the conductor with respect to the skin effect is the
real part of the right-hand side of Equation (5.56) and the reactance is its imaginary part.
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272 Design of Rotating Electrical Machines

Example 5.6: Calculate the resistive and reactive voltages and the AC impedance of the
seven subconductor bars in Example 5.5.

Solution: From Example 5.5: Rk = 0.266 m , L k = 0.185 µH, jωL k = j87.2 µ , L n =

0.0925 µH, jωL n = j43.6 µ :

k
Current, I k /A Phase/◦ U r k = Rk I k /V jωL k I γ /V Phase/◦ Ik2 Rk /W
γ =1

Conductor 1 78.33 0 0.0208 0.006 83 90 1.62

Conductor 2 82.41 18.1 0.0218 0.0138 99.3 1.80
Conductor 3 103.91 47.6 0.0277 0.0216 114.3 2.88
Conductor 4 155.28 76.4 0.0412 0.0318 144.9 6.40
Conductor 5 241.46 101.0 0.0641 0.0467 156.2 15.5
Conductor 6 370.80 123.9 0.0984 0.0696 179.3 36.4
Conductor 7 561.74 146.3 0.149 0.0525 202.4 83.7
Whole bar 1200 112.4 148.3

U AC = U r7 + jωL n I = 0.149 V · cos (146.3◦ − 112.4◦ ) + j0.149 V sin (146.3◦ − 112.4◦ )

+ j0.0525 V
U AC = (0.124 + j0.1355) V

with the total current phase of 112.4◦ as a reference direction.

Finally, for the AC impedance of the total bar at 75 Hz we get

U AC (0.124 + j0.1355) V
(RAC + jωL AC ) = = = 0.103 m + j0.113 m .
I tot 1200A

To check:

In
(RAC + jωL AC ) = Rn + jωL n
I tot

I7 561.74 A 146.3◦ 87.2
(RAC + jωL AC ) = R7 + jωL 7 = 266 µ  +j µ ,
I tot 
1200 A 112.4 ◦ 2
 
(RAC + jωL AC ) = 124.5 µ 33.9◦ + 43.6 µ 90◦ ,
(RAC + jωL AC ) = 103 µ + j69.4 µ + j43.6 µ = 103 µ + j113 µ ,

which is the same result as above.

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Resistances 273

I7
I tot

I1 + I 2 + I3
+ I4 + I5 + I6 I6

jωLk(I1 + I 2 + I 3 + I4 + I5 + I6)
U rtot
I5
U xtot
jωLk(I1 + I 2 + I 3 + I4)
U r5
jω L n I tot U r6
U r4 I4
U r7
U r3
U tot
Ur2 I3
I2
I 1, U r1

Figure 5.10 Skin effect of a seven-subconductor bar corresponding to Examples 5.5 and 5.6. The
diagram is drawn as follows. The current I1 in the resistance R1 creates a voltage difference Ur1
parallel to I1 . The reactive voltage Ux1 is perpendicular to I1 . The current I2 in the resistance R2
creates a voltage Ur2 parallel to I2 . The reactive voltage Ux2 is perpendicular to I1 + I2 , and so on.
The reactive voltage Uxtot is perpendicular to Itot

Figure 5.10 illustrates the currents and the voltages over the subconductors of the con-
ductor in Figure 5.9.

Based on Equations (5.50)–(5.55), the skin effect of a conductor divided into subconductors
can be illustrated by the equivalent circuit in Figure 5.11. The figure shows that the voltage
defined by Equation (5.55) occurs in the terminals of the equivalent circuit, through which the
total current I of the bar flows. The voltage UAC can thus be called a terminal voltage of a
conductor divided into subconductors, or it can also be called the voltage of a solid conductor
divided into imaginary sections, and RAC + jωL AC is the AC impedance of the conductor.
When a bar of an armature winding is divided into insulated subconductors that travel
transposed from slot to slot to avoid the skin effect, the previous equations may be utilized to
analyse the inductance of individual subconductors. When a series-connected individual sub-
conductor is transposed to all possible positions in different slots, the average inductances of
all subconductors become equal and the distribution of currents is equal between subconduc-
tors. When a perfect transposition is achieved, all the subconductor currents remain the same,
which makes evaluation of the inductance of a subconductor easier. If the width of the slot b
is constant and all the subconductors have the same height, we may, instead of summing the
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274 Design of Rotating Electrical Machines

U AC I
n
I = Σ Ιγ
γ =1
I n Rn Ln
n

Un

k
Ik R k
Lk
ΣI
γ =1
...k ...
I Uk

L2 I1+ I 2
I2 R 2
2
U2
L1 I1
I1 R1
1
U1

Figure 5.11 Equivalent circuit of a conductor in a slot divided into subconductors of varying width,
corresponding to the phasor diagram of Figure 5.10. U AC describes the voltage over the conductor at
alternating current. In Figure 5.10, the voltage U tot corresponds to this voltage

currents, multiply the inductance by the position number. We modify Equation (5.44) to get a
new inductance for insulated parallel subconductors

lh k
L k = kµ0 . (5.57)
bk
Now, the equivalent circuit of the connected subconductors simplifies to an equivalent cir-
cuit of the insulated, ideally transposed system in Figure 5.12 that represents the equiva-
lent circuit of one slot. The inductance of a conductor in a phase winding is L = L k + 2L k
+ · · · + n L k , which is equal to all the conductors of the slot, so there is no skin effect present
except for the skin effect of individual subconductors.

5.2.6 Double-Sided Skin Effect

In slots carrying conductors on top of each other, a double-sided skin effect is possible if the
windings are not fully transposed. A similar effect may be observed in double-squirrel-cage
rotors. We study a simple case in which there are two conductors on top of each other in a
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Resistances 275

I R1 Lk
n

U n
I R1 2 Lk
n −1

Un-1
I R1
... k ...

Uk
I

I 2 R1 (n −1) L k
U2

I 1 I1 R1 nLk

U1

Figure 5.12 Equivalent circuit of a slot with subconductors that are transposed in winding ends so that
there is no large skin effect present and all the subconductors carry the same current. There is no common
AC voltage for such conductors over a single slot. The effect of the flux created by other conductors is
taken into account by multiplying the inductance of each subconductor

slot. The uppermost bar experiences, in addition to the flux created by it, the flux created by
the lower bar, see Figure 5.13.
The behaviour of currents may be studied in the same way as in the previous section for
the single-sided skin effect. Here both the upper and the lower bars are divided into real or
imaginary subconductors. The upper bar that is divided into imaginary subconductors experi-
ences a flux created by a lower conductor. This makes the investigation of the skin effect of
the upper bar somewhat more complicated than in the previous case.
The currents of the upper subconductors k have to be divided into two imaginary sections:
I k , caused by the flux of the underlying conductor; and I k , which would be the current of the
subconductor k if it were alone in the slot. That is,

I k = I  k + I  k . (5.58)

Thus, a phasor diagram similar to the diagram in Figure 5.10 is valid as such for the sub-
currents I k . Now, we have to define the subcurrents I k . A simple calculation method can be
found in this case. The currents of the lower bar Iu create a time-varying magnetic flux density
in the area of the upper bar. The eddy current pattern created by this flux density has to be
symmetrical with respect to the centre line of the upper conductor. Consequently, it is advis-
able to divide the upper bar into an even number of subconductors. The subconductors of the
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276 Design of Rotating Electrical Machines

Io
Φ u
I' 4 In
Φ k
I' 3 I k = I 'k + I ''k
hc
I' 2
I' 1 I1

Iu
Iu

(a) (b)

Figure 5.13 Calculation of the skin effect in a bar located above another current-carrying bar in a slot.
(a) The flux created by the bottom conductor current alone and the corresponding induced currents I  k
opposing the flux created by the bottom bar. (b) Cut-away view of a slot; Io is the total current in the
upper conductor and Iu that in the bottom conductor

upper bar carry eddy currents that, according to Lenz’s law, attempt to cancel the flux created
by the lower bar current.
Therefore, the eddy current components at equal distances below and above the centre of
the conductor have to be equal in magnitude and in opposite directions:

I  k = −I  n−k+1 . (5.59)

In Figure 5.13, the currents I 1 and I 2 travel towards the observer, and the currents
I 3
and I 4 run in the same direction as the sum of currents of the lower conductor. Hence,
we get two current loops opposing the flux components Φ u .
The flux created by the current I u of the lower bar Φ u induces a current I k+1 in the
upper subconductor k + 1. This current I k+1 can be calculated in the (k + 1)th imaginary
subconductor analogously according to Equation (5.43)
 
ωL k  
k
Rk 
I  k+1 = I +j I + I u . (5.60)
Rk+1 k Rk+1 γ =1 γ

If we select Rk /Rk+1 = 1, and ωLk /Rk+1 = c, we get

 
I  k+1 = I  k + jc I  1 + I  2 + · · · + I  k + I u . (5.61)
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Resistances 277

With an even n, the subconductors k = n/2 and k + 1= n/2 + 1 constitute the centre of the
conductor. Here, we may write for the currents, according to Equations (5.60) and (5.61),
 

n/2
I  n/2+1 = −I  n/2 = I  n/2 + jc  I  γ + I u  = I  n/2 + jcI µ . (5.62)
γ =1

In the brackets, we have the sum of the currents of the lower conductor and the imaginary
currents in the lower half of the upper conductor caused by the lower conductor Iu . We solve
Equation (5.62) for the subconductor k = n/2 lying just below the centre line of the upper bar
 
jc  
n/2
jcI µ
I  n/2 = − =− I + I u . (5.63)
2 2 γ =1 γ

Again, we have to find an iterative solution. It seems easiest to make an initial guess for I µ
after which we are able to determine the currents of the subconductors. We now write for the
other lower subconductors of the upper bar, according to Equation (5.60),
 

n/2−1
 
I  n/2−1 = I  n/2 − jc  I  γ + I u  = I  n/2 − jc I µ − I  n/2 , (5.64)
γ =1

and so on, until we get for the lowest subconductor of the upper bar
 
 
n/2
I  1 = I  2 − jc I  1 + I u = I  2 − jc  I  µ − I γ  . (5.65)
γ =1

As the currents from I 1 to I n/2 have now been defined, we also know the currents from
I n/2+1
to I n based on Equation (5.59). With Equation (5.62), the sum of the currents of the
lower conductor can also be defined as

n/2
Iu = Iµ − I γ . (5.66)
γ =1

Example 5.7: Consider a double-layer winding with rectangular copper conductors di-
vided into four subconductors of width bc = 15 mm in a rectangular slot of width b =
19 mm. The height of the upper bars of 16 mm is divided into four subconductors with
a height hk = 4 mm. The length of the stator stack is 700 mm and the frequency of the
machine is 50 Hz. The copper temperature is 100 ◦ C. Calculate the skin effect in the sub-
conductors if no transposing of the windings is done, when 1000 A in the same phase is
flowing in both of the conductors. The skin effect inside individual subconductors can be
neglected.
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278 Design of Rotating Electrical Machines

Solution: All the resistances Rk of the subconductors and the inductances Lk are now
equal. The DC resistance of a subconductor is RDC,k = 0.266 m . The inductance of a
subconductor is

lh k V s 0.7 m · 0.004 m
L k = µ0 = 4π · 10−7 = 0.185 µH.
b Am 0.019 m
The ratio of all resistances Rk /Rk+1 = 1, and the ratio

ωL k 2π · 50/s · 0.185 µH
c= = = 0.218.
Rk 0.266 m

We must now solve first the eddy currents of the upper bar. With an even n = 4, the
subconductors k = n/2 = 2 and k + 1 = n/2 + 1 = 3 are in the centre of the bar. We solve
Equations (5.59) and (5.62) for the subconductors k = 2 and k = 3 lying just below and
over the centre line of the upper bar
 
j0.218  
2
I 2 =− I γ + I u  = −j0.11I µ = −I  3 .
2 γ =1

From (5.65) we get

 
 
n/2
I  1 = I  2 − jc I  1 + I u = I  2 − jc  I  µ − I γ 
γ =1
 
   

⇒I 1 = I 2 − j0.218 I µ −I 1−I 2 = −I  4
⇒ I  1 (1 − j0.218) = I  2 (1 + j0.218) − j0.218I  µ
 
I  2 (1 + j0.218) − j0.218 I  µ
I 1 = = −I  4 .
(1 − j0.218)

For the lower bar current we get I u = I µ − I 1 − I 2 .

The currents solved after iteration are Iµ = (995 + j96) A:

I k /A Phase/◦ I k,o /A Phase/◦ Ik,o /A Phase/◦ Ik,u /A Phase/◦

1 321 −68 232 0 462 −40.2 232 0
2 110 −84.4 238 12.3 250 −13.6 238 12.3
3 110 95.5 269 34.5 336 51.1 269 34.5
4 321 112 350 59.6 602 84.6 350 59.6

Figure 5.14 illustrates the phasor diagram of the currents of Example 5.7.
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Resistances 279

I I' 4
o

I 4o

I ''1o I ''4o

I '1
Iu I I '3
I 1o I ''2o
3o
I 4u
I '4 '
I2 I ''3o
I '3
I 2o
I 3u

I 1u I 2u

I '2
I'1

Figure 5.14 Phasor diagram of the subconductor currents in an induction motor rotor double cage

at locked rotor state. The subcurrents of the upper bar are written Ik,0 = Ik,o + Ik , where Ik,o

are the
   
eddy current components caused by the upper bar alone and I1 , I2 I3 I4 the eddy current components
caused by the lower bar current. The lower conductor currents behave similarly for a single bar
in a slot

Figure 5.15 depicts the RMS current density values of the subconductor currents. A
symmetrical skin effect occurs in the upper bar as a result of the currents flowing under
the observed conductor (Jo ). The resultant current density of the upper bar is J o , in which
the influence of the lower bar has been taken into account. The influence of the lower bar
on the skin effect is significant. J DC is the current density with direct current.
As we can see, the double-sided skin effect is remarkable in conductors with no trans-
position. In practice, such a winding arrangement is not acceptable.

JDC

J'o Jo

Ju

0 2 4 6 8 10 J/A/mm2

Figure 5.15 Skin effect of two solid conductors positioned on top of each other. The conductors
have been divided into four imaginary subconductors. The upper conductor has a symmetrical cur-
rent density Jo with respect to the middle of the upper conductor. Jo is created by the opposing
current densities caused by the current in the lower conductor
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280 Design of Rotating Electrical Machines

Bibliography
Küpfmüller, K. (1959) Introduction to Theoretical Electrical Engineering (Einführung in die theoretische Elek-
trotechnik), 6th rev. edn, Springer Verlag, Berlin.
Lipo, T.A. (2007) Introduction to AC Machine Design, 3rd edn, Wisconsin Power Electronics Research Center, Uni-
versity of Wisconsin.
Richter, R. (1954) Electrical Machines: Induction Machines (Elektrische Maschinen: Die Induktionsmaschinen), Vol.
IV, 2nd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1967) Electrical Machines: General Calculation Elements. DC Machines (Elektrische Maschinen: Allge-
meine Berechnungselemente. Die Gleichstrommaschinen), Vol. I, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Stoll, R. (1974) The Analysis of Eddy Currents, Clarendon Press, Oxford.
Vogt, K. (1996) Design of Electrical Machines (Berechnung elektrischer Maschinen), Wiley-VCH Verlag GmbH,
Weinheim.
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6
Main Dimensions of a
Rotating Machine

In the previous chapters, the general theory governing the design of an electrical machine
was presented: Chapter 1 addressed the necessary fundamentals of electromagnetic theory
and Chapter 2 concentrated on winding arrangements. Chapter 3 described the behaviour of
the magnetic circuit. Chapter 4 discussed the flux leakage and, finally, Chapter 5 focused on
the resistances of the windings. We should now be able to commence the discussion of the
main dimensions of electrical machine. The design of a rotating electrical machine can be
commenced by defining certain basic characteristics, the most important of which are:

r Machine type (synchronous, asynchronous, DC, reluctance machine, etc.).

r Type of construction (external pole, internal pole, axial flux, radial flux machine, etc.).
r Rated power:
– For electric motors, the shaft output power PN in W is given.
– For synchronous motors, also the power factor (cos ϕ overexcited) is given.
– For induction and DC generators, the electric output power PN in W is given. Induction
generators take reactive power from the network according to their power factor. The
reactive power must usually be compensated by capacitor banks.
– For synchronous generators, the apparent power SN is given in VA. The power factor
(typically cos ϕ = 0.8 overexcited) is also given.
r Rated rotational speed nN of the machine or rated angular speed Ω N .
r Number of pole pairs p of the machine (with frequency converter drives, this is also a subject
of optimization).
r Rated frequency f N of the machine (with frequency converter drives this is also a subject of
optimization).
r Rated voltage U N of the machine.
r Number of phases m of the machine.
r Intended duty cycle (S1–S9).
r Enclosure class and structure of the machine.

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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282 Design of Rotating Electrical Machines

r Additional information, such as efficiency, required locked rotor torque, pull-up torque,
peak torque, locked rotor current, speed-controlled drive etc.
r Standards applied in the machine design.
r Economic boundary conditions.
r Manufacturability.

In machine design, there are a considerable number of free parameters. When aiming for
an optimal solution, the task becomes extremely complicated unless the number of these free
parameters is somehow limited. Many free parameters vary only slightly, and therefore, to
simplify the task, these parameters can be assumed constant. The following 10 parameters
can be selected as free parameters:

r outer diameter of the stator stack (with the standard IEC frames, this parameter is often
fixed to certain values);
r length of the stator stack;
r width of the stator slot;
r height of the stator slot;
r diameter of the air gap;
r air-gap length;
r peak value of the air-gap flux density;
r width of the rotor slot;
r height of the rotor slot;
r pole pair number and frequency.

Actual machine design starts with the selection of the main dimensions of the machine.
The term ‘main dimensions’ refers to the air-gap diameter Ds measured at the stator bore (see
Figures 3.1 and 3.2) and the equivalent core length l (see Figure 3.10 and Equation 3.36). The
equivalent length of the core takes into account the influence of the flux fringing at possible
cooling ducts of the machine and also at the ends of the machine.
In electrical machine design, there are certain empirically defined variation ranges of cur-
rent and flux densities, which can be applied in the preliminary phase of the design. Tables
6.1 and 6.2 introduce some values of electromagnetic loadings for well-designed standard
electrical machines.
The permitted loading levels are defined for a machine on the basis of the design of the
insulation and the cooling of the machine. The values in the tables give some empirical infor-
mation related to the selection of machine parameters. In principle, machine design is a rather
complicated iteration process, in which the initial values are first selected for the dimensions
of the machine. Next, the machine is designed electrically, and finally the cooling of the ma-
chine is computed. If the cooling of the machine is not efficient enough, the design has to
be started from the beginning again by increasing the dimensions of the machine, by using
better materials or by selecting a more efficient cooling method. The material selection has a
significant influence on both the losses and the thermal resistances. If a low-loss iron material
and high-thermal-class insulation materials are selected, the output power of the machine can
be improved without increasing its size.
For permanent magnet machines, because of the limited remanence and coersivity of
present-day magnets, we may select values in the lower half of the varying range according
to Table 6.1 for synchronous machines.
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Main Dimensions of a Rotating Machine 283

Table 6.1 Permitted flux densities of the magnetic circuit for various standard electrical machines
Flux density B/T
Salient-pole Nonsalient-pole
Asynchronous synchronous synchronous
machines machines machines DC machines
Air gap 0.7–0.90 ( B̂δ1 ) 0.85–1.05 ( B̂δ1 ) 0.8–1.05 ( B̂δ1 ) 0.6–1.1 (Bmax )
Stator yoke 1.4–1.7 (2) 1.0–1.5 1.1–1.5 1.1–1.5
Tooth 1.4–2.1 (stator) 1.6–2.0 1.5–2.0 1.6–2.0
(apparent 1.5–2.2 (rotor) (compensating winding)
maximum value) 1.8–2.2 (armature winding)
Rotor yoke 1–1.6 (1.9) 1.0–1.5 1.3–1.6 1.0–1.5
Pole core — 1.3–1.8 1.1–1.7 1.2–1.7
Commutating — — — 1.3
poles

When investigating the values of Table 6.2, it is worth noticing that when the dimensions
of a slot are increased, lower values usually have to be selected than in the case of small slots.
Hence, the lower values of J are for larger machines, and the highest values of J are suitable
for small machines. Despite this, the lower values of A are valid for smaller machines and the
higher ones for larger machines. If we are constructing PMSM fractional slot windings from
small fractions with wide slots, the applicable values given in the table for pole windings are
valid also in this case.

Table 6.2 Permitted RMS values for current densities J and linear current densities A for various
electrical machines. Depending on the size of a permanent magnet machine, a synchronous machine,
an asynchronous machine or a DC machine, suitably selected values can be used. Copper windings are
generally assumed

Sailent-pole Nonsalient-pole synchronous machines

synchronous
Indirect cooling
Asynchronous machines Direct water
machines or PMSMs Air Hydrogen cooling DC machines
A/kA/m 30–65 35–65 30–80 90–110 150–200 25–65
Stator Armature Armature Armature
winding winding winding winding
J/A/mm2 3–8 4–6.5 3–5 4–6 7–10 4–9
Copper rotor Field Pole
winding winding: winding
J/A/mm2 3–8 2–3.5 2–5.5
Aluminium Multi-layer Field Compensating
rotor winding winding winding
J/A/mm2 3–6.5 2–4 3–5 3–5 6–12 3–4
Single-layer With direct water cooling, in field
windings 13–18 A/mm2 and
250–300 kA/m can be reached
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284 Design of Rotating Electrical Machines

Table 6.3 Tangential stresses σ Ftan calculated from the values of Tables 6.1 and 6.2. There are three
stress values, calculated with the lowest linear current density and flux density, with the average values
and with the highest values. The flux density and linear current density distributions are assumed
sinusoidal. For DC machines, a pole width coefficient of 2/3 is assumed. The power factor of
synchronous machines is assumed to be 1, and for asynchronous machines, 0.8
Nonsalient-pole synchronous
Totally Sailent-pole machines
enclosed synchronous
Indirect cooling
asynchronous machines Direct water DC
machines or PMSMs Air Hydrogen cooling machines
A/kA/m, RMS 30–65 35–65 30–80 90–110 150–200 25–65
Air-gap flux 0.7–0.9 0.85–1.05 0.8–1.05 0.8–1.05 0.8–1.05 0.6–1.1
density B̂δ1 /T
Tangential stress
σ Ftan /Pa
minimum 12 000* 21 000* 17 000* 51 000* 85 000* 12 000*
average 21 500* 33 500* 36 000* 65 500* 1,14 500* 29 000*
maximum 33 000* 48 000* 59 500* 81 500* 1,48 500* 47 500*
* cos ϕ = 0.8 * cos ϕ =1 * cos ϕ =1 * cos ϕ =1 * cos ϕ =1 * α DC = 2/3

In Equation (1.115) we defined the tangential stress σ Ftan in the air gap. The local value for
the tangential stress depends on the local linear current density A(x) and the local flux density
B(x), σ Ftan (x) = A(x)B(x). If a sinusoidal air-gap flux density with peak value B̂δ is assumed,
and a sinusoidal linear current density with peak value  and RMS value A is applied, we
obtain for the average tangential stress

 B̂δ cos ϕ A B̂δ cos ϕ

σ Ftan = = √ . (6.1)
2 2

This tangential stress produces the torque of the machine when acting upon the rotor surface.
Table 6.3 illustrates the guiding limit values for the tangential stress of the air gap calculated
from Tables 6.1 and 6.2.
Typical tangential stress values give us a starting point for the design of an electrical ma-
chine. We may define the size of the rotor first by using a suitable tangential stress value on
the rotor surface. If the rotor radius is rr , the rotor equivalent length is l , the rotor surface
facing the air gap is Sr , and the average tangential stress on the surface is σ Ftan , we may write
the torque T of the rotor simply as

T = σ Ftan rr Sr


= σ Ftan rr 2πrrl 
(6.2)
= σ Ftan 2πrr2l 
Dr2 
= σ Ftan π l = 2σ Ftan Vr .
2
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Main Dimensions of a Rotating Machine 285

The correct rotor volume V r to produce a certain torque can easily be estimated with
Equation (6.2).
A similar basis for the design of the machine rotor size is the machine constant C of a
well-designed electrical machine. The machine constant C expresses the magnitude of the
‘internal’ apparent power Si or the power Pi given by the rotor volume of the machine. By
employing the emf Em induced over the magnetizing inductance Lm of the phase (the emf is
calculated from the peak value Ψ̂m of the air-gap flux linkage in one phase, see Equation 7.3)
and the current I s of the stator phase, we obtain the apparent power Si for rotating-field ma-
chines rotating at a synchronous speed nsyn = f /p

Si = m E m Is . (6.3)

The air-gap emf Em can be substituted into Equation (6.3), and we obtain
1 1
Si = m √ ωΨ̂m Is = m √ ωNs kws1 Φ̂m Is . (6.4)
2 2
The maximum flux Φ̂m penetrating a phase winding will be found by integrating the air-gap
flux density Bδ (x) over the pole surface Sp

Φ̂m = Bδ dSp . (6.5)
Sp

If the air-gap flux density has a sinusoidal distribution over the pole pitch τ p and there is no
variation with respect to the length of the machine l , the surface integral can be simplified as
τp
xπ
Φ̂m = l  · B̂δ sin dx
τp (6.6)
0

= l τp α B̂δ .

The product α B̂δ represents the average value of the flux density in the air gap. In the case
of a sinusoidal distribution α = 2/π. In other cases, a suitable value for α has to be found by
integrating the flux density over the pole surface. For instance, if we have surface magnets on
the rotor, the air-gap flux density created by the permanent magnets is usually nonsinusoidal.
In such a case, the average value α for the flux density in the air gap can be defined from the
relative magnet width α PM .
The RMS value of the linear current density A of the stator may be defined from the stator
slot pitch τ s and the RMS value of slot current I u (assuming that there are no parallel paths in
the winding and the winding is a full-pitch one, I u = I s zQ ). The number of slots in the stator
is Qs . Thus
Iu
A= , (6.7)
τs
πD
τs = . (6.8)
Qs
Here D is, for generality, used instead of the stator inner or rotor outer diameter
(D ≈ Dr ≈ Ds ).
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286 Design of Rotating Electrical Machines

The number of conductors in the slot zQ with all turns in series is

Ns Ns 2Ns m
zQ = = = . (6.9)
pq Qs Qs
p
2 pm
Now we may write for the linear current density
Iu Iu Q s Is z Q Q s 2Is Ns m
A= = = = . (6.10)
τs πD πD πD
We solve the above for I s and substitute I s into Equation (6.4)

1 1 AπD 1 AπD
Si = m √ ωNs kw1 Φ̂m Is = m √ ωNs kws1 Φ̂m = √ ωkws1 Φ̂m . (6.11)
2 2 2N s m 2 2
We now substitute ω = 2pπnsyn and the peak flux from Equation (6.6) into Equation (6.11)

1 2 πD AπD
Si = √ 2 pπn syn kws1 B̂δl 
2 π 2p 2
2 (6.12)
π
= √ n syn kws1 A B̂δl  D 2 .
2
We may now rewrite this as
π2
Si = m E m Is = √ kws1 A B̂δ D 2l  n syn
2 (6.13)
= CD 2l  n syn .
The machine constant C can be written in the following form for rotating-field machines
(synchronous and asynchronous machines), according to Equation (6.13):

π2 π2
C = √ kw1 A B̂m = kws1 Â B̂δ , (6.14)
2 2
√
where A = Â/ 2. l is the equivalent length of the machine and A is the RMS value of the
linear current density, which corresponds to the tangential magnetic field strength H tan in the
air gap, see Chapter 1.
The rotor volume V r required for a certain apparent power can now be written as

π 2 π Si
Vr = Dr l = . (6.15)
4 4 Cn syn

The weight of the rotor is proportional to its volume

π pSi
m r ∼ Vr = . (6.16)
4 Cf
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Main Dimensions of a Rotating Machine 287

In DC machines, the air-gap flux density is not sinusoidal. Under the pole at no load, we
have the air-gap flux density Bmax . For DC machines, the internal power of which is defined
Pi = π2 αDC ABδ max D 2l  n syn = CD 2l  n 0 , we may write

C = π2 αDC ABδ max . (6.17)

α DC is the relative pole width coefficient for DC machines (typically about 2/3).
The dependence of the internal apparent power Si on the mechanical power Pmec of a
rotating-field machine is obtained from the power factor cos ϕ of the machine and the effi-
ciency η (which have to be estimated at this stage). Now, the machine constant of mechanical
power Cmec can be introduced:

U
Pmec = ηmUI cos ϕ = η cos ϕ Si = Cmec D 2l  n syn . (6.18)
E

In a DC machine, the internal power (Pi = EI a ) depends on the input power Pin = U a I a ;
consequently, based on their ratio, we may write

E Ia
Pi = Pin (6.19)
Ua I a

where I a is the armature current.

With Equation (6.16) and Equation (6.14), we obtain for AC machines

pSi pSi
mr ∼ ∼ . (6.20)
f A B̂δ f σ F tan

Thus, the higher the tangential stress and the supply frequency, the lower the weight of the
rotor.
By selecting a small number of pole pairs p and a high supply frequency f , we obtain,
in principle, a light machine for a certain output power. Since the output power of a machine
depends on the torque T and the mechanical angular frequency Ω, as P = Ω T, the torque of a
high-speed machine is small when compared with a low-speed machine of equal output power.
At high speeds, however, the motor power density increases together with the loss density, and
hence effective methods to reduce the losses and to improve the cooling of the machine have
to be applied. With high frequencies, suitable means to reduce the stator winding skin effect
have to be adopted so that there is no need to reduce greatly the linear current density. As the
frequency rises, in order to maintain the air-gap flux density, better stator steel materials and
more effective cooling methods have to be selected.
When analysing the weight of 22 kW serial-produced machines, we may construct a curve
according to Figure 6.1 as a function of the number of pole pairs. The dotted line in the figure
approximates the weight of the machine as a function of the number of pole pairs. We can see
that, in principle, the weight of the machine follows the equation

m = m 0 + K p. (6.21)
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288 Design of Rotating Electrical Machines

500
m/kg
400

300

200

100

m0
0 1 2 3 4 5 6 p

Figure 6.1 Weight of typical, totally enclosed, industrial 22 kW, 50 Hz, 400 V induction motors as a
function of the number of pole pairs. In the figure m0 = 40 kg

According to Equation (6.20), the weight of a machine is inversely proportional to the

frequency, and thus the weight of the machine should be
K
m = m0 + , (6.22)
fg
where m0 , K and g are constants. Further, g is usually less than one, since the linear current
density and the air-gap flux density cannot be considered constant as the frequency of the
machine increases. As a result, we obtain Figure 6.2, which illustrates the approximate weight
of a two-pole induction machine as a function of frequency f .
The allowed linear current densities and the air-gap flux densities of electrical machines are
strongly dependent on the cooling methods, as shown in Tables 6.1 and 6.2. Highly effective
cooling methods increase the permitted electromagnetic loadings 1.5–2-fold, and correspond-
ingly the weight of the machine drops by 30–50%. In well-designed machines, the linear
current density and the flux density depend on the machine size in such a way that they both
increase as the size of the machine increases. As a result, the machine constant also depends
on the size of the machine. Figure 6.3 illustrates the machine constant of induction and syn-
chronous machines of different sizes per pole power. Because of the low excitation losses
in permanent magnet machines, the machine constants for PMSMs could be high. The values
given in the tables are, however, also limitedly valid for PMSMs, because the permanent mag-
net rotor temperature must be limited to lower values than in wound rotors or die-cast rotors,
especially when NdFeB magnets are used. Typically, 100 ◦ C should not be exceeded with
NdFeB magnets to minimize the magnet demagnetization risk under the demagnetizing arma-
ture reaction. SmCo magnets tolerate high temperatures, but their remanence is remarkably
lower than that of NdFeB magnets.
The machine constants of different machine types are not exactly equal. The definition of
machine constants is based on empirical knowledge and the tradition of machine construction,
and therefore even quite contradictory values for machine constants can be found in the liter-
ature. With a constant supply frequency, the rotor peripheral speed in rotating-field machines
is proportional to the pole pitch. The permitted armature current and thereby the machine
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Main Dimensions of a Rotating Machine 289

100

m/kg 90

80

70

60

50

40

30

20

10

0
0 100 200 300 400 500 600 700 800
f /Hz

Figure 6.2 Weight of the active parts of a two-pole 22 kW induction motor as a function of frequency.
The exponent g ≈ 0.8 in Equation (6.22)

Cmec 600

kW s/m3
500
p = 2–6

400

300

p=1
200

100

0
1 10 100 1000 10000
(Pmec/2p)/kW

Figure 6.3 Machine constants of totally enclosed asynchronous and synchronous machines as a func-
tion of pole power
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290 Design of Rotating Electrical Machines

constant are functions of the pole pitch and the frequency of the machine. Since the pole pitch
of a machine cannot be deduced from its rated values, the machine constant is often given as
a function of pole power (Pmec /2p). The method can be justified by the fact that the ratio of
the length and the pole pitch is fairly constant irrespective of the number of pole pairs.

Example 6.1: The diameter of a rotor of a 4 kW, 50 Hz, two-pole (nsyn = 50/s) induction
motor is 98 mm and the length is 82 mm. Assume 1% rated slip and calculate the machine
constant and the average tangential stress.
Solution: The rated torque of the motor is

P P 4000 W
TN = = = = 12.86 N m.
Ω (1 − s)Ωsyn (1 − 0.01) · 2π · 50/s

The torque-producing area of the rotor is Sr = πDr l = 0.0252 m2 . The radius of the rotor
is 49 mm, and hence the tangential force at the rotor surface is on average

TN 12.86 N m
TN = Ftanrr ⇔ Ftan = = = 262 N.
rr 0.049 m

The average tangential stress is

Ftan 262 N
σ Ftan = = = 10 400 N/m2 .
Sr 0.0252 m2

The corresponding machine constant becomes

Pmec 4 kW
Pmec = Cmec D 2l  n syn ⇔ Cmec = 
≈ = 102 kW s/m3 .
2
n syn D l 50/s · (0.098 m)2 · 0.082 m

The pole power of the machine is now 2 kW, and consequently this point is located
somewhat higher than the curve of p = 1 in Figure 6.3.

Example 6.2: Repeat Example 6.1 for a 30 kW, 50 Hz, four-pole (nsyn = 25/s, 190 N m)
induction motor. The rotor diameter is 200 mm and the rotor length 206 mm.
Solution: T N = 190 N m.

TN 190 N m
Ftan = = = 1900 N.
rr 0.1 m

Ftan 1900 N
σtan = = = 14 700 N/m2 .
Sr π · 0.2 m · 0.206 m
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Main Dimensions of a Rotating Machine 291

The corresponding machine constant becomes

Pmec 30 kW
Cmec = ≈ = 146 kW s/m3 .
n syn D 2l  25/s · (0.2 m)2 · 0.206 m

The pole power of the machine is 7.5 kW, and this point is well within the region of
p = 2–6 of Figure 6.3.

The machine constant of doubly salient reluctance machines can with low outputs be no-
tably higher than the machine constant of an induction machine. For instance, according to
Lawrenson (1992), the machine constants of an 11 kW DC machine, an induction machine and
a doubly salient reluctance machine are in the ratio 1 : 1.23 : 1.74. Thus, in this power class,
the machine constant of a doubly salient reluctance machine is about 40% higher than the
machine constant of an induction motor. Although it was invented a long time ago, the doubly
salient reluctance machine is still at the very beginning of its development. The machine was
employed in the early twentieth century to aim the guns of British warships. Nowadays, the
development of power electronics is bringing these machines into wider use.

6.1 Mechanical Loadability

In addition to temperature rise, the output power and maximum speed of a machine are re-
stricted by the highest permissible mechanical stresses caused by the centrifugal force, natural
frequencies and by the highest permissible electrical and magnetic loadings (see Sections 6.2
and 6.3).
The highest stress σ mec caused by the centrifugal force in the rotor is proportional to the
square of the angular speed

σmec = C ρrr2 Ω 2 . (6.23)

Here
C  = 3+ν8
for a smooth homogeneous cylinder,

C = 4 for a cylinder with a small bore,
3+ν

C  ≈ 1 for a thin cylinder,

rr is the radius of the rotor,
Ω is the mechanical angular speed,
ρ is the density of the material,
ν is Poisson’s ratio (i.e. the ratio of lateral contraction to longitudinal extension in the
direction of the stretching force).

When the maximal mechanical stress of the rotor material is known, the equation can be
used to determine the maximum allowable radius r of the rotor. Typically, a safety factor has
to be used so as not to exceed the integrity of the rotor material.
Poisson’s ratios vary slightly for different materials. Table 6.4 lists some ratios for pure
materials.
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292 Design of Rotating Electrical Machines

Example 6.3: Calculate the maximum diameter for a smooth steel cylinder having a
small bore. The cylinder is rotating at 15 000 min−1 . The yield strength for the material is
300 N/mm2 = 300 MPa. The density of the steel is ρ = 7860 kg/m3 .
Solution: Poisson’s ratio for steel is 0.29. For a cylinder with a small bore

3+ν 3 + 0.29
C = = = 0.823.
4 4

The stress is calculated as σmec = C ρrr2 Ω 2

 
σyield 
  300 MPa
σyield = C ρrr2 Ω 2 ⇔ rr,max = = 

C ρΩ 2  (2 · (15 000/60) · π) 2
0.823 · 8760 kg/m3 ·
s2
= 0.13 m.

As there must be some security in the yield stress, the radius of the rotor diameter has to be
smaller than what was calculated above.
Equation (6.23) cannot be directly applied to the measurement of stresses in rotor lamina-
tions, for instance, because of the fairly complicated geometry of the laminations. However,
some informative results may be found, since the stress is always highest at the centre of a
solid plate or at the inner surface of a plate with a centre bore. At these points, the permitted
proportion of the yield stress of the material should not be exceeded.
In the case of salient-pole rotors, in small machines, the pole cores should be fastened to the
shaft for instance using screws. The screw fastenings have to be dimensioned with a sufficient
security depending on the yield stress. If a screw fastening is out of the question, a dovetail
joint may be applied.
The maximum stress in a rotor caused by the centrifugal force is, according to Equation
(6.23), proportional to the square of the peripheral speed. Thus, we can find fixed values for
a maximum peripheral speed and stress. If the rotor dimensions (diameter, length, etc.) of the
machine are assumed to be variable over the scale l (lengths and diameters are proportional
to l, areas to l 2 and volumes to l 3 ), the maximum speed of the machine becomes inversely
proportional to the scale l:

n max ∼ l −1 . (6.24)

Table 6.4 Poisson’s ratios for certain pure metals

Metal ν Metal ν
Aluminium Al 0.34 Nickel Ni 0.30
Copper Cu 0.34 Titanium Ti 0.34
Iron Fe 0.29 Cobalt Co 0.31
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Main Dimensions of a Rotating Machine 293

6.2 Electrical Loadability

Resistive losses PCu in a winding are proportional to the square of the current density J and to
the mass of the conductors

PCu ∼ J 2 m Cu ∼ J 2 l 3 . (6.25)

The thermal resistance Rth between the conductors and the teeth is

di
Rth = , (6.26)
li Si

where di is the thickness of the slot insulation, l i the thermal conductivity of the insulation
and Si the area of the slot wall. The thickness of the insulation di is constant independent of
the machine size (it depends on the rated voltage) and hence

1
Rth ∼ . (6.27)
l2

The temperature difference T between the conductors and the teeth is

T = PCu Rth ∼ J 2 l. (6.28)

Consequently, for a given temperature difference,

J 2 l = constant (6.29)

and

1
J∼√ . (6.30)
l

Thus, small machines tolerate higher current densities better than large machines.
The linear current density A in this case may be calculated as the total RMS current in a
slot JSCu,u divided by the slot pitch τ u

1
√ l2 √
JSCu,u l
A= ∼ = l. (6.31)
τu l

The linear current density A and the current density J are dimensions of the electrical loading
of a machine. As the current density in small machines can be higher than in large machines,
the linear current density behaves in the opposite sense: the linear current density is higher in
large machines than in small machines. The product of A and J is

√ 1
AJ ∼ l √ = 1 = constant, (6.32)
l
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294 Design of Rotating Electrical Machines

and thus AJ is independent of the size of the machine; it depends only on the effectiveness
of the cooling of the machine. For totally enclosed machines, AJ is smaller than for open-
circuit cooling. In air-cooled machines, the product AJ ranges from 10 × 1010 A2 /m3 to
35 × 1010 A2 /m3 , but in different machines with the same kind of cooling, the product is
approximately the same independent of the machine size. In the case of direct water cooling,
AJ attains essentially higher values.

Example 6.4: Using Table 6.2, calculate the AJ values for different machines.
Solution:

Sailent-pole Nonsalient-pole synchronous machines

synchronous
Indirect cooling
Asynchronous machines Direct water
machines or PMSMs Air Hydrogen cooling DC machines

A/kA/m 30–65 35–65 35–80 90–110 150–200 25–65

Stator winding Armature winding Armature winding Armature winding
J/A/m2 3–8 × 106 4–6.5 × 106 3–5 × 106 4–6 × 106 7–10 × 106 4–9 × 106
AJ/A2 /m3 9 × 1010 to 14 × 1010 to 10.5 × 1010 to 36 × 1010 to 105 × 1010 to 10 × 1010 to
52 × 1010 42.25 × 1010 40 × 1010 66 × 1010 200 × 1010 58.5 × 1010

The values for asynchronous, DC and air-cooled synchronous machines are similar. Hy-
drogen or the direct water-cooling method in larger synchronous machines, however, give
remarkably higher values.

6.3 Magnetic Loadability

The air-gap flux density and the supply frequency of a machine determine the magnetic load-
ing of the machine. Let us next study how the flux density varies as the speed of a machine
increases with increasing line frequency.
Iron losses PFe are approximately proportional to the square of flux density B̂δ and, with
high frequencies, to the square of frequency f and to the volume of iron V Fe

PFe ∼ B̂δ2 f 2 VFe . (6.33)

The maximum rotation speed nmax is proportional to the frequency f , and taking into ac-
count Equation (6.24) (V ∼ l 3 ∼ n −3
max ), we obtain

1 1
PFe ∼ B̂δ2 n 2max = B̂δ2 . (6.34)
n 3max n max

The temperature rise of a machine depends on the power loss per cooling area S. Assum-
ing a constant temperature rise and taking into account Equation (6.24) (S ∼ l 2 ∼ n −2
max ),
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Main Dimensions of a Rotating Machine 295

we obtain

PFe B̂δ2 B̂ 2
∼ ∼ δ n 2max = B̂δ2 n max = constant. (6.35)
S n max S n max

Thus, the air-gap flux density depends on the speed:

1
B̂δ ∼ √ . (6.36)
n max

We now get the maximum available power Pmax that can be obtained by increasing the
speed of the machine. According to Equations (6.13), (6.30), (3.36) and (6.24),

1 1 1 1 1
Pmax ∼ A B̂δ D 2l  n max ∼ √ √ 2
n max = 3 . (6.37)
n max n max n max n max n max

The power limit is inversely proportional to the cube of the speed. Figure 6.4 illustrates a
study of different types of air-cooled machines and shows the rated power that can be reached
at a required maximum speed or the maximum speed allowed for a given rated power. The
lines in Figure 6.4 are based on conventional electrical and magnetic loading. The figure gives
the average values for a large number of machines. Line e represents the limiting power of
induction motors, the rotors of which are constructed of smooth solid-steel cylinders, which

10 000

1 000
Pmax [kW]

a b c d e
100

10

1
1 000 10 000 100 000 1 000 000
nmax [min–1]
Figure 6.4 Maximum power and speed of air-cooled machines. (a) DC machines, rotor surface
speed ≤110 m/s, (b) synchronous cylindrical-rotor machines with a laminated rotor, rotor surface speed
≤130 m/s, (c) induction motors with a laminated squirrel cage rotor, rotor surface speed ≤200 m/s, (d)
machines with a solid rotor, rotor surface speed ≤ 400 m/s, (e) induction motors with a solid, copper-
coated rotor, rotor surface speed ≤ 550 m/s (a–d: Gutt, 1988; e: Saari, 1998)
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296 Design of Rotating Electrical Machines

are coated with copper cylinders. The cylinder is fixed on the rotor core by explosion welding,
which guarantees a perfect mechanical joint between copper and steel.
The limitations of materials decide the realistic upper limits for the power outputs of elec-
trical machines. Present developments in large synchronous machines have led to notable
outputs. Today, up to 1500 MW, 1500 min−1 synchronous machines are designed as genera-
tors of large nuclear power plants. For instance, the rotor dimensions of the nonsalient-pole
synchronous generator in the new Finnish Olkiluoto 1793 MW nuclear power plant are Dr =
1.9 m, lr = 7.8 m.
The length of the rotor is chiefly restricted by the critical angular speeds of the rotor. At
a critical speed, the rotor has one of its mechanical resonances. There are several bending
modes for the mechanics of each rotor. At the lowest critical speed, the rotor bends like a
banana having two nodal points. At the second critical speed, the rotor bends into an S-shape
with three nodal points, and so on. There are also torsional bending modes that may restrict the
use of a rotor. Usually, the ratio of the length of the machine to the air-gap diameter χ = l/D is
selected for operation of the rotor below the first critical rotation speed. This cannot, however,
be guaranteed. For instance, large turbogenerators generally operate between different critical
speeds. The maximum length of the rotor lmax that guarantees operation below the first critical
speed is defined according to Wiart (1982)

2
2 π EI
lmax = n
2
, (6.38)
kΩ ρ S
where
S is the area of the cross-section of the cylinder (m2 ),
E is the modulus of elasticity (Young’s modulus) of the rotor material, typically
190–210 GPa for steel,
4 
I is the second moment of inertia of area (m4 ), I = π Dout − Din4
/64 for a cylinder,
n is the order of the critical rotation speed,
k is the safety factor (the ratio of the nth critical angular speed to rated angular speed),
ρ is the density of material.

Example 6.5: Calculate the maximum length with a safety factor k = 1.5 for a smooth
solid-steel rotor operating under the first critical speed, when the rotor diameter is 0.15 m
and the rotor speed is 20 000 min−1 .
Solution:

π2 E I
2
lmax =n 2
kΩ ρ S
 
 
  π · 0.154 4
  200 GPa ·
 2  m
=
π 64
lmax 12  = 0.75 m.
 20 000  kg π · 0.152 2
1.5 2π 8760 3 m
60 s m 4
In this theoretical case lmax /rr = 10. In practice, the rotors have slits and low-diameter
shafts for bearings and so on, which reduces the lmax /rr ratio.
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Main Dimensions of a Rotating Machine 297

Table 6.5 Typical χ = l /D ratios for different electrical machines

Asynchronous
machines Synchronous machines, p > 1 Synchronous machines, p = 1 DC machines
π √ π √ 0.8 − 1.6
χ≈ 3
p χ≈ p χ =1−3 χ≈
2p 4p p

If we employ the safety factor in the yield kσ , we obtain for the ratio of the length of the
rotor to the radius, using Equations (6.23) and (6.38),

 
lmax kσ 4 C  E
= nπ . (6.39)
rr k 4σmec

This equation yields the maximum length of the rotor after the permitted rotor radius has been
defined with Equation (6.23). lmax /rr is not a function of rotation speed. If a solid-steel rotor
rotates below the first critical rotation speed, the ratio should usually be l/rr < 7. In practice,
the ratio is often l/rr ≈ 5. In the above-mentioned Olkiluoto generator l/rr ≈ 8.2.
In standard machines, the ratio of the equivalent machine length to the air-gap diameter

l
χ= (6.40)
D

varies within rather tight limits (see Table 6.5).

6.4 Air Gap

The length of the air gap of a machine has a significant influence on the characteristics of an
electrical machine. In machines in which the magnetizing current is taken from the supply
network, the length of the air gap is dimensioned to produce a minimum magnetizing current
and, on the other hand, an optimal efficiency. In principle, a small air gap gives a low magne-
tizing current, while the eddy current losses of the rotor and stator surface increase because of
permeance harmonics created by the open or semi-closed slots. A small air gap also increases
the surface losses in the rotor caused by the current linkage harmonics of the stator. Although
the air gap is of great significance, no theoretical optimum has been solved for its length, but
usually empirical equations are employed instead in the definition of the length of the air gap.
An air gap δ of a 50 Hz asynchronous machine can be calculated in metres as a function of
power P with the equations

0.2 + 0.01 · P 0.4

δ= m, when p = 1, (6.41)
1000

0.18 + 0.006 · P 0.4

δ= m, when p > 1. (6.42)
1000
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298 Design of Rotating Electrical Machines

P must be in watts. The smallest technically possible air gap is approximately 0.2 mm. In
drives for extremely heavy duty, the air gap is increased by 60%. In machines with an
exceptionally large diameter, an air-gap ratio of δ/D ≈ 0.001 has to be selected because of
the mechanical properties of the frame and the shaft of the machine.
In frequency converter drives, the air gap may be increased similarly as in heavy-duty
drives (60% increase) to get lower rotor surface losses. In large machines with prefabricated
windings and open slots, the air-gap length must be selected high enough (60–100% increase)
to reduce pulsation losses.

Example 6.6: What is a suitable air gap for a 110 kW, six-pole, heavy-duty induction
motor?
Solution:

0.18 + 0.006 · P 0.4 0.18 + 0.006 × 110 0000.4

δ = 1.6 m = 1.6 · m = 1.285 × 10−3 m.
1000 1000

If an asynchronous machine is designed for high speeds, to avoid excessive iron losses in
the stator and rotor teeth, the air-gap length has to be increased considerably from the value
obtained with Equation (6.41) or (6.42) for a standard electric motor. Also, frequency con-
verter motors may have a larger air gap than motors started direct on line. If a high-speed
machine is equipped with a solid rotor, the air gap has to be designed with special care, since
the losses at the surface of a solid rotor decrease radically when the air gap is increased,
whereas an increase in the magnetizing current in the stator leads to a notably smaller in-
crease in the losses. A suitable value for the length of the air gap has thus to be determined
individually in each case.
In DC and synchronous machines, the air gap is basically defined by the permitted armature
reaction. We have to ensure that the armature reaction (flux caused by the current linkage of
the armature) does not reduce the flux density excessively on one side of a magnetic pole. To
meet this condition, the current linkage of the field winding has to be higher than the current
linkage of the armature

Θf ≥ Θa . (6.43)

This condition may be rewritten for DC machines as

Bδ max 1
δkC ≥ αDC τp Aa . (6.44)
µ0 2

On the left of (6.44), we have the field winding current linkage expressed with the no-load
air-gap flux density, and, on the right, the armature current linkage expressed by the armature
linear current density Aa and the relative pole width α DC .
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Main Dimensions of a Rotating Machine 299

Table 6.6 Coefficient γ for the definition of the air gap of DC and synchronous machines
Salient-pole constant air-gap synchronous machines γ = 7.0 × 10−7
Salient-pole synchronous machines, the air gap of which is shaped γ = 4.0 × 10−7
to produce a sinusoidal flux density distribution
Nonsalient-pole synchronous machines γ = 3.0 × 10−7
DC machines without compensating winding γ = 3.6 × 10−7
DC machines without compensating winding and γ = 5.0 × 10−7
commutating poles
Compensated DC machines γ = 2.2 × 10−7

The same condition for a synchronous machine is given as

B̂δ 1
δkC ≥ αSM τp Aa . (6.45)
µ0 2

Then, the air gap of a DC machine must be

1 Aa Aa
δ≥ αDC µ0 τp = γ τp , (6.46)
2 Bδ max Bδ max

and for synchronous machines

1 Aa Aa
δ≥ αSM µ0 τp = γ τp , (6.47)
2 B̂δ B̂δ

where γ (Table 6.6) includes, according the type of the machine, the relative pole width of the
pole shoe α DC or α SM , µ0 and a constant 1/2.

Example 6.7: A salient-pole synchronous machine with a no-load sinusoidal air-gap

flux density has a stator linear current density of A = 60 kA/m, an air-gap flux density
amplitude of 1 T and a pole pitch of 0.5 m. Find a suitable air gap for the machine.
Solution: The sinusoidal no-load air-gap flux density of the machine results from a suitable
pole shape that produces the sinusoidal flux density. Hence, γ = 4 × 10−7 and we get

A 60 000
δ0 = γ τp = 4 × 10−7 · 0.5 · = 0.012 m.
B̂δ 1

Synchronous reluctance machines must have a high inductance ratio, which suggests se-
lecting a small d-axis air gap. To be able to compete with the performance of asynchronous
machines, synchronous reluctance motors may have to be equipped with smaller d-axis air
gaps than those in induction motors. However, if the air gap is made very small, the surface
loss, because of permeance harmonics, may increase remarkably if high-quality rotor lamina-
tions are not used.
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300 Design of Rotating Electrical Machines

In doubly salient reluctance machines, the aim is to construct as small an air gap as possible
to achieve a high inductance ratio between the direct and quadrature position of the machine.
In PMSMs, the air-gap length is determined by mechanical constraints. It is similar to
those values encountered in asynchronous machines and can be calculated from Equations
(6.41) and (6.42). The synchronous inductance depends on the air-gap length. Since the
magnet length itself has a significant influence on the magnetic air gap of the machine, the
synchronous inductance easily becomes low and the machine maximum torque high. How-
ever, in some cases, the thickness of the magnet and even the length of the physical air gap
must be increased to get a smaller synchronous inductance. Generally, the physical air gap is
made as small as possible to save the amount of material in the permanent magnet. This holds
especially for low-speed, high-torque permanent magnet machines. In higher-speed machines,
the air-gap harmonic content may cause very high losses in the permanent magnet material or
in the ferromagnetic material under the permanent magnets, and in such cases the air gap must
be increased to keep the magnet temperature low enough. In a PMSM, the determination of
the air gap and the thickness of the magnets themselves is thus a demanding optimization task.
In rotor surface magnet machines, the magnetic air gap of the machine may be calculated
as

δPM = h PM /µrPM + δe (6.48)

where hPM is the rotor surface permanent magnet thickness, µrPM the permanent magnet ma-
terial relative permeability and δ e the equivalent air gap, the physical air gap corrected with
the Carter factor (δ e = kC δ).
If the magnets are embedded, their effects in the reluctance of the magnetic circuit are
somewhat complicated and have to be taken into account in the calculation of the effective air
gap δ ef . Numerical methods are often applied.

Bibliography
Gutt, H.-J. (1988) Development of small very high speed AC drives and considerations about their upper speed/output
limits. Proceedings of Conference on High Speed Technology, August 21–24, 1988. Lappeenranta, Finland,
pp. 199–216.
Lawrenson, P.J. (1992) A brief status review of switched reluctance drives. EPE Journal, 2 (3), 133–44.
Marchenoir, A. (1983) High speed heavyweights take on turbines. Electrical Review, 212 (4), 31–3.
Miller, T.J.E. (1993) Switched Reluctance Motors and Their Controls, Magna Physics Publishing and Clarendon
Press, Hillsboro, OH and Oxford.
Richter, R. (1954) Electrical Machines: Induction Machines (Elektrische Maschinen: Die Induktionsmaschinen), Vol.
IV, 2nd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1963) Electrical Machines: Synchronous Machines and Rotary Converters (Elektrische Maschinen: Syn-
chronmaschinen und Einankerumformer), Vol. II, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Richter, R. (1967) Electrical Machines: General Calculation Elements. DC Machines (Elektrische Maschinen: Allge-
meine Berechnungselemente. Die Gleichstrommaschinen), Vol. I, 3rd edn, Birkhäuser Verlag, Basle and Stuttgart.
Saari, J. (1998) Thermal Analysis of High-Speed Induction Machines, Acta Polytechnica Scandinavica, Electrical
Engineering Series No. 90. Helsinki University of Technology.
Vogt, K. (1996) Design of Electrical Machines (Berechnung elektrischer Maschinen), Wiley-VCH Verlag GmbH,
Weinheim.
Wiart, A. (1982) New high-speed high-power machines with converter power supply, Motorcon Proceedings, Septem-
ber 1982, pp. 641–6.
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7
Design Process and Properties
of Rotating Electrical Machines

The design process of a rotating electrical machine can be carried out for instance in the
following order. This procedure can be directly applied to asynchronous motors, but it is also
applicable to the design of other machine types.

1. The initial design parameters are checked.

2. The tangential stress σ tan (Table 6.3) or the machine constant Cmec (Figure 6.3) are deter-
mined according to the power, speed and cooling method of the machine.

3. The rotor size is determined according to the required torque (T = σtanrr 2πrrlr
=
2σtan Vr ), see Equation (6.2). At the same time, a suitable ratio of the length and the air-gap
diameter χ (Table 6.5) is selected according to the machine type. This ratio, then, deter-
mines the air-gap diameter D and the equivalent length l
of the machine. If the machine
has radial air-cooling channels, the stator is built of laminated stacks 40–80 mm long with
10 mm cooling channels in between. The equivalent length of the machine is then defined
according to the rules given in Chapter 3. In the case of an axial flux machine, the diam-
eter ratio of the machine decides the radial ‘length’ of the machine. The best theoretical
diameter ratio (the ratio of the inner diameter of the stator to the outer diameter, Ds /Dse )
is approximately 0.6.
4. A suitable air gap is defined for the machine (see Section 6.4).
5. A suitable stator winding is selected for the machine. This is a decisive phase with respect
to the final characteristics of the machine. A guiding principle is that a poly-phase winding
produces the more sinusoidal current linkage, the more slots there are in the stator. The
winding factors for a slot winding usually become lower for the harmonics as the number
of slots increases (the current linkage of the winding approaches sinusoidal waveform). The
limit value for this inference is the case in which there are no slots at all, but the winding
is assembled straight into the air gap of the machine. Now, in principle, the current linkage
created by the stator currents has a smooth distribution and, because of a long air gap,
an optimum sinusoidal flux density distribution on the rotor surface. A slotless armature
winding is typical in small and in high-speed permanent magnet synchronous machines.

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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302 Design of Rotating Electrical Machines

Table 7.1 Recommended slot pitches for normal armature windings of

different machine types
Machine type Slot pitch, τ u /mm
Asynchronous machines and small PMSMs 7–45
Synchronous machines and large PMSMS 14–75
DC machines 10–30

Leaving an asynchronous motor without slots would lead, as a result of a long air gap, to
an excessive magnetizing current and therefore a poor power factor.
A large number of slots increase the number of coils and also the price of the machine.
Table 7.1 contains some recommendations for the slot pitch τ u .
The lowest slot pitches occur in small machines, whereas the highest slot pitches are
found in large machines. For instance, in a 4 kW, 3000 min−1 induction motor, the slot
pitch τ u of the stator is about 8.5 mm. On the other hand, the slot pitch τ u of the stator
in a 100 kVA four-pole synchronous machine is about 16 mm. In a low-speed 3.8 MW,
17 min−1 , direct-driven wind generator the slot pitch τ u is about 38 mm (D = 5.2 m, p =
72). The largest slot pitches are suitable in direct water cooling. Bulky copper coils are
difficult to cool if the machine is air cooled.
When the winding type and the number of slots are selected, as a result the winding
factors of the machine are also defined. The most important winding factor is the winding
factor kw1 of the fundamental. Simultaneously, attention must be paid to the winding factors
of the winding harmonics. For instance, in a symmetrical three-phase machine, the lowest
harmful harmonics are the fifth and the seventh harmonics.
6. Since the tangential stress or the machine constant has already been selected, the air-gap
flux density B̂δ has to correlate with the selected machine constant. The initial value em-
ployed in the calculation can be selected according to Table 6.1. In permanent magnet
machines, the air-gap flux density must be in a sensible relation to the remanent flux den-
sity of the permanent magnet material. From the economic point of view of this material,
the maximum air-gap flux density with permanent magnets should be about half of the
remanent flux density, namely 0.5–0.6 T. Such low values should lead to a large machine,
and hence remarkably higher values are also used in PMSMs.
7. As the main dimensions, the winding method and the air-gap density have been se-
lected, the required number of coil turns N can be defined with the desired emf. The emf
E m = ωΨm induced by the air-gap flux linkage (Ψm = Im L m ) can first be estimated
from the RMS value U1 of the fundamental terminal voltage; for induction motors it is
E m ≈ 0.96 − 0.98U1 and for generators E m ≈ 1.03 − 1.06U1 .

With synchronous machines and PMSMs, we first have to estimate the required E f or E PM
(cf. appropriate phasor diagrams in Section 7.2) which is crucial for the torque production of
a synchronous machine. The stronger the armature reaction, the higher the values of E f or
E PM have to be selected in order to reach an adequate power factor at the rated point. In syn-
chronous machines with a strong armature reaction, E f ≈ 1.2 − 2U1 and in permanent magnet
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Design Process and Properties of Rotating Electrical Machines 303

synchronous machines, typically, E PM ≈ 0.9 − 1.1U1 . It must, however, be remembered that

values at the higher end of E f ≈ 1.2 − 2U1 are fictitious values used in machine analysis. The
values are not possible at no load since the machine magnetic circuit should saturate heav-
ily. Even in high-armature-reaction machines, the no-load maximum voltage seldom exceeds
E f ≈ 1.2 − 1.3U1 .
The main flux penetrating a winding varies almost sinusoidally as a function of time

Φm (t) = Φ̂m sin ωt. (7.1)

Here Φ̂m represents the maximum value of the air-gap flux penetrating into a full-pitch wind-
ing. According to Faraday’s induction law, the air-gap flux linkage Ψ m induces in the winding
a voltage

dΨm dΦm
em = − = −ωΨ̂m cos ωt = −Nkw = −Nkw ωΦ̂m cos ωt. (7.2)
dt dt

In Equation (7.2), the peak flux linkage Ψ̂m is associated with the phase winding under
observation. The peak flux linkage occurs at a time when the peak air-gap flux density B̂δ is
on the magnetic axis of the winding. Similarly, we also define the peak flux Φ̂m penetrating
the winding. When the induced voltage is assumed sinusoidal, we obtain the RMS value of
the air-gap voltage

1 1
E m = √ êm = √ ωkw N Φ̂m (7.3)
2 2

as was shown in Chapter 6.

For the calculation, the peak value of the air-gap flux linking the winding has to be known.
This value is calculated by integrating the flux density over the pole pitch (x-coordinate) and
the equivalent length (y-coordinate) of the machine, Figure 7.1. In practice, this value may be
calculated by defining the average value of the air-gap flux density (see Example 2.7).

l
τp
Φ̂m = (Bδ ) dx dy. (7.4)
0 0

The peak value of the air-gap flux by an integral of (7.4) assuming that the flux density is
independent of the y-coordinate parallel to the axis of the machine is

Φ̂m = αi B̂δ τpl
, (7.5a)

Φ̂m = αPM B̂δ τpl
, (7.5b)

where α i is a coefficient showing the arithmetical average of the flux density in the x-direction,
which takes the value αi = 2/π in a sinusoidal flux density distribution, Figure 7.1.
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304 Design of Rotating Electrical Machines

z
y
x

B̂ stator
αi B̂ l' B̂

air gap δ wPM

τp rotor τp

(a) (b)

Figure 7.1 (a) Sinusoidal flux density distribution across a pole pitch, peak value B̂δ , average value
αi B̂δ . The cross-section of the flux density distribution is often somewhat flattened from the sinusoidal
form because of saturation in the teeth. In the case of a sinusoidal distribution α i = 2/π and in the
case of a flattened distribution α i > 2/π. (b) The air-gap flux behaviour with a rectangular permanent
magnet

In PMSMs, the magnets are often installed on the rotor surface. If the magnets have an
equal thickness over the pole pitch, the flux density in the air gap is more or less rectangular,
and the average flux may be defined by the relative magnet width αPM = w PM /τp . In such a
case, in Equation (7.5a), α PM is used instead of α i . Rotor surface magnets may, of course, be
given a form that produces a sinusoidal flux density. Embedded magnets and a suitable pole
shoe shape may also give a sinusoidal flux density in the air gap. In such cases, the average
flux density is again close to α i = 2/π.
If the machine is dimensioned in such a way that its iron parts saturate at the peak value of
the flux density, the flux density distribution is flattened. In ordinary network-supplied induc-
tion motors, both the stator and rotor teeth are saturated at the peak value of the flux density.
This leads to a higher reluctance of these teeth when compared with other teeth, and thus
α i takes notably higher values than the value corresponding to a sinusoidal distribution. The
factor α i has to be iterated gradually to the correct value during the design process. The value
α i = 0.64 of an unsaturated machine can be employed as an initial value, unless it is known
at the very beginning of the design process that the aim is to design a strongly saturating ma-
chine, in which case a higher initial value can be selected. The theoretical maximum value of a
maximally saturated machine is α i = 1. In practice, α i = 0.85 is usually not exceeded. In that
case, the magnetic potential difference Ûm,ds + Ûm,dr in the stator and rotor teeth is already
higher than the magnetic potential difference Ûm,δ of the air gap. To simplify the machine
design, the factor α i can be determined beforehand for different phases of saturation. Figure
7.2 illustrates α i as a function of saturation factor ksat :

Ûm,ds + Ûm,dr
ksat = . (7.6)
Ûm,δ
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Design Process and Properties of Rotating Electrical Machines 305

αi

0.8

0.7

0 0.5 1.0 1.5 2.0

k sat
Figure 7.2 Effect of the saturation factor on the factor α i of the arithmetical average of the flux density.
The more the teeth of the machine are saturated, the higher the value of α i becomes

This factor simply takes the teeth into account because their possible saturation is the main
reason for the flattening of the air-gap flux density distribution.

Example 7.1: Find the average flux density factor for an induction machine having
Ûm,ds + Ûm,dr = 105 + 95 A = 200 A and Ûm,δ = 800 A.
Solution:

Ûm,ds + Ûm,dr 200 A

ksat = = = 0.25.
Ûm,δ 800 A

According to Figure 7.2, the average flux density value is αi = 0.72.

We may now calculate from Equations (7.3) and (7.5a) the required number of coil turns N
in the phase winding of the machine

√ √
2E m 2E m
N= = . (7.7)
ωkw1 Φ̂m ωkw1 αi B̂δ τpl

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306 Design of Rotating Electrical Machines

Note that the peak flux Φ̂m is calculated per single pole. In a symmetrical machine, the flux
of each pole is of equal magnitude. N is the number of coil turns in series needed for the
assembly. This number can also, if required, be divided into several pole pairs. If there are
two pole pairs in the machine, for instance, they can be connected in parallel if desired, the
number of turns now being N in both pole pairs. The number of parallel paths in such a
case is a = 2. If the pole pairs are connected in series instead, the number of turns becomes
N /2 for both pole pairs, the total number being N . If possible, it is advisable to connect the
coils in series, since in that case the possible asymmetries between the pole pairs do not cause
circulating currents in the machine.

8. Next, we have to find a suitable integer closest to the previously calculated number of turns
N . In a phase winding, there are N turns in series. A single coil turn is composed of two
conductors in slots, connected by the coil ends. In a single-phase winding, there are thus
2N conductors in series. With m phases in a machine, the number of conductors becomes
2m N . There may be a number of a parallel paths in a winding, in which case the number
of conductors is 2am N . The number of conductors per slot becomes
2am
zQ = N. (7.8)
Q

Here Q is the slot number of either the stator or the rotor (in a slip-ring asynchronous motor
or a DC machine). z Q has to be an integer. When rounding z Q off to an integer, we have to
pay attention to the appropriateness of the slot number Q and the number of parallel paths a
to avoid too large a rounding-off. After rounding-off, a new number of turns N is calculated
for the phase winding.
In some cases, especially in low-voltage, high-power machines, there may be a need to
change the stator slot number, the number of parallel paths or even the main dimensions of
the machine in order to find the appropriate number of conductors in a slot.

9. The selected number of turns for the phase winding has an effect on the value B̂δ of the
air-gap flux density. A new value can be calculated with Equation (7.7).

Example 7.2: Find a suitable number of stator turns for the motor in Example 7.1 with
m = 3, p = 2, B̂δ = 1 T, l
= 0.2 m, τp = 0.2 m, f = 50 Hz, phase voltage Us,ph = 400 V
and q = 4 with no short pitching.
Solution: In the previous example, we found the average factor αi = 0.72. The fundamen-
tal winding factor for a q = 4 machine is 0.958. Now, we find for the number of turns
in series
√ √
2E m 2 · 0.97 · 400
Ns = = = 63.3.
ωkw1 αi B̂δ τpl
2π · 50 · 0.958 · 0.72 · 1 · 0.2 · 0.2

The number has to be divisible by pq = 8. Hence, we select Ns = 64. If the pole pairs
are connected in series, we have 32 turns in both of the pole pairs, which gives z Q = 8
conductors per slot. If the pole pairs are connected in parallel, we get 64 turns per pole
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Design Process and Properties of Rotating Electrical Machines 307

pair and z Q = 16 conductors per slot. If a series connection is possible, it is always safest
to select it, because with parallel paths, there exists a possibility of circulating currents if
any nonsymmetries are present in the construction. As the number of turns is very close
to the theoretical value of 63.3, the change in the air-gap maximum flux density is small.
The new value is B̂δ = 0.99 T instead of 1 T.

10. The air-gap flux density B̂δ being determined, the stator and rotor teeth are dimensioned
next. The flux densities of the stator and rotor teeth are chosen for normal machines ac-
cording to the permitted values presented in Table 6.1 In high-frequency machines, it may
be necessary to select values notably lower than the values presented in Table 6.1 to avoid
excessive iron losses. When the apparent reference flux densities are selected for the stator
and rotor teeth, the widths bds and bdr are calculated for the stator and rotor teeth using
the selected flux densities at the teeth.
11. In order to determine the dimensions of the stator and rotor slots, we have first to estimate
the stator and rotor currents. In synchronous and asynchronous motors, the stator current
Is is obtained with the shaft power P, the stator phase voltage Us,ph , the efficiency η and
the power factor cos ϕ

P
Is = . (7.9a)
mηUs,ph cos ϕ

We have to estimate the efficiency η and, for induction motors, also the power factor. For
synchronous motors, the power factor is a design parameter.
The stator current of generators is

P
Is = (7.9b)
mUs,ph cos ϕ

where P is the electric output power. For synchronous generators, the power factor cos ϕ is
a design parameter, and for induction generators it has to be estimated in this phase of the
design process.
In an induction motor, the rotor current referred to the stator is approximately of the same
magnitude as the real component of the stator current (since the magnetizing current flows
only in the stator)

Ir
≈ Is cos ϕ. (7.10)

The real rotor current is defined by the transformation ratio between the rotor and the stator.
The current of the bar of the cage winding of an induction motor is written as

zQ Q s
Ir ≈ Is cos ϕ. (7.11)
a Qr

The relationship between the rotor current and its equivalent in the stator winding will be
given in (7.46).
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308 Design of Rotating Electrical Machines

Example 7.3: Calculate the rotor bar current in a motor with Q s = 36, Q r = 24, a = 2,
z Q = 16, Is = 40 A, cos ϕ = 0.84.
Solution:
zQ Q s 16 36
Ir ≈ Is cos ϕ = 40 · 0.84 A = 403 A.
a Qr 2 24

Here we see that the rotor bar currents are really large.

The armature current of a DC motor is determined by an equation resembling Eq-

uation (7.9a)

P
Ia ≈ . (7.12)
Uη

The magnetizing windings of a salient-pole synchronous machine and a DC machine

are salient-pole windings and are thus not inserted in slots. The magnetizing winding of a
nonsalient-pole synchronous machine is a slot winding, but the space required by it can be
defined only when the total magnetizing current of the machine has been calculated.
When the stator and rotor currents have been resolved, the areas of the conductors become
Sc . The resistive losses of the windings are chiefly determined by the current densities Js
and Jr of the stator and rotor windings. In standard machines, the values in Table 6.2 can be
employed. The number a of the parallel paths has also to be borne in mind:

Is Ir
Scs = , Scr = . (7.13)
as Js ar Jr

The areas Sus and Sur of the stator and rotor slots are now obtained by taking the space
factors kCu,s and kCu,r of the slot into account

z Qs Scs z Qr Scr
Sus = , Sur = . (7.14)
kCu,s kCu,r

The space factor kCu of the slot depends principally on the winding material, the voltage level
and the winding type of the machine. The windings of small electrical machines are usually
made of round wire. In that case, the space factor of an insulated wire in a free slot (with the
area reserved for the slot insulation subtracted) varies, depending on the quality of winding
assembly, from 60 to 66%.
The space factor value is, however, defined for noninsulated slots. Values of kCu,s ∈
(0.5, 0.6) are typical for low-voltage machines. The lower limit is for round enamelled wires
and the upper limit for ideal prefabricated rectangular windings in low-voltage machines.
In high-voltage machines, the insulation takes more space and the slot space factor varies,
kCu,s ∈ (0.3, 0.45), the lower value being for round wires and the upper for rectangular wires.
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Design Process and Properties of Rotating Electrical Machines 309

hys

S us b ds
hs hd
b4

Figure 7.3 Stator tooth and two semi-closed stator slots and their main dimensions. hys is the stator
yoke height. The slot depth equals the tooth height h s = h d

The armature winding of large machines is usually constructed from preformed copper.
When using square wire or a prefabricated, preformed winding, the space factor is somewhat
better than the space factor of a round wire winding.
If aluminium bars are die cast in the induction motor, the space factor becomes kCu,r = 1
(z Qr is also now z Qr = 1). If a cage winding is produced from copper bars by soldering, a
clearance of about 0.4 mm in width and 1 mm in height has to be left in the rotor slot. This
clearance also decreases the space factor.
In point 10, the widths bds (Figure 7.3) and bdr of the stator and rotor teeth have been
selected such that the selected permitted flux densities are located at respective teeth at the
peak value of the flux density.
When the air-gap diameter and the teeth widths have been selected, the width of the slot is
automatically known. The height h s of the slot is always equal to the height of the tooth, and
it is selected to reach the area Sus required for the winding and the insulation.

12. When the air-gap diameter, the air gap, the peak value of the air-gap flux density and
the dimensions of the stator and rotor slots of the machine are known, we may start to
calculate the magnetic voltages over the air gap and the teeth. An exact definition of the
magnetic voltages in these areas requires an analysis of the flux diagram in the respective
areas. The manual solution of a flux diagram is a difficult task; however, with sufficient
accuracy, the calculations can be made to estimate the line integral of the field strength H
in this area


Um = H · dl. (7.15a)
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310 Design of Rotating Electrical Machines

Figure 7.4 The apparent peak value Φ̂sd of the stator tooth flux is obtained by calculating the flux at
the distance of a tooth pitch at the peak value of the flux density. We see that a part of the flux flows
along the air space of the slot as the teeth saturate. In the analysis, the tooth in the middle of the figure
occurs at the peak value of the air-gap flux density of the entire machine. In the middle of the tooth,
the field strength H and the differential section dl of the integration path are parallel, and therefore the
integration is easy

The magnetic voltage Um is calculated for each section individually. For instance, the flux
diagram in Figure 7.4 is analysed. Figure 7.5 shows the basically corresponding flux density
and a field strength distribution at the middle tooth.

Example 7.4: Calculate the magnetic voltage and 50 Hz losses of an induction motor
stator tooth of height h ds = 0.025 m with a constant width bds = 0.01 m and slot pitch
τu = 0.02 m when the air-gap flux maximum density is 0.8 T. The stator material is M470-
50A (see Appendix A). The stator lamination space factor is kFe = 0.97. The length of the
stator stack is l = 0.15 m.


Solution: The apparent flux penetrating the slot pitch is Φ̂sd = B̂δ τul
= 0.8 T · 0.02 m ·



l = 0.016 · l V s/m. The apparent tooth flux density



Vs


B̂d = Φ̂sd /(bds kFel
) = 0.016 l 0.01 m · 0.97 · l
= 1.65 T.
m

The corresponding field  strength in M470-50A is Hd ≈ 4400 A/m. The magnetic voltage
in the tooth is Umd = Hd · dl ≈ 4400 A · 0.025 m = 110 A. The corresponding flux den-
sity in the adjacent slot is 4400 A · µ0 = 0.0055 T. As this value is so small, we neglect
the effect of the flux in the slot. If the flux density in the tooth were higher, the effect of
the flux in the slot would be taken into account (see Section 3.3.1).
M470-50A indicates that the material loss is 4.7 W/kg at 50 Hz and 1.5 T. The volume of
the tooth is Vd = h ds bds l = 37.6 × 10−6 m3 and the density of the material is 7650 kg/m3 .
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Design Process and Properties of Rotating Electrical Machines 311

As the space factor is kFe = 0.97, we have the weight of the tooth as m Fe,n = 0.278 kg. In
induction machine stator teeth, the loss coefficient kFe,n = 1.8 (Table 3.2), and hence we
get the loss in one tooth, according to Equation (3.78), as
 2  2
B̂ W 1.65 T
PFe = kFe,n P15 m Fe,n = 1.8 · 4.7 0.278 kg = 2.85 W.
1.5 T kg 1.5 T

13. The factor α i and the saturation factor ksat were defined in point 7. Recall that the factor
αi was given as a function of the factor ksat in Figure 7.2. Now, we have to check the satu-
ration factor and determine a new α i . If α i does not correspond with sufficient accuracy to
the factor selected in the initial phase of the calculation, the peak value B̂δ of the air-gap
flux density has to be recalculated according to Equation (7.7) because N is now fixed.
Simultaneously, the flux density values of the stator and rotor teeth have to be corrected,
and new magnetic voltages have to be calculated for the teeth and the air gap. The factor
α i has to be iterated gradually to a correct value. For PMSMs with rotor surface magnets
of uniform thickness, this step is not valid.
14. The flux density maxima B̂ys and B̂yr of the stator and rotor yokes are selected according
to Table 6.1. With the peak value of the flux of the machine, together with the flux density
peaks B̂ys and B̂yr , we are able to determine the heights h ys and h yr of the rotor and stator
yokes that realize the selected flux density maxima.
15. When the air-gap diameter Ds , the heights h ds and h dr of the teeth, and the heights h ys and
h yr of the stator and rotor yokes are known, we obtain the outer diameter Dse of the stator
and the inner diameter Dri of the machine; cf. Figures 3.1 and 3.2.
16. Now all the main dimensions of the machine have been determined, next we have to
check the magnetic voltages required by different parts of the machine. The sum of the
magnetic voltages has to be covered by the current linkage Θ produced by some (or
multiples) of the windings or by permanent magnets. Magnetizing is accomplished by
different methods in different machines. A DC machine is magnetized with a separate

B, T H, A/m PFe/V , W/m3

Figure 7.5 Principle of the flux density distribution B of a nonuniform stator tooth, the absolute value
of the field strength H and the iron loss density PFe /V on the integration path in the middle of the tooth
in Figure 7.4. The curves are derived according to the stator tooth flux, the local tooth width and the BH
curve of the tooth material
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312 Design of Rotating Electrical Machines

field winding or permanent magnets, whereas an induction machine is magnetized with

the magnetizing current of the stator winding, or a synchronous machine with the current
of the rotor field winding or by permanent magnets, and so on.

In this book, systematically, half of the magnetic circuit is calculated (e.g. half of the stator
yoke, one stator tooth, one air gap, one rotor tooth, half of the rotor yoke). The magnetic
voltage sum of half of the magnetic circuit has to be covered by the current linkage amplitude
produced by the rotating-field winding or by the current linkage of one pole winding of an
excitation winding or by one permanent magnet.
At this point, the height h PM of the permanent magnets is calculated. The magnetic voltage
sum of the magnetic circuit is
Hc Ûm,ys Ûm,yr
Ûm,tot = Hc h PM = Ûm,δe + Ûm,ds + BPM h PM + + (7.15b)
Br 2 2
from which
Ûm,ys Ûm,yr
Ûm,δe + Ûm,ds + +
h PM = 2 2 (7.15c)
Hc
Hc − BPM
Br

√ rotating field produces the fundamental current linkage of amplitude Θ̂s1 =

A stator
mkw1 Ns 2Is /(π p) according to Equation (2.15) modified for the fundamental component.
The required magnetizing current can be calculated by keeping the sum Um,tot of the magnetic
voltages of half the magnetic circuit equal to the amplitude Ûm,tot = Θ̂s1 . Now we obtain the
RMS value of the stator magnetizing current
Ûm, tot π p
Is, mag = √ .
mkw1 Ns 2
For machines magnetized with pole windings, the calculation of the no-load magnetizing
current is a simple task, since the current linkage of a single pole winding is Nf If . This, again,
has to equal the sum of the magnetic voltages of half a magnetic circuit. When dimensioning
a synchronous machine excitation winding, for instance, it must be remembered that the pole
winding must also capable of compensating for the armature reaction and, hence, the amount
of copper must be large enough to carry a much larger current than at no load.

17. Since the dimensions have been defined and the winding has been selected, the resistances
and inductances of the machine are now calculated. The magnetizing inductance was
discussed in Chapter 3, the leakage inductances in Chapter 4 and the resistances in Chapter
5. With them, the equivalent circuit parameters of the machine per phase is obtained. Now
the losses, efficiency, temperature rise and torques of the machine can be determined.

In Figure 7.5, the iron losses in the teeth are solved by manual calculations. The frequency
of the flux density alternations corresponds in principle to the rated frequency of the machine.
The specific power loss (W/kg) corresponding to this frequency and the peak flux density can
be checked from the manufacturer’s catalogue, and then a dissipation power density curve
can be constructed corresponding to the flux density curve of Figure 7.5 for the determination
of losses in a single tooth, when the weight of the tooth is known. Using the same principle,
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Design Process and Properties of Rotating Electrical Machines 313

all the iron parts of the machine can be analysed. Since stresses and burrs occur in punched
plates, and since the shaped parts on both sides of the air gap cause flux pulsations, there are
notably higher losses in the teeth and also in other iron parts of the machine than the power
loss calculated with the base frequency would suggest. Further, the power losses given by the
manufacturer are presented for AC magnetizing, not for rotating magnetizing, which is the
dominant form of motion of the field in the stator yoke. These facts have led to the utilization
of the empirical factors in Table 3.2.
These factors in Table 3.2 are used to correct the iron loss calculations in the most signifi-
cant parts of the magnetic circuit of a machine. In machine design, special attention must be
paid to the fact that the frequencies in all parts of the machine are not equal. In the stators of
rotating-field machines, the base frequency is the input frequency f s of the machine. How-
ever, in the teeth of the stator and the rotor, high-frequency flux components occur, which are
based on the motion of the teeth with respect to each other. For instance, in the rotor of a
synchronous machine, the base frequency is zero, but other pulsation losses occur on the rotor
surface because of stator slotting.
Resistive losses are defined with the methods discussed in Chapter 9 by determining the re-
sistances of the windings. Following the definition of the iron and resistive losses, the windage
and friction losses and the additional losses of the machine can be defined according to the
guidelines given in Chapter 9. Now the efficiency of the machine has been resolved. The ther-
mal rise, on the other hand, finally determines the resistances of the machine, and thus also
the resistive losses, and therefore the heat transmission calculations should still be carried out
before the analysis of final losses of the machine.
The previously discussed calculation procedure can be illustrated in compact form by the
flow chart in Figure 7.6.
Next, some special characteristics of the calculation of the most common machine types
are discussed.

7.1 Asynchronous Motor

An induction motor is the most common motor type applied in industry. Usually, the rated
output powers
√ follow a geometric series, in which the ratio of rated output powers is approxi-
mately n 10. The ordinal n of the root defines a power series that can be denoted ‘a series n’.
Typically, the series 5, series 7 and series 9 are employed. Different series are employed at
different power ranges. The recommended power ranges are given in Table 7.2.
The output powers of induction motors do not strictly follow the recommendations. Usually,
the rated powers of the motors below 1000 V are the following: 0.18, 0.25, 0.37, 0.55, 0.75,
1.1, 1.5, 2.2, 3.0, 4.0, 5.5, 7.5, 11, 15, 18.5, 22, 30, 37, 45, 55, 75, 90, 110, 132, 160, 200,
250, 315, 400, 450, 500, 560, 630 and 710 kW. We see that also at the lower end of this power
series, the series 7 is approximately followed. Machines above 710 kW are often constructed
for high voltages, however, with an inverter drive; for instance, even a power of 5 MW can be
reached with a 690 V voltage.
Each rated voltage has an optimum power range, the lower and upper limits of which should
not be exceeded if a favourable construction is to be produced. If the voltage is excessively
high with respect to the power, the conductors become rather thin, and the number of turns
increases drastically. In the opposite case, the winding has to be made of preformed copper,
which increases the winding costs. In the above series, 630 kW is, typically, the limit for
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314 Design of Rotating Electrical Machines

1. set the starting values of the machine

2. determine a suitable tangential stress σtan

or machine constant Cmec

3. select a suitable length ratio χ, D and l'

4. define a suitable physical air gap δ

5. select a winding, define Qs, Qr, and kw

6. define an air gap flux density B̂

7. select αi and the number of coil turns N

8. seek a coil zQ for a slot and then a new N

9. define a new B̂
10. define the teeth widths bd

11. define the teeth heights hd

12. define the magnetic voltages of the teeth

13. define a new αi. If the accuracy is not

sufficient, return to 9.

14. define the flux densities in the yokes

15. define rest of the diameters of the machine

16. define the total magnetic voltage

Um,tot of the magnetic circuit

17. define all required machine characteristics

of the dimensions solved above

Figure 7.6 Design process of a rotating electrical machine in brief. This chart was originally intended
for induction motor design but may also be applied to other rotating-field machine types. The factor α i
behaves in a different way, especially in surface permanent magnet machines. The relative magnet width
may be used as an initial value for α i in PMSMs with rotor surface magnets of uniform thickness

Table 7.2 Power series of induction motors

√
Series (n) Power ratio ( n 10) Power range/kW
5 1.58 <1.1
7 1.39 1.1–40
9 1.29 >40
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Design Process and Properties of Rotating Electrical Machines 315

Ω = ω/3 Ω =ω
0 − 2π
0 − 6π
π Θ̂

Ds Ds α
2π, Θ̂ 5π

3π π
4π (b)
(a)

Figure 7.7 (a) Six-pole fundamental current linkage propagating at a physical angular speed Ω =
ω/3, and (b) a two-pole fundamental, propagating at a speed Ω = ω. If the angular frequency ω of the
input current is equal in both windings, the current linkage propagates in a six-pole winding locally at
one-third speed when compared with the flux of the two-pole winding. Both distributions propagate one
wavelength during one supply frequency period, which explains the propagation speed difference. The
influence of the number of pole pairs on the rotation speed of a machine is based on this fact

a 400 V machine. The rated current of such a machine is about 1080 A, which is a value
that can be considered a practical maximum for the rated current of a direct-on-line (DOL)
induction motor. The starting current of such a machine may reach even 10 kA. According
to the IEC 60034-1 standard, the minimum rated output is 100 kW for a rated voltage UN =
1–3 kV, 150 kW for UN = 3–6 kV, and 800 kW for UN = 6–11 kV.

7.1.1 Current Linkage and Torque Production of an Asynchronous Machine

The poly-phase stator winding of a rotating-field machine creates a magnetic flux wave prop-
agating in the air gap, when supplied with a symmetric poly-phase current. Figure 7.7a illus-
trates a fundamental wave ν = 1 of a six-pole machine. Figure 7.7b illustrates the fundamental
of a two-pole machine.
The amplitude of the νth harmonic of a current linkage created by an m-phase winding is
written analogously to Equation (2.15)

m kwν Ns
Θ̂ν = î,
π νp  
2π 4π (7.16)
i U = î cos ωt, i V = î cos ωt − , i W = î cos ωt − .
3 3

When a three-phase winding is fed with symmetrical three-phase currents i U , i V , i W , we

obtain, according to Figure 7.7, the fundamental current linkage propagating in the air gap,
depending on the structure of the winding.
The current linkage harmonic can thus be expressed as a function of time and position angle
α (Figure 7.8) as

Θν = Θ̂ν
ωt − να = Θ̂ν ej(ωt−να) . (7.17)
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316 Design of Rotating Electrical Machines

∂H 1
H1 + dα
∂α

two-pole linear Â1 c

current density
d H1
A1 (α ) A (α ) b
dα a
Θ (α ) A1
α
δe
0

− Â1

(a) (b)

Figure 7.8 (a) Linear current density A(α), its fundamental A1 (α) and its integral, the current linkage
Θ(α). (b) The linear current density A1 created by the poly-phase currents of a two-pole rotating-field
stator. Only the fundamental harmonic of the linear current density is illustrated. The linear current
density creates field strength in the air gap and a corresponding flux density. In this figure, the linear
current density is illustrated as poles in (a), the height of which is the slot current divided by the slot
opening width. A = z Q I /b1

This current linkage is exerted on half of the main magnetic circuit, that is a single effective
air gap δ ef including the influence of the iron (cf. Chapter 3, Equation (3.56)). The flux density
created by the stator current linkage is inversely proportional to the effective air gap. The νth
flux density harmonic is written as

µ0

Bδν = Θ̂ν = B̂δν

ωt − να = B̂δν e j(ωt−να) , (7.18)
δef
µ0 m kwsν Ns
B̂δν = î. (7.19)
δef π νp

This harmonic represents the flux penetrating the air gap, the peak value of which is

Ds l
µ0 m Dsl
kwsν
Φ̂mν = B̂δν = Ns î. (7.20)
νp π p 2 δef ν 2

The peak value of the total air-gap flux is the sum

±∞
 ±∞ kwsν
µ0 m Dsl
µ0 m Dsl
kw1
Φ̂m = Φ̂mν = Ns î ≈ Ns î. (7.21)
ν=1
π p δef
2
ν=1
ν 2 π p 2 δef
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Design Process and Properties of Rotating Electrical Machines 317

The series converges so rapidly that it normally suffices to take only the fundamental into
account in the calculation. The composition of the main flux of the fundamental and harmonics
is illustrated by Equation (7.21). It is worth remembering that the harmonics analogously
induce a voltage of base frequency in the windings of the machine.
A current is supplied to the windings mounted in the slots of the machine. The slot currents
can be replaced with sufficient accuracy by a slot’s local linear current density values Au of
the width of the slot opening b1 :

zQ I
Au = , at the slot opening, elsewhere A = 0. (7.22)
b1

Note that in some cases in this book (e.g. in Tables 6.2 and 6.3), for convenience, the
linear current density is defined as an RMS value of the fundamental component of the linear
current density. In some cases, a step function Au = z Q I /τs is also used. The amplitude of the
fundamental component of the current linkage is nevertheless the same.
We may also assume that the slot opening width is infinitesimal. In such a case, by inte-
grating the linear current density values we obtain a stepped current linkage function Θ(α)
varying as a function of the periphery electrical angle α. The current linkage waveform has
an electrical phase shift of π/2 compared with the fundamental linear current density, Figure
7.8a. The linear current density distribution can be developed into a Fourier series. Each term
ν in the series produces a corresponding flux density harmonic as a function of position. Fig-
ure 7.8b illustrates a linear current density A1 of this type on the inner surface of the stator.
An axial current Aν r dα flows in an element of the equivalent rotor length l
of the cylinder

dα Ds
dIν = Aν r = Aν dα. (7.23)
p 2p

Here dα/p is used, since the angle α obtains values from 0 to p2π as the rotor periphery is
traversed.
When the effective air gap δ e is notably smaller than the radius of the rotor (δef  r ), the
air-gap field strength Hν can be assumed constant in the direction of the radius r . According to
the penetration law, when travelling along the path a–b–c–d–a of the length l, the rotor being
currentless, we obtain
 
∂ Hν Ds
Hν dl = Hν δef − Hν + dα δef = Aν dα. (7.24)
∂α 2p

Here, we obtain the linear current density

2 pδef ∂ Hν 2 pδef ∂ Bν 2 p ∂Θν

Aν = − =− =− . (7.25)
Ds ∂α µ0 Ds ∂α Ds ∂α

Ds is the stator bore diameter and p is the number of pole pairs. By substituting the differential
of the current linkage (Equation 7.17) into this equation, we obtain a basic equation for the
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318 Design of Rotating Electrical Machines

linear current density, which is phase shifted by π/2 with the current linkage

Aν = Âν
ωt − να + π/2 , (7.26)

where

2 pm kwsν Ns
Âν = î. (7.27)
π Ds ν p

The local slot currents are, hence, replaced with an imaginary, infinitely thin, linear current
density. The linear current density creates a current linkage, which is phase shifted by 90
electrical degrees to the linear current density. The flux density distribution (7.18) created by
the current linkage is, however, in the same phase as the current linkage distribution.
A current flows in both the stator and rotor windings of an asynchronous machine operating
under load. Both currents create a current linkage of their own, and therefore the current
linkage exerted on half of a magnetic circuit is the sum of these two linkages

Θm (α) = Θr (α) + Θs (α) . (7.28)

This sum creates the real magnetic flux density in the air gap. When the machine is linearized
for the calculations, also the local flux densities can be superposed. Now we obtain for the
air-gap flux density

Bδ (α) = Bs
(α) + Br
(α) . (7.29)

The imaginary flux densities Bs
(α) and Br
(α) presented here cannot be measured, yet they
can be calculated as follows:
µ0 µ0
Br
(α) = Θr (α) ; Bs
(α) = Θs (α) . (7.30)
δef δef

Figure 7.9 illustrates a linear current density on the boundary of the rotor and air gap. At
an arbitrary position α of the air gap, the differential current is written as

r
dI (α) = A (α) dα. (7.31)
p

The prevailing linear current density at the position α can be defined according to Equation
(7.26). The air-gap flux density vector field Bδ and the rotor current I dl (where l is the unit
vector in the rotor axis direction) are perpendicular to each other and, according to Lorentz
force equation, they cause a peripheral force element dF parallel to the tangent to the cylinder

Ds l

dF (α) = l
Bδ (α) dI (α) = A (α) Bδ (α) dα. (7.32)
2p

For simplicity, Ds ≈ Dr ≈ D ≈ 2r is used in the following.

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Design Process and Properties of Rotating Electrical Machines 319

Bδ
dF

Idl
A

dα l'

α 0

Figure 7.9 Definition of the torque T acting on the rotor. The torque is defined with a peripheral force
dF exerted on the linear current density element I dl

Since the peripheral forces are tangential everywhere, their vector sum around the rotor
is zero, yet they can be employed in the calculation of the torque. The peripheral force of
a machine is solved by line integrating dF around the surface of the rotor over an angle
2πp. Simultaneously, we obtain the electromagnetic torque of the machine by multiplying the
obtained force by the diameter of the rotor radius (r ≈ D/2)

2π p
D 2l

Tem = A (α)Bδ (α) dα. (7.33)
4p
0

This result is in line with the results found in Section 1.5 where the tangential stress was first
studied based on the Lorentz force.
The fundamental v = 1 of the linear current density of the rotor is solved by substituting
the rotor current into Equations (7.26) and (7.27), and by taking into account the angular
difference ζ r of the linear current density of the rotor with respect to the stator current linkage

Ar = Âr
ωt − α − ζr + π/2 , (7.34)

where

2 pm r Nr 2 mr
Âr = kwr î r = kwr Nr î r . (7.35)
π D p π D
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320 Design of Rotating Electrical Machines

ζ r represents the phase angle of the rotor caused by the rotor impedance

Rr + sjωs L rσ = Z r
ζr .

The real air-gap flux density follows Equation (7.18). When the elements are substituted in
Equation (7.33), we may write the electromagnetic torque of the induction machine (see also
Equation 6.2) as

 B̂δ cos ζr π
Tem = πDlσtan r = πDl r = D 2l  B̂δ cos ζr . (7.36)
2 4

In (7.36), the peak values of the fundamental distributions of  and B̂δ are used. That is why
the result must be divided by two. Note also that cos ζ r corresponds to the rotor power factor.
In Chapter 6, Equation (6.1), we have cos ϕ, which corresponds to the stator power factor. In
Equation (1.115) instead, there is no angle involved, since instantaneous local values are used.
In principle, Equation (7.36) is the same equation we discussed previously in the definition
of tangential stress in Section 1.5. This is a general torque equation based on the Lorentz
force and derived from the flux and current distributions of the machine. Formally, the equa-
tion is valid for all machine types. The torque acts upon both the rotor and the stator with
equal magnitude but in opposite directions. When Equation (7.36) is repeated for stator quan-
tities, it may be applied to any rotating-field machine type. For example, if a synchronous
machine is operating with an overlapping linear current density and flux density distributions
– which are found close to stator unity power factor – the electromagnetic torque will be
Tem = πDs2l Âs B̂δ /4.
This equation shows that the torque of a machine is proportional to the volume of the rotor
and the product  B̂δ . The maximum value that a machine can produce in continuous opera-
tion is determined by the temperature rise of the machine. The maximum of the fundamental
component of the air-gap flux density is usually limited to the order of 1 T or slightly above.
If the air-gap flux density curve is rectangular and the maximum flux density is 1 T, the fun-
damental peak value reaches 4/π. On the other hand, the variation in the linear current density
A is large and depends on the cooling of the machine.

7.1.2 Impedance and Current Linkage of a Cage Winding

Figure 7.10 illustrates a simplified cage winding (a) and phasors (b) of the bar and ring cur-
rents for the cage winding. The bars are numbered from 1 to Q r . The bar and ring currents
are denoted respectively, the arrows indicating the positive directions. If the resistance of a
single bar is Rbar (the DC value of the resistance of the bar is obtained by the area S of the
slot of the rotor, the length l of the rotor core, the skew α skew and the specific conductivity
σ of the conductor material Rbar = l/(cos αskew · σ S)) and the inductance is L bar , and finally
Rring and L ring are the respective values of the ring section between two bars, then the resultant
impedance of the complete winding can be calculated as follows.
A current phasor diagram for the rotor bars is constructed for the harmonic ν in such a way
that the angular phase shift of the bar currents is ναu p. As a squirrel cage rotor can operate
with different stator pole pair numbers p, we use α u here as a mechanical angle, so then the
corresponding electrical angle is pαu (cf. Figure 7.10). Next, a polygon is constructed for
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Design Process and Properties of Rotating Electrical Machines 321

4 3 ναup
2 Ibar1 Ibar2
Ibar2 bar currents
Ibar1 1
Iring2 IringQr Iring1 Ibar3
IbarQr Qr Iring2
Iring, x-1 αu Iring1
ναup
x Ibarx Qr - 1
Iring3
Iring, x Ibar4

ring currents
(a) (b)

Figure 7.10 (a) Diagram for a cage winding; (b) a sector of a polygon of the phasors of the bar currents
and a section of the current phasor diagram. Here α u is given in mechanical degrees, and the correspond-
ing electrical degrees are given as pα u . Note that in reality the currents in the opposite sides of the cage
have different signs

the bar currents. A single sector of this polygon is illustrated by the phasors I bar1 − I bar4 in
Figure 7.10. The phasors from I ringQr to I ring3 drawn from the centre of the polygon to the
angle points are the phasors of the ring currents. They follow Kirchhoff’s first law at each
connection point of the bar and the ring – see Figure 7.10a:

I ring,x = I bar,x + I ring,x−1 . (7.37)

The mutual phase angle between the ring currents is also ναu p.
Since the bar alone comprises the phase winding of the rotor (Nr = 1/2), the bar current is
the phase current of the rotor. Now, the RMS value of the bar current induced by the νth flux
density harmonic is generally denoted by Ibar ν . Correspondingly, the RMS value of the ring
current is now denoted by Iring ν . Thus, based on Figure 7.10b, we obtain
Ibarν 2π p
Iringν = αuν ; αuν = ν . (7.38)
2 sin Qr
2
The currents create a resistive loss in the rotor
 

2  Rring 
PCuν = Q r Rbarν Ibarν
2
+ 2Rring Iringν
2
= Q r Ibarν  Rbar + αuν  , (7.39)
2 sin2
2
where Rring is the resistance of that part of the ring belonging to one bar. The resistance of a
single rotor phase is higher than the mere bar resistance Rbar ν by an amount equal to the term
of the element in the large brackets. The phase inductance is calculated by the same principle.
When we take into account the electric angular frequency supplying the machine, we obtain
the equation for the phase impedance of the rotor of an induction machine for the air-gap flux
harmonic ν for a locked rotor, s = 1

Z rν = Rrν + jωs L rν = Z rν
ζrν , (7.40)
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322 Design of Rotating Electrical Machines

Note that the angular frequency ωs of the stator is employed in the calculation of the
impedance. The effect of slip will be taken into account later. Now we can write for the
resistance and leakage inductance of the rotor

Rring L ring
Rrν = Rbar + νπ p ; L rν = L bar + νπ p . (7.41)
2 sin2 2 sin2
Qr Qr

In Equations (7.40) and (7.41), L bar and L ring are the leakage inductances of the bar and ring
sections. The leakage inductance of the end ring can be solved simply with Equation (4.67),
which replaces the latter part of Equation (7.41). When analysing the equations, we note that
the value of the phase impedance of the rotor is a function of the ordinal ν of the inducing
flux density harmonic. A cage rotor reacts only to such flux density harmonics created by the
stator, the ordinals ν of which meet the condition

νp = cQ r , where c = 0, ±1 ± 2, ±3, . . . . (7.42)

This explains the fact that for the harmonics, the ordinal of which is

cQ r
ν
= , (7.43)
p

the impedance of the rotor phase is infinite. The pitch factor kpν of these harmonics is zero.
The wavelength of the harmonic ν
is equal to the slot pitch of the rotor, or an integral part
of it. In that case, each bar always has a flux density of equal magnitude. This creates an
equal induced current linkage in each bar, and the emfs of a closed electric circuit compensate
each other, and thus the voltages induced by the harmonic ν
do not generate currents. Ac-
cording to Equations (7.40) and (7.41), a cage winding can be replaced by such an equivalent
cage, the impedance of the short-circuit rings of which is zero and the impedance of the bars
is Z̄ rν . The impedance of the cage winding or the resistance and inductance are usually trans-
ferred to the stator side. The case is analysed next.
The currents in the bars of a single pole pitch of a cage winding are all of different phases.
In a symmetrical m-phase system, the angle between the phases is 360◦ /m. Thus, there are as
many phases in the rotor as the number of rotor bars. If the number of bars is Q r in the rotor,
the phase number of the rotor is accordingly

mr = Qr. (7.44)

Generally, there has to be at least two conductors in a coil turn at a distance of about 180◦
from each other. We may thus consider that a single rotor bar comprises half a turn, and
we can write Nr = 1/2. The number of effective coil turns in a stator is m s kw1s Ns and in the
rotor m r kW1r Nr . Here kW1r = 1 and Nr = 1/2. If the slots of the stator and rotor are skewed
with respect to each other, we also have to take the skewing factor ksq into account. When
considering the current linkages of a harmonic ν, the rotor current Iν
r referred to the stator
and flowing in the stator winding has to produce an equal current linkage to the original rotor
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Design Process and Properties of Rotating Electrical Machines 323

current when flowing in the rotor. Thus we may write

m s Ns kwνs Iν
r = m r Nr ksqνr kwνr Iν r . (7.45)

The quantities with the prime symbol are referred to the stator from the rotor. The transfor-
mation ratio for the harmonic ν from the rotor to the stator therefore becomes
Iν r m s kwνs Ns
K rs,ν =

= . (7.46)
Iν r m r kwνr ksqνr Nr

By applying the above to the cage winding and the fundamental component, we obtain

m s kw1s Ns m s kw1s Ns 2m s kw1s Ns

K rs,1 = = = . (7.47)
m r kw1r ksq1r Nr Q r · 1 · ksq1r · 1/2 Q r ksq1r

If Rr is the resistance of the rotor bar added to the proportion of the short-circuit rings, and
Ir is the RMS value of the current of the rotor bar, we obtain, by writing the resistive loss of
the rotor equal in both the stator and the rotor,


m s Ir 2 Rr
= Q r Ir2 Rr . (7.48)

The phase resistance of the rotor referred to the stator can now be written as

Q r Ir2 Rr
Rr
= . (7.49)
m s Ir
2

Since

Ir
= K rs , (7.50)
Ir

the resistance of the rotor referred to the stator now becomes

 2  2
Qr Ir Qr 2 Qr 2m s kw1s Ns 4m s (kw1s Ns )2
Rr
= Rr = K rs,1 Rr = Rr = Rr . (7.51)
ms Ir
ms ms Q r ksq1r 2
Q r ksq1r

When it is necessary to refer the rotor resistance to the stator, in general, it has to be multi-
plied by the term
 2
ms Ns kwνs
ρν = . (7.52)
mr Nr ksqνr kwνr

In a squirrel cage induction motor, this is written in the form

 2
4m s Ns kwνs
ρν = . (7.53)
Qr ksqνr
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324 Design of Rotating Electrical Machines

If there is no skewing, we write further

4m s
ρν = (Ns kwνs )2 . (7.54)
Qr

The same referring factor is valid also in the referring of the inductances. It cannot, however,
be obtained based on equal stator and rotor losses (I 2 R), but on equal energy stored in the
inductance (1/2 L I 2 ). Hence we get

Rν
r = ρν Rν r ; L
ν r = ρν L νr . (7.55)

Here it is worth noting that in a rotating electrical machine, the referring deviates from the
referring in a transformer by the fact that the impedance quantities are not referred directly
with the square of the transformation ratio of the current, but we also have to take into account
the ratio of the numbers of phases.
With low values of slip, the resistance Rr can be given as a DC value, but for instance at
start-up, the rotor frequency is so high that the skin effect in the squirrel cage has to be taken
into account. Also, in rapid transients, the rotor resistance deviates notably from its DC value.
In a cage winding, there are no coils, and there can be an odd number of bars in the winding.
Therefore, the definition of the current linkage is not quite as straightforward as was the case
with the coil windings discussed previously. First, a current linkage of a single bar is defined,
and next the current linkages of all the bars are summed. The analysis can be carried out in a
reference frame attached to the rotor, since we are now analysing phenomena that occur only
between the resulting air-gap flux density harmonic ν and the rotor cage. The cage winding
itself does not form poles, but the number of pole pairs always settles to be the same as the
stator harmonic influencing it. In the analysis of a cage winding, geometrical angles ϑ are
employed as here. Now the electric angles are at the fundamental pϑ and at harmonics pνϑ.
Figure 7.10 is investigated at the instant t = 0, when the peak B̂δν of the air-gap flux density of
the harmonic ν occurs at the first bar. In a bar that is at an arbitrary position angle ϑx = x pϑ,
an emf is induced with a slip sν of a certain harmonic

eνx (t) = êνx cos (sν ωs t − xν pϑ) . (7.56)

This harmonic emf is found by calculating the flux and its time derivative and is written with
the absolute value and the phase angle as a complex number

sν ωs πDrl

eνx (t) = B̂δν

sν ωs t − xν pϑ . (7.57)
ν 2p

The bar current i νx (t) is determined by dividing the emf by the equivalent bar impedance
Z rν (s). When the case is investigated in the rotor coordinate system, the slip becomes im-
portant with respect to the impedance. The imaginary part of the impedance changes as a
function of the slip angular frequency, the phase angle of the rotor impedance for the νth
harmonic being ζ rν (sν ). Correspondingly, the angle of the current depends on the slip as sν ωs t

sν ωs πDl

i νx (t) = B̂δν
sν ωs t − xν pϑ − ζrν (sν ) . (7.58)
2 pν Z rν
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Design Process and Properties of Rotating Electrical Machines 325

ir ν 0 Θbar1 Θr1
−π ϑx
2 (a)

i rν 0 +π

+π
Θbar2
−π 0 ϑx
(b)
ir ν 0

+π
Θbar1 + Θbar2

−π 0 ϑx
(c)

Figure 7.11 (a), (b) Current linkage created by a single rotor bar at ϑ x = 0 and ϑ x = π. (c) The current
linkage created by two bars together

The amplitude of this current corresponds to the rotor bar current needed in (7.60). When
considering a current linkage of a single bar, we have to find a suitable graph for the current
linkage created by the current of the bar. With intuitive inference, we may construct a sawtooth
wave as illustrated in Figure 7.11a. Normally, a current loop is always required to produce a
current linkage, as discussed with Figure 2.19. In that figure, a single current penetrates the
system at two points, thus creating a closed loop. This kind of a loop is not unambiguously
created for a cage winding, since in a cage winding the number of bars is not necessarily even.
The current of a certain bar under investigation may be divided between several bars on the
other side of the pole pitch. Therefore, the current linkage created by a single bar has to be
observed in the analysis.
The intuitive deduction can be complemented by investigating Figures 7.11a–c. Now a
second, separate bar is mounted at a point ϑ x = π (i.e. at a distance of a pole pitch from the
first bar). The current of this bar is opposite to the current of the bar in the position ϑ x = 0.
As a result, the graph in Figure 7.11b that is opposite to the current linkage graph of 7.11a
is created, and half of the graph is shifted a full pole pitch left in the case of two poles. By
combining the graphs in Figures 7.11a and b, we obtain a familiar graph for the current linkage
of a single loop that corresponds to Figure 2.19. Therefore, with intuitive deduction, we may
draw the graph of a single bar that corresponds to Figure 7.11a. The figure also illustrates the
fundamental Θ 1r of the current linkage of one bar Θ bar (ϑ x ). We may now write the current
linkage for the bar at x = 0. Its current linkage is thus

î ν0 (π − ϑx )
Θbar, 0 = , ϑx
[0, 2π] . (7.59)
2 π
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326 Design of Rotating Electrical Machines

The current linkage of an arbitrary bar at x is obtained by substituting the current of the
original bar i ν0 with the current i νx , Equation (7.58),

î rν (π − ϑx + νx pϑ)
Θbar, x = , ϑx
[0, 2π] . (7.60)
2 π

The change in sign results from the fact that the temporal phase shift −νx pϑ corresponds
to the local position angle +νx pϑ. The function is continuous only in the range 0–2π. When
the function Θ bar,x of the current linkage of the rotor is developed into Fourier series, its term
ν r becomes

î rν

î rν j(sν ωs t−νr ϑ+βrν −(νp−νr )xϑ)

Θνxνr =
sν ωs t − νr ϑ + βrν − (νp − νr ) xϑ = e ,
2πνr 2πνr (7.61)
where βrν = − π2 − ζrν (sν ) .

Only the last term of the exponent of the constant e (Napier’s constant, also known as Euler’s
number) depends on the ordinal number x. The sum of the Fourier series taking all the bars
into account is


Qr
1 − e−j(νp−νr )Q r ϑ
e−j(νp−νr )xϑ = . (7.62)
x=0
1 − e−j(νp−νr )ϑ

Since (νp − ν r ) is an integer and Qr ϑ = 2π, the numerator is always zero. The sum obtains
values other than zero only when

νp − νr = cQ r , (7.63)

where c = 0, ±1, ±2, ±3, . . .. The harmonic ν of the resultant flux density of the air gap
can create rotor harmonics ν r that meet the condition (7.63). Equation (7.62) then takes the
limit value Q r . The ordinals ν and νr can be either positive or negative. The cage winding thus
creates current linkages

Θνr = Θ̂νr
sν ωs t − νr ϑ + βrν , (7.64)

where

Qr sν ωs Dl
Θ̂νr = î rν = B̂δν . (7.65)
2πνr 4πνpνr Z rν

The corresponding linear current density of the rotor is

Aνr = Âνr
sν ωs t − νr ϑ − ζrν , (7.66)
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Design Process and Properties of Rotating Electrical Machines 327

where

Qr
Âνr = î rν . (7.67)
πD

ζ rν is the phase angle of the rotor impedance for the harmonic ν.

7.1.3 Characteristics of an Induction Machine

The characteristics of an induction motor greatly depend on the fulfilment of Equations (7.42)
and (7.63). When the number of bars Q r is finite, c = 0 always meets the condition (7.42).
Each flux-density-producing air-gap harmonic ν that meets the condition (7.42) can induce a
vast number of rotor current linkage harmonics ν r (7.61).
Now, the equivalent circuit of an asynchronous motor per phase, the quantities of which are
calculated in the machine design, is worth recollecting. Figure 7.12 illustrates a single-phase
equivalent circuit of an ordinary induction motor per phase, a simplified equivalent circuit and
a phasor diagram.
In Figure 7.12, the stator is supplied with the voltage Us . The stator resistance Rs is the
resistance of the stator winding at the operating frequency and temperature, Us
is the stator

Us
Is Rs jωLsσIs

Is
Ps Is Pδ I′r Um
Rs Lsσ Lr'σ R'r Us '
Um Pmec, em −Ir'
PsCu Ψs PrCu
Ψm Em Ψs
Us U 's RFe Lm Ψ ' R'r(1-s)/s Im
PFe r Ψm Lsσ I s
Ψr ' Lrσ' Ir '
I Fe Im −Ir'
(a) −I r 'Rr '
(1−s)
Is L I′r L' s
Rs R'r Es =−Us '
θr
−Ir ' Rr'
1 Er Em
Us RFe Lm R'r(1-s)/s Er '−I r ' Rr '
s

I Fe Im −jωLs′σ I′r

(b) (c)

Figure 7.12 (a) Steady-state equivalent circuit of an asynchronous machine per phase. (b) A simplified
equivalent circuit of the machine, the parameters of which are calculated in the machine design. (c) A
phasor diagram of an asynchronous machine. The input stator power is Ps . In the stator resistance, a
resistive loss PsCu takes place. The iron loss is the loss PFe created in the magnetic circuit. The air-gap
power Pδ flows across the air gap to the rotor. In the rotor, some resistive losses PrCu take place. The
power Pmec,em is the electromechanical power of the machine. When friction and windage losses are
subtracted, the output power P of the machine can be found
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328 Design of Rotating Electrical Machines

voltage after the resistive voltage drop is subtracted, L sσ is the leakage inductance of the
stator, L m is the magnetizing inductance of the machine at the rated point, RFe is the resistance
describing the losses of the iron circuit of the machine, L
rσ is the rotor leakage inductance of
the machine referred to the stator, and Rr
is the rotor resistance referred to the stator. s is the
slip of the rotor. The term Rr
(1 − s)/s describes the electromechanical power produced by the
machine. A part of the mechanical power is consumed in the friction and windage losses of
the machine. Ψ s is the stator flux linkage, which includes the air-gap flux linkage Ψ m and the
stator leakage flux Ψ sσ . Correspondingly, Ψ r is the flux linkage of the rotor, which includes
the air-gap flux linkage Ψ m and the rotor leakage flux Ψ rσ . The stator voltage Us
creates the
stator flux linkage, from which, in turn, a back emf E s is derived. A voltage E m is induced
over L m by the air-gap flux linkage Ψ m . This voltage is consumed completely in the rotor
apparent resistance Rr
(1/s) and in the rotor leakage reactance. The iron loss current IFe is
small and is therefore not illustrated in the phasor diagram.
Stator power Ps is fed to the motor. Some power is consumed in the stator resistance and
in the iron loss resistance. An air-gap power Pδ crosses the air gap. In the rotor, a part of the
air-gap power is lost in the rotor resistance Rr
and a part is converted into mechanical power
in Rr
(1 − s)/s.
The fundamental flux density created by the stator and rotor currents causes a varying flux,
which in turn induces a voltage and a current acting against the flux variation. At no load,
the rotor rotates approximately with a synchronous speed, and the rotor frequency and the
currents approach zero. If the rotor is loaded, its speed decreases and the relative speed with
respect to the fundamental flux propagating in the air gap increases. Now the emf induced in
the rotor increases. Also the inductive reactance of the rotor increases as the rotor frequency
increases. The peripheral force created by the fundamental flux density of the air gap and the
rotor torque reaches its maximum at a certain slip.
If required, the rotor of an asynchronous machine can be driven by an above synchronous
speed. In that case, the rotor currents create a torque opposing the accelerating torque and the
machine acts as a generator, the slip being negative.
Let us assume that the fundamental ν = 1 of the resultant air-gap flux density follows
Equation (7.18). As the rotor rotates with a slip s with respect to the fundamental air-gap
wave, an emf is induced in the phase winding of the rotor. The peak value of the emf induced
in the rotor bars depends on the slip

êr (s) = s êrk

sωs t − π/2 . (7.68)

In this equation, there is a peak value of the emf induced in the rotor at slip s = 1

2 πD
êrk = ωs Ψ̂r = ωs B̂δlkwr Nr . (7.69)
π 2p

The impedance of the rotor circuit depends on the slip angular frequency

Z r (s) = Rr + jsωs L rσ = Z r (s)

ζr (s) . (7.70)
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Design Process and Properties of Rotating Electrical Machines 329

The peak value for the rotor current phasor now becomes

s êrk (s)

î r (s) = = î r (s)
sωs t − ζr (s) − π/2 . (7.71)
Z r (s)

The amplitude is

s êrk s êrk
î r (s) = = . (7.72)
Z r (s) Rr + s 2 (ωs L rσ )2
2

In the case of a slip-ring machine, additional impedances can be attached to the rotor circuit.
Now the total impedance of the circuit has to be substituted into the equation. The current
î r (s) represents the linear current density of the rotor surface, the amplitude of which can be
calculated from the induced voltage and the rotor impedance

Nr 2
2
m rlkwr
2p p
Âr (s) = sωs  B̂δ . (7.73)
π Rr2 + s 2 (ωs L rσ )2

When the above is substituted in the general torque Equation (7.36), and noting that

Rr
cos ζr (s) =  , (7.74)
Rr2 + s 2 (ωs L rσ )2

which corresponds to the power factor of the rotor impedance, we obtain the electromagnetic
torque

pm r s Rr
Tem (s) = E2 . (7.75)
ωs Rr2 + s 2 (ωs L rσ )2 rk

Here E rk is the RMS value √ of the emf of the phase winding of the rotor when the machine is
held at stall, E rk = êrk / 2. Also, the power distribution leads to the same equation. Thus, the
RMS value of the current in the rotor circuit of the equivalent circuit with slip s is

s E rk E rk
Ir (s) =  =  2 . (7.76a)
Rr2 + (sωs L rσ )2 Rr
+ (ωs L rσ )2
s

Transferring Equation (7.76a) to the stator side we get

E rk
Ir
(s) =  . (7.76b)
Rr
2
+ (ωs L
rσ )2
s

The rotor circuit of the equivalent circuit in Figure 7.12 follows this equation. In the figure, the
rotor resistance has been divided into two parts, the sum of which is Rr /s. Correspondingly,
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330 Design of Rotating Electrical Machines

the active power Pδ crossing the air gap is divided into the resistive loss PrCu of the rotor and
the mechanical power Pmec,em

1 − s

2 R


Pδ = Rr
I
r +
2
Rr I r = r Ir 2 = PrCu + Pmec, em , (7.77)
s s
PrCu s
= . (7.78)
Pmec, em 1−s

In motor drive, the air-gap power Pδ is the power transmitted from the stator via the air gap
to the rotor. Of this power, the proportion PrCu is consumed in the resistive losses of the rotor,
and the rest is electromechanical power Pmec,em . The mechanical power Pmec is obtained from
the shaft when friction and windage losses are subtracted from the electromechanical power.
We can write Equations (7.77) and (7.78) in the form

PrCu = s Pδ ; Pmec, em = (1 − s) Pδ
Pmec, em p p p (7.79)
Tem (s) = = Pmec, em = PrCu = Pδ .
Ω (1 − s) ωs sωs ωs

The torque can thus be solved with the resistive loss power of the rotor. The torque is always
(including when the machine is at stall) proportional to the air-gap power Pδ :

m r E rk Ir cos ϕr Pδ 2
m r E rk Rr /s 2
pm r E rk s Rr
Tem = = =  2 = ,
ωs / p ωs / p ωs / p Rr ωs Rr2 + (sωs L rσ )2
+ (ωs L rσ )2
s
(7.80a)
m s Us2 Rr
/s
Tem ≈  . (7.80b)
ωs / p Rr
2
Rs + + (ωs L k ) 2
s

Equation (7.80b) above is obtained from the simplified equivalent circuit of Figure 7.12b by
substituting Ir = s E rk /Z r and cos ϕr = Rr /Z r and, based on the simplified equivalent circuit,
by assuming that the air-gap voltage is equal to the terminal voltage of the machine. Further-
more, we employ the short-circuit inductance L k ≈ L sσ + L
rσ . Neglecting the effects of Rs ,
the highest value of Tem , the pull-out torque Tb can be found from the slip

Rr
Rr

sb = ±

= , (7.81)
ωs L sσ + ωs L r σ ωs L k
3 p Us2
Tb = ± . (7.82)
2ωs2 L k

Here we remember that L k ≈ L sσ + L
rσ ≈ 2L
rσ . We see that the peak torque is inversely
proportional to the short-circuit inductance of the machine. If the per unit value of L k is 0.2
for instance, the maximum torque is about 5Tn . Contrary to the slip value of the peak torque,
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Design Process and Properties of Rotating Electrical Machines 331

the maximum torque is independent of the rotor resistance. By substituting the peak value of
the slip in Equation (7.74) we obtain

1
cos ζr (s) =  2 . (7.83)
s
+1
sb

√
The term takes the value cos ζr (s) = 1/ 2 at peak torque slip. When the peak value of the
resultant flux density B̂δ is kept constant, according to Equations (7.73), (7.74), (7.79), (7.80),
(7.81) and (7.82),

2 T
Âr (s) cos ζr (s) = C s sb = C Tb , (7.84)
+
sb s

where C is the machine constant.

The calculation of torque introduced above can thus be simplified with the equivalent circuit
to the definition of the power of the resistance. With the single-phase equivalent circuit, the
load variations can chiefly be observed in the changes in the slip.
Somewhat more accurate results can be obtained for an asynchronous machine by again
employing a simplified equivalent circuit, but applying a reduced voltage in the calculation of
the rotor current of the machine

L sσ
Us 1 −
Lm
Ir
= 
2
2 . (7.85a)
Rs + Rr
/s + ωs L sσ + ωs L
rσ

Now, the generated electromechanical torque is

  
L sσ 2 Rr

3 Us 1 −
Lm s
Tem = 
2
2  . (7.85b)
ωs
p
Rs + Rr /s + ωs L sσ + ωs L
rσ

The starting torque produced by the fundamental is obtained by setting s = 1 in Equation

(7.80b). However, the rotor resistance is higher at large slips because of the skin effect, and
the resistance must be defined at every slip value before calculating the torque. The pull-out
torque is solved by derivation with respect to Rr
/s, after which we can write for the slip of the
maximum torque, if Rs is taken into account,

Rr

sb = ± 
2 , (7.85c)


(Rs ) + ωs L sσ + ωs L rσ
2
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332 Design of Rotating Electrical Machines

where the plus sign is for motoring and the minus sign for generating operation. The corre-
sponding torque for motoring is
  
L sσ 2
3 Us 1 −
Lm
Tb =   , (7.85d)
ωs
2
2 Rs + Rs2 + ωs L sσ + ωs L
rσ
p

and for generating

  
L sσ 2
3 Us 1 +
Lm
Tb = −   . (7.85e)
ωs
2
2 Rs − Rs2 + ωs L sσ + ωs L
rσ
p

7.1.4 Equivalent Circuit Taking Asynchronous

Torques and Harmonics into Account
The parameters of a cage winding are investigated next. When the number of bars Q r of the
rotor is finite and the factor c = 0, the condition (7.63) is always met. Each resulting air-gap
flux density harmonic ν that meets the condition (7.42) can induce a large number of rotor
harmonics ν r (7.61). In the case where c = 0, we investigate the harmonic ν r , the number of
pole pairs of which is the same as the inducing air-gap harmonic ν. The torque equation for
the pair of harmonics ν and ν r is derived in the same way as for the torque of the fundamental
(7.75). First we obtain two equations

sν ωs D 2l 2 Rrν
Tν (sν ) = Qr 2 B̂ 2 , (7.86a)
8νp Rrν + sν2 ωs2 L 2rσν mν
νp sν Rrν
Tν (sν ) = Qr 2 E2 . (7.86b)
ωs Rrν + sν2 ωs2 L 2rσν rkν

Here E rkν is the RMS value of the emf induced by the harmonic ν at the slip sν = 1. We
may now infer that each harmonic meeting the conditions behaves accordingly. Torque is a
continuous function of slip that becomes zero at the slip sν = 0, hence the term ‘synchronous
torque’.
When the machine is running at a fundamental slip s1 , the slip of the rotor with respect to
the νth stator harmonic is written as

sν = 1 − ν (1 − s1 ). (7.87)

The angular frequency of the νth harmonic in the rotor is thus

ωνr = ωs (1 − ν (1 − s1 )) . (7.88)
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Design Process and Properties of Rotating Electrical Machines 333

T
Tb

Tl
Tu

T7

1 0 s

Figure 7.13 Total torque of an induction motor with a cage winding, and the torque of the seventh
harmonic as a function of slip s. We can see that the seventh harmonic reduces the torque of the machine
at the negative peak so that the total torque can be lower than the starting torque. Tl , locked rotor torque;
Tu , pull-up torque; Tb , peak torque

Based on Equation (7.87), by setting the slip of the harmonic ν to zero, we obtain the zero
slip of the torque of the harmonic with respect to the fundamental

ν−1
s1 (sν = 0) = . (7.89)
ν

Figure 7.13 illustrates the torque curve of an asynchronous machine. At the slip of the
fundamental s1 ≈ 0.86, there is a zero point of the torque produced by the seventh harmonic
(ν = 7). The seventh harmonic is discussed because its synchronous speed is the first syn-
chronous speed after the fundamental synchronous speed at positive slips and positive speeds.
For instance, the fifth harmonic has its synchronous speed at a negative rotation speed of
the rotor. The peak values of the harmonic torques are located approximately at slips sνb =


±Rrν /ωs L kν (7.81). According to Equation (7.87), the negative peak torque at the base slip is
written as


Rrν + ωs L kν
s1 (sνb ) ≈ 1 − . (7.90)
νωs L kν

Equation (7.89) shows that the harmonic-wave-generated torques of a three-phase motor

are high at high values of slip, and therefore they may impede start-up of the motor. The
start-up and drive characteristics can be improved by various structural means in machine
construction. According to (7.81), the peak torque of an asynchronous machine shifts in the
direction of a higher slip as the rotor resistance increases. On the other hand, rotor losses can
be minimized by employing a rotor with minimum resistive losses. A high starting resistance
and a low operational resistance are achieved by designing the rotor such that the skin effect
increases the low DC resistance of the rotor bars at high slips. The rotor resistance can be
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334 Design of Rotating Electrical Machines

rotor surface

outer bar

inner bar

(a) (b) (c)

Figure 7.14 Shapes of slots and rotor bars for (a) a double cage, (b) a deep slot, (c) a typical cast-
aluminium rotor slot. The slot opening is closed to ease the squirrel cage die-cast process (no separate
mould is required)

adjusted by shaping the rotor bars. In some machines, good start-up and operation character-
istics are achieved by employing a double cage or deep rotor slots, Figure 7.14.
In Figure 7.14a, the cross-sectional area of the outer bar of the double cage is small
and therefore has a high resistance. The leakage inductance of the outer bar is low, while
the leakage inductance of the inner bar is high and the resistance low. Therefore, at start-up,
the outer bar acts as the chief current carrier and yields a good torque. The inner bar, because
of its high inductance, carries operational current only at low frequencies, that is when the
machine is running at full load. In that case, the low resistance of the bar leads to a small slip.
In a deep-slot rotor (Figure 7.14b), similar phenomena arise when the machine turns from the
start-up to continuous running. The resistance of the cages in the figure therefore changes as
a function of the rotor frequency. The resistance can be analysed at different frequencies, for
instance with the methods presented for the skin effect in Chapter 5.
The rotor resistance of a high slip can be increased also by employing a ferromagnetic mate-
rial as the conductive material of the cage winding. In ferromagnetic materials, the skin effect
is extremely strong at high frequencies, when the penetration depth is small. An example of
the influence of a high rotor resistance is a completely solid-steel rotor, the starting torque of
which is relatively high (see Figure 2.57). In practice, ferromagnetic material could be applied
in the cage winding of an induction motor, for instance by constructing the rotor bars of
copper and by soldering them to thick steel rings at the rotor ends. Now the end rings saturate
heavily during start-up, and the rotor resistance is high. One problem in the application of
iron as the conducting material of a cage rotor is that the resistivity of iron is high (for pure
iron about 9.6 µ cm, structural steels about 20–30 µ cm and ferromagnetic stainless steels
about 40–120 µ cm) when compared with aluminium (2.8 µ cm) and copper (1.7 µ cm),
and therefore a large conductor area is required to achieve adequate operational character-
istics. Additional problems arise in joining the iron to another conductor material, which
is not an easy task. Copper and iron can be soldered with silver, whereas joining iron and
aluminium is fairly difficult. Copper can also be welded to the iron by electron beam welding.
The effects of harmonics are usually investigated in asynchronous machines with the
equivalent circuit illustrated in Figure 7.15. In the circuit, each harmonic frequency forms an
individual electrical machine, which is connected in series with all the other harmonic
machines. The connection in series is justified, since the emf of the phase winding is the
sum of the emfs induced by different harmonics. The machine acts like a group of machines
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Design Process and Properties of Rotating Electrical Machines 335

Rs L R′r
A
R′
(1 − s1 ) s r
1
Lm1
L′ 1
Β
R′
(1 − s1 ) s r5
Lm5 5

L′ 5

R′
(1 − sν ) s rν
L'mν ν

L′ ν
C
Figure 7.15 Simplified total equivalent circuit of a three-phase asynchronous motor, also involving the
influence of spatial harmonics. Typically, the voltage of the harmonic machines (ν = −5, + 7, . . ., ±∞)
remains rather low. Usually, 98–99% of the total stator voltage occurs between the points A and B. Thus,
the sum voltage of the harmonic machines is only about 1–2%. However, harmonic machines are able
to produce quite high torques, and therefore they have to be taken into account in machine design. The
starting properties of squirrel cage machines in particular are affected by the harmonics. In many cases
related to the use of induction motors, the harmonic machines (−5, +7, −11, . . .) are replaced with a
single leakage inductance, or they are neglected altogether

assembled on the same axis, the windings of the machines being in series. Each machine
represents a number of pole pairs νp. The sum voltage is divided between the machines in
the ratio of the impedances. It should be borne in mind that the relative slips determine the
impedances. Phasor calculation has to be employed in the analysis of the equivalent circuit.
We may state that the torque caused by the harmonic ν (7.86) can be calculated according


to Equation (7.79) from the resistive loss of the resistance Rrν of the equivalent circuit. The
stator winding of a three-phase machine produces the harmonics presented in Table 2.2.
The resistance and inductance of a cage winding for a harmonic ν were defined earlier (see
Equation (7.41) but are repeated here for the sake of convenience:

Rring
Rrν = Rbar + αν , (7.91)
2 sin2
2
L ring
L rσν = L bar + αν , (7.92)
2 sin2
2
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336 Design of Rotating Electrical Machines

α1

α1 = 2 / 28

Figure 7.16 Cross-section of a 28-slot rotor (Q r = 28) and the definition of the angle α 1 in the case
where the number of pole pairs is p = 1. α 1 is given in electrical degrees

where Rbar is the resistance of the rotor bar and Rring is part of the segment of a short-circuit
ring. Inductance parameters behave analogously. α ν describes the rotor phase angle for the
νth harmonic
2π p
αν = ν . (7.93)
Qr

Figure 7.16 illustrates the definition of α 1 for a motor, for which p = 1 and Q r = 28. α ν is
the νth multiple of α 1 .
When analyzing the phenomena in a simplified form, we take only the influence of the
equivalent air gap into account (in other words, the machine is assumed to remain linear). Now
we may calculate the stator magnetizing inductance of the νth harmonic with the magnetizing
inductance L m1 defined for the fundamental
 2
1 kwsν
L mν = L m1 . (7.94)
ν2 kws1

In reality, the permeance of the magnetic circuit of a machine is different for different fre-
quencies, and therefore Equation (7.94) is not completely valid, but suffices as a good approx-
imation in the machine analysis. The rotor impedance of the νth harmonic is a function of slip


Rrν
Z
rν = + jωs L
rσν , (7.95)
sν

where sν = 1 − ν (1 − s) according to Equation (7.87).

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Design Process and Properties of Rotating Electrical Machines 337

The total impedance that describes the effects of the νth harmonic is a parallel connection
of the rotor circuit and the magnetizing circuit. The impedances of the cage rotor have to be
referred to the stator before connecting in parallel (Equations 7.52 and 7.53)
 2 
ms Ns kwνs 4m s Ns kwνs 2
Z
rν = Z rν = Z rν ,
m r Nr ksqνr kwνr Qr ksqνr
Z
jωs L mν
Z
ν =
rν . (7.96)
Z rν + jωs L mν

Now it is possible to determine the impedance of the total equivalent circuit of Figure 7.15


n
Z e = Rs + jωs L sσ + Z
ν , (7.97)
ν=−n

where n is the number of harmonics (in principle infinite) taken into account in the calculation.
The stator current I s is

Us
Is = . (7.98)
Ze

The current that creates harmonic torques in the rotor is

Ze
I
rν =
I s. (7.99)
Rrv

+ jωs L rσν
sν

The torque of the νth harmonic as a function of slip is written as

m s p Rsν

Tν (s) = ν Irν2 , (7.100)
ωs1 sν

and the total torque

∞

T (s) = Tν (s). (7.101)
ν=1

This equation is valid in the steady state. The time constants of electrical machines are nev-
ertheless so small that during slow acceleration, for instance, the machine follows its static
torque curve rather strictly. Figure 7.17 illustrates the influence of harmonic torques on the
total torque of the machine.

7.1.5 Synchronous Torques

Next, we investigate harmonic pairs that meet the condition (7.63) when c = 0. In that case,
we have harmonics ν and ν r that are alien to each other; in other words, they are not induced
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338 Design of Rotating Electrical Machines

40
T/N m
35
30
25
1
20 3
2
15 TN
10

0
1 0.8 0.6 0.4 0.2 0
s1

Figure 7.17 Torque curves of a three-phase, 4 kW induction motor as a function of slip s1 . The har-
monic torques have been taken into account in the calculation of the curves. 1, static torque of the
fundamental; 2, total torque with a full-pitch winding (W/τp = 1, q = 6); 3, total torque with a short-
pitched double-layer winding (W/τ p = 5/6, q = 6). A high number of slots per pole and phase lead to a
situation in which the influence of the fifth and seventh harmonics is almost insignificant. Therefore, the
torque saddle is located in the vicinity of the slip s = 1. T N gives the rated torque of the machine

by each other. It is, however, possible that such harmonics have the same number of pole pairs.
Then, the peripheral force caused by them is zero only when the position angle between the
harmonics is 90 electrical degrees. At certain slips, these harmonics may also propagate at an
equal speed. Now, a permanent force effect occurs between the harmonics. Because of this
force effect, the harmonics tend to keep the rotor speed equal to this speed. The harmonics
tend to synchronize the rotor at this synchronous speed, hence the name synchronous torque.
At other speeds of the rotor, the harmonics pass each other creating torque ripple and, in the
vicinity of the synchronous speed, fluctuations in the rotor speed. At high speeds, vibration
and noise may occur.
Next, we discuss in brief the possible slips for synchronous torques. The resultant flux
density harmonic Bν is assumed to induce a linear current density harmonic Aνr in the rotor.
Aνr meets the condition (7.63) when c = 0. Further, it is assumed that in the air gap, there is a
certain flux density harmonic Bµ which has the same number of pole pairs as the harmonic ν r :

pµ = ν r . (7.102)

The geometrical speed of the rotor harmonic ν r with respect to the rotor is

sν ωs
Ωνr = . (7.103)
pν r
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Design Process and Properties of Rotating Electrical Machines 339

When we add here the rotor’s own speed with respect to the stator, we obtain the speed of the
harmonic with respect to the stator
 
sν 1−s
Ωνrs = + ωs . (7.104)
νr p

Now we substitute the slip of the harmonic and condition (7.63), νp − νr = cQ r , where
c = 0, ±1, ±2, ±3, . . ., and eliminate the ordinal ν r . This yields
 
cQ r ωs
Ωνrs = 1− (1 − s) . (7.105)
p νr

Here s is, as always, the fundamental slip. The speed of the synchronizing harmonic with
respect to the stator is Ωµs = ωs /(µp). By setting these two equal, we may solve the funda-
mental slip at which the harmonic field has its synchronous speed

p νr
ssyn =1− 1− . (7.106)
cQ r µp

Based on condition (7.102), the absolute value of the second term in the brackets is always
one. Depending on the sign, the slip thus obtains two values

± |νr | = ± |µ| p → ssyn1 = 1,

2p (7.107)
± |νr | = ∓ |µ| p → ssyn2 = 1 − .
cQ r

The former shows that the start-up of an induction motor is impeded by a synchronous torque
at a slip ssyn1 = 1. The second synchronous slip depends on the sign of c. If c > 0, this point
occurs in the motor or generator range, otherwise in the braking range. The angular speed of
the machine at the slip ssyn2 is

 2 pΩs 2ωs
Ωr = 1 − ssyn2 Ωs = = . (7.108)
cQ r cQ r

The magnitude of the synchronous torque can be calculated from Equation (7.36) by sub-
stituting the real values of the harmonics Bµ , Aνr with a synchronous slip. In the torque
curve of the machine, the synchronous torques are indicated by peaks at the synchronous slip.
The magnitude of the harmonic torques depends greatly on the ratio of the slot numbers of
the stator and the rotor. The torques can be reduced by skewing the rotor slots with respect to
the stator. In that case, the slot torques resulting from the slotting are damped. In the design
of an induction motor, special attention has to be paid to the elimination of harmonic torques.

7.1.6 Selection of the Slot Number of a Cage Winding

In order to avoid the disturbance caused by asynchronous and synchronous torques and the
vibration hampering the operation of an induction motor, the slot number Q r of the rotor has to
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340 Design of Rotating Electrical Machines

be selected with special care. To reduce the asynchronous harmonic torques, the slot number
of the rotor has to be as small as possible. It is generally recommended that

Q r < 1.25Q s . (7.109)

Next, only machines with three-phase integral slot stator windings are investigated. To limit
the synchronous torques when the motor is at stall, the slot number of the rotor has to meet
the condition

Q r = 6 pg, (7.110)

where g may be any positive integer. To avoid synchronous torques created by slot harmonics,
the selection of the slot number has to meet the following conditions:

Q r = Q s ; Q r = 1/2 Q s ; Q r = 2Q s . (7.111)

To avoid synchronous torques during running, the following inequality has to be in force:

Q r = 6 pg ± 2 p. (7.112)

Here g is again any positive integer. The plus sign holds for positive rotation speeds and the
minus sign is valid for negative rotation speeds.
To avoid dangerous slot harmonics, the following inequalities have to be in force:

Qr =  Qs ± 2 p
Qr =  2Q s ± 2 p
Qr =  Qs ± p (7.113)
Qs
Q r = ± p.
2

Also in these conditions, the plus sign holds for positive rotation speeds and the minus sign is
valid for negative rotation speeds.
To avoid mechanical vibrations, the following inequalities have to be in force:

Qr =
 6 pg ± 1
Qr = 6 pg ± 2 p ± 1 (7.114)
Qr =  6 pg ± 2 p ∓ 1.

The above avoidable slot numbers hold basically when there is no rotor skewing. If the rotor
slots are skewed with respect to the stator, the harmonic torques and vibrations are more or
less weakened. For choosing the slot number of the rotor, the following equation is given. It
depends on the slots per pole and phase qs of the stator and the number of pole pairs p, when
the rotor bars are skewed for the amount of one stator slot pitch:

Q r = (6qs + 4) p = Q s + 4 p, (7.115)

where Q s is the number of the stator slots.

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Design Process and Properties of Rotating Electrical Machines 341

Table 7.3 Selection of the slot number. Only the combinations without a symbol are safe choices.
There are some disadvantages with all the other combinations. −, harmful torques in counter-current
braking; +, harmful torques at positive speeds; ×, harmful mechanical vibrations; ◦, harmful
synchronous torques at a standstill. Adapted from Richter (1954)

Number of pole pairs p = 1 Number of pole pairs p = 2

Ones of rotor slot number Qr Ones of rotor slot number Qr
Tens of rotor
Qs slot number 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

1 − × ◦ × + × − × ◦ × − × ◦ × + × + × ×
24 2 + × − × ◦ × + × − × − × − × ◦ × + × + ×
3 ◦ × + × − × ◦ × + × × − × × ◦ × ×
1 − × ◦ × + × − × ◦ × × ◦ × × ∓ × ◦ ×
2 + × − × ◦ × + × − × ± × × ◦ × × + ×
36 3 ◦ × + × − × ◦ × + × × − × − × ◦ × + ×
4 − × ◦ × + × − × ◦ × + × × − × × ◦ ×
5 + × − × ◦ × + × − × × + × × − × ×
1 − × ◦ × + × − × ◦ × × ◦ × × + × ×
2 + × − × ◦ × + × − × − × − × ◦ × + × + ×
3 ◦ × + × − × ◦ × + × × − × × ◦ × ×
48
4 − × ◦ × + × − × ◦ × + × × − × − × ◦ ×
5 + × − × ◦ × + × − × + × + × × − × ×
6 ◦ × + × − × ◦ × + × ◦ × × + × × − ×

Tables 7.3 and 7.4 illustrate examples of the selection of the rotor slot number for a ro-
tor with straight slots for pole pairs p = 1, 2 and 3 with different numbers of stator slots. A ◦
symbol indicates the slot numbers that predict particularly harmful synchronous torques when
the motor is held at stall. A + sign indicates the slot numbers that predict particularly harmful
synchronous torques at positive rotation speeds. A − sign shows those slot numbers that pre-
dict particularly harmful synchronous torques at negative rotation speeds (in counter-current
braking). A × symbol indicates pairs of slot numbers with harmful mechanical vibrations.
Tables 7.3 and 7.4 show that there are only a few possible combinations. For instance, for a
two-pole machine there are in practice no suitable stator–rotor slot number combinations for
general use. The slot number of the rotor has to be selected individually in such a way that
disturbances are minimized.
If no strict limits are set for the start-up noise, we may apply odd rotor bar numbers that,
according to the tables, produce mechanical vibrations (×). When Q s = 24, the slot numbers
Q r = 19, 27 and 29 may be noisy at start-up. Correspondingly, the slot number pairs Q s = 36
and Q r = 31 and also Q s = 48 and Q r = 43 may be noisy. Even slot numbers usually provide
a more silent running. If the motor is not designed for counter-current braking (s is always <
1), for instance, we may select a rotor slot number at a − sign, the permitted slot numbers for
a 24-slot stator then being Q r = 10, 16, 22, 28 and 34. For a 36- or 48-slot stator we may also
select Q r = 40, 46, 52 and 58, and for a 48-slot stator further Q r = 64.
When Q s = 24, the slot numbers Q r = 12, 18 and 24 in a p = 1 machine have to be
avoided at all instances, since they produce such high synchronous torques at stall that the
machines will not start up. Q r = 26 produces intolerably high synchronous torques at positive
rotation speeds. Further, if the motor is also running at slips s > 1, the slot number Q r = 22
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342 Design of Rotating Electrical Machines

Table 7.4 Selection of the rotor slot number. (Only the combinations without any symbol are safe
choices. There are some disadvantages with all the other combinations.) Adapted from Richter (1954)

p=3
Ones of rotor slot number Qr
Tens of rotor
Qs slot number 0 1 2 3 4 5 6 7 8 9
1 × − × − × ◦ ×
2 + × + × ×
36 3 − × − × ◦ × +
4 × + × × − ×
5 × ◦ × ×
1 × − × × ◦ ×
2 × ◦ × ◦ ×
3 ± × × ◦ ×
54 4 × + × × − ×
5 − × ◦ × + ×
6 + × × − ×
7 × ◦ × × + ×
1 × − × × ◦ ×
2 × + × ×
3 − × − × ◦ × +
4 × + × × − ×
72 5 × ◦ × ×
6 + × × − × −
7 × ◦ × + × + ×
8 × − × ×
9 ◦ × × + ×

cannot be selected under any circumstances. An example of a two-pole industrial machine is

a 4 kW, 3000 min−1 motor produced by ABB, which is equipped with a combination of slot
numbers 36/28 and also the skewing of rotor bars.
Table 7.5 illustrates the recommended numbers of slot pairs when using a skewing of one
to two stator slot pitches. The numbers for rotor slots are given in the order of superiority, the
best first.

7.1.7 Construction of an Induction Motor

The IEC has developed international standards for the mounting dimensions of electrical ma-
chines and defined the respective codes. The machines with equal codes are physically in-
terchangeable. When the shaft height of the machine is 400 mm at maximum, the IEC code
for foot-mounted electrical machines comprises the frame code and the diameter of the free
shaft end. The frame code consists of the shaft height and the letter code S, M or L, which
expresses the length of the frame. The code 112 M 28 thus designates a machine for which the
height of the centre point of the shaft, measured from the level defined by the lower surface of
the feet, is 112 mm; the stator stack of the machine belongs to the medium-length class; and
the diameter of the free shaft is 28 mm. If the frame code does not involve a letter code, the
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Design Process and Properties of Rotating Electrical Machines 343

Table 7.5 Most advantageous slot numbers for rotors with slots
skewed for a stator slot pitch 1–2. Adapted from Richter (1954)
p Qs Qr
24 28, 16, 22
36 24, 28, 48, 16
1 48 40, 52
60 48
36 24, 40, 42, 60, 30, 44
2 48 60, 84, 56, 44
60 72, 48, 84, 44
36 42, 48, 54, 30
3 54 72, 88, 48
72 96, 90, 84, 54
36 48
4 48 72, 60
72 96, 84

dimensions are separated with a dash, for instance 80–19. Table 7.6 contains some IEC codes
for small machines.
If a foot-mounted machine is also equipped with a connection flange, the code of the flange
is given, for instance 112M 28 FF215. Those machines suitable for only flange mounting are
designated according to the shaft diameter and the flange, for instance 28 FF215. IEC 60034-
8 (2007) defines the terminal markings and the direction of rotation for a rotating machine
and the dependency between these two when the machine is connected to the network. Figure
7.18 illustrates the terminal markings of the windings of ordinary three-phase rotating-field
machines. In addition to these markings, the markings of the magnetizing windings of a syn-
chronous machine are F1–F2.
The IEC 60034-7 standard defines the shaft ends of a rotating machine with letter codes
D (Drive end) and N (Non-Drive end). The rotation direction of the motor shaft is observed
either clockwise or counterclockwise at the D end. The internal coupling of three-phase elec-
trical machines is carried out in such a way that when the network phases L1, L2 and L3 are
connected to the terminals U1 , V1 and W1 , respectively, the machine rotates clockwise when
observed standing in front of the machine D end (see the illustration in Table 7.6).
The most common asynchronous machines are enclosed squirrel cage winding induction
motors of enclosure class IP 55. As typical examples of these machines, Figures 7.19a and
b illustrate the profiles of two totally enclosed fan-cooled induction motors of different sizes
manufactured by ABB.

7.1.8 Cooling and Duty Types

In electrical machines, part of the supplied energy is always converted into heat. For instance,
when the efficiency of a 4 kW standard induction machine at a rated power is 85%, the fol-
lowing percentages of the energy supplied to the terminals of the machine turn into heat: 6.9%
in the stator resistive losses, 1.9% in the stator iron losses, 0.5% in the additional losses and
4.7% in the rotor losses. The rest of the supplied energy is converted to mechanical energy
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344 Design of Rotating Electrical Machines

Table 7.6 Mechanical dimensions of electrical machines according to the IEC codes

lF

−
lG
DD +

lE
hH

bB
bA bC

Fixing
IEC code bA /mm bB /mm bC /mm DD /mm lE /mm lF /mm lG /mm hH /mm screws
71-14 112 90 45 14 30 5 11 71 M6
80-19 125 100 50 19 40 6 15.5 80 M8
90S24 140 100 56 24 50 8 20 90 M8
90L24 140 125 56 24 50 8 20 90 M8
100L28 160 140 63 28 60 8 24 100 M10
112M28 190 140 70 28 60 8 24 112 M10
132S38 216 140 89 38 80 10 33 132 M10
132M38 216 178 89 38 80 10 33 132 M10
160M42 254 210 108 42 110 12 37 160 M12
160L42 254 254 108 42 110 12 37 160 M12
180M48 279 241 121 48 110 14 42.5 180 M12
180L48 279 279 121 48 110 14 42.5 180 M12
200M55 318 267 133 55 110 16 49 200 M16
200L55 318 305 133 55 110 16 49 200 M16
225SM, p=1 356 286 149 55 110, 16, 48, 225 M18
p>1 60 140 18 53
250SM, p=1 406 311 168 60 140 18 53, 250 φ24a
p>1 65 58
280SM, p=1 457 368 190 65 140 18 58, 250 φ24a
p>1 75 67.5
315SM, p=1 508 406 216 65, 140, 18, 58, 315 φ30a
p>1 80 170 22 71
315ML, p=1 508 457 216 65, 140, 18, 58, 315 φ30a
p>1 90 170 25 81
355S, p=1 610 500 254 70, 140, 20, 62.5, 355 φ35a
p>1 100 210 28 90
355SM, p=1 610 500 254 70, 140, 20, 62.5, 355 φ35a
p>1 100 210 28 90
35ML, p=1 610 560 254 70, 140, 20, 62.5, 355 φ35a
p>1 100 210 28 90
400M, p=1 686 630 280 70, 140, 20, 62.5, 400 φ35a
p>1 100 210 28 90
400LK, p=1 686 710 280 80, 170, 22, 71, 400 φ35a
p>1 100 210 28 90
a
Fixing hole diameter.
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Design Process and Properties of Rotating Electrical Machines 345

U V W N U V W U1 V 1 W 1 1U 1V 1W 2U 2V 2W

U 2 V 2 W2
(a) (b) (c) (d)

Figure 7.18 Connections and terminal markings of three-phase machines. (a) The machine is con-
nected in star. The neutral point N is not necessarily available. (b) The machine is connected in delta. (c)
The ends of the phase windings (U1 –U2 ) of the machine are connected to a terminal board. If there are
intermediate taps in the windings, they are marked U3 –U4 . The connection of the machine in star or delta
takes place either in the terminal box or completely outside the machine. (d) The terminal markings of a
two-speed machine. The higher front number designates the winding of the higher rotation speed of the
machine

Figure 7.19 (a) ABB aluminium motor, shaft height 132 mm, 5.5 kW, 3000 min−1 . (b) ABB cast-iron
motor, shaft height 280 mm, 75 kW, 3000 min−1 . Reproduced by permission of ABB Oy
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346 Design of Rotating Electrical Machines

Table 7.7 Most common IC classes of electrical machines

Code Definition
IC 00 The coolant surrounding the machine cools the inner parts of the machine. The
ventilating effect of the rotor is insignificant. The coolant is transferred by free
convection
IC 01 As IC 00, but there is an integral fan mounted on the shaft or the rotor to circulate the
coolant. This is a common cooling method in open induction motors
IC 03 A method similar to IC 01, but with a separate motor-mounted blower having the
same power source with the machine to be cooled
IC 06 A method similar to IC 01, but the coolant is circulated with a separate
motor-mounted blower with a different power source. There can also be a single
extensive blower system supplying the coolant for several machines
IC 11 The coolant enters the machine via a ventilating duct and passes freely to the
surrounding environment. The circulation of the coolant is carried out with a
motor- or shaft-mounted blower
IC 31 The rotating machine is inlet- and outlet-pipe ventilated. The circulation of the
coolant is carried out with a motor- or shaft-mounted blower
IC 00 41 Totally enclosed internal circulation of the coolant by convection and cooling through
the frame with no separate blower
IC 01 41 As IC 00 41, but the frame surface cooling takes place with a separate shaft-mounted
blower causing circulation of the coolant. This is a cooling method in ordinary
enclosed induction motors
IC 01 51 Totally enclosed internal cooling by convection. The heat is transferred through an
internal air-to-air heat exchanger to the surrounding medium, which is circulated by
a shaft-mounted blower
IC 01 61 As IC 01 51, but the heat exchanger is mounted on the machine
IC W37 A71 Totally enclosed internal cooling by convection. The heat is transferred through an
internal water-to-air heat exchanger to the cooling water, which is circulated either
by supply pressure or by an auxiliary pump
IC W37 A81 As IC W37 A71, but the heat exchanger is mounted on the machine

but about 1% is still lost in the friction losses. The heat generated in the machine has to be
led to the medium surrounding the machine. The cooling methods of the electrical machines
are defined in IEC 60034-6 and the enclosure classes in IEC 60034-5. The class of enclosure
depends on the cooling method. For instance, the enclosure class IP 44 designates good me-
chanical and moisture protection that are not compatible with the cooling method IC 01, since
it requires an open machine. Table 7.7 gives the most common IC classes.
The duty types of electrical machines are designated as S1–S9 and described according to
IEC 60034-1 (2004).

7.1.8.1 Duty Type S1 – Continuous Running Duty

This deals with operation at constant load maintained for sufficient time to allow the machine
to reach thermal equilibrium. A machine for this kind of operation is stamped with the abbre-
viation S1. This is the most common duty-type stamping in industrial machines irrespective
of the real use of the motor.
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Design Process and Properties of Rotating Electrical Machines 347

7.1.8.2 Duty Type S2 – Short-Time Duty

This covers operation at constant load for a given time, less than that required to reach ther-
mal equilibrium. Each operation period is followed by a time at rest and de-energized, with
a sufficient duration to re-establish the temperature of the surrounding air. For machines of
short-time duty, the recommended durations of the duty are 10, 30, 60 and 90 min. The appro-
priate abbreviation is S2, followed by an indication of the duration of the duty, for instance the
stamping S2 60 min. Stampings for short periods of use, for instance S2 10 min, are common
in motors integrated in cheap tools such as small grinders.

7.1.8.3 Duty Type S3 – Intermittent Periodic Duty

This concerns a sequence of identical duty cycles, each including a time of operation at con-
stant load and a time at rest and de-energized. Thermal equilibrium is not reached during a
duty cycle. Starting currents do not significantly affect the temperature rise. The cyclic dura-
tion factor is 15, 25, 40 or 60% of the 10 min duration of the duty. The appropriate abbreviation
is S3, followed by the cyclic duration factor, for instance the stamping S3 25%.

7.1.8.4 Duty Type S4 – Intermittent Periodic Duty with Starting

This covers a sequence of identical duty cycles, each cycle including a significant starting
time, a time of operation at constant load and a time at rest and de-energized. Thermal equi-
librium is not reached during a duty cycle. The motor stops by naturally decelerating, and thus
it is not thermally stressed. The appropriate abbreviation for the stamping is S4, followed by
the cyclic duration factor, the number of cycles in an hour (c/h), the moment of inertia of the
motor (JM ), the moment of inertia of the load (Jext ) referred to the motor shaft, and the permit-
ted average counter torque Tv during a change of speed given by means of the rated torque. For
example, the stamping S4–15%–120 c/h–J M = 0.1 kg m2 − J ext = 0.1 kg m2 − T v = 0.5T N .

7.1.8.5 Duty Type S5 – Intermittent Periodic Duty with Electric Braking

This covers a sequence of identical duty cycles, each cycle consisting of a starting time, a time
of operation at constant load, a time of braking and a time at rest and de-energized. Thermal
equilibrium is not reached during a duty cycle. In this duty type, the motor is decelerated
with electric braking, for instance counter-current braking. The appropriate abbreviation for
stamping is S5, followed by the cyclic duration factor, the number of cycles per hour (c/h), the
moment of inertia of the motor JM , the moment of inertia of the load Jext , and the permitted
counter torque Tv . For example, the stamping S5–60%–120 c/h–J M = 1.62 kg m2 − J ext =
3.2 kg m2 − T v = 0.35T N .

7.1.8.6 Duty Type S6 – Continuous Operation Periodic Duty

This covers a sequence of identical duty cycles, each cycle consisting of a time of operation
at constant load and a time of operation at no load. Thermal equilibrium is not reached during
a duty cycle. The cyclic duration factor is 15, 25, 40 or 60% and the duration of the duty is
10 min. The stamping for instance is S6 60%.
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348 Design of Rotating Electrical Machines

7.1.8.7 Duty Type S7 – Continuous Operation Periodic Duty with Electric Braking
This concerns a sequence of identical duty cycles, each cycle consisting of a starting time,
a time of operation at constant load and a time of electric braking. The motor is decelerated
by counter-current braking. Thermal equilibrium is not reached during a duty cycle. The ap-
propriate abbreviation is S7, followed by the moment of inertia of the motor, the moment
of inertia of the load and the permitted counter torque (cf. S4). The stamping for instance is
S7−500c/h−J M = 0.06/kg m2 − T v = 0.25T N .

7.1.8.8 Duty Type S8 – Continuous Operation Periodic Duty

with Related Load/Speed Changes
This covers a sequence of identical duty cycles, each cycle consisting of a time of operation
at constant load corresponding to a predetermined speed of rotation, followed by one or more
times of operation at other constant loads corresponding to different speeds of rotation (carried
out, for example, by means of a change in the number of poles in the case of induction motors).
There is no time at rest and de-energized. Thermal equilibrium is not reached during a duty
cycle. The appropriate abbreviation is S8, followed by the moment of inertia of the motor,
the moment of inertia of the load and the number of duty cycles in an hour. Also a permitted
counter torque and the cyclic duration factor have to be given. The stamping for instance is

S8 − JM = 2.3 kg m2 − Jext 35 kg m2
30 c/h − Tv = TN − 24 kW − 740 r/min − 30%
30 c/h − Tv = 0.5TN − 60 kW − 1460 r/min − 30%
30 c/h − Tv = 0.5TN − 45 kW − 980 r/min − 40%.

The load and combinations of rotation speeds are stamped in the order in which they occur in
the duty.

7.1.9 Examples of the Parameters of Three-Phase Industrial

Induction Motors
In the following, typical values of equivalent circuit parameters of commercial induction mo-
tors are given. Figure 7.20 illustrates the average behaviour of the per unit magnetizing induc-
tances of certain induction motors as a function of power. The motors were produced by ABB.
A second significant parameter in the equivalent circuit of the machine is the flux leakage
of the stator. Figure 7.21 illustrates the per unit leakage inductances of the same machines
manufactured by ABB as in the previous figure. The values for the flux leakage are calculated
here by employing the catalogue values of the machine, for instance for the pull-out torque.
The rotor flux leakage per unit inductance at rated load is typically of the same magnitude
as the stator flux leakage. For manufacturing reasons, closed rotor slots are often used in die-
cast rotors, which makes the rotor leakage behaviour somewhat complicated. At low slips, the
rotor leakage inductance is high, but at larger loads the leakage flux path saturates and similar
per unit values are found as for the stator.
The behaviour of the stator resistance is a significant factor in the machines. Figure 7.22
illustrates the behaviour of the stator resistance of high-efficiency induction motors as a
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Design Process and Properties of Rotating Electrical Machines 349

lm,pu
3.5

3.0

2.5

2.0

1.5

1.0

0.5

0.0 0 100 200 300 400 500 600 700 800

PN / kW

Figure 7.20 Average behaviour of the per unit magnetizing inductances of four-pole high-efficiency
induction motors as a function of shaft output power. The curve is composed of the values of 1.1, 2.2,
5.5, 11, 45, 75, 110, 355 and 710 kW machines. Reproduced by permission of Markku Niemelä

function of shaft output power. The figure also reveals how difficult it is to compare small
and large machines, unless the resistance is calculated as a per unit value.
Figure 7.22 shows that in small machines, the resistance is a very significant component.
Already at rated current there is an 11% resistive loss in the stator resistance of a 1.1 kW
machine. Therefore, the efficiency cannot reach very high values either. With a full logarithmic
scale, both the absolute and per unit resistances seem to behave linearly.
The rotor resistances are typically of the same magnitude as the stator resistance in in-
duction motors. The resistive loss of the rotor is proportional to the slip s and takes place

lsσ,pu
0.12

0.1

0.08

0.06

0.04

0.02

0.0 0 100 200 300 400 500 600 700 800

PN / kW

Figure 7.21 Average behaviour of the per unit leakage inductances of four-pole high-efficiency induc-
tion motors as a function of shaft output power. The curve is composed of the values of 1.1, 2.2, 5.5, 11,
45, 75, 110, 355 and 710 kW machines. Reproduced by permission of Markku Niemelä
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350 Design of Rotating Electrical Machines

Rs /Ω
10

Rs = 11.84 P -1.47
1.0

0.1

0.01
1 10 100
PN / kW
rs pu
0.1

0.01

0.001
1 2 3 4 5 10 20 100
PN / kW

Figure 7.22 Stator resistances of typical modern high-efficiency, totally enclosed industrial induction
motors from ABB as a function of shaft output power, given as absolute and per unit values. Reproduced
by permission of Jorma Haataja

in the resistance Rr of the rotor. The magnitude of the rotor resistive loss is PCur = Ir2 Rr . In
small machines, the rotor resistance is proportionally smaller than the stator resistance. This
is indicated in Figure 7.23, where the different losses of the machine are illustrated as their
proportional shares. A small power factor in a small machine leads to the fact that the stator
loss in small machines is relatively high.
At a power of just 90 kW, the resistive losses of the rotor and stator approach each other.
Bearing in mind that the stator current is slightly higher than the rotor current referred to the
stator side Ir
≈ Is cos ϕ, we may infer from the loss distribution that the stator-referred rotor
resistances are typically of the same magnitude as the stator resistances.
Figure 7.24 illustrates how the power factor of the induction motors of ABB’s M3000 series
behaves as a function of power, the number of pole pairs being the parameter.
The increase in the number of pole pairs notably reduces the power factors of the induction
motors. This is due to the fact that the magnetizing inductance of a rotating field machine is
inversely proportional to the square of the number of pole pairs. As the magnetizing induc-
tance decreases, the machine consumes more reactive current, and consequently the power
factor is lower.
Although induction motors are rather well standardized, their efficiencies are not defined
in the standards. Therefore, there are notable differences between the motors of different
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Design Process and Properties of Rotating Electrical Machines 351

0.70

0.60

loss proportion
0.50
stator resistive loss
0.40

0.30 rotor resistive loss

0.20
iron loss
mechanical loss
0.10 additional loss
additional loss
mechanical loss
0.0
0 10 20 30 40 50 60 70 80 90
PN / kW

Figure 7.23 Average loss distributions of modern induction motors at powers below 100 kW. The pro-
portion of the losses is referred to the machine losses at the rated operating point. Adapted from Auinger
(1997)

manufacturers. Figure 7.25 illustrates the efficiencies of induction motors as a function of

shaft output power. These motors, manufactured by several companies, are commercially
available on the European market.

7.1.10 Asynchronous Generator

If desired, an asynchronous machine is applicable also as a generator. When connected to the
network, it has to be rotated by a power engine at a speed higher than the synchronous speed.

p=1 p=2 p=3 p=4

cosϕ

0.9

0.8

0.7

0.6

1 2 3 4 5 10 20 100 1000
PN / kW

Figure 7.24 Power factors of modern totally enclosed induction motors as a function of power, with
the number of pole pairs as a parameter (ABB M3000)
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352 Design of Rotating Electrical Machines

100

95
Efficiency [ % ]
90
EFF1
85
EFF2
80

75 EFF3

70
1 10 100
Shaft output power [ kW ]

Figure 7.25 Efficiencies of totally enclosed four-pole induction motors as a function of shaft output
power. The motors are manufactured by several companies indicated by the different symbols. The figure
also illustrates the limits of the efficiency classes in the EU. EFF1, EFF2 and EFF3 are the induction
motor efficiency categories defined by the EU. Reproduced by permission of Jorma Haataja

An asynchronous generator takes its magnetizing current from the network and, usually, has to
be compensated by a capacitor bank. Under certain circumstances, an asynchronous machine
is also used as a capacitor-excited island generator. The capacitors have to be in resonance
with the total inductance of the machine,

|X C | = |X m + X sσ | . (7.116)

The corresponding resonant angular frequency is

1
ω= √ . (7.117)
(L m + L sσ ) C

When the speed of the machine is increased from zero, the build-up of the generator re-
quires a remanence of the rotor or an external energy pulse supplied to the system. The current
flowing in the LC circuit of the system is very low until the resonant angular frequency is ap-
proached. In the vicinity of the resonance, the current of the machine increases rapidly and it
magnetizes itself. The voltage is rapidly built up. As saturation increases, the magnetizing in-
ductance is decreased and the resonance frequency is increased, and the terminal voltage of the
machine remains reasonable at a constant speed. The load affects the size of the magnetizing
capacitor, and therefore it should be adjusted as the frequency and the load fluctuate. How-
ever, asynchronous generators intended for island operation are usually dimensioned in such
a way that their magnetic circuits saturate strongly as soon as the rated voltage is exceeded at
the rated speed. In that case the capacitance of a capacitor can be increased quite high without
changing the terminal voltage. Thus we are able to construct an asynchronous generator for
island operation, the terminal voltage of which remains almost constant as the load varies.
Asynchronous generators equipped with squirrel cage rotors are fairly common. Due to
their reliability, they are utilized in unattended power plants. Since an asynchronous machine
needs no synchronizing equipment, the machinery of small power plants is kept cost effective.
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Design Process and Properties of Rotating Electrical Machines 353

Wound-rotor doubly fed induction generators are often used in wind-power applications up
to several megawatts. The rotor of a generator is connected to a frequency converter, and the
converter rating is typically about one-third of the generator rated power. This system allows
efficient control of the system, and the frequency converter is cheap compared with a full
power series converter.

7.1.11 Asynchronous Motor Supplied with Single-Phase Current

A winding supplied with single-phase current creates a flux density which does not rotate,
but pulsates and can be illustrated as harmonic phasor pairs rotating in opposite directions
in the air gap. Next, the operation of a machine is analysed with respect to a fundamental
pair ν = ±1. Of these ν = +1 is considered the actual positive-sequence field. In that case,
the equivalent circuit of a single-phase machine appears as illustrated in Figure 7.15 with the
following adjustments. Since there is only one stator winding in the machine the magnetizing
reactances X sm1 and X sm5 have to be replaced with halves of the main reactance X p = ωL p .
The leakage reactance of the rotor at a slip s = 1 is equal for the positive- and negative-phase-
sequence field. The only difference lies in the resistances of the rotor circuit. The positive-
sequence resistance is 0.5Rr
/s, and the negative-sequence resistance is 0.5Rr
/ (2 − s). Phasor
calculation is the easiest way to solve the impedances, and thus the positive- and negative-
sequence impedances of the rotor can be written in the form

0.5Rr


Z
r,ps = + j0.5X rσ ,
s
(7.118)

0.5Rr


Z = + j0.5X rσ .
r,ns
2−s

Now, the positive- and negative-sequence impedances are obtained

jX p Z
r,ps
Z ps = ,
jX p + Z
r,ps
(7.119)
jX p Z
r,ns
Z ns = .
jX p + Z
r,ns

When the stator impedance Z s = Rs + jX sσ is added to the sum of these impedances, we

obtain the total impedance Z of the machine, which is connected to the terminal voltage. Then
we obtain the current of the machine. The emf components of the machine are E ps = Z ps I ps
and E ns = Z ns I ns . They can be employed in the calculation of the corresponding components
of the rotor currents

Z ps I ps
I
r,ps = ,
Z
r,ps
(7.120)


Z ns I ps
I = .
r,ns
Z
r,ns
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354 Design of Rotating Electrical Machines

The resistive losses in the rotor resistances created by these components are

0.5Rr

PrCu,ps = I
r,ps
2
,
s


(7.121)


2 0.5Rr
PrCu,ns = Ir,ns .
2−s

These resistive loss powers both represent opposite torques. The resultant torque at a slip s is
(see Equation (7.79))

p PrCu,ps PrCu,ns
T = − . (7.122)
ω s 2−s

When the machine is at rest, the torques are equal, and therefore the machine does not start
up without assistance. At synchronous slip s = 0, the positive-sequence impedance is Z ps =
jX p and the negative-sequence impedance is |Z ns |  |Z ps |, and thus E ps E ns . X p (ωLp )
is used instead of X m because of the single arrangement. When both the emf components
are induced in the same coil, it means that at low values of slip the torque of the counter-
rotating field is low. It nearly disappears and the machine operates almost like a symmetrically
supplied poly-phase machine. As the resultant emf has to be almost the magnitude of the
terminal voltage, correspondingly the positive-sequence field is so high that it alone induces
the required emf. The amplitude of the negative-sequence field is damped almost to zero at
low values of slip. Figure 7.26a illustrates the static torque curves of the machine.
This motor type is actually of no use, since a starting torque is lacking. Therefore, there
are some starting techniques commonly used to start these motors. An improvement of the
torque–speed characteristic can be achieved by an auxiliary winding with a capacitor in series.
Such an arrangement will be analysed below. Single-phase motors are in practice two-phase
motors supplied with a single-phase voltage. Figure 7.26b illustrates such a machine. There
is a two-phase winding in the stator of the machine. The magnetic axes of the coils D and Q

T
Tps I
Ttot ID
U D C
2 1 0 s pos. seq.
0 1 2 s neg. seq. Q
IQ

Tns

(a) (b)

Figure 7.26 (a) Static torque curves of a single-phase induction motor and the sum curve of the torque
as a function of slip. Tps is the positive-sequence torque and Tns the negative-sequence torque. Ttot is the
sum of these components. At zero speed, the sum of torques is zero (Ttot = 0). (b) Model of a single-
phase-supplied capacitor motor
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Design Process and Properties of Rotating Electrical Machines 355

are located at a distance of 90 electrical degrees. There is an additional impedance connected

in series with the coil Q, usually a capacitance C, which causes a certain temporal phase
shift between the currents of the windings when the machine is supplied with a single phase.
Usually, there is a cage winding in the rotor. There is usually also a different number of turns
in the stator windings of a capacitor motor and NQ > ND . This asymmetry complicates the
analysis of the machine’s characteristics considerably.
The voltage equations of the main (D) and auxiliary (Q) windings can be written in the
form (Matsch and Morgan, 1987)

U D = (RsD + jX sσ D ) I D + E 2D

 (7.123)
U Q = RsQ + jX sσ Q + RC + jX C I Q + E 2Q .

RsD + jX sσ D = Z 1 and RsQ + jX sσ Q = Z 1Q are the stator impedances of the main and aux-
iliary windings. E 2D includes, in addition to the two rotating flux components of the main
winding, the effects of the two rotating components of the auxiliary winding. RC + jX C is the
impedance of the capacitor. The direction of rotation of a capacitor motor is from the auxiliary
winding to the main winding, since the capacitor shifts the current of the auxiliary winding
temporally ahead of the current of the main winding. When the main winding is open, the
voltage equations are written in the form

U D = E 2D

 (7.124)
U A = RsQ + jX sσ Q + RC + jX C I Q + E 2Q

where

E 2Q = E psQ + E nsQ (7.125)

is the sum of the positive-sequence component (ps) and the negative-sequence component
(ns) of the emf. Since the main winding is located at a distance of 90 electrical degrees from
the auxiliary winding, the voltage induced by the positive-sequence flux component of the
auxiliary winding has to be 90 electrical degrees lagging, and the voltage induced by the
negative-sequence flux component has to be 90 electrical degrees leading. Thus

E psQ E nsQ
E 2D = −j +j , (7.126)
K K

where K is the ratio of the effective number of coil turns of the main winding to the effective
number of coil turns of the auxiliary winding. When both windings are connected to the net-
work, the effect of all flux components has to be taken into account, and the voltage equations
are thus written in the form

E psQ E nsQ
U D = Z 1 I D + E psD − j +j + E nsD ,

 K K (7.127)
U A = Z 1Q + Z C I Q + E psQ + jK E psD + E nsQ − jK E nsD .
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356 Design of Rotating Electrical Machines

ID RsD XsσD IQ R sQ Xs
XC Q
2
0.5Xrσ' K 0.5X 'rσ
UC 2
K 0.5R'r
EpsD 0.5X 0.5R'r
EpsQ K 20.5X m
s
m
s

UD ED -jEpsQ/K +jKEpsD
0.5X rσ' UA UQ EQ K 0.5Xr'σ
2

0.5R'r K 0.5R'r
2
EnsD 0.5X EnsQ K 20.5Xm
m
2-s 2-s

+jEnsQ/K -jKEnsD

(a) (b)

Figure 7.27 Equivalent circuits of the main and auxiliary windings of a capacitor motor. (a) Main
winding, (b) auxiliary winding

Figure 7.27 illustrates the equivalent circuit of a capacitor motor constructed based on
Equation (7.127). Also this equivalent circuit is based on the equivalent circuit of Figure
7.15, which has been modified to take into account the voltage components created by differ-
ent axes. Both the rotor quantities of the equivalent circuits of both phases are referred to the
number of turns of the main winding.
With the equivalent circuit of Figure 7.27, we may simplify the voltage equations in the
form

 j Z ps − Z ns
U D = Z 1 + Z ps + Z ns I D − IQ
K (7.128)
  
U Q = jK Z ps − Z ns I D + Z C + Z 1Q + K 2 Z ps + Z ns I Q .

Since the phases of a capacitor motor are usually connected in parallel, we may write

UD = UA = U. (7.129)

The total current supplied in the motor is

I = I D + I Q. (7.130)

The difference between the positive- and negative-sequence power components of both
windings is
   
Pδps − Pδns = Re E psD − E nsD I ∗D + j E psQ − E nsQ K I ∗Q . (7.131)
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Design Process and Properties of Rotating Electrical Machines 357

UD I

UC ID
ϕD ϕ

IQ ϕD

UQ=UD /K

Figure 7.28 Phasor diagram of a capacitor motor at a symmetry point

The torque of the machine is now written as


p Pδps − Pδns
Tem = . (7.132)
ωs

A symmetry should prevail between the phases at the rated operation point of a capacitor
machine. The negative-sequence field disappears at a symmetry point where the current link-
ages of the D and Q windings are equal. Such a point may be found at a certain slip. Now the
emfs of the windings are phase shifted by 90 electrical degrees, and they are proportional to
the numbers of coil turns

ED kwD ND UD
K = = ≈ . (7.133)
EQ kwQ NQ UQ

The voltage of the capacitor is 90 electrical degrees behind the current I Q being thus in the
direction of I D . On the other hand, the sum U Q + U C = U D . A phasor diagram can now be
drawn according to Figure 7.28. According to the phasor diagram and Equation (7.133),

UQ kwQ NQ 1
tan ϕD = = = . (7.134)
UD kwD ND K
IQ UD
UC = = . (7.135)
ωC cos ϕD

Since at the symmetry point, the current linkages of the windings are also equal

kwD ND ID = kwQ NQ IQ , (7.136)

the symmetry requires a capacitance

ID cos2 ϕD
C= . (7.137)
ωUD sin ϕD
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358 Design of Rotating Electrical Machines

The phasor diagram shows that the voltage of the capacitor is notably higher than the rated
voltage of the machine. Therefore, a high voltage rating is required for the capacitor.
The rated point of the machine is usually selected as the symmetry point. The torque re-
quires a certain resistive loss of the rotor PrCu (7.121), half of which is provided by the phase
winding D to the rotor. The phase current of the rotor is calculated from this loss by employing
the rotor resistance (7.41). When it is referred to the winding D, we obtain the current ID ≈ Ir

(7.45).
Instead of a capacitor, we may also employ a resistance or an inductive coil. However, they
do not produce as good starting properties as the capacitor does. In shaded-pole motors, the
salient-pole section of the stator is surrounded by a strong copper short-circuit ring, where the
induced voltage creates a current temporally delaying the flux of this shaped pole, thus pro-
ducing the phase required for starting. Because of the great losses, this method is applicable
only in very small machines.

7.2 Synchronous Machine

Synchronous machines constitute an entire family of electrical machines. The main types of
the electrical machine family are (1) separately excited synchronous machines (SMs), (2)
synchronous reluctance machines (SyRMs) and (3) permanent magnet synchronous machines
(PMSMs). Separately excited machines are either salient or nonsalient-pole machines. In these
machines, there is usually a three-phase winding in the stator, whereas the rotor is equipped
with a single-phase field winding supplied with direct current. A synchronous machine and
a permanent magnet machine differ essentially from an asynchronous machine by the fact
that their resulting current linkage component created by the rotor is generated either by field
winding direct current or by permanent magnets which, at steady state, work independent of
the stator. In asynchronous motors, the rotor currents are induced by the air-gap flux as a slip
occurs. In synchronous machines, the air-gap flux change caused by the stator current linkage,
that is the armature reaction, is not compensated spontaneously, but the rotor field winding
current has to be adjusted if necessary. If a synchronous machine carries a damper winding,
its behaviour during transients is very similar to the behaviour of an asynchronous machine
squirrel cage under slip. Since the current linkage of permanent magnets cannot normally be
altered, some problems occur in the use of permanent magnet machines. Further, a special fea-
ture of permanent magnet machines is that, unlike in machines excited by field winding cur-
rent, the source of the current linkage itself, the low-permeability permanent magnet material,
belongs to the magnetic circuit. Therefore, the magnetizing inductances of permanent mag-
net machines are relatively low when compared with ordinary synchronous machines. Thus,
correspondingly, the armature reaction also remains lower than the armature reaction of sepa-
rately excited synchronous machines. Table 7.8 lists synchronous machines of different types.
The design of a synchronous machine proceeds in the same way as the design of an asyn-
chronous machine. Section 3.1.2 discusses the different air gaps of a synchronous machine,
which together with the windings determine the inductances of synchronous machines. When
considering the stationary operation of the machine, the load angle equation forms a signifi-
cant design criterion.
In the case of rotor-surface-mounted permanent magnets, a permanent magnet machine is,
in principle, of the nonsalient-pole type. The air gap is long and the inductances are low. In
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Design Process and Properties of Rotating Electrical Machines 359

Table 7.8 Family of synchronous machines

SYNCHRONOUS MACHINES

SEPARATELY MAGNETIZED SYNCHRONOUS RELUCTANCE PERMANENT MAGNET SYNCHR.

SYNCHRONOUS MACHINES SM MACHINES SyRM MACHINES PMSM

Salient pole m. Non salient p. m. RM RM, PMSM, PMSM,

permanent with non
Ld/Lq > 1 Ld/Lq = 1 Ld>>Lq magnet saliency salient

assisted Lq/Ld > 1 Ld/Lq = 1

Ld>>Lq
Brushless: With brushes Brushless: With brushes
(a) –rotating (a) –rotating
(b) magnetizing (b) magnetizing PMSM PMSM
(c) machine (c) machine embedded pole shoes
–thyristor –thyristor magnets
bridge bridge

The different brushless excitation systems (a), (b) and (c) are discussed briefly in Section 7.2.9.

the case of embedded magnets instead, the rotor is a salient-pole construction, the inductance
of the direct axis being typically lower than the inductance of the quadrature axis.
In the case of a synchronous reluctance machine, the objective is to create a maximum in-
ductance difference between the direct and quadrature axes. The goal is reached by employing
a minimum direct axis and a maximum quadrature air gap.

7.2.1 Inductances of a Synchronous Machine in Synchronous Operation

and in Transients
The inductances chiefly decide the characteristics of synchronous machines. The air gaps of
a synchronous machine may vary in the direct and quadrature directions, which leads also to
different stator inductances in the direct and quadrature directions, L d and L q , respectively.
These inductances are composed of the direct and quadrature magnetizing inductance and the
leakage inductance L sσ .
A salient-pole synchronous machine, connected to a three-phase network rotating syn-
chronously but with no rotor field winding current (a synchronous reluctance machine), takes
its magnetizing current from the network. A symmetrical three-phase current linkage creates
a rotating flux with constant amplitude in the air gap. In the natural position (correspond-
ing to the minimum of the reluctance), the direct axis (d-axis) of the salient-pole rotor is
aligned with the axis of the rotating current linkage of the stator. Unlike a nonsalient-pole
machine, the salient-pole machine keeps on running at a synchronous speed, and when op-
erating as a motor or as a generator produces a low torque even without rotor field wind-
ing current. A machine of this kind, when running at no load, takes a current from the
network

U s,ph
Id = . (7.138)
jωs L d
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360 Design of Rotating Electrical Machines

Here
I d is the direct-axis current of the stator winding,
Us,ph is the phase voltage of the stator,
L d is the direct-axis inductance.

The direct-axis synchronous inductance consists of the direct-axis magnetizing inductance

and the leakage inductance

L d = L md + L sσ . (7.139)

Since there is a relation dΨmd = L md di d between the flux linkage and the inductance, the
direct-axis inductance of the stator can be calculated using the main flux linkage of the ma-
chine. If the machine does not saturate, the direct-axis air-gap flux linkage of the phase is

2
Ψ̂md = kws1 Ns τpl
B̂δd . (7.140)
π

In a saturating machine, another average flux density value of α i than 2/π is used. On the
other hand, the magnetic flux density of the air gap can be defined by the current linkage of the
phase; in other words, the current linkage Θ̂sd of the stator creates in the effective direct-axis
air gap δ def (see Eq. (3.56)) a flux linkage

2 µ0 Θ̂sd

Ψ̂md = kws1 Ns τpl . (7.141)
π δdef

The effective air gap δ def takes into account the slotting and magnetic voltages in iron parts
of the magnetic circuit.
The amplitude of the direct-axis current linkage of a single-phase winding, when the current
is on the direct axis, is written as

4 kws1 Ns √
Θ̂sd = 2Is . (7.142)
π 2p

Substitution yields for the main flux linkage

2 µ0 4 kws1 Ns
√
Ψ̂md = kws1 Ns τpl 2Is , (7.143)
π δdef π 2 p
2 1 4 τp
√
Ψ̂md = µ0 l (kws1 Ns )2 2Is . (7.144)
π 2 p π δdef

When the peak value of the air-gap flux linkage is divided by the peak value of the stator
current, we obtain the main inductance L pd of a single stator phase in the d-direction

2 1 4 τp

L pd = µ0 l (kws1 Ns )2 . (7.145)
π 2 p π δdef
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Design Process and Properties of Rotating Electrical Machines 361

In a multiple-phase machine, other windings also affect the flux, and hence the magnetizing
inductance L md of the direct axis of an m-phase machine can be solved by multiplying the
main inductance L pd by m/2

m2 1 4 τp
2mτp

L md = µ0 l (kws1 Ns )2 = µ0 2 l (kws1 Ns )2 . (7.146)
2 π 2 p π δdef pπ δdef

This equation corresponds to the general equation of the magnetizing inductance for a
rotating-field machine written in Chapter 1, and is applicable as such to different machine
types, providing that the equivalent air gap has been determined correctly. If the machine op-
erates at a constant frequency, for instance as a power plant generator drive, reactances can
be employed. The magnetizing reactance X md corresponds to the magnetizing inductance of
Equation (7.146) in the d-axis direction

X md = ωL md . (7.147)

A corresponding expression may be written for X mq = ωL mq . If the machine is magnetized

with the stator rotating-field winding alone and the machine is running in synchronism at no
load with the reluctance torque, we obtain the current of the stator

Us
Is = . (7.148)
jωs L d

In practice, the no-load current is almost purely on the d-axis and Equation (7.148) gives
the d-axis current.
If a nonexcited synchronous machine or a synchronous reluctance machine can be made
to run 90 electrical degrees away from its natural direct-axis position, the largest effective air
gap δ qef of the machine is constantly at the peak of the rotating current linkage. To magnetize
this large air gap, a notably higher current is required in the stator

Us
Iq = . (7.149)
jωs L q

The quadrature-axis synchronous inductance is, in analogy to Equation (7.139),

L q = L mq + L sσ . (7.150)

L mq is calculated analogously to L md by employing δ qef as the air gap instead of δ def . Cor-
respondingly, the leakage inductance of the stator is calculated with the methods discussed
in Chapter 4. The flux leakage on the direct and quadrature axes is usually assumed equal,
although the length of the air gap also affects the flux leakage. The flux leakage of the direct
axis is somewhat lower than the flux leakage of the quadrature axis, since the current-carrying
d-axis magnetizing conductors are located in practice on the quadrature axis, where the air
gap is notably longer than on the direct axis.
The characteristics of a synchronous machine are strongly influenced by the quality of the
damping of the machine. Previously, the core principles of the dimensioning of the damper
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362 Design of Rotating Electrical Machines

winding were briefly discussed in the winding section in Section 2.18. The guidelines are
based mainly on empirical knowledge. Damper windings resemble the rotor windings of in-
duction motors, and the design principles of cage windings can be applied also in the design
of damper windings. The damper windings of salient-pole machines are usually mounted
in the slots of the pole shoe. The slot pitch of the rotor has to be selected to deviate by
10–15% from the slot pitch of the stator to avoid the harmful effects of flux harmonics, such
as noise. If there is skewing in the damper winding (usually for the amount of a single sta-
tor slot pitch), the same slot pitch can be applied in both the stator and the rotor. The bars
of the damper winding are connected with short-circuit rings. If the pole shoes are solid,
they can, as in the solid rotor of a nonsalient-pole machine, act as a damper winding, as
long as the ends of the pole shoes are connected with firm short-circuit rings. A separate
damper winding is seldom used in nonsalient-pole machines. However, conductors assem-
bled under the keys or the slot keys themselves can be employed as bars of the damper
winding.
In generators, one of the functions of damper windings is to damp counter-rotating fields
created by unbalanced load currents. Therefore, in such a case, a minimum resistance is se-
lected for the damper windings. The cross-sectional area of the damper bars is usually selected
to be 20–30% of the cross-sectional area of the armature winding. The material of the bars
is usually copper. In single-phase generators, cross-sectional areas above 30% are employed.
The area of the short-circuit rings is selected to be about 30–50% of the cross-sectional area
of the damper bars per pole.
In synchronous motors, the damper bars have to damp for instance the fluctuation of the
rotation speed caused by pulsating torque loads, and ensure an optimal starting torque as an
asynchronous machine. Thus, to increase the rotor resistance, brass damper bars are used.
If copper bars are used, their cross-sectional area is selected to be only 10% of the cross-
sectional area of the copper of the armature winding.
In permanent magnet synchronous machines, in axial flux machines in particular, the
damper winding is easily constructed by assembling a suitable aluminium plate on the ro-
tor surface, on top of the magnets. The above principles can be applied to the dimensioning
of the aluminium plate. The cross-sectional area of the aluminium plate can be dimensioned
to be about 15% of the total cross-sectional area of the stator copper material.
During transients, the inductances of a synchronous machine first obtain the subtransient
values L

d and L

q and then the transient value L
d , which can be dimensioned precisely by mea-
suring or employing time-stepping numerical calculation methods, cf. Figure 7.30 below. The
magnitude of these inductances is basically influenced by the characteristics of the damper



winding and the field winding. The time constant τd0 of the machine is usually relatively


small when compared with the time constant τd0 . The solid-rotor frame of a nonsalient-pole
machine forms a corresponding path for the eddy currents. At the beginning of the short cir-
cuit, as the stator current increases rapidly, there is an abrupt change in the current linkage of
the stator, and the current linkage immediately tries to alter the main flux of the machine. The
damper winding reacts strongly and resists the change by forcing the flux created by the stator
winding of the machine to leakage paths in the vicinity of the air gap. This makes the initial
subtransient inductances L

d and L

q low when compared with the synchronous inductance
L d . Correspondingly, the field winding of the machine resists the change during the transient.
When calculating the short-circuit currents for this period, we employ the transient inductance
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Design Process and Properties of Rotating Electrical Machines 363

ωΨq
Rs L uf
id

id+iD+if iD if
Ψd Ψmd
ud Lmd L L
RD Rf

(a)
ωΨd L
iq Rs

iQ
iq+iQ
uq Ψq Ψmq Lmq L
RQ

(b)

Figure 7.29 (a) Equivalent circuit of a synchronous machine in the d-direction according to the space
vector theory. i d and u d are the d-axis components of the stator current and voltage. Ψ d and Ψ q are
the direct- and quadrature-axis components of the stator flux linkage. i D is the direct-axis current of
the damper winding. i f is the current of the field winding. Rs is the stator resistance, RD is the direct-
axis resistance of the damper winding and Rf is the resistance of the field winding. L sσ is the leakage
inductance of the stator, L md is the direct-axis magnetizing inductance, L Dσ is the direct-axis leakage
inductance of the damper winding and L fσ is the leakage inductance of the field winding. u f is the
supply voltage of the field winding, all variables of the rotor are referred to the stator. (b) Equivalent
circuit of a synchronous machine in the q-direction according to the space vector theory. i q and u q are
the q-axis components of the stator current and voltage. Ψ d and Ψ q are the direct- and quadrature-axis
components of the stator flux linkage. i Q is the quadrature-axis current of the damper winding. Rs is the
stator resistance, RQ is the resistance of the quadrature damper winding. L sσ is the leakage inductance
of the stator, L mq is the quadrature-axis magnetizing inductance, L Qσ is the quadrature-axis leakage
inductance of the damper winding all referred to the stator voltage level

L
d and the time constant τd
, by which the short-circuit currents are damped to the values of
the continuous state, calculated with the synchronous inductances L d and L q .
As a result of the magnetic asymmetry of a synchronous machine, such a machine has to
be analysed separately in the direct and quadrature directions in a reference frame attached to
the rotor. Figure 7.29 illustrates these equivalent circuits of a synchronous machine according
to the space vector theory. The theory is not discussed in detail here; however, the presented
equivalent circuits are useful from the machine design point of view.
We can derive different equivalent circuits for synchronous machines from the above cir-
cuits to illustrate different states, Figure 7.30:

a) at steady state, there is a direct-axis synchronous inductance L d = L md + L sσ dominating

together with
b) the quadrature-axis synchronous inductance L q = L mq + L sσ ;
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364 Design of Rotating Electrical Machines

Lsσ Lsσ

(a) Ld Lmd (b) Lq Lmq

L sσ L

(c) L′d Lmd

Lsσ Lfσ Lsσ

(d) L′d′ Lmd L (e) Lq′′ Lmq LQσ

Lsσ Lfσ Rf

(f) Lmd τd0′

Lsσ Lfσ Rf

(g) Lmd τd′

Lsσ L fσ Lsσ

RD RQ
(h) Lmd τd0′ (i)
Lmq τq0
′′
LDσ LQσ

Lsσ L L

RD RQ
( j) Lmd τd′′ (k) Lmq τq′′
LDσ LQσ

Figure 7.30 Equivalent circuits of transients that can be derived from the steady-state equivalent cir-
cuits of a synchronous machine, and some parameters related to these circuits

c) the direct-axis transient inductance L
d is the sum of the stator flux leakage and the par-
allel connection of the direct-axis magnetizing inductance and the field winding leakage
inductance

L md L fσ
L
d = L sσ + ;
L md + L fσ
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Design Process and Properties of Rotating Electrical Machines 365

d) the direct-axis subtransient inductance L

d is the sum of the stator leakage inductance and
the parallel connection of the direct-axis magnetizing inductance, the damper winding
direct-axis leakage inductance and the field winding leakage inductance

L Dσ L fσ
L md
L Dσ + L fσ
L

d = L sσ + ;
L Dσ L fσ
L md +
L Dσ + L fσ

e) the quadrature axis has no field winding, and therefore the quadrature-axis subtransient
inductance is

L mq L Qσ
L

q = L sσ + .
L mq + L Qσ

In the figure, we also find the equivalent circuits for the time constants τd0 , τd

, τd0


, τd
, τq0

and τq

. The time constants are denoted as follows:

(f) τd0 is the direct-axis transient open-circuit (stator terminals open) time constant;
(g) τd
is the direct-axis transient short-circuit time constant;



(h) τd0 is the direct-axis subtransient time open-circuit constant;



(i) τq0 is the quadrature-axis subtransient open-circuit time constant;
(j) τd

is the direct-axis subtransient short-circuit time constant;
(k) τq

is the quadrature-axis subtransient short-circuit time constant.

A machine designer should be capable of giving values for all the above-listed param-
eters; in principle, this is quite a straightforward task and may be performed by using the
methods discussed in this book. In practice, however, it is a very demanding task since the
magnetic conditions vary from one operating point to another. This means that the induc-
tances and the resistances are not constant in the equivalent circuits. As an example, it could
be mentioned that even the stator leakage inductance saturates when large stator currents
are present. The best results for the above-mentioned parameters are found by experiment
or by transient finite element analysis (FEA). If the machine is large, only the FEA method
is available.

7.2.1.1 Referred Rotor Parameters

Resistance of Field Winding Referred to the Stator and its Flux Leakage
First, we analyse the field winding parameters referred to the stator. The DC resistance of the
field winding is RfDC . The effective number of turns for a field winding per pole is Nf . There
may be ar parallel paths in the rotor. If we wish to refer the rotor resistance to the stator, in
general it has to be multiplied by the term given in Section 7.1.2 (Equation (7.52))
 2
ms Ns kwνs
ρν = . (7.52)
mr Nr ksqνr kwνr
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366 Design of Rotating Electrical Machines

The number of turns is Nf on one pole and thus there are 2Nf turns on a pole pair, and,
in the whole rotor, a total of 2 pNf /ar turns in series. The winding factor of a salient-pole
field winding can be assumed to be one for the fundamental harmonic, kw1f = 1. The winding
factor of a nonsalient-pole rotor must be calculated, kw1f < 1. The phase number of the field
winding is one, m r = 1. Thus, Equation (7.52) can be rewritten for a field winding as

 2
ms Ns kw1s
ρ1 = . (7.151)
1 2 pkw1f Nf /ar

The resistance of the field winding of the rotor referred to the stator thus becomes

 2
Ns kw1s
Rf
= m s RfDC . (7.152)
2 pkw1f Nf /ar

Correspondingly, the leakage inductance of the field winding can be referred to the stator

 2
Ns kw1s
L
fσ = m s L fσ . (7.153)
2 pkw1f Nf /ar

The actual leakage inductance was calculated in Chapter 4. There, we obtained the leakage
inductance L fσ = µ0lm,rp Nf2 lp for a salient-pole rotor. By substituting the above quantities,
we obtain the leakage inductance of the complete salient-pole rotor

 2
2 pNf
L fσ = µ0lm,rp lp . (7.154)
ar

The leakage inductance of a nonsalient-pole rotor is calculated accordingly by using the

methods introduced for slot windings.

Damper Winding
Next, the resistance and the leakage inductance of a damper winding are investigated. The
simplest damper winding is a solid-rotor construction, in which eddy currents can be induced.
The calculation of such a solid body is a challenging task, which cannot be solved analytically.
However, if we assume that the rotor material is linear, we are able to derive equations analyt-
ically for the material. Figure 7.31 illustrates the observation between the stator winding and
the surface current.  
Now, Ampère’s law H · dl = S J · dS is applied to the area between the stator and rotor
surfaces along the integration path of Figure 7.31 for the determination of the impedance of the
solid material of the rotor, observed from the stator. When the rotor surface moves at a speed
that is different from the current linkage harmonic of the stator, currents are induced in the
solid rotor. A field strength Hr caused by the damper currents acts upon the rotor surface. The
corresponding additional current of the stator is detectable as an additional current linkage
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Design Process and Properties of Rotating Electrical Machines 367

H · dl

stator material

linear current density

Hr0 δ

rotor material
rotor motion

Figure 7.31 Application of Ampère’s law between the surface currents and the stator currents. Note
that boldface l indicates the general integration route, not the length of the machine. The field strength
Hr0 is measured at the very surface of the solid rotor surface

of the stator. Now, the fundamental component Θ 1 of the current linkage of the stator and
the tangential field strength Ĥr (time-harmonic field strength vector amplitude) of the rotor
surface, assumed sinusoidal, are written equal to each other

τp
m 4 kw1 Ns √
π
Θ̂1 = 2Ir = Ĥr0 ejax dx, a= . (7.155)
2π p τp
0

 
In (7.155), the variable x runs on the rotor surface along one pole pitch x ∈ 0, τp .
We may now write for the rotor current referred to the stator

√

2jπ p
Ir= Ĥ r0 . (7.156)
amkw1 Ns

Ĥr0 is the amplitude of the time-harmonic field strength represented as a complex vector on
the rotor surface containing information on the phase angle.
The amplitude of the complex harmonic field strength Ĥr on the rotor surface corresponds
to the currents of the rotor. When the concept of surface current is employed, we can state that
the magnetic field at the interface equals the time-harmonic complex surface current ĴS with
a normal vector direction

ĴSr = n × Ĥr0 . (7.157)

n is the normal unit vector of the surface, pointing away from the metal. The surface current
is thus in the direction of the rotor axis when the field strength is tangential.
To be able to define the rotor ‘damper winding’ impedance, we have to solve the corre-
sponding induced voltage. Let us denote by B̂δ the amplitude of the air-gap flux density on
the rotor surface in complex form. First, the flux is integrated, and then the flux linkage and
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368 Design of Rotating Electrical Machines

the voltage referred to the stator are calculated

τp
kw1 Ns 2kw1 Nsl

U
r = −jωs √ B̂δ ejax l
dx = jωs √ B̂δ (7.158)
2 2a
0

where l
is the electromagnetic length of the machine. We obtain the rotor impedance referred
to the stator

U
r ωs (kw1 Ns )2 ml
B̂δ
Z
r =
= . (7.159)
Ir πp Ĥr0

The air-gap flux density is usually known, and also the field strength can be obtained in
some cases, if the damping currents of the rotor are known, for instance from the numerical
field solution. If the rotor is a disc made of magnetically linear material, we are able to cal-
culate the surface impedance Z Sr = RSr + jX Sr of the rotor (which has to be referred to the
stator)

Êr0 (0, t) Êr0 (0, t) 1+j ωr µ
Z Sr = = = = (1 + j) = RSr + jX Sr (7.160)
ĴSr (t) n × Ĥr0 (t) δσ 2σ

where δ is the penetration depth. The above can be applied for instance to the evaluation of
the characteristics of a damper winding produced
√ from aluminium sheet, if the sheet is thick
compared with the penetration depth δ = 2/ωr µσ . This is valid in particular for the har-
monics. The fundamental component, however, usually travels through the aluminium sheet.
The simplest way to evaluate such a plate is to divide it into fictional bars and to apply Equa-
tions (7.45)–(7.55) in analysing the ‘squirrel cage’. The angular frequency in the rotor with
respect to the harmonic ν at the fundamental slip s1 is

ωνr = ωs (1 − ν (1 − s1 )) . (7.161)

The above rotor surface impedance can be referred to the stator quantity

ωs (kw1 Ns )2 ml

Z
r = Z Sr . (7.162)
πp

If the rotor is made of a magnetically nonlinear material, an accurate analytic solution

cannot be obtained, but the field solution of the rotor has to be carried out numerically or semi-
analytically, for example with the multi-layer transfer matrix method (discussed in Pyrhönen,
1991). After the field solution, the average complex Poynting’s vector is calculated on the
rotor surfaces using the complex time-harmonic amplitudes of the E- and H-fields

∗
Êr0 · Ĥr0
Sr = . (7.163)
2
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Design Process and Properties of Rotating Electrical Machines 369

The value of Poynting’s vector is integrated over all the rotor surfaces, and thus we obtain
the apparent power S r of the rotor. Now the referred impedance of the rotor is obtained with
the peak value Ûm of the air-gap magnetic voltage

Ûm2 m
Z
r = . (7.164)
2S ∗

If the damper winding is constructed as a cage winding, its resistance RD
can be estimated
approximately as
 2
ms aslDs DDr σDs
RD
= 2 + κ, (7.165)
σDs NDs SDs π pSDr σDr

where
(kws1 Ns )2
κ= , (7.166)
p
τDs
as = (NDs − 1) , (7.167)
τp

m s is the phase number of the stator, σ Ds is the conductivity of the damper bar material, τDs
is the slot pitch of the damper winding referred to the inner diameter of the stator, NDs is the
number of damper bars per pole, σDr is the conductivity of the material of the short-circuit ring,
SDs is the cross-sectional area of the damper bar, lDs is the length of the damper bar, SDr is the
area of the short-circuit ring and, finally, DDr is the average diameter of the short-circuit ring.
First, the inductance of the damper winding is calculated with a constant air gap
 2
as as D
L
D

= 8µ0 ωs m sl lDs + 0.133 κ · 10−2 . (7.168)
NDs pNDs kC δ0

The permeance factor of a round damper bar is

b4 h1
lDs = 0.47 + 0.066 + ,
b1 b1

see Figure 4.10g; kC is the Carter factor, and δ 0 is the air gap of the nonsalient-pole machine
and the smallest air gap measured in the middle of the pole arc of a salient-pole machine.
In the case of a salient-pole machine, the direct- and quadrature-axis leakages can be ex-
pressed by Equation (7.168)

L
D
L
Dd = , (7.169)
ζd

L
D
L
Dq = , (7.170)
ζq
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370 Design of Rotating Electrical Machines

where ζ d and ζ q are, for salient-pole machines,

0.2913
ζd = 1.746 − 0.422as − , (7.171)
as − 0.138

0.102
ζq = 1.222 − 0.1as − . (7.172)
as − 0.1

7.2.2 Loaded Synchronous Machine and Load Angle Equation

A synchronous machine can operate either as a motor or as a generator. A synchronous ma-
chine may also operate either as over- or underexcited. The terms ‘overexcitation’ and ‘un-
derexcitation’ seem to have two different definitions in the literature. For instance, Richter
(1963) has defined overexcitation in two ways:

I. In an overexcited synchronous machine, the field winding current is larger than at no load
at the rated voltage.
II. An overexcited machine has a field winding current large enough to be capable of sup-
plying inductive load magnetizing current.

In practice, according to Definition I, a synchronous machine operates almost always

overexcited. This definition is, therefore, not very useful.
The second definition necessitates a remarkably larger field winding current before overex-
citation is reached. According to this second definition, a machine may be underexcited while
operating overexcited according to Definition I. This may be seen for instance in Figure 7.38b,
where the stator current has a d-axis component opposing the field winding current. Accord-
ing to Definition I the machine operates overexcited, whereas according to Definition II the
machine operates underexcited.
In the following, we will, however, use Definition II, since it is very practical and may be
used on various occasions. Hence, an overexcited synchronous machine supplies the reactive
current required by the inductive loads to the network. The overexcited machine appears as
a capacitor to the network, and correspondingly, when underexcited, it takes the required
additional magnetizing from the network appearing thus as a coil to the network. Normally, the
synchronous machines run overexcited in the network, cos ϕ = 0.7–0.8. The machines seldom
operate underexcited, but in a situation where a large generator supplies a long transmission
line with a power below the natural power of the line, the voltage tends to increase towards
the end of the line, and the machine itself may then run underexcited. Figure 7.32 illustrates
the effect of various load currents on the magnetization of the generator. This generator is
operating alone in an island.
In each case, there is a peak value î = 1 of the current flowing in the generator winding
U1–U2 at the moment of observation. Since in a symmetrical three-phase system the sum of
phase currents is zero, there is a negative current i = −1/2 flowing in the windings V1–V2
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L load
(a)
i=1
i=½ i=½
moment of observation
φf ef
V2 U1 W2
em i, φ
φm a

U2
W1 V1 L md L L load

φa φf ef em us

(b) C load

i =1
i =½ i=½ moment of observation

U1
V2 W2 φm em

ef

i , φa φf

U2 L md L C load
W1 V1

ef em us
φa φf

RCload
(c)
i=1 moment of observation
U1
i=½ i=½
i, φ a
φ m ef
V2 W2 φf

φa RC load
Lmq L
W1 V1
φf ef em us
U2

Figure 7.32 (a) Effect of an inductive load on the magnetization of a generator. The armature reaction
φ a of the stator created by the inductive load current i tends to weaken the flux φ f generated by the field
winding. The air-gap flux is a sum of φ f and φ a . The armature reaction weakens the flux produced by
the magnetization of the field winding. The d-axis equivalent circuit with L md is used. (b) Effect of a
capacitive load current i on the flux of a synchronous generator. The armature reaction φ a strengthens
the flux φ f produced by the field winding. (c) Effect of internally resistive load current on the flux of a
synchronous machine. The armature flux φ a created by the resistive current i is normal to the flux φ f
created by the field winding. Note that now the inductance in the equivalent circuit is changed to L mq as
the q-axis of the machine is magnetized
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372 Design of Rotating Electrical Machines

and W1–W2. Now, in Figure 7.32a, we see that when the inductive current is 90◦ behind the
emf ef (t) induced by the flux linkage, the flux φ a that is created by the armature current and
that is at the same phase as the load current has a phase shift of 180◦ with the flux φ f created
by the actual field winding. The flux φ a thus weakens the flux φ f . If we wish to keep the emf
of the machine at a value corresponding to the nominal voltage, the DC field winding current
of the generator has to be increased from the no load value to compensate for the armature
reaction caused by the inductive load current; the generator is then operating overexcited.
Figure 7.32b illustrates a generator supplying a capacitive load. The moment of observation
is selected at the negative peak value of the load current in the winding U1–U2. Now the
armature winding creates a flux with the capacitive current, this flux being parallel to the flux
φ f created by the magnetizing current. Thus, the DC field winding current of the generator
can be reduced from the no load value while the terminal voltage remains constant.
Figure 7.32c investigates an armature reaction caused by an internally resistive current.
An internally resistive load current is a current that is resistive with respect to the emf. The
emf and the load current are temporally in the same phase. Since the internal reactance of the
generator is inductive, to reach the situation described above we have to connect the capacitors
in parallel with the load resistances. The absolute values of the reactances of these capacitors
have to be equal to the absolute value of the reactance of the generator. At the moment of
observation, the current of the winding U1–U2 is at maximum. Now the current linkage of the
stator winding creates a flux Φ q , which is transverse to the flux of field winding Φ f . A large
air gap in a salient-pole machine restricts the flux created by the quadrature current linkage.
The situation of Figure 7.32c is illustrated as a phasor diagram in Figure 7.33.

q-axis Is X q

Ef

Is Us

Φ{ Φs
Φq Φm
d-axis
Φf If

Figure 7.33 RMS value phasors corresponding to the instantaneous values of the generator of Figure
7.32c according to generator logic. Φ f is the flux created by the field winding that induces the emf E f of
the machine, Us is the terminal voltage, Is is the phase current, Φ q is the quadrature flux of the armature
reaction, which includes also the effect of the flux leakage, Φ s is the total flux of the stator, Is X q is the
inductive voltage drop created by the internally resistive load current at the quadrature reactance. An
internally resistive load has no DC component. The ‘generator logic’ discussed in Chapter 1 is followed
here
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Design Process and Properties of Rotating Electrical Machines 373

Example 7.5: A synchronous machine has the following per unit quantities: lsσ = 0.1,
lmd = 1.5, lmq = 0.6, rs ≈ 0. Calculate the per unit field winding current needed to main-
tain ψs = 1 at no load, or when the machine is loaded with an inductive current i L = 0.5,
a capacitive current i C = 0.5 or an internally resistive current i R = 0.5.
Solution: At no load, the field winding current must alone produce the stator flux linkage
absolute value of ψsd = 1, and hence i f = ψsd /lmd = ψmd /lmd = 1/1.5 = 0.67. We can
see that the magnetizing inductance size defines how much field winding current is needed.
In this case, the d-axis magnetizing inductance lm is fairly large, and the no-load i f is fairly
small. If lm is small, the armature reaction is also small, but more i f is needed.
During an inductive load, the armature reaction is opposing the field winding cur-
rent linkage, and hence we define the current as negative. The armature reaction is
now ψsd = lmd × i L = 1.5 × (−0.5) = −0.75. The d-axis stray flux linkage is ψsσd =
lsσ × i L = 0.1 × (−0.5) = −0.05. The d-axis stator flux linkage is found as ψsd = lsσ ×
(i L ) + lmd (i L + i f ). The field winding current must produce an extra flux component to
compensate for the armature reaction and the stray flux linkage. As the stator flux linkage
must remain at its initial unity value, we have 1 = lsσ · i L + lmd (i L + i f ).
Now we get

i f = (1 − lsσ · i L − lmd i L )/lmd , i f = [1 − 0.1 · (−0.5) − 1.5 · (−0.5)]/1.5 = 1.2.

During a capacitive load, the armature reaction is + lmd × i C = +1.5 × 0.5 = +0.75.
The stator stray flux linkage is +lsσ × i C = +0.1 × 0.5 = +0.05. Both of these val-
ues are now increasing the stator d-axis flux linkage, which means that the field wind-
ing current has to be decreased by i f = −0.537. Now i f = [1 − 0.1 × (+0.5) − 1.5 ×
(+0.5)]/1.5 = 0.133.
Hitherto, all the flux and current phenomena have to take place on the d-axis. During
an internally resistive load, however, the armature reaction and the leakage flux linkage
are, according to Figure 7.33, on the quadrature axis. The absolute value of the quadra-
ture armature reaction is lmq × i R = 0.6 × 0.5 = 0.3. The quadrature-axis stray flux link-
age is again lsσ × i R = 0.1 × 0.5 = 0.05. Together these flux linkages change the quadra-
ture flux linkage by ψ sq = 0.35. On the d-axis, there is only the field winding current
and the flux linkage created by it. We write now for the stator flux linkage

  

2
ψs = ψsd
2
+ ψsq
2 = (i flmd ) + i Rlsσ + i Rlmq = 1 = (i f 1.5)2 + 0.352 → i f = 0.624.
2

Figure 7.34 illustrates the phasor quantities of a salient-pole machine when the power factor
of an external load is inductive, the load current being thus behind the terminal voltage.
Assuming the voltage I s Rs over the resistance Rs of the stator winding to be zero (the
underlining denotes a phasor, while a symbol without underlining denotes an absolute
value), we may now employ the synchronous inductances L d and L q (L d = L md + L sσ ,
L q = L mq + L sσ ). All the quantities in the equations are phase quantities assuming a star
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374 Design of Rotating Electrical Machines

q, Im
jωs Lmq Iq

Ef jωLmd Id

jωs L sσ Is
U s, E s
Em
LmdI d Lsσ Is Ψs δ
ϕ Is

LmqI q Ψm
δ Iq
d, Re
Ι f,Ψ f Id

Figure 7.34 Phasor diagram of the steady state of a salient-pole generator with an inductive load cur-
rent Is (an overexcited generator). Is is divided into two components. Id is the direct-axis current, since
it creates a parallel but a counter-rotating flux with the flux linkage Ψf of the DC field winding current.
Iq is the quadrature-axis current, since it creates a quadrature flux. The quadrature-axis current Iq is also
called an internal active current, since it is in the same phase with the emf E f . The angle δ, which is
the angle between E f and the terminal voltage Us , is the internal load angle of the machine. The fig-
ure is constructed with per unit values, although the notations are in principle real values. In the figure
lmd = 1, lmq = 0.7 and lsσ = 0.1, u s = 1 and i s = 1. Note that the quantities in the phasor diagram are
phase quantities. Thus, for example, Us is now the phase voltage

connection:

E f − I d jωs L d = (U s cos δ)ejδ , (7.173)

I q jωs L q = U s sin δ e+j( 2 +δ) = jU s sin δ ejδ .

π
(7.174)

Equations (7.173) and (7.174) yield for the currents I d and I q

−U s cos δ ejδ + E f
Id = , (7.175)
jωs L d

U s sin δ ejδ
Iq = . (7.176)
ωs L q

Since I s = I d + I q , we obtain

− cos δ ejδ sin δ ejδ Ef

Is = Us + Us + . (7.177a)
jωs L d ωs L q jωs L d
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Design Process and Properties of Rotating Electrical Machines 375

Using the relations cos δ = (ejδ + e−jδ )/2 and j sin δ = (ejδ − e−jδ )/2, Equation (7.177a)
reduces to

U s
jδ  Us
 Ef
Is = −e − e −jδ e jδ + (−j) e jδ − e −jδ e jδ +
2jωs L d 2ωs L q jωs L d
U s
j2δ  U s
j2δ  Ef
=j e +1 −j e −1 −j (7.177b)
2ωs L d 2ωs L q ωs L d
 
U 1 1 U 1 1 E
=j s + +j s − e j2δ − j f .
2ωs L d Lq 2ωs L d Lq ωs L d

Next, the power P = 3U sph I s cos ϕ is calculated with the phase quantities. Choosing U s
as the real axis and substituting for E f = E f (cos δ + j sin δ), we get for the real component
of I s

Us 1 1 Ef
ReIs = − − sin 2δ + sin δ (7.178)
2ωs Ld Lq ωs L d

and for the power

√
P = 3Usph Is cos ϕ = 3Us Is cos ϕ
 (7.179)
Usph E f 2 Ld − Lq
=3 sin δ + Usph sin 2δ .
ωs L d 2ωs L d L q

This equation is known as the load angle equation of a salient-pole machine. Equation (7.179)
shows that with a nonsalient-pole machine, for which L d = L q , the equation is simplified as
the latter term becomes zero. If the voltages of the equation are written as line-to-line volt-
ages, the factor 3 in front of the large bracket is omitted. When the mechanical power is zero
and the losses are neglected, the reactive power is obtained from Equation (7.177b) by substi-
tuting δ = 0
 
Usph E f − Usph
2
Q=3 ; (7.180)
ωs L d

in other words, it is the imaginary part of (7.177b) multiplied by Usph .

Figure 7.35 illustrates the graphs of the load angle equation as a function of load angle. The
figure shows the notable effect of the dimensioning of the magnetic circuit on the operation
of the machine. When the synchronous inductances of the machine diverge in the direct and
quadrature direction, the load angle curve of a salient-pole machine is created. The load an-
gle curve of a nonsalient-pole machine comprises a single sine term only. The highest power
is reached with a nonsalient-pole machine at a load angle δ = 90◦ . The maximum torque
and power of a salient-pole machine are reached at a load angle of less than 90◦ . One of the
core tasks of a designer is to design a synchronous machine in such a way that the required
inductance values are reached, since these values have a considerable influence on the char-
acteristics of the machine.
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376 Design of Rotating Electrical Machines

1.5

torque, power
a
1
b
0.5
c
0

–0.5

–1

–1.5
–180 –135 –90 –45 0 45 90 135 180
o
load angle δ /

Figure 7.35 Graph of the load angle equation of a salient-pole machine (a) and a nonsalient-pole
machine (b). The curve (c) illustrates the reluctance torque of a salient-pole machine

Figure 7.35 also illustrates the principle of a synchronous reluctance machine. In Equa-
tion (7.179), the latter term, based on the magnitude of the difference between the direct and
quadrature inductances, describes the load angle equation of a synchronous reluctance ma-
chine. Such a machine is thus in principle a salient-pole machine without a field winding. In
the case of a synchronous reluctance machine, the target is to maximize the difference between
the direct and quadrature reactance so that curve (c) of Figure 7.35 produces a maximum peak
torque.

7.2.3 RMS Value Phasor Diagrams of a Synchronous Machine

There are two basic logical systems in the phasor diagrams: a ‘generator logic’ and a ‘motor
logic’, see Chapter 1. In the generator logic, the flux created by the rotor excitation induces the
stator emf, and then the stator current is created as a result of the induced emf; therefore, it is
approximately parallel to it (within ±90◦ ). In the motor logic, the supplied stator terminal
 volt-
age is first integrated with respect to time to obtain the stator flux linkage Ψs (t) ≈ u s (t) dt;
the emf is considered a counter-rotating electromotive voltage es (t) = − (dΨs (t) /dt). The
current is considered to be created as an influence of the terminal voltage, and therefore, in
the motor drive, its phasor is approximately in the same direction as the voltage.
Next, phasor diagrams of various synchronous machines with different load conditions are
investigated. The phasor diagram gives a clear picture of the phase shifts between different
waveforms of the machines. However, the RMS value phasor diagram is valid only for sinu-
soidal quantities at steady state. With phasor diagrams corresponding to RMS value diagrams,
we are able also to investigate dynamic states, which, however, are outside the scope of this
chapter.
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Design Process and Properties of Rotating Electrical Machines 377

7.2.3.1 Nonsalient Synchronous Machine

A nonsalient synchronous machine is nearly symmetric, since the uniformity of the air gap
is disrupted only by the slotting of the stator and the rotor. The rotor slots are usually not lo-
cated regularly on the periphery of the rotor to produce as sinusoidal a flux density as possible
with the rotor current linkage, as discussed in Figure 2.3. If a uniform slot pitch is selected,
normally two-thirds of the rotor surface is equipped with slots and windings. Therefore a
slight magnetic asymmetry occurs also in nonsalient-pole machines. In these machines, the
stator resistance Rs causes a voltage drop. The magnetizing reactance X m obtained from the
magnetizing inductance L m and the leakage reactance X sσ obtained from the leakage induc-
tance L sσ of the stator phase winding are impedances, over which a voltage can be considered
to take place. In reality, the flux linkages created in these inductances reduce the total flux
linkage of the machine so that the voltages induced in the machine remain lower than the
imaginary emf induced by the rotor flux linkage. When the equivalent circuits are presented,
it is usually advisable to interpret the phenomena arising in the inductances as voltages. In
the phasor diagrams, we employ a direct-axis synchronous inductance L d , which is the sum
of the magnetizing inductance L md and the leakage inductance L sσ . Figure 7.36 illustrates
a suitable equivalent circuit for a nonsalient-pole machine. This is an RMS value equivalent
circuit corresponding to the equivalent circuit of the d-axis of a previously discussed phasor
equivalent circuit.
The emf E f induced by the flux linkage Ψf created by the rotor field winding is the driv-
ing force in the equivalent circuit. The terminal voltage is U s = E f − I s Rs − I s jωs L sσ −
I s jωs L m . The magnetizing flux linkage Ψf is 90◦ ahead of the emf E f . In the stator cir-
cuit, a current I s is created by the emf. This current in turn creates an armature flux link-
age Ψ a = L m I s + L sσ I s . The armature flux linkage, that is the armature reaction, is thus in
the same phase as the current. The resulting total flux linkage, or the stator flux linkage, is
Ψ s = L m I s + L sσ I s + Ψ f .

7.2.3.2 Phasor Diagram of a Nonsalient-Pole Synchronous Generator

A synchronous generator may be connected either to an active network containing other ma-
chines that maintain the grid voltage, or to a passive island load where the generator alone is
responsible for the voltage. In a network drive, we assume that the network determines the

Lm L Rs Is

Um U s'
Ef Ef Us
Em Es

Figure 7.36 RMS value equivalent circuit of a nonsalient-pole generator in synchronous operation
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378 Design of Rotating Electrical Machines

terminal voltage of the generator and the field winding current of the generator determines
the reactive power balance of the generator. In an island drive, the load determines the power
factor of the generator and the field winding current is used to adjust the terminal voltage
of the generator. In principle, a phasor diagram construction is independent of the operating
mode of a generator. In this presentation, however, the phasor diagrams are drawn with a fixed
terminal voltage. In synchronous generator drives, such a case may be reached in both island
and rigid network operation.
As a synchronous machine operates as a generator, we assume naturally that the emf E f
produces the current I s . Therefore, in the phasor diagrams of a synchronous generator, the
active components of the voltage U s and the current I s are illustrated as being approximately
parallel. In the diagram, there is also voltage U
s , which is the terminal voltage reduced by
the resistive voltage loss I s Rs of the stator. The voltage U
s is employed in the determination
of the direction of the stator flux linkage Ψ s . The field-winding-created flux linkage Ψ f is
illustrated 90◦ ahead of the emf E f and the armature reaction plus leakage Ψ a = L m I s +
L sσ I s parallel to the stator current. For the geometric sum of the magnetizing flux linkage Ψ f
and the armature reaction flux linkage plus leakage (Ψ a = L m I s + L sσ I s ), we obtain the total
flux linkage Ψ s , which is 90◦ ahead of the voltage U
s . Figure 7.37 illustrates the RMS value
phasor diagrams of a nonsalient-pole generator, (a) overexcited and (b) underexcited.
In Figure 7.37a, the current of the nonsalient-pole synchronous generator is lagging the
voltage, and therefore the machine operates overexcited supplying inductive reactive power
to the network (the phase shift of the external load is inductive). An overexcited machine
is easily recognizable from the magnitude of the emf E f , the absolute value of which
for an overexcited machine is significantly higher than the terminal voltage Us . Note that
the load angle remains notably lower in the case of an overexcited machine when com-
pared with an underexcited machine. Overexcited synchronous machines are used in many

I s Rs
Ef
j ω s L mI s
Us Es
q
jωsLmIs
jω s L I s jωs L I s
Em Ef
Us', Es, Us Is E Us', Es
m

L Is Ψs L Is Ψs Us
Is
δ ϕ δ
LmIs Ψm LsIs Ψm ϕ

d d
Ιf, Ψf Ιf, Ψf
(a) (b)

Figure 7.37 Phasor diagrams of a nonsalient-pole synchronous generator operating at a constant ter-
minal voltage U s,pu = 1 according to generator logic (a) overexcited (lagging power factor, delivers
inductive power to the network) and (b) underexcited (leading power factor, absorbs inductive power
from the network). A salient-pole shoe, despite the nonsaliency of the machine, is depicted to show the
direction of the rotor excitation
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Design Process and Properties of Rotating Electrical Machines 379

industrial plants to provide the magnetizing power, that is inductive reactive power for the
asynchronous machines and other inductive loads in the plant. Figure 7.37b shows that the
phase shift angle ϕ of the synchronous generator is below 90◦ and capacitive. We may some-
times read that the generator, when operating underexcited, supplies the network with ca-
pacitive reactive power. This, however, is a misleading conception, implying that the capac-
itor would consume capacitive reactive power (and thus, in terms of dual thinking, would
produce inductive reactive power). As we know, a capacitor is not assembled to consume
capacitive reactive power, but to compensate for the effects of inductive loads in the net-
work. A capacitor is an electrical energy storage device, in which for instance the energy
stored in magnetic circuits can be transferred and released over time. In the case of a syn-
chronous machine, the most unambiguous way to describe the situation is to speak, ac-
cording to Definition II in 7.2.2, about over- or underexcited machines, and thus to avoid
misunderstanding.

7.2.3.3 Nonsalient-Pole Synchronous Motor

Figure 7.38a illustrates the phasor diagram of an overexcited nonsalient-pole motor. The direct
armature flux is, as a result of overexcitation, partly opposite to the field winding flux, and the
total flux corresponding to the terminal voltage U
s of the machine tends to decrease from its
no-load value. Since the network voltage decides the terminal voltage U s of the motor, and in
the real machine U
s and U s are approximately equal because of the small stator resistance,
the field winding current of the machine has to be adjusted in order to keep the reactive
power conditions unchanged. In the figure, the imaginary emf E f is higher than the terminal
voltage U s .
For a machine disconnected from the network and running at no load, the terminal voltage
U s , U
s and the electromotive force E f are equal. If a synchronous motor is employed in
the compensation of inductive loads (the reactive current equals the reactive current of the
overexcited synchronous generator), the motor has to be overexcited.
Figure 7.38b illustrates the phasor diagram of the corresponding underexcited synchronous
motor. The current still has a small negative direct component that resists the field winding
magnetization of the rotor. However, we can see that the armature flux enforces the effect
of the magnetizing flux when compared with the previous case of overmagnetizing: Ψ s is
higher than Ψ m . This is necessary, since the terminal voltage is defined by the supplying net-
work, and the voltage U
s induced by the total flux has to remain close enough to the terminal
voltage U s .
Figures 7.38a and b illustrate the motor logic. When a voltage is connected to the stator
winding, the stator flux linkage is created. We know that the flux linkage can be given as an
integral of the voltage, Ψs (t) = (u s (t) − i s (t) R) dt. This flux linkage is about 90 electrical
degrees behind the voltage, when the motor operates in a stationary state with sinusoidal
quantities. Even if there existed a flux linkage created by the rotor current in the machine
before the stator voltage was connected, after the transience, the flux linkage of the machine
would settle to correspond to the integral. The real stator flux linkage Ψ s corresponds to the
terminal voltage U
s . Note that this flux includes, in addition to the air-gap flux, the influence
of the stator flux leakage. Therefore, the flux related to this flux linkage cannot be directly
measured, although it induces the emf E s of the stator, which is opposite to the voltage U
s
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380 Design of Rotating Electrical Machines

q
q

Us = 1 Us = 1 Is = 1
Is = 1 Lsó I s = 0.1
s =1
s =1 Lsó I s = 0.1
m Lm I s = 0.65
m
Lm I s = 0.65

d d
f = 1.42 If = 2.18 f = 1.08 If = 1.66

Es
Es Em
Em j s Lsó I s Ef j sLsó I s
j sLm I s
Ef j sLm I s

(a) (b)

Figure 7.38 Phasor diagrams of a nonsalient pole synchronous motor with i s = 1, u s = 1, lm = 0.65
and lsσ = 0.1. At no-load ψf = ψm = ψs = 1 and i f = ψf /lm = 1.53. At load (a) overexcited, ψf = 1.42
and i f = ψf /lm = 1.42/0.65 = 2.18 and (b) underexcited ψf = 1.08, i f = 1.08/0.65 = 1.66. Despite
the nonsaliency of the motor, the pole shoes are illustrated to show the directions of the d- and q-axes.
The synchronous inductance in the case is relatively small, ls = 0.75

that created the stator flux linkage. The current of the machine is defined in this logic by the
small sum voltage of U s and E s , which creates a current in the stator resistance Rs of the
machine.
It is worth emphasizing that in reality only the air-gap flux Φ m can be measured. The air-
gap flux linkage Ψ m corresponds to this flux. When the leakage flux linkage Ψ sσ = L sσ I s is
added to the air-gap flux linkage, we obtain the sum flux linkage, that is the stator flux linkage
Ψ s , which is created as an effect of all the currents in the machine. The logic is based on
the principle according to which the total flux linkage of the machine is the superposition of
the magnetizing flux linkage Ψ f (the time derivative of which creates the imaginary emf), the
armature flux linkage Ψ a and the leakage flux linkage Ψ sσ , all of which create an induction
of their own (Ψ f vs. E f , Ψ a = L m I s vs. −jωs L m I s , and Ψ sσ = +L sσ I s vs. −jωs L sσ I s ). In
reality, only a single total flux linkage occurs in the machine, namely the stator flux linkage
Ψ s , and in the armature windings, only the electromotive voltage E s is induced as a result of
the total flux linkage. In a loaded machine, the emf E f is only imaginary, since there exists
no corresponding flux linkage component Ψ f in reality, as the armature reaction Ψ a and the
leakage Ψ sσ have reduced the real flux linkage of the machine to the sum flux linkage Ψ s .
If the machine is running at no load (as a generator), disconnected from the network and
excited with the rotor field winding current, no armature current occurs in the machine, and
thus E f can be measured from the terminals of the machine (Ψ f = Ψ m = Ψ s ). Ψ f values as
high as illustrated with a loaded machine in the phasor diagrams can never be measured from
a real machine, since it should be heavily saturated at no load with a field winding current
corresponding to the state of rated loading.
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Design Process and Properties of Rotating Electrical Machines 381

7.2.3.4 Salient-Pole Synchronous Machine

Because of the rotor structure of a salient-pole machine, the air gaps are of different sizes in
the direct and quadrature directions. As a result of this magnetic asymmetry, the equivalent
circuits of synchronous inductances illustrating the inductances of a salient-pole machine are
given separately for direct and quadrature directions in Figure 7.30. The direct synchronous
inductance is, according to Figure 7.30a, L d = L md + L sσ , where L md is the direct-axis mag-
netizing inductance and L sσ is the leakage inductance of the stator. The quadrature-axis syn-
chronous inductance is correspondingly L q = L mq + L sσ , where L mq is the quadrature-axis
magnetizing inductance.
The stator current I s of a salient-pole machine is composed of two components, namely
the direct-axis current I d and the quadrature-axis current I q , and is called the internal active
power current of the machine, since it is in the same phase as the emf E f of the machine.
The load current creates the armature flux linkage, which is divided into direct and quadrature
components. The direct-axis armature flux linkage Ψ d is at an angle of 180◦ to the magne-
tizing flux linkage Ψ f , and the quadrature-axis flux linkage Ψ q is at an angle of 90◦ . The
stator flux linkage Ψ s is the geometric sum of the direct- and quadrature-axes armature flux
linkages and the flux linkage of the DC excitation Ψ f . According to the generator logic, the
stator flux linkage is 90◦ ahead the terminal voltage U s , cf. Figure 7.39. The terminal voltage
is U s = E f − I s Rs − jI d ωs L md − jI q ωs L mq − jI s ωs L sσ (cf. the salient-pole machine phasor
diagrams in the following).

7.2.3.5 Salient-Pole Synchronous Generator

With respect to the reactive power of the network, an overexcited synchronous machine acts
like a capacitor. In the phasor diagram of a synchronous generator, the stator current I s is
behind the voltage U s . Figure 7.39 illustrates the phasor diagrams of an overexcited and an
underexcited salient-pole synchronous generator according to the generator logic. An under-
excited generator operates like a coil with respect to the reactive power of the network, and

j ω s L mqI q

Ef j ω sL md Id
jωs Lmq Iq
jωs LmdId
jω s L I s j ωs L I s
E f I Em
U s, E s s
Em L Is Ψ Us
L Is Ψ ϕ
LmdI d s δ Lmd Id
s Es
ϕ Is δ
Ψm
LmqIq Ψm LmqIq
δ Iq δ Iq
Ι f, Ψ f Id Ι f, Ψ f Id
(a) (b)

Figure 7.39 Phasor diagram of a salient-pole generator with i s = 1, u s = 1, lmd = 1, lmq = 0.65, lsσ =
0.1 and rs = 0 (a) overexcited and (b) underexcited
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382 Design of Rotating Electrical Machines

− j I dω s L − jI qω sL q
I sR s
U '
s
Is
Em U s

δ
Iq
ϕ

Ψs

Ψq
δ

Ψd Ψm Id

Figure 7.40 Synchronous reluctance generator phasor diagram drawn according to the generator logic
with i s = 1, u s = 1, lmd = 3.44, lmq = 0.14 and lsσ = 0.1. L d /L q = 15 is as high as possible, and E f =
0. The stator current must have a component Id that magnetizes the machine d-axis

thus takes the required extra magnetizing from the network. The stator current I s is now ahead
of the voltage U s . This may seem confusing, but the terminal voltage and current phasors in
the case of a generator describe the current of the generator load. When the load is inductive,
the current lags the voltage, and when the load is capacitive, the current leads the voltage.
By removing the rotor field winding current, a salient-pole machine is turned into a syn-
chronous reluctance machine. A synchronous reluctance machine can naturally operate either
as a motor or as a generator. Figure 7.40 illustrates the operation of a synchronous reluctance
machine with a phasor diagram. There is no magnetizing current, and thus the respective flux
linkage is lacking in the machine. The flux linkage components have to be created by the sta-
tor currents if this generator is working direct on line with constant voltage and frequency. If
not, there must be a set of capacitors brought to the terminals as noted in the section on the
induction generator.

7.2.3.6 Salient-Pole Synchronous Motor

Figure 7.41a illustrates the phasor diagram of an overexcited salient-pole motor. The angle
δ
between the emf E f and the air-gap emf E m or the field winding flux linkage Ψ f and the
air-gap flux linkage Ψ m is the internal load angle. Correspondingly, the angle δ between the
emf E f and the emf E s or the field winding flux linkage Ψ f and the stator flux linkage Ψ s
is the load angle. The higher the angles, the more torque the synchronous machine yields as
long as the pull-out point is not exceeded. Here −jωL mq I q is the voltage over the quadrature-
axis reactance and −jωL md I d the voltage over the direct-axis reactance. Is Rs is the voltage
over the resistance of the stator winding. The direct-axis armature flux reduces the relative
length of the field winding flux. This is necessary to keep the voltage U
s in proper proportion
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Design Process and Properties of Rotating Electrical Machines 383

Us
Us Iq Is
Is U s'
L Is
Ψs I sL Lmd Id Ψs L md I d
ϕ U 's
Iq ϕ
L mqI q Ψm L mq I q
Ψ m

δ δ
δ ' δ'
Id Ιf , Ψ f Id Ιf, Ψ f
δ '
δ'
δ δ
Es
Es
Em
−jω s L I s
Ef E m − jω s L I s
− j ω s Lmd I d
− j ω s L mq I q
− j ω s L md I d
Ef

− j ω s L mq I q
(a) (b)

Figure 7.41 (a) Overexcited salient-pole motor with i s = 1, u s = 1, lmd = 1, lmq = 0.65 and lsσ = 0.1.
The direct-axis armature flux considerably reduces the flux of the DC magnetizing. (b) Phasor diagram
of an underexcited salient-pole motor. The direct-axis current here is also still slightly negative and
reduces the flux linkage created by the field winding magnetizing

with respect to the terminal voltage, since a strong network or a converter chiefly determines
the terminal voltage U s . The voltage U
s defines the stator flux linkage. The currents of the
machine have to adjust themselves so that they also produce the same stator flux linkage.
According to the equivalent circuits of Figure 7.29 and the phasor diagrams, we can under-
stand that,
  in the motor
mode, the stator
 flux linkage is formed by integrating the voltage
Ψ s = Usd − Id Rs + j Usq − Iq Rs dt and the currents have to adapt themselves to the
flux linkage determined by the voltage so that exactly

the same
 stator
 flux linkage is obtained
as Ψ s = Id L sσ + (Id + ID + If ) L md + j Iq L sσ + Iq + IQ L mq .
Figures 7.41a and b show that usually the armature flux opposes the effect of the
magnetizing flux. This is valid for both over- and underexcited machines according to
Definition II.

7.2.4 No-Load Curve and Short-Circuit Test

To determine the characteristics of a synchronous machine, an extensive series of tests has to
be carried out. The methods are standardized (e.g. in the European standard IEC 60034-4). Of
these methods, only the two simplest are discussed here.
If a constant voltage source has a constant inductance, the corresponding impedance can
be determined as the ratio of the voltage of the open circuit to the corresponding short-circuit
current. This can be applied also to synchronous generators. When the inductance is a function
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384 Design of Rotating Electrical Machines

air gap straight line

U, Ik rve
no-load cu
UN L

ine
uit l
irc
rt c
IN sho
Ik0
I'k0

0
0 If
I'f 0
If 0

If k

Figure 7.42 No-load curve of a synchronous machine and the short-circuit straight line. The figure
also illustrates the air-gap straight line, which the no-load curve would follow if the permeability of iron
were infinite. The machine can also be linearized with a straight line passing through point L corre-
sponding to the rated voltage of the machine UN . The figure also illustrates the behaviour characteristic
of synchronous machines: the short-circuit current can be lower than the rated current in a permanent
short circuit. This is due to the direct-axis synchronous inductance. A synchronous machine produces
temporarily a high short-circuit current only at the initial state of short circuit. In no-load conditions,
the field winding current If0 corresponds to the rated stator voltage (in a machine with infinite iron per-
meability, the no-load field winding current should be replaced by If0
). If the stator is short-circuited,
the short-circuit stator current is Ik0 at the same If0 . In short circuit, the field winding current Ifk cor-
responds to the rated stator current. Based on the ratio of these two currents, the referring factor from
stator to rotor is defined: g = If0 /Ik0 . This referring factor is of particular importance in power electronic
synchronous motor drives, where the field winding current takes part in the vector control

of the no-load voltage, as is the case in the saturating iron circuit, a no-load curve in generating
mode is required. The so-called unsaturated synchronous inductance is, however, constant,
since it is determined by the air gap of the machine.
To determine the no-load curve, the machine is rotated at rated speed, and the terminal
voltage is measured as a function of field winding current. In the sustained short-circuit test,
the machine is rotated at rated speed, the terminals are short-circuited, and the phase currents
are measured as a function of field winding current. The results of these tests are illustrated in
Figure 7.42.
The machine is excited in these tests with a rotor field winding current If . As the machine
rotates at constant speed, a no-load curve can be created for the machine running at no load.
Typically, the curve saturates immediately after the rated voltage, since the iron parts of the
magnetic circuit begin to saturate. However, the curve is linearized in two ways: the air-gap
straight line gives only the effect of the air gap, whereas the straight line that passes through
the point L includes also the effect of the iron linearized to this exact point.
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Design Process and Properties of Rotating Electrical Machines 385

Ef = ωsΨf

jωsLmIk

Em
Ψm
Ψa jωs L Ik Ik

Ψf, I'f IkRs=U's

Us = 0 ,Ψs = 0

Figure 7.43 Phasor diagram of a short-circuit nonsalient-pole generator at steady state. The flux link-
age Ψ a of the armature reaction nearly compensates for the flux linkage Ψ f of the magnetizing current,
leaving a low flux linkage Ψ m in the air gap, which creates a voltage that is consumed as an effect of
Ik in the stator resistance Rs and in the leakage inductance L sσ . Note that in the short-circuit test, the
current linkages (as If
and I k are about the same size when referred to the stator side, as is the case
here) of the stator and rotor are approximately equal but opposite. Thus, it is possible to approximate the
referring factor of the rotor current with the short-circuit test

The phasor diagram of a steady-state short circuit is illustrated in Figure 7.43.

The unsaturated synchronous impedance is determined with the air-gap straight line. With
the notation of Figure 7.42 we obtain

UN
Z d
= √
, (7.181)
3Ik0

where UN is the rated line-to-line voltage of the machine. However, the most cost-effective
solution is usually reached when the machine is saturated with its rated voltage. The corre-
sponding synchronous impedance is

UN
Zd = √ , (7.182)
3Ik0

which corresponds to the impedance of a linearized machine (the straight line 0L). To de-
termine the synchronous inductance, the stator resistance is measured and the impedance is
divided into its components


Z d2 − Rs2 Zd
Ld = ≈ . (7.183)
ωs ωs
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386 Design of Rotating Electrical Machines

The short-circuit ratio (kk ) is the ratio of the magnetizing current required to produce the
rated voltage at the rated rotation speed If0 to the magnetizing current that is required to
produce the rated current in a short-circuit test. The same ratio is valid also for the stator
currents Ik0 and IN . With the notation of Figure 7.42, we can write

If0 Ik0
kk = = . (7.184)
Ifk IN

The short-circuit test is regarded as an indicator of the physical size of the machine. If
we double the air gap of the previous machine (Figure 7.43), and the influence of the iron
in the magnetic voltage is neglected, a double-field-winding current If0 is required compared
with the previous no-load test. Correspondingly, the synchronous inductance L d would be
cut into half, and thus only half of the original flux linkage would be required to produce
the short-circuit current corresponding to the rated current. Thus, the field winding current
corresponding to this short-circuit current would have remained unaltered. The size of the
field winding has to be increased to create a flux sufficient to produce the voltage. This in turn
increases the size of the machine.

7.2.5 Asynchronous Drive

Among synchronous machines, synchronous motors in particular are usually equipped with a
proper damper winding. Above all, a damper winding is necessary in a machine that is sup-
plied from a network. The present vector-controlled motor drives, synchronous motor drives
included, operate very well without a damper winding. In these drives, a damper winding
can even be harmful, if the switching harmonics of the frequency converter heat the damper
winding excessively.
In a machine supplied from a network, the function of the damper winding is, in addition to
keep the machine in synchronous running, to produce a sufficient starting torque. The motors
are often of salient-pole type, and therefore the magnetic circuit and also the damper winding
of the rotor are asymmetric. Next, the starting characteristics of a salient-pole machine will
be briefly discussed.
In an asynchronous drive, the saliency and the asymmetric cage winding together create
a pulsating flux bound to the rotor itself. This pulsating flux can be described as a sum of
positive- and negative-sequence flux components both bound up with the rotor. The electrical
angular speed of the negative-sequence flux component ωns of a counter-rotating field depends
on the slip s of the machine as

ωns = ωs (1 − 2s) . (7.185)

At synchronism (s = 0, Ω r,pu = 1), there is no pulsating field, hence no counter-rotating

field at all in the rotor, and its speed, in principle, is the stator synchronous speed. When the
slip s increases, for instance at s = 0.25 (s = 0.25, Ω r,pu = 0.75), ωns = ωs (1 − 1/2) = ωs /2
with respect to the stator. At s = 0.5 (s = 0.5, Ω r,pu = 0.5), ωns = ωs (1 − 1) = 0 with respect
to the stator. At s = 0.75 (s = 0.75, Ω r,pu = 0.25), ωns = ωs (1 − 1.5) = −ωs /2 with respect
to the stator. Hence, the rotation direction of the rotor counter-rotating field changes with
respect to the stator at the slip s = 0.5. Simultaneously, the torque produced by the field
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Design Process and Properties of Rotating Electrical Machines 387

T 1
2

0 0.5 1 Ω r, pu

Figure 7.44 Asynchronous torque components of a synchronous motor at start-up and the total torque
as a function of angular speed. 1, total torque; 2, asynchronous torque produced by the stator syn-
chronously rotating flux component; 3, torque of the counter-rotating field of the rotor. The curves are
plotted as a function of mechanical angle per unit frequency

changes its direction. Figure 7.44 depicts the torque components of a salient-pole machine
during start-up, and the generated total torque.

7.2.5.1 Effect of Saliency

Because of saliency, the inductances of the phase windings of a synchronous motor depend on
the position of the rotor. If we compare the magnetizing inductance L md of a nonsalient-pole
machine with the magnetizing inductance of a salient-pole machine, we may state that the
direct- and quadrature-axis magnetizing inductances of a salient-pole machine are

L md = kd L mδ , (7.186)

L mq = kq L mδ , (7.187)

where kd ≈ 0.85 and kq ≈ 0.35 in typical machines. Thus, Schuisky (1950) shows that the
current I ns produced by the counter-rotating field at the beginning of start-up is

Ins k 2
d − k 2
q Z1
=
2
 (7.188)
Is kd + kq Z 1 + Z
2

where

Z 1 = (Rs + jX sσ ) , (7.189)


RD

Z
2 =

+ jX Dσ . (7.190)
s
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388 Design of Rotating Electrical Machines

If, in addition to the typical values of kd and kq , Z 1 = 3Z 2
at start-up, we obtain the ratio
for the starting torques
 2
Tns Ins Z1 1
= ≈ 0.312 = 0.032. (7.191)
Ts Is Z 2
3

The torque of a counter-rotating field is so small that it can be neglected, at least at these
starting values. At start-up, the field winding has to be short-circuited in order to avoid dam-
agingly high voltage stresses in the winding.

7.2.5.2 Asymmetric Cage Winding

Since the machine is a salient-pole one and asymmetric, the cage winding is not symmet-
ric either, but there are bars missing when compared with the cage winding of an induction
machine. Further asymmetry is caused by the single-phase field winding, which is normally
short-circuited during start-up to damp high overvoltages.
The missing bars cause distortion in the linear current density of the cage winding. There
is more current flowing in the bars closest to the pole edges, that is in the outermost bars,
compared with the case of a symmetrical winding, Figure 7.45.
In an ideal, imaginary winding, there would be 1/α more bars than in a real winding. Be-
cause of this lack of bars, the rotor winding produces a lower fundamental than an ideal wind-
ing. This can be taken into account by determining new, lower winding factors of the direct and
quadrature axes for the rotor phases. The winding factor of an ideal winding is one, kw = 1.

asymmetrical
2 2

1 1
symmetrical

0 0

α α

τp τp

(a) (b)

Figure 7.45 Distortion of the linear current density of an asymmetric cage winding (a) at high frequen-
cies (at the beginning of start-up) and (b) at low frequencies. The level of reference is the level of the
linear current density of a symmetric winding. α describes the relative width of the pole shoe. Adapted
from Schuisky (1950)
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Design Process and Properties of Rotating Electrical Machines 389

Schuisky (1950) determines the harmonic factors ζ d and ζ q for salient-pole cage windings.
These factors describe the distributions of the currents of an asymmetric cage winding. With
the harmonic factors, we may also define the new winding factors for the cage winding of the
rotor in the direct and quadrature directions

kw = ζ. (7.192)

Harmonic factors are not constant, for instance, with respect to frequency. Figure 7.46
illustrates the behaviour of the harmonic factors as a function of relative pole width for two
different frequency ranges.
For synchronous motors, the leakage factor of a damper winding usually approaches the
value σ2 = X Dσ / X m = 0.05. The air-gap ratio δq,ef /δd,ef is a fictional value that is not di-
rectly proportional to real air gaps. For normal synchronous machines (α = 0.7), this ratio
is usually, for instance because of the saturation, of the scale δq,ef /δd,ef = 6. For common
induction machines, we obtain δq,ef /δd,ef = 1 even if some of the rotor bars are omitted.
During an asynchronous start-up, we may employ mainly the values of figures (a) and
(b). For ordinary synchronous motors, we obtain ζ d = 0.9 and ζ q = 0.95 on average. Near
synchronous running, the average values ζ d = 0.45 and ζ q = 0.8 can be employed.
The starting current and the torque can now be approximated by an equivalent direct and
quadrature circuit. In the equivalent circuit of a synchronous machine, we have the magne-
tizing inductance, the damper branch and the short-circuited field winding in parallel. Next,
admittances are solved for the direct and quadrature-axis impedances connected in parallel.
When calculating referred rotor quantities, we may employ the above harmonic factors that
yield the winding factors of the rotor damping:

j Rf
/s − jX f
RDd /s − jX Dd
Y rd = − +
 2
+
2
2 , (7.193)
X md Rf
/s + (X f )2

RDd /s + X Dd

j RDq /s − jX Dq
Y rq = − + 2 2 . (7.194)
X mq


RDq /s + X Dq

The corresponding impedances of parallel connections are

1
Z rd = − , (7.195)
Y rd

1
Z rq = − . (7.196)
Y rq

Next, during start-up, we employ the average value of d- and q-axes

Z rd + Z rq
Zr ≈ − . (7.197)
2
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390 Design of Rotating Electrical Machines

1.0 1.0
6
ζd σ 2 = 0.01 ζq
0.9 3
0.9
σ 2 = 0.05
0.8 0.8
f > 5 Hz f > 5 Hz
0.7 0.7

0.6 0.6

1.0 0.9 0.8 0.7 0.6 0.5 1.0 0.9 0.8 0.7 0.6 0.5
α α
(a) (b)

1.0 1.0
ζd ζq 1
0.8 0.9
f < 2 Hz
0.6 0.8
3
f < 2 Hz
0.4 0.7
6
0.2 0.6

1.0 0.9 0.8 0.7 0.6 0.5 1.0 0.9 0.8 0.7 0.6 0.5

α α
(c) (d)

Figure 7.46 Harmonic factors as a function of relative pole width at various rotor frequencies. (a)
The harmonic factor of the direct-axis current distribution for rotor frequencies above 5 Hz. The leakage
factor σ2 = X Dσ / X m of the damper winding is the parameter. (b) The harmonic factor of the quadrature-
axis current distribution for rotor frequencies above 5 Hz. As the parameter we have the ratio δ q,ef /δ d,ef
of the effective air gaps of direct and quadrature axes. (c) The harmonic factor of the direct-axis current
distribution for rotor frequencies below 2 Hz. (d) The harmonic factor of the quadrature-axis current dis-
tribution for rotor frequencies below 2 Hz. As the parameter, we have the effective air-gap ratio δq,ef /δd,ef

The stator impedance created by the resistance and the leakage inductance is written as

Z s = Rs + jX sσ . (7.198)

The starting current is now approximately

Us
I s,start ≈ , (7.199)
Zs + Zr
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Design Process and Properties of Rotating Electrical Machines 391

and the corresponding starting torque is approximately


2
p Iso Re Z r ηN cos ϕN
Ts,start ≈ . (7.200)
ωs

We employ the rated efficiency ηN and the power factor cos ϕ N in the equation.

7.2.6 Asymmetric-Load-Caused Damper Currents

According to Equation (2.15), the rated three-phase current IN of the stator creates a funda-
mental current linkage

3 kw1 Ns √
Θ̂s1 = 2IN . (7.201)
π p

The fundamental component of the flux density caused by the armature reaction in the
d-axis air gap is

µ0
B̂s1 = Θ̂s1 . (7.202)
4
k C δ0
π

Here the effective d-axis air-gap length defined in Chapter 3 is used. Let us assume that there
are two phases with a rated current, and one phase is currentless. We have a pulsating flux
that may be described with positive- and negative-sequence components. In this case, the
counter-rotating flux component amplitude is 50% of the positive-sequence amplitude

B̂s,ns = 0.5 B̂s,ps . (7.203)

This flux density induces a voltage at double the supply frequency in the rotor damper bars.
This voltage causes a current opposing the asymmetric armature reaction in the rotor damping.
The peripheral speed v ns of the flux propagating in the opposite direction is

v ns = 2 · 2 · τp f s1 . (7.204)

A flux propagating at this speed induces in a bar of length lD a voltage alternating at double
the stator frequency, the RMS value of which is

lD v ns B̂s,ns
Uns = √ . (7.205)
2

The reactance of a single rotor bar at double the frequency is

X ns,D = 2π2 f s1 µ0lD lD . (7.206)

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392 Design of Rotating Electrical Machines

The permeance factor of a round damper bar is

b4 h1
lD = 0.47 + 0.066 + ,
b1 b1

see Figure 4.10. The current of the damper bar is now

lD v ns B̂s,ns
I ns = √ . (7.207)
2 (RD + j2π2 f s1 µ0lD lD )

The power created by the counter-rotating field in the damper bar is

Pns = Ins
2
RD . (7.208)

This power constantly heats the damper bars of a machine at asymmetric load, and therefore
a sufficient heat transfer from the bars has to be ensured.
Frequency converter supply is a demanding case also with respect to the damper bars of a
synchronous machine. The amplitude ripple of the air-gap flux density at the switching fre-
quency similarly induces currents of switching frequency in the damper bars. These currents
may in some cases even damage the damper winding. Therefore, the use of damper winding
in a frequency converter drive should be carefully considered. A frequency converter drive is
able to control a synchronous machine even without damping.

7.2.7 Shift of Damper Bar Slotting from the Symmetry Axis of the Pole
To reduce the slot harmonics in the generator voltages, and the disturbances in the motor start-
ups, the damper bar slotting can be shifted by the following method of cancelling the slot
harmonics. Figure 7.47 illustrates the shift χ of a damper bar slotting of a single pole pair.

τ pr

DD /2

Figure 7.47 Shift of the damper bar slotting of the rotor in order to reduce slot harmonics and distur-
bances during start-up. The pole pitch on the pole surface τ pr , the diameter at which the damper bars are
positioned, is DD and the shift χ
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Design Process and Properties of Rotating Electrical Machines 393

First, we investigate a factor c, which should approach zero. The factor is defined as a
multiple of two geometrical factors kp and kχ as

sin ( pνus π) π χ
c = kp · kχ = · sin νus + νus π , (7.209)
p sin (νus π) 2 τpr

where νus is the ordinal number of stator slot harmonics

Qs
νus = 1 + k = 1 + k · 2mqs = 1 + k · 6qs ; k = ±1, ±2, . . . . (7.210)
p

In the shift of the damper bar slotting, we may present separate cases for integral and
fractional slot windings of the stator:

1. qs (of the stator winding) is an integer. Thus kp = 1 and therefore kχ has to be zero. For the
first slot harmonics k = 1 and

π χ
kχ = sin (1 ± 6qs ) + (1 ± 6qs ) π .
2 τpr

The ordinal number 1 ± 6qs is odd and kχ is zero if

χ 1
(1 ± 6qs ) = ,
τpr 2

from which
τpr πDD
χ=  = , (7.211)
Qs 4 ( p ± Qs)
2 1±
p

where
πDD
τpr = . (7.212)
2p

2. qs is a fraction, the denominator of which is two. Again, kp = 1, and thus kχ has to be zero.
Now, 1 ± 6qs is even and we can choose χ = 0 for the shift.
3. qs is a fraction, the denominator being four. Now, when k = ±1 the ordinal number 1 ±
k6qs is a fractional number and kp = 0, and when k = ±2 the ordinal number 1 ± k6qs is
an integer and kp = 0. Thus the shift can be made by employing the second-order k = ±2.
The magnitude of the shift is selected such that kχ = 0

Qs χ πDD
kχ = sin 1±2 π =0⇒χ = . (7.213)
p τpr 2( p ± 2Q s )

Other fractions are not favoured.

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394 Design of Rotating Electrical Machines

2.5
Is, pu cos ϕ = 0 . 8 underexcited
2.0 P = 1.5

1.5 P = 1.0

1.0 P = 0.5
cos ϕ = 1.0
0.5 P=0
cos ϕ = 0 . 8 overexcited
0
0 0.5 1.0 1.5 2.0 2.5
If, pu

Figure 7.48 V curve of a synchronous machine. The current axes and the power parameters are pre-
sented in per unit values

7.2.8 V Curve of a Synchronous Machine

When a synchronous machine operates in a network at a constant voltage and frequency, the
armature current is a function of field winding current. If the stator resistance is neglected, and
we investigate a nonsalient-pole machine, we are able to construct V curves, when the stator
current of the machine is illustrated as a function of field winding current. The solid curves
of Figure 7.48 indicate the V curves of an unsaturated synchronous machine, when the syn-
chronous inductance as a per unit value is ld,pu = 1.0. The dotted lines indicate constant cos ϕ
values. Usually, synchronous motors operate overexcited producing a magnetizing current for
the induction motors operating parallel to them. A synchronous motor can also be employed
as a synchronous capacitor, in which case the motor runs at no load and overexcited, which
means the right side of the curve P = 0 is valid. This way, by controlling the field winding
current, it is possible to construct a ‘stepless controllable capacitor’.

7.2.9 Excitation Methods of a Synchronous Machine

In principle, there are two ways to magnetize a separately excited machine (see also
Table 7.8):

1. The field winding current is conducted via slip rings to the rotor. The current is supplied
either by a thyristor bridge or by a rotating exciting DC generator. The DC generator may
be mounted on the same axis as the synchronous machine, and in that case the mechani-
cal power needed for excitation is obtained from the turbine shaft. A disadvantage of this
method is that the field winding current passes through both the commutator of the DC ma-
chine and the slip rings of the AC machine, and therefore two sets of brushes are required.
These brushes carry high currents and require constant maintenance. When the field wind-
ing current is brought via slip rings to the rotor, and the excitation circuit is dimensioned
to allow a considerable voltage reserve, we are able to construct a quite fast-responding
excitation control despite the high inductance of the field winding.
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Design Process and Properties of Rotating Electrical Machines 395

2. By using brushless excitation. There are several different brushless excitation systems.
Some of the main principles will be discussed here.
(a) There are two or even three synchronous machines on a common shaft: (i) the main
synchronous machine; (ii) an outer pole synchronous generator having its field wind-
ings in the stator and the armature on the rotor supplying the field winding current for
the main machine. Machine (ii) is excited either with a network supply or with a per-
manent magnet generator rotating on the same shaft. A thyristor bridge is needed to
control the current. A permanent magnet generator excitation system is totally inde-
pendent of external exciting electric power if only the prime mover can rotate the main
machine and the auxiliary machines.
There is also a rotating diode bridge that rectifies the current supplied by the main
excitation machine. This system is totally independent of auxiliary exciting electric
power. Another and simpler version of this excitation system is the one in which the
outer pole synchronous machine (ii) has one permanent-magnet-excited pole pair which
suffices to excite the main machine so that its voltage may be used to magnetize the
excitation machine.
(b) There is a rotationally symmetrical axial transformer at the end of the shaft having its
magnetic circuit divided into a rotating and stationary part and a diode rectifier and
being supplied with a stationary switched-mode AC power supply.
(c) There are two rotating machines on a common shaft: (i) the main machine and (ii) a
wound-rotor induction generator. The field winding current is rectified by a rotating
diode bridge. The stationary part of the wound-rotor induction generator is supplied by
a controllable three-phase voltage. This method is applicable for converter-fed motors
that have to produce full torque also at zero speed. In the control, a three-phase triac
controller is often used.

Figure 7.49 illustrates some brushless generator excitation constructions. In Figure 7.49a,
an outer pole synchronous generator is mounted on the shaft of the synchronous machine. This
machine gets its excitation from a network supply. The current produced by the generator is
rectified by diodes rotating along the machine, Figure 7.49. A brushless synchronous machine
is quite maintenance free. On the other hand, the slow control of the field winding current of
the machine is a disadvantage of this construction.
With regard to motors, a brushless magnetizing can be arranged also with a rotating-field
winding in the magnetizing machine. This winding is supplied with a frequency converter
when the main machine is not running. Now the main machine can be excited also at zero
speed.

7.2.10 Permanent Magnet Synchronous Machines

What has been written above about synchronous machines is in many cases valid also for
permanent magnet machines. For example, the phasor diagrams are similar except that in
PMSMs, the magnets create a constant Ψ PM instead of controllable Ψ f . The Ψ PM induces an
emf E PM instead of E f . Permanent magnet excitation makes it possible to design very high-
efficiency machines. As there are, in principle, no losses in the excitation, the efficiency should
inherently be high. Unfortunately, permanent magnets are conductive, and hence Joule losses
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396 Design of Rotating Electrical Machines

Figure 7.49 Excitation of a brushless synchronous generator. (a) Two machines have been mounted on
a common shaft. The machines are either the main machine and an outer pole synchronous generator for
excitation, or the main machine and a wound-rotor induction generator for the main machine excitation.
In addition to the field winding of the main machine, the armature winding of the outer pole synchronous
machine or the rotating field winding of the induction machine has been mounted on the rotor to produce
the required magnetizing power for the main machine. The outer pole generator excitation is obtained
either from network or from a permanent magnet generator rotating on the same shaft: The excitation
is controlled by a thyristor bridge. The wound-rotor induction motor configuration may also operate at
zero speed, when the stator of the magnetizing is supplied, for example with a three-phase triac. (b) An
axial flux transformer with an air gap supplies the excitation energy needed

take place in them. The permanent magnet excitation cannot be changed, which gives some
boundary conditions for machine design. As the magnets have a very low permeability, the
inductances of permanent magnet machines become usually low. The synchronous inductance
also has to be low, because the maximum torque of a PMSM is inversely proportional to the
synchronous inductance. The load angle in Equation (7.179) is valid for a PMSM in the form

Usph E PM 2 Ld − Lq
P=3 sin δ + Usph sin 2δ , (7.214)
ωs L d 2ωs L d L q

where we write E PM instead of E f . If by the permanent-magnet-induced emf ePM = 1 and the

supply voltage u s = 1, we have to select ls = 0.625 to achieve peak power Pmax and torque
Tmax per unit value of 1.6, which is normally required by standards. In permanent magnet
motors, the per unit ePM is typically selected to vary between 0.9 and 1, and in generators
ePM = 1.1 is typically selected. The designer must remember that the remanence of magnets
usually decreases as the temperature increases.
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Design Process and Properties of Rotating Electrical Machines 397

d d d
N q N q N
q
S S S S S
N N
S N N S S N N S
S S
S S N N N
(a) (b) (c)
N N S
d d q d d
q q q
N N
S S S S
S N N S
S N N S N N N N
S N N S
S S
S S N
N (g)
(d) (e) (f )

Figure 7.50 Rotors of permanent magnet machines. (a) Rotor-surface-mounted magnets, (b) magnets
embedded in the surface, (c) pole shoe rotor, (d) tangentially embedded magnets, (e) radially embedded
magnets, (f) two magnets per pole in the V position, (g) a synchronous reluctance rotor equipped with
permanent magnets. Reproduced by permission of Tanja Hedberg, based on Morimoto, Sanada and
Taniguchi (1994)

Permanent magnet motors have gained popularity in low-speed, high-torque drives,

which suit this machine type very well. The magnetizing inductance in Section 3.9 was
found to be inversely
proportional
 to the square of the pole pair number p, L m =
m Dδ µ0l
(kws1 Ns )2 / π p 2 δe . This makes multiple-pole low-speed induction motor charac-
teristics poor, for instance, because the low magnetizing inductance causes a poor power
factor for an induction machine. A PMSM does not suffer this because the magnetizing is
arranged by permanent magnets. As the permanent magnets are very conductive, low-speed
applications are easy also for rotor surface magnets because, at low speeds, the losses in the
magnets remain low. In higher-speed applications, special care must be taken to avoid losses
in permanent magnet material.
The characteristics of a permanent magnet machine are determined from the rotor construc-
tion. Figure 7.50 illustrates different permanent magnet rotor constructions. If the magnets are
mounted on the rotor surface, the rotor is in principle nonsalient, since the relative permeabil-
ity of neodymium–iron–boron magnets, for instance, is approximately one (µr = 1.04–1.05;
see Table 3.3). Magnets embedded in the rotor construction produce almost without exception
a machine for which the quadrature-axis synchronous inductance is higher than the direct-axis
synchronous inductance. Also, the pole shoe construction produces a similar inductance ratio.
Such machines do produce some reluctance torque according to (7.214).
Embedding the magnetic material completely inside the rotor structure wastes a significant
proportion, typically a quarter, of the flux produced by the magnet. The flux is consumed in
leakage components of the rotor, Figure 7.51. On the other hand, the embedded magnets are
protected both mechanically and magnetically. In embedded mounting, we may employ two
magnets per pole (Figure 7.50f), in which case it is possible to reach a rather high air-gap
flux density in no-load conditions. If there is iron on the rotor surface of a permanent magnet
machine, a considerable armature reaction occurs, somewhat weakening the characteristics of
the machine, Figure 7.52.
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398 Design of Rotating Electrical Machines

Figure 7.51 Air-gap flux of a V-magnet machine and the leakage fluxes of the magnet. In the bottom
illustration, the leakage flux is reduced by constructing a flux barrier of air. Reproduced by permission
of Tanja Hedberg

Figure 7.52 Quadrature armature reaction in a V-magnet machine. Reproduced by permission of Tanja
Hedberg
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Design Process and Properties of Rotating Electrical Machines 399

Figure 7.53 Comparison of the pole constructions and no-load air-gap densities of (a) a V-magnet
machine with variable air gap and (b) a surface-magnet machine with constant air gap. Reproduced by
permission of Tanja Hedberg

The permanent magnet material is best utilized in surface-magnet machines (Figure 7.50a).
Because of the high magnetic circuit reluctance, the synchronous inductances are low and ma-
chines of this type produce the proportionally highest pull-out torque. However, rotor surface
magnets are liable to mechanical and magnetic stresses and also eddy current losses. In some
cases, even the NdFeB magnets may be demagnetized. Figure 7.53 compares the air-gap den-
sities of a V-magnet machine and a surface-magnet machine. Figure 7.53b also shows how
the flux density is nearly constant in the area facing the magnet and zero elsewhere. Hence,
the average flux of the permanent magnet machine may be calculated simply by using the rel-
ative magnet width (α PM = wPM /τ p ). Because of the rough flux plot, the figure does not reveal
the surface-magnet leakage flux at all. Typically, however, about 5–10% of the flux of a sur-
face magnet is lost in leakage in the magnet edge areas.
In particular, in the case of a rotor surface-magnet machine, special attention has to be paid
to minimizing the cogging torque. The relative width of a permanent magnet has a significant
influence on the quality of the torque of the machine. The quality of the torque has been
investigated for instance by Heikkilä (2002), Kurronen (2003) and Salminen (2004).
Permanent magnet machines are mostly applied in frequency converter drives, where no
damping is necessary. A damper winding is, however, necessary in network drives. The ma-
chine constructions of Figure 7.50c–f offer the best possibilities of embedding a damper wind-
ing in the poles, but also a rotor surface-magnet machine may be equipped with a damper;
however, to obtain enough conducting surface, some compromises have to be made. A thin
aluminium plate for instance on top of the magnets is not enough, because, for example, 30%
(see Chapter 2 for damper winding principles) of the stator copper amount has to be reached
in the damper.
If the machine E PM is high, a line start is not possible despite the damper construction.
Hence, generators may not achieve a line start property. This is explained by the fact that as
a permanent magnet machine starts as a motor rotating in a network supply, the permanent
magnet flux linkage generates an asynchronous E PM , which is short-circuited via the network
impedance. A high current and a high braking torque are created in this short-circuit process,
but the asynchronous torque created by the damper winding is too weak to accelerate the
generator to synchronous speed. Such a machine has to be synchronized to the network as a
traditional synchronous generator. In motors, E PM may be lower (ePM  1) and a line start-up
may be possible with a correctly designed damper winding.
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400 Design of Rotating Electrical Machines

Under certain circumstances, synchronous reluctance machines are equipped with auxiliary
magnets, Figure 7.50g. In that case, the function of the magnets is to improve the power factor
of the machine.

7.2.11 Synchronous Reluctance Machines

The synchronous reluctance machine (SyRM) is the simplest of synchronous machines. The
operation of an SyRM is based on the difference between the inductances of the direct and
quadrature axes. The power of an SyRM is obtained from the load angle equation; see also
Equations (7.179) or (7.214)
 
Lq
2 Ld − Lq
2
3Usph  1 − Ld 
P = 3Usph sin 2δ =   sin 2δ. (7.215)
2ωs L d L q 2ωs  L q 

We can see in (7.215) that the smaller the quadrature-axis inductance and the higher the
direct-axis inductance, the higher the power and torque at a certain load angle. In practice, the
limiting value for L q is the stator leakage inductance L sσ ; consequently, L q > L sσ . There-
fore, it is the task of the designer to maximize the inductance ratio L d /L q to achieve a good
performance.
In practice, a high-inductance-ratio machine may be driven only by a frequency converter
irrespective of whether the rotor carries a damper winding or not. The high rotor saliency ratio
means that the rotor will not start at its full speed in direct network drive but remains at half
speed. This is due to the phenomenon discussed previously in conjunction with the asymmet-
ric damper windings (cf. Figure 7.44). The rotor-bound counter-rotating field produces such
a high torque at high saliency ratios that the rotor will not start.
Figure 7.54 illustrates the rotors of an SyRM converted from the rotor of an induction
motor. This manufacturing method produces a relatively low inductance ratio, a poor power
factor and a poor efficiency. This kind of machine may, however, be operated in DOL
applications.

Figure 7.54 Early synchronous reluctance machines converted from the rotor of an induction machine.
Inductance ratio L d /L q is typically of the order 2–3. Reproduced by permission of Jorma Haataja
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Design Process and Properties of Rotating Electrical Machines 401

Fe
Al
Fe
Fe
Al
Fe
Fe
Fe
Al
Fe
Al

Al
Al
Al

Al
(a) (b)

Figure 7.55 (a) Stator and rotor laminations. The rotor has been punched from a single sheet, and
therefore, to keep the shape of the construction, several bridges have been left between the flux barriers
and the flux guides. The bridges notably reduce the inductance ratio. With the presented structure, and
by applying a small air gap, an inductance ratio of L d /L q = 10 may be reached. (b) Stator and rotor
laminations of a two-pole synchronous reluctance machine with axially placed rotor laminations. The
rotor consists of rectangular iron and aluminium laminations of different sizes. The iron sheets act as flux
guides and the aluminium sheets as flux barriers. This type of rotor creates a very small quadrature-axis
inductance, yet the direct-axis inductance may be large. Very large inductance ratios may be obtained.
The construction, however, is difficult to manufacture and the rotor iron losses tend to be high. In the
figure, aluminium and steel sheets are placed one after another. Instead of aluminium, stainless steel or
some nonconducting composite can be used. A four-pole configuration is also possible but even more
difficult to manufacture

Previously, the tendency in the research on SyRMs was to create rotor constructions that
would reach a high inductance ratio. Figure 7.55a illustrates the stator and rotor lamination
of an SyRM, produced from round, thin electrical sheet laminations. The steel conducting
the magnetic field is called a flux guide and the air between the flux guides is called a flux
barrier. An optimum inductance ratio is reached when there are flux guides and flux barriers
approximately in the ratio of 50 : 50. There must also be several flux guides and barriers per
pole. If just one flux guide is used, we end up with an inductance ratio typical of traditional
synchronous machines. In such a case, the flux guide forms a construction resembling the
pole shoe construction. A wide pole shoe adjacent to the air gap guarantees a good route
to quadrature flux, and this kind of construction produces an inductance ratio in the range
of L d /L q = 2. At best, the construction illustrated in Figure 7.55a produces an inductance
ratio in the range of L d /L q = 10. If higher inductance ratios are desired, the rotor should be
constructed by placing the laminates in the direction of the rotor shaft. Figure 7.55b illustrates
a two-pole arrangement that reaches a very high inductance ratio.
Figure 7.56 shows the phasor diagram of an synchronous reluctance motor. We can see that
the lower the quadrature-axis synchronous inductance L q is, the lower the power angle δ will
be. On the other hand, the higher the direct-axis inductance, the lower the current needed to
magnetize the d-axis, and the better the power factor of the machine.
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402 Design of Rotating Electrical Machines

Iq
Ψs Ψq = LqIq
Is
δ
Us
κ Ψd = LdId
ϕ
Id

Es

ωsΨd
ωsΨq

Figure 7.56 Phasor diagram of a synchronous reluctance machine. In the figure, the per unit values
are ld = 2 and lq = 0.15, and therefore the inductance ratio is approximately 13

Figure 7.57 illustrates the effect of the inductance ratio on the torque production capability
of the machine and the current angle. As the figure shows, the synchronous reluctance motor
never produces a very high pull-out torque. The current angle κ is measured between the
d-axis and the stator current.
A high inductance ratio leads to a small current angle, and thus to a small load angle and a
good power factor, Figure 7.58.
Figure 7.59 depicts the behaviour of the power factor of the motor as a function of the
shaft output power (motor power). The figure clearly indicates the importance of a high in-
ductance ratio for obtaining good machine characteristics. In practice, an inductance ratio of
20 is within the bounds of possibility.

2
T / pu
1.5
L d/L q= 50

L d/L q= 10
1
L d/L q= 5

0.5

0
0 10 20 30 40 50 60 70 80 90 κ /o

Figure 7.57 Effect of the inductance ratio on the torque production capability of a synchronous reluc-
tance machine and the current angle κ. In the calculation, the rated current of the corresponding stator
of an induction machine is employed. The values are calculated for a 30 kW, four-pole, 50 Hz machine.
L d /L q = 50 is indicated in the figure for academic interest. Reproduced by permission of Jorma Haataja
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Design Process and Properties of Rotating Electrical Machines 403

cosϕ
0.9
0.8
0.7
Ld/L q= 50
0.6
Ld/L q= 10
0.5
0.4 L d/L q= 5

0.3
0.2
0.1
0
0 15 30 45 60 75 δ /o 90
1
cosϕ

0.9
0.8
0.7
L d/L q= 50
0.6
L d/L q= 10
0.5
0.4 L d/L q= 5

0.3
0.2
0.1
0
15 30 45 60 75 κ /ο 90

Figure 7.58 Power factor of a synchronous reluctance machine as a function of current angle and load
angle at various inductance ratios. The values are calculated for a 30 kW, four-pole, 50 Hz machine. The
impractical L d /L q = 50 is indicated in the figure only for academic interest. Reproduced by permission
of Jorma Haataja

1
cosϕ

0.9
0.8
0.7
0.6
0.5
0.4 L d / L q=50
0.3
L d / L q=10
0.2
0.1 L d / L q =5
0
0 0.5 1 1.5 P, pu 2

Figure 7.59 Power factor of a synchronous reluctance machine as a function of shaft output power at
rated speed. The values are calculated for a 30 kW, four-pole, 50 Hz machine. L d /L q = 50 is indicated
in the figure for academic interest. In practice, such an inductance ratio may not be reached. Reproduced
by permission of Jorma Haataja
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404 Design of Rotating Electrical Machines

7.3 DC Machines
Although in practice almost all electrical energy is produced and distributed by AC systems,
a remarkable proportion of the electrical energy is consumed in the form of direct current.
DC motors are still applicable to various industrial processes that demand precise control of
speed and torque. DC drives offer a rotation speed control covering a wide speed range, a
constant torque or a constant power control, rapid accelerations and decelerations, and good
control properties in general. DC machines are, however, more expensive, more complicated
and, because of the copper losses in the complicated armature reaction compensation winding
arrangements, usually offer a lower efficiency than AC machines. In the era of frequency-
converter-supplied AC drives, their importance has declined. The main practical problem of
the DC machine is the commutator service, which makes the operation of a drive expensive
in process industries. The commutator and the brushes require regular maintenance. A long
manufacturing tradition offers, however, competitive prices at least over small power ranges
and in low-power applications, such as auxiliary drives in automotives.

7.3.1 Configuration of DC Machines

Operation of a DC machine is based chiefly on the cooperation of two windings, namely a
rotating armature winding and a stationary field winding. The armature winding is embedded
in slots on the outer periphery of the electrical sheet core and, although the flux variations in
the iron core of the field winding are not significant, the pole shoes are also made of electrical
sheet. The pole shoes are fastened to the yoke that closes the magnetic circuit.
In order to operate properly, several other windings are required as well in practical DC
applications, as shown in Figure 7.60. The function of shunt and series windings in DC ma-
chines is to produce the main magnetic field in the machine, or the main field. Therefore,
these windings are together called field windings. The shunt winding E1–E2 is connected in
parallel with the armature, whereas a separate field current is led to the separate field winding
F1–F2. The resistance of the windings E1–E2 and F1–F2 is high because of the thin wire
and a high number of coil turns. The series winding D1–D2 is connected in series with the
armature A1–A2, and thus it magnetizes the machine with the load current. Because of the
high armature current, there are few coil turns in the winding, and its cross-sectional area is
large. The windings of a DC machine were discussed in Chapter 2.
An alternating voltage is induced in the armature winding A1–A2. The induced AC voltage
has to be rectified in the generator and, in the case of a motor, the supplying DC voltage has
to be inverted to AC. The DC-to-AC inversion and the AC-to-DC rectification are carried out
mechanically, together with brushes, by a commutator composed of copper strips.
The function of the commutating pole winding B1–B2 is to ensure nonsparking commuta-
tion. In this function, the winding partly compensates the armature field created by the arma-
ture current. The commutating pole winding is connected in series with the armature, but it is
fixed on the stator on the geometrically neutral axis.
The function of the compensation winding C1–C2 is to compensate for the effects of the
armature reaction. Therefore, it is connected, as shown in Figure 7.60, in series with the
armature winding, and embedded in the slots of the pole shoes. Similar to the other series
windings, this winding is constructed of thick copper in order to achieve a low resistance. The
number of coil turns is also kept low.
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Design Process and Properties of Rotating Electrical Machines 405

D2 F2, E2

B2 C1
B1
A1
A2
C2

D1 F1, E1

Figure 7.60 Terminal notations of the windings of a DC machine and the connection of the armature,
commutating pole and the compensating windings. A1–A2, armature winding; B1–B2, commutating
pole winding; C1–C2, compensating winding; F1–F2, separate field winding; E1–E2, shunt field wind-
ing; D1–D2, series field winding

7.3.2 Operation and Voltage of a DC Machine

A DC generator converts mechanical energy into electrical energy. A power engine rotates
the armature in the magnetic field generated by a field winding, and as a result an alternating
voltage is induced in the armature winding. The voltage is now rectified by the commutator.
An alternating voltage is induced in each coil turn of the armature winding. The commutator
acts as a mechanical rectifier connecting the AC armature to the external DC circuit.
The torque of the machine is produced when a force F is exerted on the rotor winding ac-
cording to the Lorentz force. This torque-producing force is the cross-product of the current I
and the flux density B: F = I × B. In a full-pitch winding extending across a full pole pitch,
when one coil side occurs at the middle of the pole N, the other coil side occurs at the adjacent
pole S. Thus in a two-pole machine, the coil sides are located on opposite sides of the rotor.
Now, if there are a number of 2p poles in the machine, the coil span is 2π/2p rad. In DC ma-
chines, a completely homogeneous field distribution cannot be achieved, but the flux density
varies, as illustrated in Figure 7.61a, over a distance of two pole pitches. Figure 7.61b illus-
trates the voltage induced in a corresponding full-pitch winding, rectified by a commutator.
The voltage is uniform with the flux density. Next, a full-pitch winding inserted in two slots
is investigated. The number of coil turns is N, and the winding positioned at θ in Figure 7.61a
is rotating at an electric angular speed ω.
The flux linkage of the armature over a distance of the differential angle θ = dωt is

dΨ = N B (ωt) dS, (7.216)

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406 Design of Rotating Electrical Machines

B dωt E

0 θ π ωt 0 π ωt

(a) (b)

Figure 7.61 (a) Flux density waveform over a distance of two pole pitches and (b) rectified voltage in
no-load operation

where dS = (D/2)l dωt; that is, the area of the path of the flux, when D is the diameter and
l is the length. The equation can now be written as

N Dl B (ωt) dωt
dΨ = . (7.217)
2
The flux linkage is obtained by integration


θ+π
N Dl
Ψ = B (ωt) dωt. (7.218)
2
θ

Since the flux density is symmetrical (B(θ + π) = −B(θ )), it can be presented as a series
of odd harmonics

B (ωt) = B1 sin ωt + B3 sin 3ωt + · · · + Bn sin nωt. (7.219)

By substituting this in Equation (7.218) we obtain the result of the integration


1 1
Ψ = N Dl B1 cos θ + B3 cos 3θ + · · · + Bn cos nθ . (7.220)
3 n

The voltage induced in the coil is

dΨ
e=− , (7.221)
dt

and by substituting (7.220) into the above equation we obtain

e = ωN Dl (B1 sin θ + B3 sin 3θ + · · · + Bn sin nθ ) . (7.222)

This shows that the voltage follows the curvature form of the flux density, when ω is constant.
We obtain a rectified voltage as presented in Figure 7.61b. As there are several coils instead
of a single coil in practical applications, being connected via a commutator, the coils together
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Design Process and Properties of Rotating Electrical Machines 407

0 π ωt

Figure 7.62 Common voltage of two rotor coils located electrically at a distance of π/2

produce a practically rippleless voltage. Figure 7.62 depicts the curvature form of the voltage,
created by two coils located at a distance of π/2.
Based on Figures 7.61 and 7.62, it is obvious that the relative amplitude of the voltage
ripple of two coils is half the case of a single coil. Simultaneously, the frequency is doubled.
When we increase the number of coils, we reach a rather even voltage. The voltage of several
coils in series equals the number of coils multiplied by the average voltage of a single coil.
The average voltage of a single coil is

π
1
E= e dωt. (7.223)
π
0

By substituting (7.222) in (7.223) we obtain, based on (7.219),

π
ω
E= N B (ωt) Dl dωt, (7.224)
π
0

where Dl dωt = 2 dS, and thus

π
2ωN
E= B (ωt) dS. (7.225)
π
0

The integral term in (7.225) yields the flux per pole Φ p , and thus the voltage induced in the
full-pitch coil is

2ωN Φp
E= . (7.226)
π

Equation (7.226) is valid both for two-pole machines or for machines with multiple poles,
bearing in mind that ω is electric angular speed. If n [1/s] is the rotational speed, the mechan-
ical angular speed Ω is

Ω = 2πn. (7.227)
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408 Design of Rotating Electrical Machines

When the number of poles is 2p, we obtain the electric angular speed

ω = pΩ. (7.228)

In general, we obtain for the average voltage of a coil with N turns

E = 4 pN Φp n. (7.229)

The previous discussion has concerned a single full-pitch coil, that is a coil that covers a
single slot per pole, and is of the width π in electrical degrees. However, Equation (7.229)
holds with sufficient accuracy also for nonfull-pitch windings common in DC machines. The
coil span is usually more than two-thirds of the pole pitch, and the maximum flux density is
nearly equal to the full-pitch winding. If now

2a is the number of parallel current paths of the armature winding,

p is the number of pole pairs,
Na is the number of turns in the armature winding,
n is the rotation speed and
Φp is the flux per pole,

then the number of coil turns of the armature between the brushes is Na /2a and the induced
armature voltage E a is approximately (irrespective of the coil span)

4 pNa nΦp 2 pNa ΩΦp p z

Ea ≈ = = Φp Ω, (7.230)
2a π2a a 2π

where z is the number of all armature conductors z = 2Na . Based on the above discussion,
we may now present the simplified equations for the DC machine. The emf depends on the
magnetic flux per pole, the rotation speed n and the machine-related constant kE

E a = kE nΦp . (7.231)

The electric power Pa of the armature of the machine is a product of the emf Ea and the
armature current Ia

Pa = E a Ia . (7.232)

The torque corresponding to this power is

Pa
Te = . (7.233)
Ω

When we substitute (7.231) and (7.232), we obtain

kE nΦp Ia
Te = . (7.234)
Ω
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Design Process and Properties of Rotating Electrical Machines 409

7.3.3 Armature Reaction of a DC Machine and Machine Design

Although a detailed description of the design of a DC machine is beyond the scope of this
material, some design principles are still worth mentioning. The methods presented previ-
ously are applicable to the design of a DC machine with certain adjustments. One of the most
important special features of a DC machine is the armature reaction and, in particular, its
compensation.
According to the IEC, the armature reaction is the current linkage set up by the currents in
the armature winding or, in a wider sense, the resulting change in the air-gap flux. Since the
brushes are on the quadrature axis, the armature current produces the armature reaction also
in the quadrature direction; that is, transversal to the field-winding-generated flux. Figure 7.63
depicts the armature reaction in the air gap of a noncompensated DC machine.
As a result of the armature reaction, the air-gap flux density is distorted from the no-load
value, and the flux density at the quadrature axes no longer remains zero. This is extremely
harmful from the commutating point of view. To enhance the commutating procedure, the
quadrature-axis flux density has to be brought to zero. Figure 7.64 illustrates the air-gap flux
density behaviour in a noncompensated DC machine.
The armature reaction has a remarkable influence on the current commutating and spe-
cial attention has to be paid to the design of successful commutation. Commutation is most
successful in machines in which the quadrature-axis flux density is brought to zero with a
compensating and commutating pole winding. The operation of the compensating and the
commutating pole windings is illustrated in Figure 7.65.
The focus of the design of the magnetic circuit and the windings of the machine has to be
on the dimensioning of the commutating poles, their windings and the compensating wind-
ing. The machine is equipped with a turning brush rocker to ensure nonsparking commu-
tation. Dimensioning of the compensating windings was discussed in brief in Section 2.15.

q d q d q

b b b

armature

Ba, Θa
Θa

Ba

Figure 7.63 Armature reaction of a DC machine. The direct (d) and the quadrature (q) axes and the
brushes (b) of the armature circuit are indicated in the figure. Θ a is the armature current linkage and Ba
the corresponding air-gap flux component, differing by shape from Θ a mainly in the q-axis area, where
the air gap and hence the magnetic reluctance are very high
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410 Design of Rotating Electrical Machines

q d q d q

b b b

armature
B air gap flux density

Ba
armature reaction

field winding
flux density

Figure 7.64 Resulting air-gap flux density as a sum of the field winding flux density and the armature
reaction. As a result of the armature reaction, the flux densities at the quadrature axes are not zero. This
is harmful for the commutation of the machine

Since it is not possible to remove completely the quadrature-axis flux density, a commutating
pole winding is employed in addition to the compensating winding. In low-power machines,
the disadvantages of commutating are usually compensated only with a commutating pole
winding.
If we want to supply a DC series machine with an AC voltage supply (known as a universal
motor), the commutating arrangements get even more complicated. As an exception to normal
DC drive, we have to construct the entire magnetic circuit from laminated electrical sheet.

q d q d q

commutating
pole winding

armature winding
B compensating
winding
Bk Ba

Bcp

Figure 7.65 Operation of the compensating and the commutating pole windings. The armature reac-
tion flux density Ba is totally compensated by the compensating flux density Bk and the commutating
pole flux density Bcp
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Design Process and Properties of Rotating Electrical Machines 411

These small applications are still employed in various high-speed consumer electronics such
as drills, angle grinders, vacuum cleaners and the like.

7.3.4 Commutation
The current flowing in the armature winding is alternating current, whereas the current of the
external circuit flowing through brushes is direct current. The commutator segment acts as
an end point of the coil. When the commutator segment passes under a brush, the direction
of current flow is always changed in the coil. The time interval required for this switching
is known as the commutation period. Commutation is said to be linear when the current of
the armature winding changes its polarity at constant speed, as shown in Figure 7.66. Linear
commutation is the simplest way of to analyse commutation. Figure 7.66 illustrates the four
steps of commutating. In the figure, the armature windings are presented simplified as coils
connected to parallel commutator segments. There is a current I flowing per brush. When the
commutator segment reaches the leading edge of the brush, the current of the coil is I /2 and,
correspondingly, when the segment is passing the trailing edge of the brush, the current of the
coil has attained the value −I /2.

I/2 I/2 I/2 I/4 I/2 I/2

* *
0 0 I 0 0 0 I/4 3I/4 0 0

t = t1 t = t2
I I

I/2 I/2 I/2 I/4 I/2 I/2

0
* *
0 I/2 I/2 0 0 0 3I/4 I/4 0 0

t = t3 t = t4
I I
tc
i
I/2

t = t4 t = t5
t = t1 t = t2 t = t3 t

-I/2

Figure 7.66 Phases of simplified linear commutation of an armature winding (indicated by an

asterisk * ) at the commutator and the current reversal during linear commutation in the armature wind-
ing. tc is the commutation period in the armature winding
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412 Design of Rotating Electrical Machines

tc
i
I/2
I

II t
III
-I/2
IV

Figure 7.67 Current of an armature winding coil short-circuited by commutation: I, undercommuta-

tion; II, linear commutation; III, ideal commutation where at tc , di/dt = 0; IV, overcommutation

Commutation is a fairly complicated process, and in reality it is not a completely linear

process. Resulting from the change of current direction, a voltage is created by the leakage
fluxes of the armature winding in the coil that is short-circuited by the brush. This voltage
must be compensated either by turning the brush rocker or by commutating pole windings, or
the inversion of the current flow direction must be retarded, and undercommutation occurs.
As a result, the current decreases at an accelerated rate towards the end of the commutation
period. This in turn causes an increase in the current density at the trailing part of the brush. If
the current reversal is not completed when the commutator segment leaves the brush, sparking
occurs at the trailing end of the brush. An excessive sparking burns the brushes and destroys
the surface of the commutator. If the brush rocker is turned too much, or the influence of the
commutating poles is excessive, an overcommutation occurs, and the direction of the current
flow changes too rapidly. In the current reversal, the opposite current may increase too high,
and the current density at the leading part of the brush is increased. Figure 7.67 illustrates the
changes in the short-circuit current of a coil at different states of commutation.
In addition to the voltage induced in the short-circuited armature coil, the commutation is
also affected by the contact with brushes. In general, commutation can be stated to take place
in four steps. In commutation, a current flows in the commutator segment via point-like areas.
When currentless, these areas are covered with a thin oxide layer. Therefore, when a brush
comes into contact with the tip of a commutator segment, there is no current flowing in the
first, so-called blocking phase, since there is quite a high blocking voltage u b1 between the
brush and the commutator segment, Figure 7.68a.
Only when the contact voltage between the brush and the segment exceeds the reverse
voltage that sinks rapidly because of the simultaneously occurring contact points does the
actual contact formation begin between the commutator segment and the brush. The contact
points gradually turn conductive as the voltage strength of the oxide layer decreases. The
process takes place before the brush completely covers the commutator segment. In this phase,
to create a current, a raised voltage level is required contrary to the next, quasi-stationary
phase. In this phase, the quasi-stationary characteristic curve u c = f (JB ) is valid (Figure
7.68b) and gives the contact voltage as a function of current density JB . The final phase of the
commutation is characterized by rapid changes in current density, which the contact formation
process cannot follow. In a borderline case, an excessive change in current density leads to
a constant contact resistance, represented by a linear characteristic curve that approaches the
dynamic characteristic curve of Figure 7.68b. The dynamic characteristic curve is valid when
the change in current density is of the order dJB /dt > 105 A/cm2 s.
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Design Process and Properties of Rotating Electrical Machines 413

i, JB I II III IV
i

JB

dynamic
t uc characteristic
curve

u ub1 quasi-stationary
characteristic curve
uc

tc t JB

(a) (b)

Figure 7.68 (a) Phases of commutation. The current i and the current density in the brush JB . I, block-
ing phase; II, contact formation; III, quasi-stationary phase; IV, end phase. In the voltage graph, the solid
line u c depicts the real function of commutation voltage, and u b1 is the blocking voltage of the oxide
layer. The dotted line indicates the time function of the voltage corresponding to the quasi-stationary
characteristic curve. (b) The characteristic curve of the brush contact, with the commutation voltage
as a function of current density. The dynamic characteristic curve is approached during the high-speed
change of the current density at the end phase of the commutation

The final phase of the commutation depends on the possible sparking between the brushes
and the commutator segments. Sparking occurs when the current at the end of commutation
deviates from the current of the armature winding (over- or undercommutation), and the com-
mutator segment in question shifts away from below the brush, in which case the commutation
has to be completed via the air gap. An arc is struck between the commutator segment and the
brush. The arc disappears when the current has reached the correct value.
In general, brushes consist of carbon, graphite and organic materials. In low-voltage de-
vices, such as in the 12 V starting motor of a car engine, the resistance between the brushes
and the commutator has to be kept low. Therefore, carbon-coated graphite brushes are
employed.
A thin layer of copper oxide, covered with graphite, occurs on the surface of the commutator
(patina). This layer affects the operating life of the brush and the wear of the commutator.
Graphite acts as a lubricant, and the resistance of the layer is high enough to restrict the short-
circuit current and to create resistance commutation.

7.4 Doubly Salient Reluctance Machine

A doubly salient reluctance machine is an electrical machine that operates with intelligently
controlled power electronics. The machine is also called a switched reluctance machine
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414 Design of Rotating Electrical Machines

(SR machine) because it cannot operate without power electronic switches. The development
of semiconductor power switches and digital technology has opened up new opportunities for
controlled electric drives. The development of electric drives can be seen for instance in the
increased application of frequency-converter-supplied induction machines among controlled
electric drives.
Although simpler induction motor alternatives have been found to replace DC machines,
neither the dynamic performance nor the power density have improved with the controlled
electric drives. In particular, with low rotation speeds or at standstill, both drive types have
problems in producing satisfactory torques. This is clearly visible for instance in machine
automation, where high torques are produced by hydraulic motors. A doubly salient, power-
electronics-controlled reluctance machine may in some cases provide improvement in the
torque production at low rotation speeds.
A reluctance machine has already been employed for a long time in stepper motor drives,
in which continuous, rippleless torque control has not been necessary. Only the development
of power electronics and control systems has enabled the application of a reluctance machine
in the power range of a few hundred kilowatts, while stepper motor applications have so far
been limited to a few hundred watts at maximum.
The basic construction of a switched reluctance motor was introduced as early as in 1838
by Robert Davidson in Scotland, but the machine was not utilizable before the development of
power electronics and suitable components. The motor construction and the theory of control
were quite well reported by the end of the 1970s, and development has been continuous ever
since, particularly in the field of control technology.

7.4.1 Operating Principle of a Doubly Salient Reluctance Machine

The English term for a switched reluctance motor originates from the fact that it always
requires a controlled power source, that is an inverter. In the German literature, the term
‘doubly salient reluctance machine’ occurs repeatedly (Reluktanzmaschine mit beidseitig aus-
geprägten Polen). The latter term describes the geometry of the machine well, as shown in
Figure 7.69.

C B
b
a
A A
a
b

B C

Figure 7.69 A 6 : 4-pole (six stator poles and four rotor poles), three-phase, doubly salient reluctance
machine and the semiconductor switches controlling a single phase of the machine. Rotor poles have
just passed their unaligned position with respect to stator phase A and the poles (a) will be in the aligned
position with the stator poles A–A when the rotor moves counterclockwise towards the excited phase
A–A
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Design Process and Properties of Rotating Electrical Machines 415

The operating principle of a switched reluctance machine is based on the power effects of
the magnetic circuit that tend to minimize the reluctance of the magnetic circuit. If current
is led to phase A of the machine in Figure 7.69, the rotor tries to turn counterclockwise so
that the reluctance of the magnetic circuit of phase A would reach the minimum and also the
energy of the magnetic circuit would thus be minimized.
When the energy minimum of phase B has been reached, the magnetic forces try to keep
the rotor in a position in which the energy minimum of the magnetic circuit is preserved.
Now the magnetic energy has to be removed from phase B to make the machine rotate again.
Correspondingly, current supply is started to phase A at an instant when the poles of the rotor
and the stator are about to overlap. By connecting the currents to different phases in turn at
the correct instants and with suitable magnitudes, a high, almost smooth sum torque can be
reached over a wide rotation speed range. Also, the loading of the rotor at zero speed is easier
than with traditional electrical machines.

7.4.2 Torque of an SR Machine

The torque calculation of an SR machine is based on solving the flux diagram and the deter-
mination of Maxwell’s stress tensor. If we have the Ψ i graphs of the machine, we can employ
the principle of virtual work in the torque calculation, as discussed in Chapter 1.
The calculation of the torque is problematic because of the dependence of the inductance
of the magnetic circuit on both the rotor angle and the stator current. The dependence results
from the excessive saturation of the magnetic circuit at certain rotor positions and with high
stator currents, Figure 7.70.

100
i/A
80

60
0
40 γ

20 π
0

-20

-40
-60

-80

-100
-1.5 -1 -0.5 0 0.5 1 1.5
Ψ/V s

Figure 7.70 Current of a 15 kW, 1500 min−1 SR machine as a function of flux linkage, the rotor po-
sition angle γ being a parameter. When the poles are in the aligned position, the iron circuit makes the
machine very nonlinear. When the poles are in the unaligned position, the large air gap makes the de-
pendence quite linear. γ = π corresponds to the aligned rotor position and γ = 0 the unaligned position
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416 Design of Rotating Electrical Machines

The instantaneous electromagnetic torque Tem is the ratio of the change of mechanical en-
ergy to the rotation angle. It can be written in the form

dWmec ∂Ψ ∂ Wem
Tem = =i − . (7.235)
dγ ∂γ ∂γ

The torque equation can be simplified by replacing the electromagnetic energy Wem with
magnetic coenergy W
. The magnetic coenergy is determined as

i


W = Ψ di. (7.236)
0

The geometric interpretation for magnetic energy and coenergy is the area between the
magnetizing curve and the i-axis presented in an iΨ plane, Figure 1.15:

Wem + W
= iΨ. (7.237)

By deriving W
with respect to the angle γ , the derivative of the coenergy can be written as

∂W
∂Ψ ∂ Wem
Tem = =i − . (7.238)
∂γ ∂γ ∂γ

By comparing the result with Equation (7.235) for the torque, we can see that the torque of a
reluctance machine is equal to the change in the magnetic coenergy per angular change.

7.4.3 Operation of an SR Machine

The operation of an SR machine is governed in the linear region by the constant variation
of the inductance as a function of the rotation angle of the machine. Furthermore, the ma-
chine saturates at the pole edges, and therefore the definition of the inductances is difficult in
different rotor positions and with different currents. Saturation is clearly visible for instance
in the dependence between the flux linkage and the current, illustrated in Figures 7.70 and
7.72. The higher the inductance difference between the aligned and unaligned positions, the
higher the average torque of the machine. As stated previously, the instantaneous torque of
the machine can be calculated from the change in coenergy as a function of rotation angle.
In motoring action, the current of the machine is often kept constant with a switched-mode
power supply, Figure 7.71.
The energy supplied from the voltage source cannot be completely converted into mechan-
ical work, but a part of it is returned to the current source at the end of each working stroke.
Figure 7.72 illustrates the behaviour of the flux linkage and the current during a single stroke.
The required energies are also indicated in the figure. The figure is constructed assuming that
the rotation angular speed Ω of the reluctance machine remains constant.
When the supply voltage Ud (converter DC link voltage) and the phase resistance are con-
stant, the speed is constant and the resistive voltage drop remains low, there is a linear increase
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Design Process and Properties of Rotating Electrical Machines 417

stator
rotor
unaligned aligned
position position
L current is
increased

rotor angle γ
motoring generating

γD
motoring current
γc
γD
generating current
γc
Figure 7.71 Inductance of a saturating reluctance motor as a function of rotor angle with current as
a parameter, and the current pulses of a motor drive and a generator drive, when the voltage of the
intermediate circuit remains constant. In motor or generator drive, the phase is commutated with the
angle γ c . The total conduction angle of the supplying positive voltage pulse has a length of γ D (Switch
ON). The current of the motor does not quite reach zero before the aligned position is reached. Now a
slight braking takes place as the machine shifts from the aligned position. In generating, the machine is
excited at the aligned position and the current is commutated well before the unaligned position

in flux linkage Ψ as an integral of voltage Ud after the switching of the voltage:

 
1
Ψ (t) = (Ud − Ri) dt = (Ud − Ri) dγ .
Ω

The increase in current i is also initially linear because the inductance L remains low and
almost constant in the vicinity of the unaligned position.
When the poles approach the aligned position, the inductance increases rapidly, and the
resulting back emf restricts the current. This phase is illustrated as the period 0–C (Fig-
ure 7.72a). With the rotor angle γ C at point C, the phase in question is commutated. Now
the energy brought into the system is Wmt + Wfc (the bright + shaded areas). Here Wfc is the
energy stored in the magnetic field and Wmt is the energy converted into mechanical work
when the transistor is conducting (see Figure 7.78a). In this phase, the mechanical work is
approximately equal to the energy stored in the magnetic circuit. After the commutation, the
polarity of the voltage is changed and the energy Wd is returned through the diode to the
voltage source (see Figure 7.78c), and the remaining energy Wmd is the obtained mechanical
work in the interval C–0, Figure 7.72b. During the complete working stroke, the mechanical
work is thus Wmec = Wmt + Wmd and the energy returning to the voltage source is WR = Wd .
The complete working stroke is illustrated in Figure 7.72c. According to the example in the
figure, the proportion of mechanical energy of the total energy is about 65%. The rest of the
originally supplied energy is ‘reactive energy’ of the reluctance machine that is stored either
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418 Design of Rotating Electrical Machines

Ψ d
aligne
(a)
C
Wfc
Wmt

unaligned
0 i

Ψ
(b) C
Wd
Wmd

0 i

Ψ
(c) C
WR
Wmec

0 i
Figure 7.72 (a) Transistor conduction period, (b) diode conduction period (see also Figure 7.69, (c)
energy conversion loop

in the electric field of the capacitor of the intermediate circuit (DC link) or in the magnetic
field of the magnetic circuit of the machine.
Usually, an energy ratio Γ is determined for an SR machine. This ratio expresses the energy
that can be converted into mechanical energy during the energy conversion loop

Wmec Wmec
Γ = = , (7.239)
Wmec + WR Wel

where Wmec + WR is the apparent power delivered by the power electronic circuit. The energy
ratio is to some degree a quantity analogous to power factor in AC machines. In the example
of Figure 7.72 the energy ratio has a value of approximately Γ = 0.65.
The average torque of an SR machine can be determined when the number of strokes per
revolution is known. In one revolution all poles Nr of the rotor must be worked on by all stator
phases, and therefore the number of strokes per revolution is m Nr . The average electromag-
netic torque over one revolution thus obtains the value

m Nr
Tem av = Wmec . (7.240)
2π
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Design Process and Properties of Rotating Electrical Machines 419

The input energy Wel supplied by the power electronics to the machine can be expressed as
a fraction k of the product i c Ψc (Wel = kΨc i c ), where Ψ c is the value of the flux linkage at the
instant of commutation and ic is the value of the current at that respective instant. If the flux
linkage increases linearly during the flux formation period 0–C as illustrated in Figure 7.72,
then

Ψc = Ud γ /Ω. (7.241)

Here γ is the angle during which the power bridge supplies power to the machine. We now
obtain

Wmec kUd γ i c
Wel = = , (7.242)
Γ Ω

and since i c is the peak value of the current yielded by the power electronics, the required
apparent power Sm processing ability of the output stage in an m-phase system is

mWmec Ω 2πT Ω
Sm = mUd i c = = . (7.243)
Γ kγ Nr Γ kγ

The product of the torque and angular speed corresponds to the air-gap power Pδ , and the
product Nr γ is constant, the maximum value of which is about π/2 at the base rotation speed
of the machine. The power-processing capability of the power bridge thus has to be

4Pδ
Sm = . (7.244)
kΓ

The required power is therefore independent of the phase number and the number of poles,
and it is inversely proportional to the energy conversion ratio Γ and the fraction k. Both Γ
and k depend greatly on the static magnetizing curves of the machine, and on the curves of
the aligned and unaligned position in particular. These curves, however, are in practice highly
dependent on the pole number Nr , which thus has a strong indirect effect on the dimensioning
of the power stage of the machine. When the power processing capability of the power stage
is compared with the shaft output power, we can determine, assuming that k = 0.7 and Γ =
0.6, that Sm /Pδ ≈ 10. This value is typical of SR motor drives. Inverter power stages of the
same scale are required in induction motor drives also.

7.4.4 Basic Terminology, Phase Number and Dimensioning

of an SR Machine
The geometry of SR motors is typically either symmetric or asymmetric. The stator and ro-
tor poles of a regular machine are symmetric with respect to their centre lines, and the poles
are located at even distances with respect to the peripheral angle. High-power machines are
usually symmetrical. Asymmetrical rotors are employed mainly in single- and two-phase ma-
chines to produce starting torque.
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420 Design of Rotating Electrical Machines

laminated stator

rotor

phase winding

Figure 7.73 A three-phase 6 : 4 (βs = 30◦ , βr = 32◦ ) and a four-phase 8 : 6 doubly salient reluctance
motor

An absolute torque zone is defined for an SR machine, referring to the angle through which
a single phase of the machine may produce torque. In a regular machine, the maximum angle
is π/N r .
An effective torque zone refers to the angle through which the machine can produce an
effective torque comparable with its rated torque. The effective torque zone corresponds in
practice to a smaller one of the stator and rotor pole arcs. For instance, in Figure 7.73 βs =
30◦ and βr = 32◦ , and thus the effective torque zone equals the stator pole angle βs = 30◦ .
The stroke angle ε of the machine is defined by the number of strokes during a full circle

2π 360◦
ε= = . (7.245)
m Nr m Nr

The absolute overlap ratio ρ A is the ratio of the absolute torque zone and the stroke angle

π/Nr π/Nr m
ρA = = = . (7.246)
ε 2π/ (m Nr ) 2

In a symmetrical motor, this value has to be at least one in order to produce torque at all
position angles of the rotor. In practice, the absolute overlap ratio has to be greater than one,
since a single phase alone is not capable of producing smooth torque at the distance of the
whole absolute torque zone. Therefore, the effective overlap ratio ρ E is defined as the ratio of
the effective torque zone and the stroke angle

min (βs , βr )
ρE = . (7.247)
ε

For instance, in Figure 7.73, β s = 30◦ , ε = 360◦ /3 × 4 = 30◦ and thus we obtain ρ E =
30 /30◦ = 1. At least the value of one has to be reached with the geometry of the machine in
◦

order to attain good starting torque with all rotor positions when only one phase is conducting.
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Design Process and Properties of Rotating Electrical Machines 421

In the construction of an efficient SR motor, usually the pole numbers presented in Figure
7.73 are employed. The ratio of the stator and rotor pole numbers is thus either 6 : 4 or 8 : 6.
These machines are three- or four-phase ones respectively. However, other topologies are also
possible. An increase in the pole number improves the operational accuracy of the motor and
the quality of the torque, but simultaneously the structure and control of the converter switches
get more complicated.
The poles of this motor type are typically long and narrow. As a result of the shape of the
poles, the magnetic flux of the machine is smaller, and therefore more coil turns are required
than in an AC motor operating at the same voltage. The rotor is usually long and thin in order
to reduce the moment of inertia. The air gap should be as short as possible to reach a maximum
average torque at small rotor volume. The length of the air gap is usually selected to be about
0.5–1% of the rotor diameter.
There are a few basic rules governing the selection of the number of poles and phases and
the angles between the poles. The ratio of the rotor speed n and the base switching frequency
can be determined when we assume that the poles connected to the same phase are at the
opposite sides of the stator. Now, as the rotor pole passes the phase, a torque pulse is produced.
The base frequency f 1 is thus

f 1 = n Nr , (7.248)

where n is the rotation speed and Nr is the number of poles in the rotor.
For a three-phase 6 : 4 motor, the stroke angle is ε = 30◦ and for a four-phase 8 : 6 motor
ε = 15◦ . The number of poles in the stator is usually higher than in the rotor. The angles
between the poles are determined by the mechanism producing the torque. The pair of the
rotor and the stator poles to be magnetized always has to be partially overlapping in order to
produce torque in all rotor positions. To ensure continuous, smooth torque without difficult
profiling of the phase current, there should be at least four phases, Figure 7.74.
The phase inductance difference, which alters with rotor position, should be maximized in
order to produce torque at a wider range when the rotor rotates. When the rotor pole is in the
position between the stator poles of two phases, the poles are not aligned, and therefore the
inductance remains low. The rotor poles are usually made of equal width or slightly wider than
the stator poles to leave enough room for the windings and to increase the inductance ratio.
Figure 7.75 illustrates different alternatives for the stator and rotor pole arcs of the machine.
In the motor of Figure 7.75a, there is plenty of room for the stator windings and also a
high inductance ratio. Thus, the efficiency and the power density are high, whereas the torque
ripple is higher than in cases b and c of Figure 7.75. Also, the starting torque of the motor
is low. In the stator of the motor in Figure 7.75b, there is enough room for the coils, but the
minimum inductance of the machine remains high in the unaligned position, since the poles
are constantly aligned to some extent. In Figure 7.75c, the inductance of the motor is far too
high in the unaligned position, and there is not enough room for the windings either. Miller
(1993) presents the different alternatives for pole arcs in graphical form. In the graphical
presentation, the feasible pole arcs are given in the form of a triangle ABC, Figure 7.76.
An optimum value can be solved for the pole size. This optimum value yields the maximum
inductance ratio and simultaneously the maximum average torque. In addition, several other
factors affecting the operation of the machine have to be taken into account, such as the torque
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422 Design of Rotating Electrical Machines

Tem

o
120 3-phase machine t

Tem

o
90 4-phase machine t

Tem

o
72 5-phase machine t

Figure 7.74 Torque pulses produced by the phases of a three-, four- and five-phase reluctance machine
with single pulse control. To achieve smooth torque, the phases of the machine have to be controlled in
such a way that in the commutating phase, two phases together produce the total torque. With three-
phase machines, to smooth the total torque, quite high currents have to be employed in the commutation
area, since, as shown above, at the intersections of the torque curves of different phases the sum of the
torques does not reach the level of the peak torque of single phases. In four- and five-phase machines,
the production of smooth torque is easier than with the three-phase machine, due to the torque reserve
at commutation

ripple, starting torque and the effects of saturation, and therefore no general solution can be
attained.
Table 7.9 introduces various SR motor configurations for reluctance machines with 1–5
phases. Although several other combinations are possible, the table presents only those com-
binations most likely to be met in practice.

7.4.5 Control Systems of an SR Motor

SR motors always require an individual control system, the performance of which decides
the overall characteristics of the machine drive. SR machines may not be operated directly on

(a) (b) (c)

Figure 7.75 Examples of different pole arc combinations for a three-phase machine with a topology
of 6 : 4 with different values of β s and β r
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Design Process and Properties of Rotating Electrical Machines 423

βs /o

80 βs /o
βs + βr = 90 o

60 60
C βs + βr = 90o
40 40
C
A B
20 βs = βr 20 A B
βs = βr
0 0
βr / o βr / o
10 50 90 10 50 90

(a) (b)

Figure 7.76 Feasible pole arcs for the stator and rotor poles of an SR motor; (a) 6 : 4 three-phase motor;
(b) 8 : 6 four-phase motor. Angles of the triangles ABC correspond in principle to the combinations of
Figures 7.75a, b and c. The pole arcs should lie within the triangular boundaries. Adapted from Miller
(1993)

line. That is why power electronic controllers are briefly discussed here. The control system
comprises switched-mode converters and the control and measuring circuits controlling them.
The torque of a reluctance motor does not depend on the direction of the phase current, and
therefore unidirectional switches can be employed in the converter. An advantage of direct
current is the reduction of hysteresis losses.
In the circuits of Figure 7.77, the switches can be either power FETs (Field-Effect Tran-
sistors), or IGBTs (Insulated-Gate Bipolar Transistors). The phases are independent of each

Table 7.9 Selection of feasible pole numbers for reluctance machines with 1–5 phases. m is the phase
number, N is the number of poles, µ is the number of pole pairs operating simultaneously per phase
and ε is the stroke angle
m Ns Nr µ ε /◦ Strokes/revolution
1 2 2 1 180 2a
2 4 2 1 90 4b
3 6 4 1 30 12
3 6 8 1 15 24
3 12 8 2 15 24
3 18 12 3 10 36
3 24 16 4 7.5 48
4 8 6 1 15 24
4 16 12 2 7.5 48
5 10 6 1 12 30
5 10 8 1 9 40
5 10 8 2 18 20
a
Needs assistance for starting.
b
An asymmetric rotor is needed to create starting torque.
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424 Design of Rotating Electrical Machines

(a)

(b)

Figure 7.77 Converters operating a three- and four-phase SR motor. (a) Three-phase machine: each
phase has a separate chopper leg comprising two switches, which can be controlled independent of the
other phases. (b) In the control circuit of a four-phase machine, the transistor of the upper branch is
shared by two phases. However, when the phases are selected appropriately, it is possible to control the
machine in all the possible modes of Figure 7.78. When a transistor, located in the upper leg of a three-
phase machine, is employed jointly for all three phases, the transistor of the upper leg has to be nearly
always conducting, in which case some of the controllability is lost. In principle, the upper transistor
controls the value of the current and the lower transistors guide the current to different phases

other, unlike in AC inverters for instance. The chopper switch is well protected in fault situa-
tions, since the phase winding of the motor is in series with both switches. The control circuit
of the switches can be made far simpler when compared with an AC inverter. In the circuit
of Figure 7.77b, fewer switches are required than in the circuit of Figure 7.77a without any
significant decline in applicability. At high speeds, the energy of the magnetic field cannot be
discharged fast enough with the circuit of Figure 7.77b, since the polarity of the voltage of the
phase winding cannot be changed. Now a braking torque is created, and the losses increase
rapidly.
The inductance varies with rotor position and therefore, with a fixed switching frequency,
also the current ripple changes. This can be prevented by applying variable switching fre-
quency, in which case the switching frequency varies according to the angle between the rotor
and the stator. The switching frequency is usually selected above 10 kHz, as in other motor
drives, in order to reduce noise. With high power values, low switching frequencies are se-
lected because of the slowness of large switches; therefore, large and slow motors are usually
quite noisy.
At low rotation speeds, the switches are usually controlled so that one transistor of the
branch is employed for commutation and the other to control the current. At high rotation
speeds, both transistors are constantly conductive, since the emf restricts the maximum value
of the current, in which case the current curvature depends on the motor characteristics.
Figure 7.78 illustrates the current flow during the conduction period. When the transistors
are conducting, the current passes through them and the phase winding (7.78a). When the
current reaches the upper limit, the upper chopping transistor is brought to a nonconducting
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Design Process and Properties of Rotating Electrical Machines 425

T1 D1

i i i

D2 T2

T1 and T2 T2 and D2 D1 and D2

conducting conducting conducting
(a) (b) (c)

Figure 7.78 Application of power electronics to control the current of a single SR machine phase: (a)
positive voltage, (b) zero voltage, (c) negative voltage in the coil

state, the current of the winding passes through T2 and D2, and the voltage over the winding
is close to zero (7.78b). At the commutation point, both transistors change state, the current
transfers to the diodes, and the polarity of the voltage of the winding is changed (7.78c). This
control method is called soft chopping.
The second alternative is always to control both transistors simultaneously. When the tran-
sistors are in the nonconducting state, the current flows through the diodes to the DC voltage
source. In this method, the current ripple increases and simultaneously also the torque ripple
and the noise increase. This hard chopping is used mainly in the braking of the rotor, that is in
the generator drive. Nevertheless, some manufacturers constantly apply hard chopping in the
control systems of their SR motors.
For the proper operation of the motor, it is important that the pulse of the phase current
occurs at an instant when the inductance is increasing and the opposite poles of the rotor ap-
proach the stator poles of the respective phase. The timing of the current and the duration
decide the torque, efficiency and other performance characteristics. There is no clear relation-
ship between the phase current and the torque in a reluctance motor, as there is for instance in
DC motors. Therefore, the production of a smooth torque requires highly intelligent control
capable of detecting the rotor position and controlling the control as desired.
To improve the reliability of the motor and to simplify the construction, the target has been
to develop an indirect position control without any devices attached to the rotor (position
sensorless control). It has been shown that the rotor position can be determined with sufficient
precision by analysing the current and voltage curves of the motor. The varying inductance
of the motor can be defined from these curves. Another, corresponding method is an active
method in which the rotor angle is determined by supplying an instantaneous voltage pulse to
a currentless phase.

7.4.6 Future Scenarios for SR Machines

Traditionally, reluctance machines have been controlled in the same way as stepper motors
by supplying constant voltage and current pulses to the stator at a frequency defined by the
rotor angle. This results in a considerable torque ripple, which has made reluctance machines
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426 Design of Rotating Electrical Machines

unsuitable for several applications. Recently, various control methods have been introduced to
bring the torque ripple to the level of traditional electrical machines. The methods are based
on the exact measurement of the reluctance machine to analyse the magnetic properties of the
machine. The control utilizes these documented measurement results. Therefore, the control
has to be customized for each machine type individually.
The advantages of a reluctance machine when compared with traditional electric drives are
for instance the following:

r No winding is required in the rotor; the rotor construction is simple and easy to manufacture.
r The moment of inertia of the rotor is low, a fact that improves the dynamics of a controlled
electric drive.
r The stator winding is easy to construct, and the losses of an end winding are lower than in
a corresponding induction machine.
r Most of the losses occur in the stator, and therefore cooling of the motor is easier, and a
higher loadability is achieved.
r The large free spaces in the rotor enable efficient ventilation throughout the machine.
r The torque of the machine is independent of the direction of current, thus giving more
degrees of freedom in the inverter and control solutions.
r The machine can produce a very high torque also at small rotation speeds and with a steady
rotor at low current.
r The machine constant of an SR machine is higher than the machine constant of an induction
motor.
r The torque is independent of the direction of the phase current, and therefore, in certain
applications, it is possible to reduce the number of power switch components.
r In the event of a failure, the voltage of an open circuit and the short-circuit current are low.
r In reluctance motor applications, the power electronic circuits do not have a shoot-through
path, which facilitates the implementation of the control system.
r Extremely high rotation speeds are possible. This, together with a high machine constant,
makes the machine type interesting in aviation applications as a jet engine starter–generator.

A disadvantage of an SR motor is the discontinuous torque that causes vibration in the con-
figuration and also acoustic noise. Over a low-speed range, the torque ripple can be restricted
to 5–10% or less, which is comparable to induction motor drives. Over a high-speed range, the
restriction of the torque ripple is impossible in practice. This is not a problem thanks to me-
chanical filtering. At present, the best drives produce a very low degree of torque ripple at low
speeds. The fact is that the smoothest torque is required only at low speeds, when the loads
are most vulnerable to the harmful effects of torque ripple. In small motors, the noise can be
damped at high speeds by selecting a switching frequency above the range of audibility.
In the torque control, the power is taken from the DC link in a pulsating manner, and
therefore efficient filtering is necessary. In this sense, the drive does not differ considerably
from the inverter drive of an induction motor. A small air gap advantageous to the operation
of the motor increases the production costs. A small air gap is required to maximize the
inductance ratio.
Despite notable advantages, the reluctance motor has so far been restricted in its application
by the problems in smooth torque production over a sufficiently wide rotation speed range.
In order to solve these problems, the operating principle of an SR machine requires new
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Design Process and Properties of Rotating Electrical Machines 427

inverter and control solutions. On the other hand, the present processor technology and power
electronics allow control algorithms of complicated electric drives also.
The design of an SR machine depends to a large extent on field calculation. In this calcula-
tion process, the shape of the magnetic circuit of the machine and the inductances at different
rotor positions are determined. This is manually a demanding task because of the local sat-
uration at salient-pole tips, which is typical of the operation of an SR machine. Because of
the saturation, it is difficult to employ an orthogonal field diagram. Therefore, field calcu-
lation software is required in the design of an SR machine. The task becomes easier as the
field solutions can usually be made at steady state excluding the problems caused by eddy
currents. However, the use of an SR machine is so far so limited that no extensive calculation
instructions can be found in the literature.
Speed control has become more common in pump and blower drives, thus improving their
efficiency. In drives of this kind, SR motors are not yet competitive with frequency-converter-
driven induction motors, for instance, because of their complicated control. The torque of an
SR motor is very high at low rotation speeds, and therefore the motor type may become more
popular in applications in which a high starting torque is required. Permanent magnet AC
motors, however, seem to be more popular even in this application area.
The applicability of SR motors to electric tools has also been investigated. In these appli-
cations, the size and the torque properties of reluctance motors are most beneficial. A dis-
advantage of the universal current motor, which is commonly used at present, is wear of the
mechanical commutator and electromagnetic disturbances caused by the commutation. These
problems could be solved with an SR drive. Due to its durability and other favourable quali-
ties, an SR motor is also a suitable power source for electric vehicles.

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8
Insulation of Electrical Machines

Here, an insulator refers to a nonconducting material or an insulating material with a very low
conductivity. An insulation system comprises insulating materials and insulation distances.
The main function of insulation is to separate components of different electric potentials or of
different electric circuits. Further, insulators improve the strength of the winding structures;
they also have to act as heat conductors between the winding and the surroundings, and they
have to protect the winding from external stresses such as dirt, moisture and chemicals.
In electrical machines, there are typically insulation distances of three types. First, a clear-
ance in air is simply an air gap between the objects, the insulating strength of which is deter-
mined by the distance between the objects, their shape and the state of the air. A clearance in
air can be defined by either insulated or noninsulated surfaces. In certain cases, the medium
of the insulation distance, which also simultaneously acts as a coolant, can be a gas other than
air. In the case of a homogeneous electric field, the breakdown voltage depends on the width
of the air gap according to the Paschen curve, Figure 8.1.
The Paschen law essentially states that the breakdown characteristics of a gap are a function
of the product of the gas pressure and the gap length. Figure 8.1 shows a special case with
constant pressure. Air in an insulation construction is often prone to partial discharges. Partial
discharges take place inside the insulation construction, especially in places where materials
with different permittivities are connected in parallel. This takes place for instance in an insu-
lation having air bubbles in the insulating resin. The dielectric strength of the air bubble is far
smaller than the resin itself, and small partial discharges take place inside the air bubble. The
sensitivity for partial discharges can be estimated using the Paschen curve. If there is 500 V
over a 10 µm air bubble (E = 50 MV/m), partial discharges will take place. The insulation
starts to deteriorate in these places and, finally, partial discharges may destroy the insulation
if the materials selected do not tolerate partial discharges. Mica is used in high-voltage insu-
lations since it tolerates partial discharges without deteriorating. The present-day switching
power supplies may cause partial discharges also in low-voltage machines, especially in the
first turn of the winding because of the nonuniform division of the fast-rising voltage in the
winding.
Second, an insulation distance created by solid insulation is chiefly composed of solid in-
sulators, in which the electric field is not significantly oriented along the interfaces of the

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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430 Design of Rotating Electrical Machines

10000
5000

û/V

1000

500
min 320 V

100
1 5 10 50 100 500 1000
l/ m

Figure 8.1 Paschen curve illustrating the voltage strength of an insulation distance formed from a
homogeneous air gap at a pressure of 101 kPa. l is the gap spacing between the electrodes

insulators. In this case, the insulating strength is determined by the thickness of the insulation
and by the relative permittivity of the insulating material.
Third, a creepage distance is an insulation distance in which a bare live part is connected to
a conductive or insulated component in another electric potential, such as the earthed frame
of the machine. We have a creepage insulation distance also when a live part is only weakly
insulated. Surface discharges may occur, or a flashover in the creepage distance, if the effective
electric field has a component parallel to the surface in question. Typically, such a point occurs
in an electrical machine on the surface of slot insulation just outside the iron core.
An open creepage distance may gather dirt or moisture that may produce creepage currents
and discharges on the surface of the insulation. In machines below 1000 V, the creepage cur-
rents are chiefly a risk factor. With high voltages, surface discharges may also damage the
insulation. The track resistance of a material describes the ability of the material to resist the
formation of a carbonized track when a high voltage is applied to it. The track resistance of
an insulating material is defined by the Comparative Tracking Index (CTI). As the track re-
sistance is defined by the voltage (which will cause failure by tracking), the unit of CTI is the
volt. The test method is defined for instance in the IEC 600112 standard.
In an electric circuit, there always has to be insulation, which naturally takes up some
room. This is a fact that has to be taken into account in the dimensioning of the magnetic
circuit and the winding. Real insulation is always slightly conductive, and it can be damaged
by electrical, thermal, mechanical or ambient stress, or by chemical attack. Ambient stresses
include for instance humidity, abrasive particles in cooling air, dirt and radiation. An insulating
material has to have a sufficient voltage resistance to avoid flashovers in the voltage test or
when exposed for instance to overvoltages. The estimation of stresses to which the insulation
may be exposed during its service life and the dimensioning of the insulation based on this
analysis together are called insulation coordination.
The conductivity of the insulation and the dielectric losses should remain low during op-
eration. The insulation has to be thermally resistant to short-term overloads during operation
and also to cumulative ageing caused by the stresses mentioned above. Although at present
there are hundreds or even thousands of suitable alternatives for insulating materials, the most
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Insulation of Electrical Machines 431

common insulating materials in electrical machines are easily listed: mica, polyester films,
aramid paper and epoxy or polyester resins. Insulation materials somewhat less common in
electrical machines are materials made of polyester fibre (Dacron, Terylene, Diolen, Mylar,
etc.), polyimide films (Kapton) and silicon resins employed in the impregnation.

8.1 Insulation of Rotating Electrical Machines

Insulation can be roughly divided into two main categories: groundwall and conductor insu-
lation. The function of groundwall insulation is to separate those components that may not be
in galvanic contact with each other; for example, groundwall insulation galvanically separates
the coil from the iron core of the machine. Conductor insulation separates the wires and turns
of a coil. Usually, standards are not as high for conductor insulation as they are for groundwall
insulation, and therefore the former is usually notably thinner than the latter. Consequently, a
conductor or turn-to-turn insulation is usually, and in small machines in particular, a varnish-
ing on the wire.
The main types of insulation are:

r slot insulation and the slot closer;

r phase-to-phase insulation in the slot and in the coil end;
r pole winding insulation;
r insulation of the connection leads and the terminals;
r impregnating varnish and resin; and
r surface varnish and protective paint.

The outermost layer of the slot insulator has to have a good mechanical strength, since
sharp edges may occur in the slot. A polyester film, for instance, is a suitable material for
slot insulation. If two insulating materials are employed in the slot, the inner layer is usually
selected to be aramid paper since it has better thermal resistance and impregnation properties
than polyester film. Aramid papers efficiently absorb the resin, and the resin is well fixed to
the surface compared with polyester surfaces that are glossy and nonporous. In phase-to-phase
spacings, flexible, cloth-like insulation materials are selected for the end windings. When a
high voltage strength is required, mica is employed, and when a high mechanical strength is
needed, thermoplastics reinforced with fibreglass are used.
Mica is an inorganic natural substance occurring commonly in bedrock. Micas belong to
the monoclinic system, and they are composed of thin flakes of silicate tetrahedra which are
elastic and transparent. These silicate sheets are composed of interconnected six-membered
rings, which form the typical pseudohexagonal symmetry structure of micas.
For the past hundred years mica has been a significant component in the insulation of high-
voltage machines, due chiefly to its excellent partial discharge strength. Chemically, mica is
composed of potassium, aluminium silicate or some other closely related mineral. The crystals
of mica comprise layers of thin flakes or sheets that can be easily separated from each other.
This crystal structure enables the flakes to be split into thin strips that are flexible and thus
suitable as an insulation material for electrical machines.
The thermal endurance of mica is very high. (See also thermal classes presented in
Table 8.1.) At the lowest, the mica qualities start to lose their crystal water at a tempera-
ture of 500 ◦ C, although some qualities endure even above 1100 ◦ C. For electrical machines,
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432 Design of Rotating Electrical Machines

Table 8.1 Thermal classes of insulating materials. Adapted from standards IEC 60085, IEC 60034-1.
Permitted average
Permitted design winding temperature
temperature rise/K, determined by
Previous Hot spot when the ambient resistance
Thermal class designation allowance/◦ C temperature is 40 ◦ C measurement/◦ C
90 Y 90
105 A 105 60
120 E 120 75
130 B 130 80 120
155 F 155 100 140
180 H 180 125 165
200 200
220 220
250 250

these values are more than adequate, since the highest permitted temperatures for the machine
parts are usually about 200 ◦ C at the maximum. Mica has excellent chemical resistance; it is
resistant to water, alkalis, various acids and common solvents. Only sulfuric acid and phos-
phoric acid dissolve mica. However, mica does not resist oil, because oil penetrates between
its flakes separating them from each other.
The dielectric strength of mica is high, the dielectric losses are low and the surface re-
sistance is high. Creepage currents do not damage mica, and it resists the effects of partial
discharges far better than the best organic insulators. Therefore, mica is almost an indispens-
able material in high-voltage electrical machines, in which there are always some partial dis-
charges. Partial discharges are difficult to handle. Usually in machines with a rated voltage
above 4 kV, some partial discharges occur during operation. Mica tolerates this. It is, how-
ever, possible that even in large low-voltage machines, there may be some partial discharges
in the converter supply. This is because the steep-edged voltage pulses are not evenly dis-
tributed in the winding turns, but may stress heavily the first turn of the winding. In such a
case, the electric field strength may be large enough to cause partial discharges, and if there is
no mica present the insulation will fail sooner or later.
In the mica insulator, the flakes of mica are bound with a suitable binding agent. Further,
some layers of a suitable auxiliary substance are required, such as glass fabric or polyester
foil to improve the tensile strength of the insulation. Nowadays, mica is used mainly as
a paper in the insulation of electrical machines. Mica paper is an insulator composed of
extremely small flakes of mica and produced in the same way as paper, hence the name.
Thus, despite the term ‘paper’, the material does not include any cellulose fibres. Natu-
ral mica is crushed either mechanically or with heat into small flakes that are glued with
resin into a flexible, paper-like material. The properties of mica insulators are presented
in Table 8.2.
Insulating films constitute a rather diverse group of insulators (Table 8.3). The films are
usually duroplastics, the thermal resistance of which is restricted by the melting temperature
and rapid ageing far below this temperature.
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Insulation of Electrical Machines 433

Table 8.2 Characteristics of mica insulators. Adapted from Paloniemi and Keskinen (1996)
Characteristic Commutator Moulding Mica Glass– Epoxy glass mica
micanite micanite folium mica tape paper tape
Mica content/% 95–98 80–90 40–50 40 45–55
Binder content/% 2–5 10–20 25–40 18–22 35–45
Content of the supporting — — 20 40 15
material
Compression 110–170 — — — —
strength/N/mm2
Tensile strength/N/mm2 — — 30–50 40–80 80–120
Compression/% 2–6 —a — — —
Continuous operating temperature/◦ C, binder:
Shellac F155b Fb B130 B130 F155
Alkyds, epoxy H180c Hc F155 F155
Silicone — — H180 H180
Voltage strength/kV/mm 25 20 20 16–20 20–30
(1 min, 50 Hz)
a
In the production process, mica flakes glide with respect to each other. When the binder has set, the
compression is 4–8%.
b
In the commutators of insulation class F machines.
c
In the commutators of insulation class H machines.

Table 8.3 Characteristics of insulating foils. Adapted from Paloniemi and Keskinen (1996)
Characteristic Unit Polyester PETP Polyimide Polysulphone PS
Tensile strength N/mm2 140–160 180 90
Elongation at break % 75 70 25
Modulus of elasticity N/mm2 3900 3000 2500
Density g/cm3 1.38 1.42 1.37
◦
Continuous operation temperature C 130 220 180
◦
Instantaneous thermal resistance C 190 400 210
◦
Softening point C 80–210 530 235
◦
Melting point C 250 Does not melt
Shrinkage at 150 ◦ C % 3 — —
Burning Slow Does not burn Does not keep up
burning
Moisture absorbency % by weight 0.5 3 1.1
Chemical strength Graded 0–4
Acids 2 3 3
Alkalis 1 0 3
Organic solvents 4 4 1
Specific resistivity
cm 1019 1018 5 × 1016
Voltage strength kV/mm 150 280 175
Trade names Mylar Kapton Folacron
Melinex PES
Hostaphan
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434 Design of Rotating Electrical Machines

Figure 8.2 Mylar polyester construction. The material contains hydrogen (H), oxygen (O), carbon (C)
and benzene hexagons (C6 H6 ). The encircled part is an ester. The ester group is prone to hydrolysis,
hence the material does not tolerate heat and moisture simultaneously

Polyester film is produced for various purposes at nominal thicknesses from 6 µm to

0.4 mm. PETP (polyethyleneterephthalate) membrane is a tough polyester film, which is
used as such or as a laminated insulator as slot insulation and a phase coil insulation in
small- and medium-size machines. Figure 8.2 illustrates the chemical composition of a Mylar
polyester film.
Aromatic polyamides, or aramid fibres (trade name Nomex), have better heat-resistance
qualities than the previous ones, but they are not quite as ductile as PETP films. Therefore,
aromatic polyamides are often used as laminated insulators together with PETP or polyimide
films. Figure 8.3 illustrates the chemical composition of aramid fibres.
Polyester film has the best mechanical strength of the insulating foils available; its yield
limit and tensile strength approach the values of soft copper. Films are employed as such in
the slot insulation of small machines, and in the slots of large machines, together with fibre
insulation (aramid or polyester paper). The melting temperature of polyester film is approx.
250 ◦ C. However, polyester has an inadequate resistivity to moisture at high temperatures. In
such cases, aramid fibres are used alone.
Polyimide film endures constant temperatures of even 220 ◦ C, and its instantaneous thermal
resistance is as high as 400 ◦ C. Further, the mechanical properties of the film are relatively
good, and its breakdown voltage is high. It is not affected by organic solvents. The thick-
nesses of the film vary usually between 0.01 and 0.12 mm. Polyimide insulation is rather ex-
pensive, but as a thin insulator it leaves more space for instance for the windings, thus being
an advantageous alternative in certain cases. Figure 8.4 illustrates the polyimide construction.

Figure 8.3 Nomex aramid fibre chemical structure. The material contains hydrogen (H), oxygen (O),
carbon (C), nitrogen (N) and benzene hexagons (C6 H6 ). This simple construction tolerates different
stresses well, even heat and moisture simultaneously
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Insulation of Electrical Machines 435

Figure 8.4 Kapton polyimide. The circled NC2 O2 functional groups are the imide groups. The material
contains oxygen (O), carbon (C), nitrogen (N) and benzene hexagons (C6 H6 ). The imide groups are
prone to hydrolysis, and the material does not tolerate heat and moisture simultaneously

Insulation of conductors is the most demanding task in the insulation construction of an

electrical machine, since the insulation is located closest to the hot copper wire and, moreover,
it is the thinnest insulation component. Conductor insulation is often varnish-like thermoplas-
tic. There are both crystalline and amorphous regions in the varnish. The crystallinity of the
material improves thermal resistance, it forms an impermeable sealing against solvents, and,
further, it improves the mechanical properties of the insulator. The amorphous property, on
the other hand, makes the insulator flexible. The most common conductor varnishes used in
electrical machines are ester–imides or amide–imides. Figure 8.5 shows the polyamide–imide
polymer chain. They are thus related both to polyester and polyimide films. The highest per-
mitted temperatures for ester–imides are of the order of 180–200 ◦ C.
Conductor insulation can be formed from two or more different types of varnish. Two
different varnishes are employed in order to achieve better thermal resistance, better me-
chanical properties and improved cost efficiency than with a single material. In practice,
the varnish coating comprises several layers also in the case of a single varnishing mate-
rial. In the coating, the bare conductor is heat treated and coated with varnish. Next, the
solvent is vaporized by heating the wire in the oven, and the wire is coated with a new layer
of varnish. The process is repeated 4–12 times. The wires are divided into three grades ac-
cording to the thickness of the coating: ‘single’ (Grade 1), ‘double’ (Grade 2) and ‘triple’
(Grade 3). In reality, as previously mentioned, there are always several layers of varnish.

Figure 8.5 Polyamide–imide polymer. The material contains hydrogen (H), oxygen (O), carbon (C),
nitrogen (N) and benzene hexagons (C6 H6 ). The imide groups are prone to hydrolysis
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436 Design of Rotating Electrical Machines

Figure 8.6 Chemical structure of FEP fluoropolymer. The structure, which contains two carbons and
four fluorines and repeats n times, is the chemical structure of a PTFE fluoropolymer

Furthermore, the thickness of the varnishing of each grade is always proportional to the diam-
eter of the wire.
Polyimide films and aramid papers can also be used as conductor insulation. They are
wrapped on a wire-like tape. They can be considered for special applications, but they are too
expensive for common machines. For extremely harsh environments, fluoropolymer (Teflon)
insulation can be used. It is extruded on the wire in the manufacturing process. Fluoropoly-
mers offer good chemical resistivity and excellent resistivity to moisture even at high temper-
atures. However, their breakdown voltage can be one-fourth of that of polyester–imides and
polyamide–imides, which has to be taken into account when designing an insulation system.
Figure 8.6 illustrates the chemical composition of Teflon.
PEEK(polyether-etherketone) polymer is a very good conductor insulation material in de-
manding environments. PEEK is reported to have an excellent resistance even to hydrolysis up
to 250 ◦ C. PEEK is, unfortunately, not readily available. Figure 8.7 illustrates the composition
of PEEK.

8.2 Impregnation Varnishes and Resins

The function of an impregnating varnish or resin is to reinforce mechanically the winding,
to protect it from moisture, dirt and chemicals, and to improve its thermal conductivity. On
the other hand, excessive varnishing decreases thermal conductivity, for instance in the coil
ends. An impregnating varnish comprises a base component (linear polymers), monomer
(a cross-linking agent), solvents and possible oils. Depending on the composition, the var-
nishes are divided into oil-based and polyester coatings. The setting of oil-based varnishes
requires oxygen, and therefore they should not be used in compact and thick windings. The
electrical properties of oil-based varnishes are good, but their mechanical strength is rather

Figure 8.7 Chemical structure of PEEK

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Insulation of Electrical Machines 437

Figure 8.8 Polyester resin composition. The material contains hydrogen (H), oxygen (O), carbon (C),
benzene hexagons (C6 H6 ) and reactive parts (R). The encircled parts are esters. The monomer binds
itself to the reactive parts indicated by R when the material is cured to a thermoplastic

poor. Polyester varnishes are nowadays the most common varnishing materials, Figure 8.8.
They are either single- or two-component varnishes, the hardening of which usually requires
heat treatment. In the curing process, the solvent is vaporized, monomer from one end at-
taches to the reactive part of one base component and from the other end to the reactive
part of the other base component. This is called cross-linking, because the polymer chain
of the monomer sets perpendicular to the polymer chain of the base component. This way,
a complex three-dimensional polymer structure is formed. A plastic created this way is a
thermoplastic.
In the impregnating varnishes, approximately half of the volume is an evaporable solvent,
which is replaced by air when the varnish hardens. Therefore, alkyd- or polyester-based var-
nishes including solvents have mostly been replaced by impregnating resins that are polyester
or epoxy based; they do not contain solvents and are chemically hardening impregnants. In
common machines, polyester resins are used, because they have a low price and are easy to
handle. In a polyester resin, the base component and the monomer are quite similar substances
in nature and viscosity, and mix easily. Moreover, it is possible to use convenient mixing ra-
tios, such as one to one. Epoxy resins are very reliable and have the composition illustrated in
Figure 8.9.
A disadvantage of epoxy resins is their high price when compared with polyester resins.
However, epoxy resins are usually employed in machines above 250 kW because of their
good mechanical strength, adhesiveness and low shrinkability. In harsh environments, epoxy
resins are favoured. They have good resistivity to chemicals, moisture and radiation. On
the other hand, polyester resins have better resistivity to oils, such as transformer oil. In

Figure 8.9 Chemical composition of basic epoxy resin. Epoxide functional groups are circled. These
groups are characteristic for every epoxy, but the polymer chain in between them can vary
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438 Design of Rotating Electrical Machines

special cases, as in traction motors involving very high temperatures (over 200 ◦ C), sili-
cone resins can be used. They offer excellent thermal properties, but have a poor mechanical
strength.
Surface varnish improves the surface quality of the insulation. Surface varnish forms an im-
permeable coating that is easy to clean and that improves the track resistance of the insulation.
Table 8.4 introduces the properties of insulation varnishes, resins and surface varnishes.
The impregnation of the insulation has an influence on the track resistance of the insulation.
Since the insulation is composed of several different components, one of the components is
often an air gap. Air gaps may also be left in undesired places, for instance in a slot, when
the impregnation has not been complete or there are bubbles in the varnish. This has to be
taken into account in the dimensioning of the insulation and the selection of the impregnation
method. The electric field strength E in a single material of thickness d is

U
E= . (8.1)
d

The electric field density D through the insulation must be constant in a homogeneous
insulation and equal throughout the insulation construction made of several layers:

E · ε = D. (8.2)

When two different insulation materials 1 and 2 (thicknesses d1 and d2 ) are in series in the
same outer field, we have the corresponding field strengths E 1 and E 2 and voltages U1 and U2
according to Equations (8.1) and (8.2):

E1 ε2
= (8.3)
E2 ε1

and

U1 d1 ε2
= · . (8.4)
U2 d2 ε1

When there is a voltage U = U1 + U2 over the insulation, we may write for the voltages

d1
ε1
U1 = U · (8.5)
d1 d2
+
ε1 ε2

and

d2
ε2
U2 = U · . (8.6)
d1 d2
+
ε1 ε2
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Table 8.4 Characteristics of insulating varnishes and impregnating resins. Adapted from Paloniemi and Keskinen (1996)
November 25, 2008

Insulation of Electrical Machines

Characteristic, Grades 0–4 Impregnating varnishes Impregnating resins Coating (surface) varnishes
Continuous operating 155 180 155 180 130 155 180
16:46

temperature/◦ C
Mechanical strength at 3 1 3 4 2 2 1
operating temperature
Flexibility 3 2 2 2 4 3 2
Moisture resistance 3 3 3 4 3 4 4
Chemical strength 3 3 3 4 3 4 3
Track resistance 3 3 3 2 3 2 3
Typical materials Alkyd polyester Silicone epoxy Polyester alkyd Polyester Alkyd Alkyd Alkyd
Epoxy Epoxy Polyurethane Polyurethane Silicone
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Epoxy
439
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440 Design of Rotating Electrical Machines

Example 8.1: The thickness of insulation is 4 mm and its permittivity ε1 = 5. Inside

the insulation, there is a 0.25 mm air gap with ε2 = 1. The voltage over the insulation is
U = 12 kV. How is the voltage divided between the insulation and the air gap, and how
high is the field strength in the air gap?
Solution: With Equations (8.5) and (8.6), we obtain the voltages U1 = 9.14 and
U2 = 2.86 kV. The electric field strength in the air gap is E 2 = 2.86 kV/0.25 mm =
11.44 kV/mm, which may exceed the breakthrough field strength. Even a small air gap
in the insulation may cause partial discharges that may age the insulation. Even though
the partial discharge in the air space remaining inside the insulation did not result in an
immediate flashover in the complete insulation, it might, through local overheating and
wear, rapidly cause a breakdown in the complete insulation construction.

We may take two epoxy-coated polyester films as an example: they are relatively heat re-
sistant when not in contact with air. The dielectric strength of this kind of construction can
be even dozens of times higher compared with the voltage at which the air gap between the
films starts to spark, thus wearing the coating and insulating foils. However, exceeding this
inception voltage of sparking drastically cuts the service life of the insulation, whereas the
breakdown voltage has almost no influence on the service life of the insulation.
Therefore, nowadays such impregnation methods are selected that ensure adequate pene-
tration of the impregnant and an impermeable construction. A possible method is provided
for instance by vacuum pressure impregnation (VPI) technology. This method is employed at
both low and high voltages in the temperature classes 155–220 (cf. Table 8.1).
For operation under special conditions, the windings can be cast in plastic. An advantage
of the method is that the winding becomes completely waterproof. Further, the mechanical
strength of the coil is improved. A disadvantage is the high price of the insulation. The plastics
used in the method are either polyester or epoxy plastics. The method is seldom used in
industrial motor applications.
Since chemicals are always released from the insulation during operation, it has to be en-
sured that these chemicals are not harmful to other insulating materials. The dissolved oxygen
molecules creating ozone in partial discharges also rapidly weaken several polymers. The im-
pregnating varnish in particular has to be compatible with other insulators. The manufacturers
recommend testing insulating material combinations to ensure compatibility.

8.3 Dimensioning of an Insulation

The mechanical, electrical and thermal stresses that the insulation is exposed to are contribut-
ing factors to the dimensioning of an electrical machine. These stresses degrade the properties
of the insulation. Further, in the selection of the insulating material, stresses caused by the
operating conditions, such as accumulating dirt, chemicals, oils, moisture and radiation, have
to be taken into account.
The compression strength of the insulation is usually higher than the tensile strength, and
therefore, in the design, we should aim at insulations that are exposed to compression rather
than tension. For instance, fibreglass bindings can be employed to receive the tensile stresses
exerted on the insulation (cf. binding of the rotor of a DC machine). The end windings are also
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Insulation of Electrical Machines 441

F
I 0 π 2π
B

Figure 8.10 Lorentz force caused by the flux in the conductor in the slot on the periphery of the
machine

exposed to shearing stresses. Thus, the insulation has to be dimensioned according to these
stresses. Although rigidity is also required of the insulation, under certain circumstances it
has to be flexible too. Usually, and in low-voltage machines in particular, it suffices that the
insulation adapts to the deformation caused by the thermal expansion of the copper wire.
An insulation construction is often employed to support the winding. Therefore, the struc-
ture has to withstand vibration and electrodynamic forces, such as starting and short-circuit
currents. The more securely the coil end is supported, the higher the natural frequency gets.
The target is to raise the natural frequency of the insulation construction to a level above the
frequency range of the electrodynamic forces. The most important natural frequency to be
avoided is the frequency that is double the supply frequency. This force is created as a re-
sult of the magnetic flux and the winding current. The direction of this force is illustrated in
Figure 8.10.
In addition to the normal operating voltage, the insulation construction of an electrical ma-
chine also has to withstand temporary overvoltages at operating frequency, switching over-
voltages and exposed overvoltages. These short-term overvoltages have to be taken into ac-
count particularly in the dimensioning of the air gap, since an insulation composed of solid
insulators endures rather well the quite high temporary voltage stresses. In practice, a high-
voltage insulation is usually designed with an effective field strength of 2–3 kV/mm in the
insulation. An approximate value for the minimum thickness of the insulation layer is ob-
tained by applying Equation (8.1)

d = U/E max , (8.7)

where d is the thickness of the insulating material, U is the voltage over the insulation and
E max is the highest allowable field strength in the material concerned.
If the insulation is composed of several layers, the thicknesses of these layers can be esti-
mated from the following:


d1 d2
U = E 1 d1 + E 2 d2 = D + . (8.8)
ε1 ε2

According to the IEC standard for rotating electrical machines (IEC 60034), the voltage
test should be carried out with an AC voltage at a frequency of 50 or 60 Hz. With low-voltage
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442 Design of Rotating Electrical Machines

three-phase motors, the test voltage for motors below 1 kW has to be

Utest = 2UN + 500 V. (8.9)

For motors above 1 kW, the test voltage has to be

Utest = 2UN + 1000 V (but at least 1500 V), (8.10)

where UN is the rated line-to-line voltage and Utest is the test voltage. The test period is 5 s for
used motors, the power of which is less than or equal to 5 kW, and for new motors, 1 min.
For DC machines, the insulation level is tested between the winding and the frame with
a 50 Hz AC voltage of 1.5 kV, when the rated voltage is from 50 to 380 V, and 2.5 kV when
the rated voltage is from 380 to 1000 V. It is worth noting that if the test period is 1 min, the
voltage must not exceed 50% of the test voltage. After this period, the test voltage can be
raised to the peak voltage in 10 s.
High-voltage machines also have to withstand impulse waves. The impulse wave tolerance
level should be at least

Ûsj = 4UN + 5 kV. (8.11)

Here Ûsj is the peak value of the impulse voltage. Due to the risk of failure, a new, complete
machine is not tested with this voltage; however, separate coils can be tested in the laboratory.
The impulse voltage is adjusted to have a rise time of 1.2 µs and a duration of 50 µs.
Equation (8.11) yields the peak value for the overvoltage for high-voltage machines. This
peak value is the basis for the dimensioning of the turn insulation. Further, in addition to
the overvoltage strength, in the dimensioning of the insulation it has to be borne in mind
that the electric field has an ageing effect on the construction. To ensure long-term durabil-
ity, the partial discharge level of the insulation construction should remain as low as pos-
sible. This can be tested by a tan δ measurement. The tan δ value increases when the test
voltage is raised, since the amount of partial discharges is increased. Therefore the slope
of the tan δ voltage curve can be considered an indirect indicator of the partial discharge
level.
Insulating materials are classified according to their ability to resist high temperatures with-
out failures. Table 8.1 shows the temperatures according to the IEC standard, and the previous,
although still commonly used, thermal classes with letter codes. The hot-spot allowance gives
the highest permitted temperature that the warmest part of the insulation may reach. The
temperature rise allowance indicates the highest permitted temperature rise of the winding at
rated load.
The most common thermal class in electrical machines is 155 (F). The classes 130 (B) and
180 (H) are also of common occurrence.
The ageing of the insulation puts a limit on its long-term thermal resistance, that is on its
temperature rise allowance. When evaluating the long-term thermal resistance of a single in-
sulator, the concept of temperature index is employed. The temperature index is the maximum
temperature at which the insulator can be operated to yield an average life of 20 000 h, or 2.3
years. This is a very short lifetime; in practice, the lifetime is longer than 2.3 years, because
it is assumed in the preparation of the insulation classification standards that in reality the
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Insulation of Electrical Machines 443

winding temperature does not remain continuously at the allowed upper limit. It is assumed
that the machine runs intermittently at partial load, the ambient temperature seldom reaches
its upper allowed limit, and there is some nonoperating time, too. Manufacturers often design
the temperature rise for instance for the class 130 (B), but then use an insulation system be-
longing to the class 155 (F). This underclassification leads to a longer expected insulation life.
It is also worth noting that the temperature index of the insulation belonging for instance to
the class 155 has to be at least 155. When the thermal class of the insulation is determined, the
temperature index is rounded down to the nearest thermal class. If a machine is running 24 h
a day all year round (a situation typical in power plants), the temperature rise of the machine
windings should be designed below the permitted value given in Table 8.1.
Short-term thermal resistance refers to thermal stresses, the duration of which is a few
hours at maximum. During this stress, the insulator may melt, or bubbles may occur, or it
may shrink or become charred. The insulation should not be damaged in any of these ways if
the temperature is moderately exceeded in any situation under normal operating conditions.
In Table 8.1, temperature rise refers to a permitted temperature rise in a winding at rated
load. This temperature rise does not cause premature ageing of the insulator. An excessive
temperature fluctuation may cause the development of brittleness and cracks in the insulator.
It has to be borne in mind that when there are several ageing factors, such as temperature and
moisture, at the same time, the critical temperature will be lower and must be approximated
individually for each case. In certain operating situations, frost resistance may also decide the
selection of the insulating material.
Thermal ageing is commonly estimated by the Arrhenius equation for the reaction rate

k = η e−Ea /RT (8.12)

where η is an experimental pre-exponential constant, E a is the activation energy, R is the gas

constant and T is the absolute temperature.
Practical insulator constructions have shown that a temperature rise of 8–10 K cuts the
expected life expectancy in half.

8.4 Electrical Reactions Ageing Insulation

Partial discharge is an electrical breakdown in an air spacing, at least one side of which is
confined to an insulator. Thus, a partial discharge does not immediately result in a breakdown
of the complete insulation. The energy released in the partial discharge is relatively small,
corresponding to the energy of a small capacitance discharged in this air spacing plus the
discharging energy of a capacitance of the insulation section that is in series with this ca-
pacitance. A single partial discharge is not harmful to the insulation. It can only break some
bonds in the polymer structure of the insulator. When this activity continues, the air spacing
will expand and unite with other air spacings. In this way, long channels, or trees, are formed
inside the insulator. The walls of the trees are at least partly conducting. When the tree is long
enough, reaching nearly all the way from the stator core to the conductor, a breakdown will
occur. Consequently, repeated partial discharges may deteriorate the insulation and lead to a
failure. Only mica tolerates continuous partial discharges, and therefore it is frequently used
in high-voltage insulation.
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444 Design of Rotating Electrical Machines

If there is a notably high creepage current flowing in the creepage distance, the insulation
may gradually become damaged. As an influence of the current, the moist surface layer dries.
Drying is unevenly distributed. When the creepage current disrupts, sparking occurs in the
air in the vicinity of the insulator surface. In high-voltage machines, the voltage against the
ground is so high that the breakdown strength of the air in the corner of the sheet stack may be
exceeded, and the discharge occurring in the air spacing proceeds along the surface of the in-
sulation until the field parallel to the surface becomes too low and the discharge extinguishes.
Here, the discharge energy is far lower than in the sparking of creepage currents; however,
repeated surface discharges may damage the insulation.
When the voltage at the surface discharge exceeds the gliding discharge voltage limit, the
energy of the discharges is suddenly increased and the discharge starts to glide along the
surface of the insulation. The discharges may glide even a distance of dozens of centimetres,
and as the voltage rises further, they eventually reach a weaker insulation at the end of the
coil, or a noninsulated point, and a breakdown occurs. Both gliding discharges and surface
discharges can be decreased for instance by employing a layer containing silicon carbide in
the insulation. The conductivity of silicon carbide is highly dependent on the electric field,
and it increases in proportion to the fifth power of the field strength. As a result, the field
strength peaks are substantially balanced out on the surface of the insulation.
Mathematical modelling of electrical ageing is a challenging task, since at least the dis-
charge inception voltage creates a clear discontinuation point. Usually, ageing caused by elec-
trical stress is described with a power equation that expresses the lifetime of the insulation, t,
as a function of electric field strength E,

t = k E −n , (8.13)

in which case the breakdown period has been shown to follow approximately the Weibull
exponential distribution.
In reality, estimation of the lifetime of an insulation construction is always a statistical
problem that requires a set of tests; even then, the influence of several simultaneous stresses
has to be taken into account as well as possible. This is of particular significance when fast
results are required in accelerated ageing tests.

8.5 Practical Insulation Constructions

In practice, the most important factor influencing the structure of the insulation is the rated
voltage of the machine. Based on the rated voltage, electrical machines can be divided into
high-voltage and low-voltage machines. A low-voltage machine is a machine the rated volt-
age of which is below 1 kV. In low-voltage machines, the voltage strength of the insulation is
not usually a decisive design criterion. If the insulation construction is mechanically strong
enough to endure the assembly, and the creepage currents of the insulation construction are
in control, the voltage strength is sufficient enough. Nonsparking during operation has yet
to be ensured, since the present, most common organic materials do not resist sparking. In
high-voltage machines instead, the strength is a decisive factor in the design in the pres-
ence of partial discharges. Next, some practical examples of insulation constructions will be
discussed.
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Insulation of Electrical Machines 445

Inner Slot Liner

Outer Slot Liner

Figure 8.11 Insulation of a stator slot of a low-voltage AC machine. A distance of 0.2–0.3 mm from
the slot wall has to be reserved for the insulation. In other words, the slot insulation is finished before
placing the coil in the slot. The coils are fed in the slots wire by wire or in groups of a few wires

8.5.1 Slot Insulations of Low-Voltage Machines

The slot insulation usually consists of two layers, namely an outer and an inner liner. Figure
8.11 illustrates the positioning of the liners in the slot. The inner insulation forms a funnel-
shaped guide that facilitates the wire assembly. The stator slot is finally closed at the slot
opening with a slot key or a slot wedge.
If the winding is constructed such that there will be more than one coil side in a single
slot, an additional insulation (a slot separator) is required between the coil sides. This is not
usually problematic in machines below 1 kV. The voltage between different coil sides is of
the magnitude of the line-to-line voltage at maximum. Figure 8.12 illustrates a slot with two
coil sides closed with a slot key. The insulation has to extend outside the slot at the ends.
For instance, the overhang has to be 5 mm at minimum when the rated voltage is 500 V at
maximum. This overhang is important, since a local electric field maximum is created at the
position where the slot ends, creating creepage currents.
Nowadays there are durable materials available, the voltage strength of which is high
enough (e.g. polyester films) and which can be used to construct a single-layer slot insula-
tion. In that case, the coils are mounted in the slots with auxiliary guides or by employing
extra-wide insulation films that lead the wires in the slot without damaging them. After the
coils are mounted in the slot, the extra guides are removed or the wide insulation films cut and
the slot is closed with a lid.

8.5.2 Coil End Insulations of Low-Voltage Machines

In the previous chapter, phase coil insulations in a slot were discussed. Also at the coil ends,
the different phases have to be separated. Pieces of insulating cloth are employed as a phase
coil insulator. The pieces are stuffed into place after assembly of the windings, the end wind-
ings are tied with glass fibre bands, and finally the whole insulation system is hardened with
an impregnant.
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446 Design of Rotating Electrical Machines

Slot Key

Folding of Insulation

Insulation between
Coils (slot separator)

Figure 8.12 Key-closed slot of a double-layer winding arrangement. The winding is made of round
enamelled wires. The winding is constructed by winding the wires on a coil former neglecting the order
of the wires. When the coil is fed into the stator slots, the order of the wires may get mixed even further,
and therefore the winding is called a random-wound winding. In the dimensioning of the cross-sectional
area of the slot, it has to be borne in mind that the highest possible space factor kCu of the free space
for a round wire winding is in practice, its wire insulators included, about 0.66 (cf. Equation 7.14; the
theoretical limit is π/4 = 0.785). Usually, the space factor varies between 0.6 and 0.66. Further, when
the room required by the slot insulation is taken into account, we can see that less than half of the total
area of the slot can be filled with actual wire copper. The insulation is thus of great significance in the
determination of the resistive losses of the machine. In small machines, the proportion of resistive losses
is relatively high, and therefore, when considering the efficiency of the machine, the slot filling deserves
special attention

In addition to the previously mentioned types of insulation, connection leads also have to
be insulated at lead-ins by using an insulating sleeve of suitable thickness. Finally, before
impregnation, the coils are tied with bands. Special attention has to be paid to the reliability
of the fastening of the connection wires and leads to ensure that the winding cannot move and
thus wear mechanically.

8.5.3 Pole Winding Insulations

In DC and synchronous machines, DC windings are employed. These windings are called pole
windings or field windings. Concentrated windings are also used in fractional slot PMSMs.
These windings are very similar to the field windings of DC or synchronous machines. The
poles are often wound with preformed copper, which is typically of rectangular shape, al-
though round-shaped coils are also employed. In both cases, varnishing is the most common
insulation method. The insulated winding is assembled from inside around an iron core. Nor-
mally, the dimensioning of the pole winding is not problematic, and therefore the thickness
of the insulation does not set any limits on the construction. Commutating poles of DC ma-
chines are wound separately, like the coils. First, a layer of insulation is assembled and then
the winding is wound on it.
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Insulation of Electrical Machines 447

8.5.4 Low-Voltage Machine Impregnation

Low-voltage machines can be impregnated with the dip and bake method by simply soaking
the motor into the resin (dip) and then curing the resin in an oven (bake). This is a traditional
method and has been in use since the early days of electrical machines. However, the method
is still widely used because it is easy and cheap and requires no heavy or expensive facilities,
such as vacuum pumps. Vacuum pressure impregnation (VPI) is used in special machines with
a purpose-designed insulation, such as those to be driven by inverter drives. The method will
be discussed in detail in the next section. For small machines, the trickle impregnation method
can be applied. In this method, the stator is attached to a rotating, sloped bench. Current is
applied to the windings to preheat them. The preheated resin is trickled onto the windings
from the upper end of the machine, hence the name. Simultaneously, the bench begins to
rotate slowly. The resin flows through the stator slots and fills them. When the resin begins
to drop out from the lower end winding of the machine, it is turned upside down and the
same procedure is repeated. When the desired impregnation is achieved, the resin is cured in
an oven.

8.5.5 Insulation of High-Voltage Machines

In the insulation of high-voltage machines, partial discharges may prove a significant cause
of the ageing of the insulation. High-voltage machines can be wound with round wire, when
the rated voltage is 3 kV or below. At voltages above this, prefabricated coils made of pre-
formed copper are nearly always selected. Figure 8.13 illustrates a cross-section of a slot of
a preformed copper winding, known as a form-wound winding. Usually, from 6 kV onwards,
there is also a conductive corona protection between the insulator and the stator stack in the
slot. The function of this layer is to prevent sparking in the voids between the insulator and

Slot key

main insulation

Conductive
fillers
or Bakelite

corona
protection

Figure 8.13 Insulation construction of a stator slot in a high-voltage machine. The figure shows
that the proportion of the insulation is notably higher than in the slot of the low-voltage machine in
Figure 8.12. On the other hand, preformed copper has been employed in the slot, and therefore the space
factor of the copper becomes relatively high
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448 Design of Rotating Electrical Machines

the sheet stack. Semi-conductive and conductive materials can also be employed as slot fill-
ing. The most common insulating material of the coil in high-voltage machines is a mica tape
wound in layers around the conductors. Due to its excellent partial discharge resistance and
performance properties, mica has maintained its dominant position as the insulator in high-
voltage machines for more than a century. In the insulation of high-voltage machines, the
amount of voids in the impregnation has to be kept to a minimum. Therefore, only the VPI
and resin-rich (RR) methods are usually applied.
In the VPI method, the object to be impregnated is placed in a vacuum chamber, which
is closed, and a vacuum is created to a pressure of typically about 1 millibar. Next, resin that
has been pretreated (viscosity checked, curing agent added, cooled) and degassed in a separate
container is pumped into the vacuum chamber through a heat exchanger where the resin is pre-
heated to about 70 ◦ C until the object to be impregnated is completely covered with warmed-
up resin. The preheating of the resin is very important, because it significantly decreases the
viscosity, and thus the resin can more easily penetrate the slots and fill them completely.
The vacuum is then released and the chamber is allowed to pressurize from 3 to 5 bar for
a period of several hours. Finally, the resin is pumped through the heat exchanger back to the
cool container. The cooling in the storage container is important to extend the lifetime of the
unhardened resin. The object to be impregnated is then placed in the oven, where the resin
is hardened. The VPI method is particularly well suited for preformed copper windings, the
insulation thicknesses of which can be dimensioned precisely. Thus the thickness of the resin
layers can also be controlled.
In the RR method, almost all the selected insulators and other materials are preimpregnated.
The binding agent is usually epoxy resin, which is in a precured state, in which the resin
is solid but malleable, the insulator thus being easy to process. The coils are insulated with
several turns of mica tape wrapped around the coil from end to end. This is the main insulation
of the coil. Finally, the epoxy resin of the insulation is hardened at a high temperature (about
160 ◦ C) and high pressure. Usually, insulation of this type meets the requirements of thermal
class 155 (F).
The VPI method differs from the RR method by the fact that in the former, the insulat-
ing materials used are porous, and do not contain a considerable amount of binding agents.
When the insulation is mounted in place, its air spacings are carefully impregnated with an
impregnating resin. When applying the VPI method, with accurate dimensioning it is possible
to decrease the amount of fillers required in the key fitting. The finished insulation is in every
respect equal in quality irrespective of the selected method.
As shown in Figure 8.13, in the RR method in particular, filler strips can be employed.
One purpose of these strips is to ensure that the slot key evenly wedges the bar. Sometimes
even flexible filler strips are selected to avoid loosening the coils. This loosening can also be
avoided by applying a method in which the winding is aged by exposing it to mechanical force
and heat. This method is called hot prewedging. It ensures a high and permanent compression
force of the key fitting.
The insulation of the end windings is constructed in the same way as in the slots, only
without filler strips. A conductive material is not used, unlike in the slot section. Nevertheless,
at the point where the stator stack ends, semiconductive coating materials can be employed on
the surface of the conductor. The most common stress grading materials are a semiconductive
silicon carbide tape or paint.
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Insulation of Electrical Machines 449

8.6 Condition Monitoring of Insulation

The ageing process reduces the insulation capacity of the insulating materials. To ensure re-
liable performance of an electrical machine, the insulation has to be monitored regularly to
anticipate a possible loss in insulation capacity. The most common monitoring methods are
the measurement of insulation resistance and the tan δ measurement; however, in large ma-
chines, various on-line monitoring methods are common nowadays.
The insulation resistance of a winding consists of a surface resistance and a volume re-
sistance. Usually, the requirements for the volume resistance are relatively low in electrical
machines, since in these machines, far higher dielectric losses can be tolerated than for in-
stance in the case of capacitors. The values of the volume resistance do not usually depend on
the ambient humidity, unless the insulation is hygroscopic. The insulation resistance of a new
low-voltage machine is typically between 5000 and 10 000 M
. This corresponds to a spe-
cific resistance of approximately 1014
m. However, a low-voltage machine is still in a quite
acceptable condition when its insulation resistance has decreased to 1 M
, corresponding to a
specific resistance of approximately 1010
m. With regard to dielectric losses, even a notably
lower specific resistance, maybe about 107
m, could be permitted. Hence, the ideal value of
the insulation resistance is negligible in the dimensioning of the thickness of the insulation.
Surface resistance is highly dependent on the accumulating dirt and moisture on the surface
of the insulation. Dirt accumulates on the insulated surfaces that act as creepage distances.
This dirt is often conductive, but also hygroscopic. The insulation resistance of a dirty and
damp winding can drop below the above-mentioned level of 1 M
, thus endangering the
durability of the winding.
A creepage distance of electrical machine insulation is created for instance across the end
of the slot insulation from the copper conductor to the stator stack. The effective length of the
creepage distance exceeds its physical length because of the insulation of the conductors and
the impregnation of the winding. Nevertheless, there may be occasional voids in the insulation
and impregnation of the winding. The most critical creepage distances are open insulating
distances, for instance on the commutator of a DC machine, which often gathers carbon dust
during operation.
The measurement of insulation resistance is the most common method in the condition
monitoring of electrical machines. The measurement is carried out with a relatively low
(500–1500 V) DC voltage. The method is quite easy and fast, and does not require any ex-
pensive special equipment. However, no far-reaching conclusions on the internal state of the
insulation can be drawn from these measurement results. Insulation resistance measurements
can nevertheless be recommended particularly as a commissioning test and in routine condi-
tion check-ups. Temperature has a significant influence on the results of insulation resistance
measurements. Unlike the resistance of conductors, the resistance of insulating materials de-
creases as the temperature rises.
Surge comparison testing is applied in the monitoring of the integrity and voltage strength
of a turn insulation. The surge comparison test instrument creates a closed oscillating circuit
between the voltage source and the tested winding, resulting in an oscillating voltage between
the coil ends. The test result is displayed on the instrument’s oscilloscope screen. If the two
windings to be compared are identical, the reflected images are identical and appear as a
single trace. With this test method, the interturn fault, earth–fault and impedance difference
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450 Design of Rotating Electrical Machines

tanδ 4 tanδ
3

2 tan δ

U 0.2 0.4 0.6 0.8 1.0 U/U N

(a) (b)

(c)

Figure 8.14 (a) Different tan δ(U) curves: 1, an ideal curve; 2, a typical curve of a healthy insulation; 3,
extra partial discharges; 4, the behaviour of aged insulation. (b) Measurement in steps of 0.2U N , where
U N is the rated voltage of the machine. The slope is defined as  tan δ/(0.2U N ). (c) The test result
of a real machine with a healthy insulation corresponding to curve 2 in Figure 8.14a. Reproduced by
permission of ABB Oy

can be detected as a deviation of the frequency, amplitude and the damping period of the
oscillation.
The measurement of the dielectric loss factor (tan δ) of an insulator is an advantageous and
common measuring method that is especially suitable for large machines. The tan δ curve is
usually drawn as a function of voltage, the voltage being raised at least to the highest operating
voltage of the machine. When evaluating the test results, special attention can be paid both to
the magnitude of the tan δ value and to its increase as the voltage is increased. Figure 8.14a
illustrates the shapes of a tan δ(U) curve with some examples. Curve 1 represents an ideal case.
In practice, for a healthy insulator, tan δ is almost constant as a function of voltage, as shown
by curve 2. The shape of the curve also gives some information about the factors causing an
increase in the value of tan δ. A tan δ curve such as curve 4 may indicate excessive ageing of
the insulation. On the other hand, curve 3 illustrates a situation in which tan δ values start to
increase abruptly, when a certain voltage stress is reached. This is a sign of the occurrence
of remarkable partial discharges in the insulation. Since the discharges are local, the actual
partial discharge measurement is usually a far more sensitive indicator of partial discharges
than the method described above.
A tan δ value as such expresses the relative magnitude of dielectric losses. An excessive
dielectric loss may result in local or complete overheating of the insulation.
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Insulation of Electrical Machines 451

I
U
IC IR
U C I
R
δ IR
IC

Figure 8.15 Equivalent circuit of an insulation construction and calculation of the loss angle. An ideal
insulation forms a capacitance. The dielectric losses of a practical insulation are seen as resistive current
real power in the insulation. The ageing of the insulation is seen as increasing resistive current and hence
increasing tan δ

When carrying out tan δ measurements, it has to be borne in mind that the temperature of
the insulation may influence the test results. In some cases, it may prove advisable to take the
measurements at several temperatures. In many insulation constructions,  tan δ = 10
is
considered the highest permitted value.
The measurement of the dielectric loss angle (δ) is carried out as a bridge measurement.
The objective of the method is to determine the ratio of dielectric losses to the capaci-
tive reactive power in the insulation, Figure 8.15. The circuit for measuring is illustrated in
Figure 8.16.
Partial discharge measurement is applied to determine partial discharges occurring in the
winding insulation. With these measurements, it is possible to anticipate insulation failures,
their nature and approximate location. A notable advantage of the method is the applicability
of the results in the evaluation of the insulation condition. Partial discharges are measured with
special measuring equipment consisting of a transformer, a capacitor, a measuring impedance
Z and a partial discharge measuring instrument, Figure 8.17. The measurement is carried out
in phases against the stator frame and the other phases connected to it. Disturbances during the
measurement have to be minimized by careful selection of the components of the measuring
circuit and by selecting a measuring frequency that minimizes radio disturbances.
As a result of measurement, we obtain the values of partial discharge as a function of
voltage. Figure 8.18 illustrates two printouts, example (a) including the measurement results
in all three phases, and example (b) including the values for partial discharge measured at
three different frequencies.

Cn

R3 C4 R4

Figure 8.16 tan δ measurement circuit with Schering bridge. Cn is a normal capacitor
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452 Design of Rotating Electrical Machines

adjustable transformer

Z pC,

µV,
dB

Figure 8.17 Measuring circuit of partial discharge

k1

pd pd f1
k2
f2

k3

f3

0 U 0 U
(a) (b)

(c)

Figure 8.18 Printout of the partial discharge measurement. pd is the partial discharge (typically in nC),
the level of partial discharge. k1 , k2 and k3 illustrate different windings in different insulation conditions,
and f 1 , f 2 and f 3 different measuring frequencies. The pd values start to increase when the voltage is
increasing. The lower the pd values, the better the insulation. The graph (c) illustrates the measure-
ment result of a real healthy machine using a Haefely Trench Tettex partial discharge measurement
unit. The measurement time is 2 minutes and the measurement voltage 8 kV, 50 Hz. The figure indicates
the amount of partial discharges as a function of apparent charge in nC and temporal phase angle of
the sinusoidal test voltage. Note that there are more partial discharges during the negative phase of the
voltage. Note also that the Hn (ϕ, q) symbol on the vertical axis indicates the number of partial discharges
having different amounts of electric charge (q in nC) and phase angle (ϕ in degrees). Reproduced by per-
mission of ABB Oy
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Insulation of Electrical Machines 453

8.7 Insulation in Frequency Converter Drives

Frequency converter drives that are widely used nowadays set special requirements for the
insulation constructions of electric motors. The voltage of a frequency converter includes
a considerable number of harmonics that cause additional losses and temperature rise in the
winding. As a result of this thermal rise, the maximum rated power cannot be constantly taken
from a machine dimensioned for network operation, or, as an alternative, we have to accept
accelerated thermal ageing of the construction. The current created by frequency converters
that apply a high switching frequency is so sinusoidal that the efficiency of the machine is
reduced by only about 1%, and in this sense the loadability of the machine is not weakened
significantly in a frequency converter drive. When applying a very low switching frequency
(<1 kHz), the rated power of the machine has typically to be decreased by about 5%.
The voltage of a frequency converter consists of pulses, the peak value of which may deviate
notably from the peak value of normal sinusoidal voltage. Further, the rate of voltage rise can
be so high that the pulse behaves like a surge (impulse) wave in the winding, being nonlinearly
distributed in the winding and causing a voltage increase by reflection.
With frequencies notably higher than the normal operating frequency, the motor supply ca-
ble can no longer be described by concentrated cable parameters, but distributed parameters
have to be employed. Now the resistance, inductance, leakage conductance and the capaci-
tance of the cable are considered to be evenly distributed along the total cable length. The
inductance and the capacitance per unit length determine the characteristic impedance Z 0
individually for each cable

l
Z0 = , (8.14)
c

where c is the capacitance per unit of length and l is the inductance per unit of length.
The structure and the insulation of the cable determine the magnitude of the characteristic
impedance Z 0 , which is thus independent of the cable length. The value for the characteristic
impedance of a cable is typically of the order of 100
. The pulse velocity in the cable depends
on the materials of the cable. The term ‘material’ refers here to the media surrounding the
cable, not the conductor itself. The maximum velocity is the speed of light that can be reached
in a vacuum. The pulse velocity v can be defined by the characteristic values of the cable

C 1
v= √ =√ . (8.15)
µr εr lc

The characteristic impedance of the machine always differs notably from the characteristic
impedance of the cable, reflections thus being inevitable. An impulse wave propagates in a
motor cable typically at a speed of 150 m/µs. The propagation distance of a wave required by
a perfect reflection, that is the critical cable length lcr , is thus

tr v
lcr = . (8.16)
2
where tr is the rise time of the voltage pulse and v is the propagation speed of the voltage
pulse.
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454 Design of Rotating Electrical Machines

Assuming for a wave that v = 150 m/µs and tr = 100 ns (IGBT), the critical cable length
becomes 7.5 m.
The ratio of the reflected to the incoming pulse is described by a reflection factor ρ. This
factor depends on the characteristic impedance Z 0 of the motor cable and the characteristic
impedance Z M of the motor (winding) experienced by the wave

ZM − Z0
ρ= . (8.17)
ZM + Z0

As shown by the equation, the value of the reflection factor varies over 0 ≤ ρ ≤ 1, when
Z M ≥ Z 0 . However, the calculation of the characteristic impedance of the motor is nearly
impossible. Nevertheless, by measuring reflections in the poles of the machine, it is√possible
to estimate the scale of the characteristic impedance of the machine. Since Z 0 = l/c, we
may conclude that the characteristic impedance of the motor is high because of the high
inductivity of the motor.
The foundation of insulation design of electrical machines lies in the IEC 60034 standards
that are based on long experience of insulation design. Further, when the stresses during op-
eration of the machine, such as heat and operating conditions, are also taken into account, the
insulation construction of the machine can be designed. Usually, in addition to mechanical
and nonsparking requirements, it is not necessary to pay any special attention to the electrical

Table 8.5 Characteristics of fibre insulators. Adapted from Paloniemi and Keskinen (1996)
Characteristic Unit Cotton fibres Polyester fibres Glass fibres Aramid paper
2
Tensile strength N/mm 250–500 500–600 1000–2000 1250
Elongation at break % 6–10 20–25 1.5 17
Modulus of elasticity N/mm2 5000 70 000 —
Tear strength Moderate Good Good Good
◦
Continuous operating C 105a 155 130–200b 210
temperature
◦
Instantaneous thermal C 150 190 >600 300
resistance
◦
Softening point C — 210 670 Does not soften
◦
Melting point C — 260 850 Does not melt
Thermal conductivity W/m ◦ C 0.07–0.14 0.99 0.1
Burning Burn Slow burning Do not burn Does not burn
Moisture absorbance % by weight 10 0.4 — 7–9
Chemical strength Graded 0–4
Acids 1 2 4 3
Alkalis 2 1 3 3
Organic solvents 4 4 4 4
Voltage strength kV/mm — — — 20c
a
Impregnated.
b
Depends on the impregnant.
c
1 min, 50 Hz test.
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Insulation of Electrical Machines 455

security of the insulation construction of low-voltage machines. In high-voltage machines,

however, it is usually necessary to design some protection to reduce partial discharges.
The tendency seems to be that controlled drives are becoming increasingly popular among
low-voltage machines. Now, as the supply cable is of considerable length, and the rated volt-
age is for instance 690 V, the voltage of the machine may, as a result of the reflecting wave,
increase so high that partial discharges occur in the winding between the turns belonging to
the same coil. As the switches in power electronics become constantly faster, the pulse rise
times get shorter. As a result, the compatibility of the drive, the cable and the machine gain
further significance together with the proper 360◦ concentric conductor earthing of the cable.
Furthermore, the cable has to be as short as possible. Utilization of various low-pass filters
also becomes more common for reasons other than the limitations set by the insulation alone.
In order to create a single partial discharge pulse, there must be several thousand fast voltage
pulses, each having a rise time below 200 ns. Hence, there must be tens of thousands of pulses
in 1 second. The number of pulses can be decreased with proper control of the machine;
this is nevertheless not always possible. The designer of the machine also has some tools to
reduce partial discharge activity. It is possible to select a partial-discharge-resistant conductor
for the windings. These conductors include mica or some metal oxide, which can tolerate
partial discharges. Also, additional insulation can be applied on different turns. Furthermore,
the use of the VPI method considerably decreases the number of air spacings in the slot
(Tables 8.2–8.5).

Bibliography
IEC 60034 (various dates) Rotating Electrical Machines. International Electrotechnical Commission, Geneva.
IEC 60034-1 (2004) Rotating Electrical Machines. Part 1: Rating and Performance. International Electrotechnical
Commission, Geneva.
IEC 60085 (2007) Electrical Insulation – Thermal Evaluation and Designation. International Electrotechnical Com-
mission, Geneva.
IEC 600112 (1979) Method for Determining the Comparative Tracking Index of Solid Insulating Materials Under
Moist Conditions. International Electrotechnical Commission, Geneva.
Nousiainen, K. (1991) Fundamentals of High-Voltage Engineering. (Suurjännitetekniikan perusteet), Study material
144. Tampere University of Technology, Tampere.
Paloniemi, P. and Keskinen, E. (1996) Insulations of electrical machines. (Sähkökoneiden eristykset), Lecture notes.
Helsinki University of Technology, Espoo.
Walker, J.H. (1981) Large Synchronous Machines, Clarendon Press, Oxford.
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9
Heat Transfer

Heat transfer always occurs when there is a temperature difference in a system. The tempera-
ture difference evens out naturally as heat transfers from the higher temperature to the lower
according to the second law of thermodynamics.
In electrical machines, the design of heat transfer is of equal importance as the electro-
magnetic design of the machine, because the temperature rise of the machine eventually de-
termines the maximum output power with which the machine is allowed to be constantly
loaded. As a matter of fact, accurate management of heat and fluid transfer in an electrical
machine is a more difficult and complicated issue than the conventional electromagnetic de-
sign of an electrical machine. However, as shown previously in this material, problems related
to heat transfer can to some degree be avoided by utilizing empirical knowledge of the ma-
chine constants available. When creating completely new constructions, empirical knowledge
is not enough, and thorough modelling of the heat transfer is required. Finally, prototyping
and measurements verify the successfulness of the design.
The problem of temperature rise is twofold: first, in most motors, adequate heat removal
is ensured by convection in air, conduction through the fastening surfaces of the machine
and radiation to ambient. In machines with a high power density, direct cooling methods can
also be applied. Sometimes even the winding of the machine is made of copper pipe, through
which the coolant flows during operation of the machine. The heat transfer of electrical ma-
chines can be analysed adequately with a fairly simple equation for heat and fluid transfer.
The most important factor in thermal design is, however, the temperature of ambient fluid, as
it determines the maximum temperature rise with the heat tolerance of the insulation.
Second, in addition to the question of heat removal, the distribution of heat in different
parts of the machine also has to be considered. This is a problem of heat diffusion, which is a
complicated three-dimensional problem involving numerous elements such as the question of
heat transfer from the conductors over the insulation to the stator frame. It should be borne in
mind that the various empirical equations are to be employed with caution. The distribution of
heat in the machine can be calculated when the distribution of losses in different parts of the
machine and the heat removal power are exactly known. In transients, the heat is distributed
completely differently than in the stationary state. For instance, it is possible to overload the
motor considerably for a short period of time by storing the excess heat in the heat capacity
of the machine.

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6
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458 Design of Rotating Electrical Machines

The lifetime of insulation can be estimated by statistical methods only. However, over a
wide temperature range, the lifetime shortens exponentially with the temperature rise Θ of
the machine. A rise of 10 K cuts the lifetime of the insulation by as much as 50%. The ma-
chines may withstand temporary, often-repeated high temperatures depending on the duration
and height of the temperature peak. A similar shortening of the lifetime applies also to the
bearings of the motor, in which heat-resistant grease can be employed. In critical drives, oil
mist lubrication can be used, in which case the oil is cooled elsewhere and then fed to the bear-
ings. Even ball bearings can be used at elevated speeds if their effective cooling is ensured,
for instance by oil lubrication.
The temperature rise of the winding of an electrical machine increases the resistance of the
winding. A temperature rise of 50 K above ambient (20 ◦ C) increases the resistance by 20%
and a temperature rise of 135 K by 53%. If the current of the machine remains unchanged,
the resistive losses increase accordingly. The average temperature of the winding is usually
determined by the measurement of the resistance of the winding. At hot spots, the temperature
may be 10–20 K above the average.

9.1 Losses
Power losses in electrical machines are composed of the following elements:
r resistive losses in stator and rotor conductors;
r iron losses in the magnetic circuit;
r additional losses;
r mechanical losses.

Resistive losses in conductors are sometimes called Joule losses or copper losses, and there-
fore the subscript Cu is used in the following for resistive losses.
Figure 9.1 illustrates the power balance of a typical totally enclosed 4 kW induction motor.
Here 15% of the electrical energy is converted into heat at the rated power of the machine.
The proportion of the resistive losses in this case is high: 77% of the total losses and 11.8%
of the rated power. The proportion of iron losses remains low, 1.9% of the rated power, al-
though the iron circuits are usually strictly dimensioned. Friction losses are also low, 1% of
the rated power. The temperature rise of the machine in Figure 9.1 is dimensioned according
to the thermal class 130 (B) and the insulation according to the class 155 (F) (see Table 8.1).

9.1.1 Resistive Losses

Resistive losses in a winding with m phases and current I are

PCu = m I 2 RAC , (9.1)

where RAC is the AC resistance of the phase winding. The AC resistance is

Nlav
RAC = kR , (9.2)
σ Sc
where kR is the skin effect factor for the resistance equation (5.34), N the number of turns,
lav the average length of a turn, Sc the cross-sectional area of the conductor and σ the specific
conductivity of the conductor.
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Heat Transfer 459

Pin 100 %, 4.7 kW

P Fe
1.9%
PCus
6.9% Pad 0.5%
P out 85%, 4.0 kW
Pδ
255

PCur P ρ 1.0%
4.7%
300

Figure 9.1 Sankey diagram of a 4 kW two-pole induction motor. PFe , iron losses; PCus , resistive losses
of the stator; Pad , additional losses; Pδ , air-gap power; PCur , resistive losses of the rotor; Pρ , friction
losses. The losses (700 W in total) have to be removed from the machine at an acceptable temperature
difference to the ambient

The mass of the conductors is

m Cu = ρ Nlav Sc , (9.3)

where ρ is the density of the conductor.

Solving Nlav from Equation (9.3), substituting it into Equation (9.2) and substituting Equa-
tion (9.2) into Equation (9.1) yields for the resistive losses
kR I 2 kR 2
PCu = m I 2 RAC = m Cu = J m Cu , (9.4)
ρσ Sc2 ρσ
where J = I /Sc is the current density in conductors.
In commutator and slip-ring machines, there are losses in brushes. The resistive losses in
brushes are very small because the current density in brushes is low, about 0.1 A/mm2 , but
the contact voltage between brushes and commutator may produce significant losses. The
contact voltage drop varies depending on the type of brushes, the applied brush pressure and

Table 9.1 Additional losses as a percentage of input power in electrical machines

Machine type Additional losses of input power
Squirrel cage motor 0.3–2% (sometimes up to 5%)
Slip-ring asynchronous machine 0.5%
Salient-pole synchronous machine 0.1–0.2%
Nonsalient-pole synchronous machine 0.05–0.15%
DC machine without compensating winding 1%
DC machine with compensating winding 0.5%
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460 Design of Rotating Electrical Machines

the brush current, being typically Ucontact = 0.5–1.5 V for carbon and graphite brushes and
Ucontact = 0.2–0.5 V for metalline brushes. The brush losses PB with brush current IB per
brush pair are
PB = 2IB Ucontact . (9.5)

9.1.2 Iron Losses

Losses in the iron circuit have been discussed in Chapter 3. In practice, Equation (3.78) gives
good enough results if we have experience with the correction coefficients needed in using
Equation (3.78). The coefficients are given in Table 3.2, but depending on the construction
and dimensioning of the machine, and the manufacturing system, the coefficients may differ
from the values in Table 3.2. The coefficients are determined by statistical means by analysing
the no-load tests of a large group of the same kinds of machines.

9.1.3 Additional Losses

Additional losses lump together all the electromagnetic losses which are not included in the
resistive losses and iron losses calculated according to Sections 9.1.1 and 9.1.2. Additional
losses in iron parts have already been discussed in Section 3.6.2.
Additional losses are very difficult to calculate and measure. This is the reason why in the
IEC standards the additional losses are assumed to be 0.5% of the input power in induction
motors when the efficiency of the motor is calculated indirectly from the loss measurements.
The resistive losses are calculated from the DC resistance of the winding in efficiency calcu-
lations, so 0.5% of the input power includes the additional losses caused by the skin effect
in conductors. The iron losses are determined from the no-load test, and consequently they
include the additional losses at no load; therefore, the loss of 0.5% of the input power covers
losses that the load current and its harmonics cause in windings, laminations, the frame and
other constructed parts. Typical additional loss values in different machine types are presented
in Table 9.1 (Lipo, 2007; Schuisky, 1960).
Additional losses are proportional to the square of the load current and to the power of 1.5
of the frequency, that is

Pad ∼ I 2 f 1.5 . (9.6)

If additional losses are measured or known for one pair of the current and frequency, they
can be determined for another pair of current and frequency using Equation (9.6).

9.1.4 Mechanical Losses

Mechanical losses are a consequence of bearing friction and windage. Bearing losses depend
on the shaft speed, bearing type, properties of the lubricant and the load on the bearing. Bear-
ing manufacturers give guidelines for calculating bearing losses. According to SKF (1994),
bearing friction losses are

Pρ, bearing = 0.5 ΩµF Dbearing , (9.7)

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Heat Transfer 461

where Ω is the angular frequency of the shaft supported by a bearing, µ the friction coefficient
(typically 0.0010–0050), F the bearing load and Dbearing the inner diameter of the bearing.
Windage losses become more and more significant with increasing machine speed. These
losses are a consequence of the friction between the rotating surfaces and the surrounding gas,
usually air. The rotor can be modelled as a rotating cylinder in an enclosure. Saari (1995) gives
an equation for the power associated with the resisting drag torque of the rotating cylinder:

1
Pρw1 = kCM πρΩ 3 Dr4lr , (9.8)
32

where k is a roughness coefficient (for a smooth surface k = 1, usually k = 1–1.4), CM the

torque coefficient, ρ the density of the coolant, Ω the angular velocity, Dr the rotor diameter
and lr the rotor length. The torque coefficient CM is determined by measurements. It depends
on the Couette Reynolds number

ρΩDr δ
Reδ = , (9.9)
2µ

where ρ is the coolant density, Dr the rotor diameter, δ the air-gap length and µ the dynamic
viscosity of the coolant. The torque coefficient is obtained as follows:

(2δ/Dr )0.3
CM = 10 , Reδ < 64, (9.10)
Reδ
(2δ/Dr )0.3
CM = 2 , 64 < Reδ < 5 × 102 , (9.11)
Reδ0.6
(2δ/Dr )0.3
CM = 1.03 , 5 × 102 < Reδ < 104 , (9.12)
Reδ0.5
(2δ/Dr )0.3
CM = 0.065 , 104 < Reδ . (9.13)
Reδ0.2

The end surfaces of the rotor also create friction losses. These parts can be modelled as
discs rotating in free space (assuming that there are no fan wings in short-circuit rings in
high-speed machines). The power loss is, according to Saari (1995),

1

Pρw2 = CM ρΩ 3 Dr5 − Dri5 , (9.14)
64

where Dr is the outer diameter of the rotor, Dri the shaft diameter and CM the torque coeffi-
cient, which is now

3.87
CM = , Rer < 3 × 105 , (9.15)
Rer0.5
0.146
CM = , Rer > 3 × 105 . (9.16)
Rer0.2
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462 Design of Rotating Electrical Machines

Rer is known as the tip Reynolds number

ρΩ Dr2
Rer = . (9.17)
4µ

The windage losses caused by the rotating parts of the machine Pρw are the sum of Equa-
tions (9.8) and (9.14)

Pρw = Pρw1 + Pρw2 . (9.18)

Besides bearing losses and windage losses of the rotating parts, ventilator loss also belongs
to mechanical losses. The ventilator can be coupled to the shaft of the electrical machine or it
can be driven by another motor, as is usual in speed-controlled drives.
Schuisky (1960) gives an experimental equation for the sum of windage and ventilator
losses:

Pρ = kρ Dr (lr + 0.6τp )νr2 , (9.19)

where kρ is an experimental factor (Table 9.2), Dr the rotor diameter, lr the rotor length, τp
the pole pitch and νr the surface speed of the rotor. Equation (9.19) is valid for normal-speed
machines. For high-speed machines, Equations (9.8) and (9.14) have to be used.

9.2 Heat Removal

The heat is removed by convection, conduction and radiation. Usually, the convection through
air, liquid or steam is the most significant method of heat transfer. Forced convection is, in-
evitably, the most efficient cooling method if we do not take direct water cooling into account.
The cooling design for forced convective cooling is also straightforward: the designer has to
ensure that a large enough amount of coolant flows through the machine. This means that the
cooling channels have to be large enough. If a machine with open-circuit cooling is of IP class
higher than IP 20, using heat exchangers to cool the coolant may close the coolant flow.
If the motor is flange mounted, a notable amount of heat can be transferred through the
flange of the machine to the device operated by the motor. The proportion of heat transfer by
radiation is usually moderate, yet not completely insignificant. A black surface of the machine
in particular promotes heat transfer by radiation.

Table 9.2 Experimental factors for windage and bearing losses, Equation (9.19)
Cooling method kρ /W s2 /m4
TEFC motors, small and medium-sized machines 15
Open-circuit cooling, small and medium-sized machines 10
Large machines 8
Air-cooled turbogenerators 5
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Heat Transfer 463

9.2.1 Conduction
There are two mechanisms of heat transfer by conduction: first, heat can be transferred by
molecular interaction, in which molecules at a higher energy level (at a higher temperature)
release energy for adjacent molecules at a lower energy level via lattice vibration. Heat transfer
of this kind is possible between solids, liquids and gases.
The second means of conduction is heat transfer between free electrons. This is typical
of liquids and pure metals in particular. The number of free electrons in alloys varies con-
siderably, whereas in materials other than metals, the number of free electrons is small. The
thermal conductivity of solids depends directly on the number of free electrons. Pure metals
are the best heat conductors. Fourier’s law gives the heat flow transferred by conduction

Φ th = −lS∇T, (9.20)

where Φ th is the heat flow rate, l the thermal conductivity, S the heat transfer area and ∇T
the temperature gradient.
Thermal conductivity depends on the temperature; a typical property of metallic substances
is that the thermal conductivity decreases as the temperature increases. On the other hand, an
insulator’s capability to transfer heat increases as the temperature rises.
The thermal conductivity of gases increases with increasing temperature and decreasing
molecular weight.
Usually, the thermal conductivity of nonmetallic liquids decreases as the temperature rises;
however, the properties of water for example are different. The thermal conductivity of wa-
ter is at its highest (688 W/K m) at about 410 K and 330 kPa (saturated liquid). The thermal
conductivity decreases from this point in both directions of temperature change. Glycerin
and ethylene glycol are further exceptions, because their thermal conductivity increases as a
function of temperature.
Table 9.3 lists the heat transfer properties of some materials at room temperature. The
equation for the conduction of heat is simplified if heat is flowing in one direction, in the
direction of the x-coordinate. For an object with a cross-sectional area of S and a length l,
Equation (9.20) takes the form

dT Θ
Φth = −lS ≈ −lS . (9.21)
dx l

Here, Θ is the temperature difference across the object and l is the thermal conductivity of
the material, which is often expressed as a function of temperature l(T ). Often, materials are
not isotropic but the conductivity varies in different directions. Materials are, however, usually
considered isotropic in calculations. Materials with high electrical conductivity are, generally,
also good thermal conductors. On the other hand, the insulators used in electrical machines
are, unfortunately, usually poor thermal conductors. There are also exceptions in insulators,
because metallic oxide layers are relatively good thermal conductors compared with plastics,
but still good electrical insulators. Diamond is also an exception: It is an electrical insulator
and a good thermal conductor.
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464 Design of Rotating Electrical Machines

Table 9.3 Heat transfer properties of some materials at room temperature (293 K) if not otherwise
declared
Thermal Specific heat
conductivity capacity Density Resistivity/
Material l/W/K m c/kJ/kg K ρ/ kg/m3 m·10−8
Air, stagnant 0.025 1
Aluminium, pure 231 0.899 2700 2.7
Aluminium, electrotechnical 209 0.896 2700 2.8
Aluminium oxide, 96% 29.4
Beryllium oxide, 99.5% 300 K 272 1.03 3000
Copper, electrotechnical 394 0.385 8960 1.75
Ethylene glycol 0.25 2.38 1117
Insulation of elec. machine, bonding 0.64
epoxy
Insulation of elec. machine, glass fibre 0.8–1.2
Insulation of elec. machine, Kapton 0.12
Insulation of elec. machine, mica 0.5–0.6
Insulation of elec. machine, 0.2–0.3
mica–synthetic resin
Insulation of elec. machine, Nomex 0.11
Insulation of elec. machine, Teflon 0.2
Insulation of elec. machine, treating 0.26
varnish
Insulation of elec. machine, typical 0.2
insulation system
Iron, pure 74.7 0.452 7897 9.6
Iron, cast 40–46 0.5 7300 10
Mercury, 300 K 8540 0.1404 13.53
Permanent magnet, ferrite 4.5
Permanent magnet, NdFeB 8–9 0.45 7500 120–160
Permanent magnet, Sm–Co 10 0.37 8400 50–85
Plastics 0.1–0.3
Silicon 300 K 148 0.712 12 300
Steel, carbon steel 0.5% 45 0.465 7800 14–18
Steel, electrical sheet, in the direction 22–40 7700 25–50
of lamination
Steel, electrical sheet, normal to 0.6
lamination
Steel, stainless 18/8 17 7900
Steel, structural 35–45
Transformer oil 313 K (40 ◦ C) 0.123 1.82 850 108 –1014 m
Water vapour, 400 K 24.6 2.06 0.552
Water 293 K 0.6 4.18 997.4 2–5 × 103 m
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Heat Transfer 465

Equation (9.20) is analogous to the current density equation known in electrical engineering

J = −σ ∇V (9.22)

or in the one-dimensional case

dV
V
I = JA = −σS = −σS = −σSE, (9.23)
dx l

where J is the current density, S the current-conducting area, σ the electric conductivity, ∇V
the electric potential gradient, E the electric field strength, I the current and l the length of the
conductor.
Analogous to the electric resistance, defined as the ratio of the potential difference to the
current, we can define the thermal resistance Rth as a ratio of the temperature difference Θ to
the heat flow rate Φth

Θ l
Rth = = . (9.24)
Φth lS

Example 9.1: Calculate the thermal resistance of a rectangular bar (Figure 9.2), the
length of which is l = 0.2 m, height h = 0.05 m, width w = 0.03 m and conductivity
l = 17 W/K m (stainless steel).

Figure 9.2 Proving an equation for a rectangular bar

Solution: According to Equation (9.24),

l 0.2 K K
Rth,bar = = = 7.84 . (9.25)
lhw 17 · 0.05 · 0.03 W W
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466 Design of Rotating Electrical Machines

Example 9.2: Calculate the thermal resistance of a pipe in the radial direction (Figure 9.3).
The length of the pipe is l = 0.2 m, inner radius r1 = 0.02 m, outer radius r2 = 0.025 m
and conductivity l = 0.2 W/K m (plastics).

r1

r2

Figure 9.3 Proving an equation for a pipe

Solution: The heat transfer area S in Equation (9.24) now changes and the thermal resis-
tance is the integral:
   
r2 0.025
r2 ln ln
1 r1 0.02 K K
Rth,cyl = dr = = = 0.89 . (9.26)
ll · 2πr 2πll 2π · 0.2 · 0.2 W W
r1

9.2.2 Radiation
Next we consider radiation, the second form of heat transfer. Heat radiation is electromagnetic
radiation, the wavelength of which lies in the range from 0.1 to 100 µm. This wavelength
range includes visible light, infrared radiation and the long wavelengths of ultraviolet radia-
tion (0.1–0.4 µm). In contrast to the other two heat exchange phenomena, radiation does not
require a medium for heat exchange. When radiation meets an object, part of it is absorbed into
the object, some of it is reflected back from the surface of the object and some may transmit
through the object. The rate that a surface absorbs radiation energy is denoted by absorptivity
β, the reflected energy by reflectivity η and the transmitted energy by transmissivity κ. The
sum of these is equal to one:

β + η + κ = 1. (9.27)
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Heat Transfer 467

irradiation, E reflection irradiation reflection

ηE ηE

βE βE
absorption

κE
(a) (b)

Figure 9.4 (a) Illustration of an opaque surface; (b) illustration of a semi-transparent surface. The
incoming irradiation intensity is E, given in W/m2

A reflective surface (η > 0) is called opaque, and if the radiation is partly transmitted
(κ > 0) through the material, the surface is called semi-transparent. Figure 9.4 illustrates
semi-transparent and opaque surfaces. Semi-transparent surfaces are not used in electrical
machines, hence in practice κ = 0 and

β + η = 1. (9.28)

Air consists principally of oxygen and nitrogen, which neither absorb nor emit radiation.
Thus, the radiation from an electrical machine to its surroundings and inside the machine can
be assumed to travel only between two surfaces.
The heat flow density qth of radiation is defined by the Stefan–Boltzmann equation

Φth

qth = = εthr σSB T14 − T24 , (9.29)
S
where T1 is the thermodynamic temperature of the radiating surface (1), T2 the thermodynamic
temperature of the absorbing surface (2) and σSB the Stefan–Boltzmann constant, 5.67 ×
10−8 W/m2 K4 . εthr is the relative emissivity between the emitting and absorbing surfaces and
depends on the characteristics of the surfaces and on the position of surfaces to each other. If
all the radiation that a surface S1 is emitting meets a surface S2 , εthr becomes
 
1 1 S1 1
= + −1 , (9.30)
εthr εth1 S2 εth2

where εth1 and εth2 are the emissivities of surfaces 1 and 2.

The emissivity of a black object is εth = 1. In reality, black objects do not exist, but the
best objects reach an emissivity of εth = 0.98, the emissivity of a black-painted object being
approximately εth = 0.9 and the relative emissivity between a grey-painted electrical machine
and its surroundings εthr = 0.85.
The concept of a black body is rather complex. The ‘colour’ of a body cannot be deter-
mined visually, because most of the heat radiation does not fall within the visible light range.
An ideal black body is defined, irrespective of the wavelength, as a perfect absorber or emit-
ter, whereas its opposite, an ideal white body, is a total reflector. The blackness of a body
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468 Design of Rotating Electrical Machines

is determined by emissivity, which depends on the temperature, radiation direction and the
wavelength of the radiation. Emissivity is the ratio of body radiation to black-body radiation
at equal temperatures. It expresses how close to a black body the body (material) is. To facil-
itate the evaluation of a body’s emissivity, a total hemispherical emissivity is used; it is the
average emissivity of a surface over all directions and wavelengths.
Next, grey and diffuse surfaces are defined to simplify the observation of radiation heat
exchange. A grey surface is a surface, the emissivity and absorptivity of which are independent
of radiation wavelength. A diffuse surface is a surface, the radiation properties of which are
independent of the direction of radiation. In reality, fully direction-independent surfaces do not
exist, but emissivity can be assumed to be fairly constant if the angle of radiation deviates less
than 40◦ from the plane normal for conductors, and less than 70◦ for insulators. In practice,
emissivities are usually given in the direction normal to the surface.
In analogy to conduction, the thermal resistance of radiation is defined as

T1 − T2 T1 − T2 1
Rth = =
 = , (9.31)
Φth εthr σSB T14 − T24 S αs S

where

T14 − T24
αr = εthr σSB (9.32)
T1 − T2

is the heat transfer coefficient of radiation. It depends strongly on the temperatures of the
emitting and absorbing surfaces. The temperature difference between the outer surface of an
electrical machine and the surroundings is usually about 40 K and the ambient temperature
20 ◦ C (293 K). These temperatures and a relative emissivity εthr = 0.85 yield

αr = 6 W/m2 K. (9.33)

The thermal resistance of radiation gives a linearization to radiation heat transfer that is
similar to convection heat transfer. This makes it possible to compare radiation and convection
heat transfer efficiency.

Example 9.3: How much heat does an object with a relative emissivity of 0.85 radiate to
the ambient if (a) the temperature of the object is 100 ◦ C and the ambient temperature is
50 ◦ C, (b) the temperature of the object is 50 ◦ C and the ambient temperature is 20 ◦ C?
Solution: The heat flow densities are
Φth W W
(a) qth = = 0.85 · 5.67 · 10−8 2 4 (3734 K4 − 3234 K4 ) = 408 2 .
S m K m
W W
(b) qth = 0.85 · 5.67 · 10−8 2 4 (3234 K4 − 2934 K4 ) = 169 2 .
m K m
These yield radiation heat transfer coefficients for (a) 8.16 W/m2 K and (b) 6.65
W/m2 K.
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Heat Transfer 469

Table 9.4 Emissivities of some materials used

in electrical machines
Material Emissivity
Polished aluminium 0.04
Polished copper 0.025
Mild steel 0.2–0.3
Cast iron 0.3
Stainless steel 0.5–0.6
Black paint 0.9–0.95
Aluminium paint 0.5

Heat transfer by radiation is of considerable significance in the total heat transfer of an

electrical machine if, besides radiation, there is only natural convection without any fan in the
system. Table 9.4 lists the emissivities of some materials in typical electrical machines.

Example 9.4: Consider two concentric spheres in a vacuum. The radii of the spheres
are Ri and Ro (Ri < Ro ). The temperatures of the surfaces of the spheres are Ti and To .
The distance between the spheres is small compared with the radii (Ro − Ri  Ri ). (a)
Calculate the radiated heat flow rate from the inner sphere outwards. (b) A third spherical
surface is inserted between the two sphere surfaces, so that there are now three concentric
spheres. What is the heat flow rate radiated from the innermost sphere surface outwards?
Solution: According to Equation (9.29),


(a) Φth,a = εthr σSB S Ti4 − To4 , where S = 43 πR 3 and R is the average of the radii.
(b) Let the temperature of the middle sphere surface be Tm . The radiated power is



Φth,b = εthr σSB S Tm4 − Ti4 = εthr σSB S To4 − Tm4 ,

from which we can solve

1
4 
Tm4 = T + To4 .
2 i

Substituting Tm4 into the equation for Φth,b , we get

 
1
4  1
 1
Φth,b = εthr σSB S To4 − To + Ti4 = εthr σSB S To4 − Ti4 = Φth,a .
2 2 2

We can see that the third sphere halves the heat flow rate from the inner sphere outwards;
that is, the thermal resistance between the inner and outer spheres is in case (b) two times
the resistance in case (a).
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470 Design of Rotating Electrical Machines

9.2.3 Convection
Heat is always transferred simultaneously by conduction and convection. Convection is de-
fined as the heat transfer between a region of higher temperature (here, a solid surface) and
a region of cooler temperature (a coolant) that takes place as a consequence of motion of the
cooling fluid relative to the solid surface. (At the molecular level, this means that the warmer
molecules displace the cooler fluid molecules.)
Knowledge of the boundary layers is essential in the analysis of the heat and mass transfer
between the solid surface and the coolant flowing by the surface. In convection heat transfer,
there are three boundary layers, defined as the velocity, thermal and concentration boundary
layer.
Let us consider the case represented in Figure 9.5. The stream of air meets a plane. The
velocity of the stream is zero on the surface of the plane, and inside the boundary layer the
speed increases to the speed in free space. The thickness of the velocity boundary layer δ v is
defined as the height from the surface where the speed of the stream is 0.99 times the speed
in free space. Above this limit, the shear stresses and velocity gradient are negligible.
The temperature of the plane Ts is assumed to be higher than the temperature of the stream
of air. Close to the surface, the heat transfers by conduction through the thermal boundary
layer. The temperature profile is similar to the velocity profile. The thickness of the thermal
boundary layer δ T is defined as the height from the surface where the ratio of the difference of
the surface and boundary layer temperatures, Ts and T, respectively, to the difference between
the surface and the ambient temperature T∞ is 0.99.
The concentration boundary layer occurs when a binary mixture of species flows across a
surface (convection mass transfer, e.g. water vapour in an air stream). The thickness of the
concentration boundary layer δ c is defined at the height where the ratio of the difference of
the surface and boundary layer molar concentrations to the difference between the surface and
ambient molar concentrations is 0.99. The form of the concentration boundary layer is similar
to the form of the velocity and thermal boundary layers (evaporation at a liquid surface and
sublimation at a solid surface, respectively).

v T

v∞ T∞

δv δT

Ts

Figure 9.5 Development of the velocity and thermal boundary layers; δ v (x) and δ T (x) are the thick-
nesses of the layers
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Heat Transfer 471

The three important expressions in the boundary layer theorems are surface friction, con-
vection heat transfer and convection mass transfer, which are crystallized into three important
parameters: friction coefficient Cf and the convection heat and mass transfer coefficients α
and α m .
To facilitate the calculation process and minimize the number of parameters to be solved,
certain dimensionless parameters have been generated. Of the numerous such parameters
available in the literature, the three most important ones when calculating heat transfer from
solid surfaces to the coolant are the Nusselt number Nu, the Reynolds number Re and the
Prandtl number Pr.
Convection heat transfer coefficient α can be expressed with the dimensionless Nusselt
number Nu as

αL
Nu = , (9.34)
l

where L is the characteristic surface length and l is the thermal conductivity of the coolant.
The Nusselt number describes the effectiveness of convection heat transfer compared with
conduction heat transfer.
The ratio between inertia and viscous forces is described by the Reynolds number Re and
can be described by the equation

vL
Re = , (9.35)
υ

where v is the speed of the coolant on the surface, L is the characteristic length of the surface
and υ is the kinematic viscosity of the coolant. The value of the Reynolds number at which
the flow becomes turbulent is called the critical Reynolds number Recrit . For flat surfaces Recrit
is 5 × 105 and for a tube flow it is 2300. For tubes, the characteristic length is described by
the equation

4S
L= , (9.36)
lp

where S is the area of the tube cross-section and lp is the wetted perimeter of the tube.
The third dimensionless number is the Prandtl number, which describes the relation be-
tween momentum and thermal diffusivity. In other words, it describes the thickness ratio of
velocity and the thermal boundary layers. The Prandtl number is described by the equation

cp µ
Pr = , (9.37)
l

where cp is the specific heat capacity, µ the dynamic viscosity and l the thermal conductivity
of the coolant. When Pr is low (<1), the heat transfer of thermal diffusivity is large compared
with the heat transfer rate gained with the fluid speed, and when Pr is unity, it means that the
thermal and velocity boundary layers are equal. The Pr numbers for gases and air are between
0.7 and 1, and for water between 1 and 13, depending on the temperature and pressure.
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472 Design of Rotating Electrical Machines

For gases, the velocity and thermal boundary layers are of the same order of magnitude.
Between the velocity and thermal boundary layers, the following equation is valid:

δT = δv Pr1/3 . (9.38)

Because Pr is close to one for gases, δ T ≈ δ v .

Fanning friction coefficient Cf is useful in internal flow calculations when defining pump or
fan power requirements, but it is valid for fully developed laminar flow only. When calculating
a fully developed turbulent flow (which is usually the case), it is preferable to use empirical
results for surface friction. Friction factors for a wide range of Reynolds numbers are found
for example in the Moody diagram (Moody, 1944), which is valid for circular tubes.
The pressure drop
p in a tube can be calculated from the equation

ρu m

p = f L, (9.39)
2D

where f is the dimensionless Moody friction factor, ρ is the density of fluid, L is the tube
length, D is the tube diameter and u m is the mean fluid velocity in the tube, which can be
calculated from the required mass flow rate.
From the pressure drop, the power P required to sustain an internal flow is obtained from
the equation

qm
P =
p , (9.40)
ρ

where qm is the mass flow rate in the tube.

As mentioned above, the convection heat transfer always takes place in the direction of a
lower temperature. Convection can be divided into forced and natural convection. In forced
convection, external instruments such as pumps or blowers assist the flow of coolant. Natu-
ral convection is caused by density variations resulting from temperature differences: as the
coolant is heated, it changes its density, and the local changes in density in the coolant–solid
interface result in buoyancy forces that cause currents in the coolant. Newton’s law of cooling
defines the heat flow density qth created by convection

Φth
qth = = αth Θ (9.41)
S

and hence the thermal resistance of convection is

Θ 1
Rth = = . (9.42)
Φth αth S

Here α th is the heat transfer coefficient. The value of the heat transfer coefficient depends
for instance on the viscosity of the coolant, the thermal conductivity, specific heat capac-
ity and flow velocity of the medium. Traditionally, the heat transfer coefficient has been de-
fined by various empirical correlations. In the calculation of an electrical machine, for natural
convection in the air around a horizontally mounted, unfinned cylindrical motor of diameter
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Heat Transfer 473

D [m] with ambient temperature close to room temperature, Miller (1993) employs a correla-
tion depending on the temperature difference Θ [K] between the cylinder and the surroundings
 0.25  
Θ W
αth ≈ 1.32 . (9.43)
D m2 K

Example 9.5: What is the heat transfer coefficient and heat flow density between a cylin-
der and the ambient, if the temperature of the cylinder is 50 ◦ C above the ambient and the
diameter is 0.1 m?
Solution: For the heat transfer coefficient of natural convection, Equation (9.43) gives the
value
 0.25    
Θ W 50 0.25 W W
αth ≈ 1.32 2
= 1.32 2
= 6.24 2 .
D m K 0.1 m K m K

Natural convection is thus of the same order as heat transfer by radiation. The density of
the heat flow is

qth = αth Θ = 6.24 · 50 W/m2 = 312 W/m2 .

Forced convection increases the convective heat transfer coefficient even 5-6-fold depend-
ing on the air velocity. The increase in heat transfer coefficient is approximately proportional
to the square root of the air velocity v (Miller, 1993)
  
v W
αth ≈ 3.89 . (9.44)
l m2 K

Here l is the length of the frame of the machine in metres and the speed v is given in m/s.

Example 9.6: What is the heat transfer coefficient on the surface of a cylinder of 0.1 m
length if the speed of coolant is 4 m/s?
Solution: According to Equation (9.44),
   
v W 4 W W
αth ≈ 3.89 = 3.89 = 24.6 2 .
l m2 K 0.1 m2 K m K

This coefficient is about fourfold when compared with the previous value of natural
convection.

For a typical radial flux electrical machine, there are three significant convection coeffi-
cients related to the frame, air gap and coil ends. The first can be approximated for example
by Miller’s equations, but the other two are more complex cases, the coil ends in particular.
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474 Design of Rotating Electrical Machines

The convection coefficient for an annulus depends on the air-gap length, rotation speed of
the rotor, the length of the rotor and the kinematic viscosity of the streaming fluid. The Taylor
equation can be used to determine the flow type and the convection heat transfer coefficient
in the annulus. The validity of the Taylor equation is, however, somewhat restricted, and the
annular flow in the tangential direction is usually referred to as Taylor–Couette flow or Taylor
vortex flow. It differs from the flow between two parallel plates (one moving) by the toroidal
vortices that appear as a result of tangential forces. These eddies influence the heat transfer
characteristics of the air gap. The Taylor vortices are described by the Taylor number Ta,
which describes the ratio of viscous forces to the centrifugal forces

ρ 2 Ω 2 rm δ 3
Ta = , (9.45)
µ2

where Ω is the angular velocity of the rotor, ρ the mass density of the fluid, µ the dynamic
viscosity of the fluid and rm the average of the stator and rotor radii. The radial air-gap length
δ and the rotor radius are taken into account by a modified Taylor number

Ta
Tam = , (9.46)
Fg

where Fg is the geometrical factor defined by

 
2rm − 2.304δ
π 4
.
2rm − δ
Fg =  
  . (9.47)
2rm − 2.304δ 2 δ 2
1697 0.0056 + 0.0571 1−
2rm − δ 2rm

In practice, the air-gap length is so small compared with the rotor radius that Fg is close to
unity and Tam ≈ Ta.
According to Becker and Kaye (1962), the Nusselt number is

Nu = 2 for Tam < 1700 (laminar flow)

Nu = 0.128Ta0.367
m for 1700 < Tam < 104 (9.48)
Nu = 0.409Ta0.241
m for 104 < Tam < 107

which can be used to determine the heat transfer coefficient from the rotor to the air gap and
from the stator to the air gap (one air-gap surface) by the equation

Nul
αth = , (9.49)
δ
where l is the thermal conductivity of air.
The roughness of the surfaces affects the heat transfer in two ways. It enlarges the cooling
area and increases turbulence. Gardiner and Sabersky (1978) and Rao and Sastri (1984) have
studied the effect of roughness of the stator and rotor air-gap surfaces. According to these two
studies, a rough rotor has a heat transfer coefficient 40 to 70% higher than a smooth rotor.
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Heat Transfer 475

Stator end winding

Stator

Rotor

Rotor fan blade

Figure 9.6 End winding space of a squirrel cage induction motor and the air circulation in the space

The convection heat transfer coefficient in the coil ends is the most difficult to approximate
because the flow field is too complex to model. The cooling method of the electrical machine
also affects the convection heat transfer coefficient of the coil ends, as does the type of wind-
ing. The end winding space of a squirrel cage induction motor is illustrated in Figure 9.6. The
end winding space can be divided into two parts: the space between the end winding and the
rotor and the space between the end winding and the frame. In the space between the rotor
and the end winding, the rotation speed of the rotor determines the heat transfer coefficient.
The geometry corresponds to that of the air gap, and Equations (9.45)–(9.49) can be used to
calculate the heat transfer coefficient on the surface of the stator winding.
In the space between the end winding and the frame, the speed of the air stream is far
smaller than in the space between the rotor and the end winding. The flow may be assumed to
be laminar. This means that natural convection occurs in that space, and also radiation has to
be taken into account.
Usually, the heat transfer between two interconnected objects is described by the junction
thermal resistance. The heat transfer across the gap between the joint surfaces depends on
the finish of the surfaces. The heat transfer coefficient α th between two metal surfaces with
a roughness of 30 µm is approximately 1100 W/m2 K, a value corresponding to a thermal
resistance of 9.1 K/W in an area of 1 cm2 . In the case of ground surfaces (a roughness of
1 µm), the thermal transmittance is doubled and thus the thermal resistance can be halved.
The same result can be reached by adding heat transfer lubricant to the joint of the rough
surfaces to fill in the voids.
The equivalent thermal resistance of joint surfaces can also be modelled by equivalent air-
gap conduction. Imagine that between the surfaces there is a small air gap because of surface
roughness. The resistance of the equivalent air gap between the surfaces can then be calculated
by using Equation (9.24). The equivalent air-gap length and contact heat transfer coefficients
are presented in Table 9.5.
In electrical machines, the thermal resistances of joint surfaces are the most significant
insecurity factor. The most important thermal resistances of joint surfaces in this respect are
those between the conductors and the slot insulation, the slot insulation and the stator or rotor
stack, and the stator stack and the stator frame. Determination of these thermal resistances may
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476 Design of Rotating Electrical Machines

Table 9.5 Equivalent joint air-gap lengths and contact heat transfer coefficients
Joint equivalent air-gap Contact heat transfer
Joint type length/mm coefficient/W/m2 K
Stator winding to stator core 0.10–0.30 80–250
Frame (aluminium) to stator core 0.03–0.04 650–870
Frame (cast iron) to stator core 0.05–0.08 350–550
Rotor bar to rotor core 0.01–0.06 430–2600

prove difficult without measurements. However, these contact thermal resistances determine
chiefly the heat transfer of the machine and therefore, in order to be able to calculate the heat
transfer of the machine, certain empirical values of contact thermal resistances have to be
known.
If rated torque is required at a low rotation speed, a shaft-mounted blower may not be
able to produce sufficient forced convection on the motor outer surface to cool the motor. In
DC motors and speed-controlled AC motors, an additional cooling fan is employed, because
these motors are often operated for a long period with a high torque at a low rotation speed.
Since in DC machines most of the heat is generated in the rotor, a good internal cooling flow
is required.

9.3 Thermal Equivalent Circuit

9.3.1 Analogy between Electrical and Thermal Quantities
The heat-removal calculation only tells us whether enough heat can be removed from the ma-
chine surface in the stationary state. Further, the calculation guides the selection of the cooling
method. However, when considering the operation of the machine, it is essential to define the
internal temperature distribution, which is regulated by the flux densities, frequencies and
current densities in the machine parts.
To determine the internal temperature distribution, a thermal equivalent circuit is used for
modelling the heat transfer of the machine. The heat flow is analogous to electric current
flow, as we saw in the previous chapter. Table 9.6 shows the analogous thermal and electrical
quantities. Resistive losses, iron losses, windage losses and friction losses are represented by

Table 9.6 Analogous thermal and electrical quantities

Thermal flow Symbol Unit Electric flow Symbol Unit
Quantity of heat Qth J Electric charge Q C
Heat flow rate Φ th W Electric current I A
Heat flow density qth W/m2 Current density J A/m2
Temperature T K Electric potential V V
Temperature rise Θ K Voltage U V
Thermal conductivity l W/m K Electric conductivity σ S/m = A/V m
Thermal resistance Rth K/W Electric resistance R = V/A
Thermal conductance Gth W/K Electric conductance G S = A/V
Heat capacity Cth J/K Capacitance C F = C/V
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Heat Transfer 477

individual heat flow sources. The thermal resistances of iron cores, insulation, the frame and
so on are given as resistances.
The heat capacity is analogous to the electric capacitance, as shown below.
The electric charge Q stored in a capacitor is

Q = C
V = CU, (9.50)

where C is the capacitance of the capacitor and U the voltage over the capacitor.
The quantity of heat Q th stored in a body is

Q th = mcp Θ, (9.51)

where m is the mass of the body, cp the specific heat capacity and Θ the temperature rise
caused by the heat Q th .
Comparing Equation (9.50) with Equation (9.51), we find that the heat capacity

Cth = mcp (9.52)

is analogous to the capacitance C.

9.3.2 Average Thermal Conductivity of a Winding

The windings of electrical equipment are thermally inhomogeneous; in the winding, heat
flows through a conductor with very good heat-conducting properties, but also through a
poorly heat-conducting insulation. Usually, we need to know the average temperature of the
winding. In this case, the winding may be replaced with a homogeneous material having the
same thermal resistance as the real inhomogeneous winding.
As an example, let us consider the winding represented in Figure 9.7a. Heat is assumed to
flow only in the x-direction. As the thermal conductivity of copper is about a thousand times as
high as the thermal conductivity of the insulation, we may assume that the thermal resistance
of copper is zero. Our task is to determine the resistance (rres ) of the two parallel-connected
insulation pieces A and B (Figure 9.7b). The resistance of A per unit length is

b
rA = , (9.53)
l i δi

where l i is the thermal conductivity of the insulation. The resistance of B per unit length is

δi
rB = . (9.54)
li h

The parallel connection yields

rA rB b b
rres = =   =  . (9.55)
rA + rB b δi b h
li h + li + δi
δi h δi
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478 Design of Rotating Electrical Machines

δi
δi
b
x
B

h
h'

h'
A

δi
h'
h
b' b'

b
b'
(a) (b) (c)

Figure 9.7 Winding made of rectangular conductors (figures a and b) is replaced with a homogeneous
material (figure c) having the same outer dimensions (b and h ) as the real conductor with insulation and
the same thermal resistance in the x-direction as the real inhomogeneous conductor consisting of copper
and insulation

The resultant resistance rres should be equal to the resistance of the homogeneous body having
the thickness b , width h  and thermal conductivity l av (Figure 9.7c):

b b
rres = =   , (9.56)
lav h  bh
li + δi
δi

from which we obtain for the average thermal conductivity

 
b h δi
lav = li 
+  . (9.57)
h δi h

With the same procedure, we may determine the average thermal conductivity of the wind-
ing shown in Figure 9.8a where extra insulation is placed between the winding layers:



h b + δa δi
lav = li + . (9.58)
h  (δi + δa ) h 

If we have a round wire winding (Figure 9.8b), and the spaces between the wires are filled
with impregnation resin, the average thermal conductivity is

 
d δi
lav ≈ li +  . (9.59)
δi d
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Heat Transfer 479

b'

d'
d
h'

δi
δa

(a) (b)

Figure 9.8 (a) Winding of rectangular wires and with extra insulation between the layers. (b) An im-
pregnated round wire winding

9.3.3 Thermal Equivalent Circuit of an Electrical Machine

A thermal equivalent circuit of a typical electrical machine is shown in Figure 9.9. For sim-
plicity, it is assumed that the heat flows in the stacks only in the radial direction because the
thermal conductivity in the axial direction is notably lower than in the radial direction. Further,
it is assumed that the heat flows from the slots to the teeth but not directly to the yoke. This is
reasonable because slots are normally deep and narrow, whereupon the heat flow from a slot to
the yoke is small. There are 21 nodes in total in the equivalent circuit. Nodes, where the losses
of the machine are supplied, are indicated by a circle and the node number inside the circle.
The circuit is connected to the cooling flow through the nodes from 18 to 21. Descriptions of
the individual parameters will be given below.
The modelling of a winding with rectangular-shaped conductors in a slot is studied first
(Figure 9.10). Between the copper and the tooth, there is the main wall insulation and the
wire insulation. The temperature of copper is assumed constant in every cross-section of the
winding, but it varies in the axial direction. In the tooth, the temperature is assumed constant
in the axial direction. Resistive losses are distributed uniformly in the winding.
The winding and the tooth are presented in a simplified form in Figure 9.11a. The ther-
mal equivalent circuit with distributed constants is presented in Figure 9.11b. The winding is
divided into small sections of length dx. Resistive losses PCu divided by the core length l is

p = PCu /l. (9.60)

The thermal resistance R between the points a and b divided by the core length is
r = R/l = 1/(lCu SCu ), (9.61)
where l Cu is the thermal conductivity and SCu the total cross-sectional area of the conductors
in a slot.
The thermal conductance G (the inverse of the thermal resistance) from the conductors to
the tooth per unit core length is
g = G/l. (9.62)
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480 Design of Rotating Electrical Machines

Frame 19

Yoke
Rs1
R s2 R s3
2 1
Stator
R s2 Tooth Slot
R s4
Rs5 R s6
End 3 4 7 End
winding R s4 winding
R s8
R s15 R s14 R s12 R s7 R s10 R s9 R s9 Rs11 R s13 Rs14 R s16
5 6
End 8 End
winding winding
space 17 Air gap space
Air gap
18 R r15 R r14 R r12 R r10 R r9 12 Rr9 Rr11 R r13 R r14 Rr16 20
9 10
R r7
R r8
R r4 Rr5 R r6
End End
14 13 11 winding
winding
R r4
R r2 R r3 Tooth Slot
Rotor 16
15
R r2
R r1 Yoke

Shaft 21

Figure 9.9 Thermal equivalent circuit of a typical electrical machine

The conductance G includes the insulation resistance and the contact resistance between the
insulation and the tooth. The inverse of G, using the symbols presented in Figure 9.10, is

 
1 δi 1 δi 1 1 1
= + = + = , (9.63)
G li h s l αth h sl li αth h sl kth h sl

where l i is the thermal conductivity of insulation and α th the heat transfer coefficient between
the insulation and the tooth. The term kth

kth = 1/(δi /li + 1/αth ) (9.64)

is called the overall heat transfer coefficient. Now, we obtain for the conductance per unit
length

g = kth h s . (9.65)
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Heat Transfer 481

hs
y
x

δi

bs

Figure 9.10 Cut-away drawing of a winding with rectangular conductors in a slot

The equivalent circuit with lumped constants is presented in Figure 9.11c. The circuit gives
the temperature rises of points a and b and also the average temperature rise Θ av of the winding
part located in the slots, between points a and b. The total losses PCu in the slots are supplied
to the node presenting the average temperature.
Next, the components of the equivalent circuit Figure 9.11c are determined. First, we
have to solve the temperature distribution in the circuit with the distributed constants in
Figure 9.11b, of which a part at distance x from point a (the origin) is presented in
Figure 9.12.
In Figure 9.12, at point A at distance x from the origin, the temperature rise is Θ and the
x-direction heat flow in copper Φ th . The heat generated at A is p dx. The heat flow through the
insulation is Θg dx. At point B at distance dx from A, the temperature rise and heat flow are
∂Θth ∂Φth
Θ+ dx and Φth + dx
∂x ∂x
as indicated in Figure 9.12. Now we apply the following rule to node A: the sum of incoming
heat flows in a node is equal to the sum of leaving heat flows. Thus, we obtain
∂Φth
Φth + gΘ dx = p dx + Φth + dx,
∂x
and after reduction
∂Φth
gΘ = p + . (9.66)
∂x
The temperature rise of node B
 
∂Θth
Θ+ dx
∂x
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482 Design of Rotating Electrical Machines

P Cu
x Copper

y
Φ tha
a
b Φ thb

(a) Θ a Θb

l
Tooth
Insulation
R = rl

P Cu

Φ tha rdx Φ thb

rdx rdx rdx rdx rdx
a b
gdx
gdx

gdx

gdx
gdx

(b) Θa Θb

G = gl Tooth iron temperature

Φ tha R0 R0 Φ thb
a b
R1
P Cu
av
Θa Θ av R2
(c) Θb
Φ thb − Φ tha + PCu

Tooth iron temperature

Figure 9.11 (a) Simplified presentation of Figure 9.10; (b) its thermal equivalent circuit presented with
distributed constants; and (c) the circuit presented with lumped constants

is equal to the temperature difference between nodes B and A plus the temperature rise of
node A, that is

∂Θ
Θ+ dx = Φthr dx + Θ,
∂x

and after reduction

∂Θ
= Φthr. (9.67)
∂x
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Heat Transfer 483

∂Φ th
Φ th + dx
∂x
Φ th pdx
pdx
Φ tha A rdx B Φ thb
a b
Θ gdx

gdx
gdx
∂Θ
Θa Θ Θ + dx Θb
∂x

x
dx

Figure 9.12 Deriving the differential equation for the heat flow in a winding

By differentiating Equation (9.66) with respect to x we obtain

∂ 2 Φth ∂Θ
=g ,
∂x 2 ∂x

and substituting Equation (9.67) for ∂Θ/∂ x

∂ 2 Φth
− rgΦth = 0. (9.68)
∂x2

Equation (9.68) has a solution of the form

√ √
Φth = C1 e rgx
+ C2 e− rgx
, (9.69)

where C1 and C2 are integration constants. According to Equation (9.66), the temperature is

1  √ √rgx √ √ 
Θ= C1 rge − C2 rge− rgx + p . (9.70)
g

The integration constants are determined in accordance with two boundary conditions

x = 0,
Θ = Θa ,
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484 Design of Rotating Electrical Machines

and

x = 0,
Φth = Φtha .

Substituting the boundary conditions into Equations (9.69) and (9.70), we obtain
  
1 g p
C1 = Φtha + Θa − √ , (9.71)
2 r rg
  
1 g p
C2 = Φtha − Θa + √ . (9.72)
2 r rg

Substituting these for C1 and C2 in Equations (9.69) and (9.70) and simplifying yields


√  g
√  p
√ 
Φth = Φtha cosh rgx + Θa sinh rgx − √ sinh rgx , (9.73)
r rg

r
√ 
√  p
√ 
Θ = Φtha sinh rgx + Θa cosh rgx + 1 − cosh rgx . (9.74)
g g

The average temperature is

l  √  √ 
1 1 1 √ sinh( rgl) p sinh( rgl)
Θav = Θ dx = [cosh( rgl) − 1]Φtha √ Θa + 1− √ .
l l g rg g rg
0
(9.75)
Taking into account the definitions of p, r and g, that is Equations (9.60), (9.61) and (9.62),
we obtain
√  √ 
1  √  sinh RG PCu sinh RG
Θav = cosh RG − 1 Φtha + √ Θa + 1− √ . (9.76)
G RG G RG

Now, we can determine the components of the equivalent circuit with lumped constants by
calculating the temperature rise and heat flow at point b (Figure 9.11c) from Equations (9.73)
and (9.74) and from the equivalent circuit Figure 9.11c. The results have to be identically
equal. Equations (9.73) and (9.74) yield with x = l

√ G √ PCu √
Φthb = Φtha cosh( RG) + Θa sinh( RG) − √ sinh( RG), (9.77)
R RG

R √ √ PCu √
Θb = Φtha sinh RG + Θa cosh RG + [1 − cosh( RG)]. (9.78)
G G
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Heat Transfer 485

From the equivalent circuit of Figure 9.11c we obtain

Θa = −Φtha R0 + (Φthb − Φtha ) (R1 + R2 ) + PCu R2 , (9.79)

Θb = Φthb R0 + (Φthb − Φtha ) (R1 + R2 ) + PCu R2 . (9.80)

From Equations (9.79) and (9.80) we can solve

 
R0 1 R2
Φthb = Φ tha 1 + + Θa − PCu , (9.81)
R1 + R2 R1 + R2 R1 + R2
   
R0 R0 R0 R2
Θb = Φtha R0 2 + + Θa 1 + − PCu . (9.82)
R1 + R2 R1 + R2 R1 + R2

Equation (9.77) yields the same result for Φ thb as Equation (9.81) if the coefficients of Φ tha
are equal and the coefficients of Θ a are equal. In addition, the coefficients of PCu have to be
equal. The same thing applies for Equations (9.78) and (9.82) . These conditions yield

R0 √
1+ = cosh RG, (9.83)
R1 + R2
  
R0 R √
R0 2 + = sinh RG, (9.84)
R1 + R2 G

1 G √
= sinh RG, (9.85)
R1 + R2 R
R2 1 √
= √ sinh RG. (9.86)
R1 + R2 RG

Dividing (9.86) by (9.85) yields

1
R2 = . (9.87)
G

Substituting (9.87) for R2 in (9.86) yields

 √ 
1 RG
R1 = √ −1 . (9.88)
G sinh RG

The value of R1 is negative. Now, Equations (9.83) and (9.84) yield

 √  √
R sinh RG R RG
R0 = √ = tanh . (9.89)
G cosh RG + 1 G 2

Finally, we have to make sure that we get the average temperature of Equation (9.76) also
from the equivalent circuit with the resistances (9.87), (9.88) and (9.89):

Θav = R2 (Φthb − Φtha ) + R2 PCu .

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486 Design of Rotating Electrical Machines

By substituting Φ thb from Equation (9.81) with R0 , R1 and R2 , we obtain after simplification

R2 R2 R2
Θav = R0 Φtha + Θa + R1 PCu
R1 + R2 R1 + R2 R1 + R2  
√ √
1  √  sinh RG PCu sinh RG
= cosh RG − 1 Φtha + √ Θa + 1− √ ,
G RG G RG

which is the same as Equation (9.76), that is the analytical solution.

In the thermal circuit of Figure 9.9, the part of the stator winding that is located in the slots
is represented by the resistances Rs6 , Rs8 and Rs9 and node 7. The node represents the average
temperature rise, and the resistive losses in the slots are supplied to this node. The resistance
Rs6 is calculated from Equation (9.87), Rs8 from Equation (9.88) and Rs9 from Equation
(9.89), where R is the thermal resistance of the conductors in the slots and G the conductance
between the conductors and teeth.
The end winding can also be represented by the equivalent circuit of Figure 9.11c. In the
end winding, the highest or lowest temperature is in the middle of the coil overhang, and
thus the heat flow Φ tha is zero if terminal b is connected to the winding in the slots. We can
now omit the resistance R0 at terminal a. Then, the left-hand-side end winding in Figure 9.9
can be represented by resistances Rs10 , Rs12 , Rs14 and Rs15 and node 5. The resistance Rs10
has the form of R0 in Equation (9.89), R12 is a small negative resistance of the form of R1
in Equation (9.88) and the sum Rs14 + Rs15 has the form of R2 in Equation (9.87); that is,
Rs14 + Rs15 is the resistance from the winding end conductors to the winding end space. The
resistance Rs14 is the resistance from the conductors to the surface of the winding end and Rs15
is the convection resistance from the winding end surface to the end winding space. On the
right-hand side, the winding end is represented in the same way by the resistances Rs11 , Rs13 ,
Rs14 and Rs16 and node 6. Nodes 5 and 6 give the average temperature rises in the winding
ends, and the resistive losses of the winding ends are supplied to nodes 5 and 6.
The teeth are represented in Figure 9.9 by the resistances Rs4 , Rs5 and Rs6 and node 4, where
the iron losses in the teeth are supplied. The resistance Rs4 has the form of R0 in Equation
(9.89), Rs5 is a small negative resistance of the form of R1 in Equation (9.88), and Rs6 is the
common resistance with the winding. The resistance R in Equations (9.88) and (9.89) is now
the resistance of the teeth from the tip of the tooth to the root.
Due to symmetry, heat is flowing in the yoke only in the radial direction. This means that
the resistance R2 in the equivalent circuit of Figure 9.11c (the conductance G in Figure 9.11b)
is missing. The equivalent circuit now has the form of Figure 9.13.

Φ tha R0 R0 Φ thb
a b
R1
P
av
Θa Θb
Θav

Figure 9.13 Equivalent circuit in a case in which the resistance R2 (the inverse of the conductance G)
of Figure 9.11 is missing (e.g. because of symmetry, the heat flow is only radial)
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Heat Transfer 487

The resistances R0 and R1 can be derived in a similar way as in the general case presented
in Figure 9.11. The result is

R
R0 = , (9.90)
2
R
R1 = − , (9.91)
6

where R is the thermal resistance between points a and b in Figure 9.13 and P is the total loss
produced in the body.
The yoke is represented in Figure 9.9 by the resistances Rs2 and Rs3 and node 1. Node 1
gives the average temperature rise of the yoke, and the iron losses of the yoke are supplied
to node 1. The resistance Rs2 is calculated from Equation (9.90) and the resistance Rs3 from
Equation (9.91). The resistance R is the thermal resistance of the yoke from the slot bottom
to the outer surface of the yoke.
The resistance Rs1 in the equivalent circuit of Figure 9.9 is the convection and radiation
resistance from the outer surface of the yoke to the surroundings or to the coolant.
The equivalent circuit in Figure 9.11c was derived for rectangular-shaped conductors, as-
suming that the temperature is constant in the cross-section of the winding. If we have a
round wire winding (Figure 9.14), the temperature in a cross-section cannot be assumed to be
constant. Assuming that heat flows from the winding only into the tooth in Figure 9.14, the
equivalent circuit has the form of Figure 9.13, which is valid for unidirectional heat flow in
a body where losses are distributed uniformly over the body. Due to the symmetry, the maxi-
mum temperature is on the centre line of the slot, and heat does not flow over the centre line.
We may cancel the right-hand-side R0 resistance in Figure 9.14a, so the equivalent circuit has
the form of Figure 9.14b. The resistance Ri in Figure 9.14b includes the resistance of the slot
insulation and the contact resistance between the insulation and the tooth. The resistances R0
and R1 are calculated from Equations (9.90) and (9.91). Their sum Rc (Figure 9.14c) is

R R 1 1 b 1 b
Rc = R0 + R1 = − = R= = , (9.92)
2 6 3 3 2lav h sl 6 lav h sl

b/2

Ri R0 R0 Ri R0 Ri Rc

hs R1 R1
PCu PCu PCu

(a) (b) (c)

Figure 9.14 Thermal equivalent circuit of a round wire winding

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488 Design of Rotating Electrical Machines

where R is the thermal resistance from the centre line of the slot to the slot insulation, b and
h s the slot dimensions shown in Figure 9.14, l the stack length and l av the average thermal
conductivity of the winding (Equation 9.59).
If the winding is a round wire winding, the resistance Rs6 in the equivalent circuit of
Figure 9.9 is

Rs6 = Ri + Rc .

The resistance Rs14 is calculated accordingly in the end windings.

The equivalent circuit of the rotor in Figure 9.9 is a mirror image of the stator circuit.
The thermal resistances of the rotor are calculated as the stator resistances but using rotor
parameters.

9.3.4 Modelling of Coolant Flow

The simplest way to model the coolant flow is to assume the coolant temperature to be constant
and equal to its mean value. That gives adequate results if the temperature rise of the coolant
is small, as it normally is in totally enclosed fan-cooled (TEFC) motors. If the temperature
rise of the coolant is high, as in motors having open-circuit cooling, the constant temperature
approximation alone does not suffice. We can estimate the temperature rise of the coolant
in different parts of the motor. After solving the thermal network, we know the heat flow
distribution and we can recalculate the temperature rise of the coolant, correct our estimation,
and solve the network again to obtain a more accurate result.
The most accurate way to consider the coolant flow is to handle the heat flow equations
and the coolant flow equations at the same time. The system equations of thermal networks
with passive components are linear and the system matrix is symmetrical. This results in the
property of reciprocity: the temperature rise of any part A per watt in a part B is the same as
the temperature rise of the part B per watt in the part A. The equations describing the tem-
perature rises of the coolant in different motor parts are also linear, but they do not have the
properties of symmetry and reciprocity. This is the reason why the coolant flow cannot be
modelled by passive thermal components.
The coolant flow can be modelled by heat-flow-controlled temperature sources in the ther-
mal network. General circuit analysis programs such as Spice, Saber or Aplac can be used
to analyse thermal networks with heat-flow-controlled sources. The heat-flow-controlled tem-
perature source is described by a current-controlled voltage source in the program. If the
network is small, it can also be solved manually.

9.3.4.1 Method of Analysis

Let us examine the cooling of the stator of an open motor (Figure 9.15). The coolant flow q
enters one of the end winding regions. The losses Pew1 absorbed from the end winding and
the friction losses Pρ1 in the end winding region warm up the coolant. The temperature rise is

Pew1 + Pρ1
Θ1 end = = 2Rq (Pew1 + Pρ1 ), (9.93)
ρcp q
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Heat Transfer 489

P1 P2
2

1 3
P ys
q q
Pew1 Pew2

Θ
Θ3end
Θ3
Θ2end
Θ2
Θ1end
Θ1

Figure 9.15 Temperature rise of the coolant in an open-circuit machine

where ρ is the density and cp the specific heat capacity of the coolant, q the coolant flow and
the term

1
Rq = . (9.94)
2ρcp q

Rq has the dimension of the thermal resistance [K/W]. It is assumed that the mass flow ρq
does not depend on the temperature of the coolant.
The temperature rise of node 1 (Θ 1 ) in Figure 9.15 can be assumed to be the average
temperature rise in the end winding region. According to Equation (9.93), we get

Θ1 end
Θ1 = = Rq (Pew1 + Pρ1 ). (9.95)
2

The losses Pys absorbed from the stator yoke warm up the coolant by the amount of

Pys
Θ2 end − Θ1 end = . (9.96)
ρcp q

Substituting Θ 1 end from Equation (9.93) and using the term (9.94) we get

Θ2 end = 2Rq (Pew1 + Pρ1 ) + 2Rq Pys . (9.97)

The temperature rise of node 2 (Θ 2 ) in Figure 9.15 is the average temperature rise of the
coolant over the stator yoke:

Θ1 end + Θ2 end

Θ2 = = 2Rq Pew1 + Pρ1 + Rq Pys . (9.98)
2
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490 Design of Rotating Electrical Machines

–
Θ2

Θ1 P1 + P2
Θ3
2
– + + –
1
P ys 3

Pew1 Pew2

Figure 9.16 Interpretation of the coolant as heat-flow-controlled temperature sources Θ 1 , Θ 2 and Θ 3

Analogously, we get for node 3:

Θ3 = 2Rq (Pew1 + Pρ1 ) + 2Rq Pys + Rq (Pew2 + Pρ2 ). (9.99)

Equations (9.95), (9.98) and (9.99) can be interpreted as heat-flow-controlled temperature

sources; for instance, for the source Θ 2 there are two controlling heat flows, Pew1 + Pρ1 and
Pys . The thermal network in Figure 9.16 matches Equations (9.95), (9.98) and (9.99).
The rule for writing the temperature source equations is formulated as follows:

Rule 1: The temperature source connected between a coolant flow node and earth is equal
to the sum of two products. The first is 2Rq multiplied by the losses absorbed by the coolant
before the coolant flow node and the second is Rq multiplied by the losses absorbed in the
coolant flow node under consideration.

According to Figure 9.15, the temperature rises Θ 2 and Θ 3 can also be written in the form

Θ1 end Θ2 end − Θ1 end Θ2 end

Θ2 = Θ1 + + = Θ1 +
2 2 2 (9.100)
= Θ1 + Rq (Pew1 + Pρ1 ) + Rq Pys = Θ1 + Θ12 ,

Θ2 end − Θ1 end Θ3 end − Θ2 end Θ3 end − Θ1 end

Θ3 = Θ2 + + = Θ2 +
2 2 2 (9.101)
= Θ2 + Rq Pys + Rq (Pew2 + Pρ2 ) = Θ2 + Θ23 ,

where the heat-flow-controlled temperature sources are

Θ12 = Rq (Pew1 + Pρ1 + Pys ), (9.102)

Θ23 = Rq (Pys + Pew2 + Pρ2 ). (9.103)
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Heat Transfer 491

Θ 12 Θ 23

– + – +
P1 2 P2
Θ1
– +
1 3
Pys

Pew1 Pew2

Figure 9.17 Interpretation of the coolant as heat-flow-controlled temperature sources Θ 1 , Θ 12 and Θ 23

The equivalent network satisfying Equations (9.95), (9.100) and (9.101) is shown in
Figure 9.17. The rule for writing the temperature source equations is now:

Rule 2: The temperature source between two coolant flow nodes m and n is equal to the
sum of losses absorbed by the coolant in the nodes m and n multiplied by Rq .

Example 9.7: Form the coolant flow part of the thermal network for a totally enclosed
fan-cooled induction motor, in which there is also an inner coolant flow (Figure 9.18).
The outer and inner coolant flows are qo and qi . The friction losses in the winding end
regions and in the outer fan are Pρ1 , Pρ2 and Pρ3 , respectively. The losses transferred
from the nondrive end winding region and from the stator core to the outer coolant flow
are P62 and Ps3 . The losses transferred from the drive end winding region to the ambient
are P40 . It is assumed that the outer coolant flow does not cool the bearing shield in the
drive end. The losses from the stator and rotor core to the inner coolant flow are Ps5 and
Pr7 . The losses from the stator and rotor end windings to the inner coolant flow are Pews6 ,
Pews4 , Pewr6 , Pewr4 .

qo
3

2 5
P62
Pρ3 Pews6 Pews4
Ps5 Ps3
4
P40
1 6 P ewr4
Pewr6
qi P r7

Pρ1 7 qi P ρ2

Figure 9.18 TEFC motor with outer and inner coolant cycles
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492 Design of Rotating Electrical Machines

Solution: The thermal network of the coolant flow is shown in Figure 9.19. The re-
sistances R62 and R40 are the thermal resistances over the bearing shields. The coolant
flow is modelled according to Rule 2 and Figure 9.17. The heat-flow-controlled sources
are

Θ01 = Rqo Pρ3

Θ12 = Rqo (Pρ3 + P62 )
Θ23 = Rqo (P62 + Ps3 )
Θ45 = Rqi (Pρ2 + Pewr4 + Pews4 − P40 + Ps5 )
Θ56 = Rqi (Ps5 + Pρ1 + Pewr6 + Pews6 − P62 )
Θ67 = Rqi (Pρ1 + Pewr6 + Pews6 − P62 + Pr7 )

where

1
Rqo = ,
2ρcp qo
1
Rqi = .
2ρcp qi

Note the correct signs of the heat flows in the equations for Θ 45 , Θ 56 and Θ 67 . The heat
flows P62 and P40 have a negative sign because they flow in a direction opposite to the
other heat flows in nodes 4 and 6 (Figure 9.19).

Θ23
3
- +
2 Θ45
P62 Θ56 Ps3
Θ12 + + - 5 + -
R62
Ps5
- Pews6 Pews4
Pρ3 4
R40 P40
Θ01 1 Pewr6
6 Pr7 Pewr4
- + - +
Pρ1 Θ67 7 Pρ2

Figure 9.19 Thermal network of the coolant flow for the TEFC motor presented in Figure 9.18

Note also that the equivalent circuit representing the inner coolant flow is not a closed
loop but an open loop, because a voltage source between nodes 7 and 4 would short-circuit
the circuit representing the inner coolant flow, and the heat flow would be infinite. If we
write the heat-flow-controlled temperature source between nodes 7 and 4 according to
Rule 2, we find that the source is a linear combination of the temperature sources Θ 45 ,
Θ 56 and Θ 67 . We may use any node of the coolant flow as a starting point; in Figure 9.19,
node 4 has been chosen. The end point is the last node in the coolant cycle before the cycle
closes, node 7.
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Heat Transfer 493

10
Outer surface
of yoke
PFey
R1
R2 R3
Stator 2 1
Pρ1 R2 PCuu Pρ2
PFed
R4
R5 R6
PCuw 3 4 7 PCuw
R8 11
9 End q
End 5 6 winding
winding R15 R14 R12 R10 R9 8 R9 R11 R13 R14 R16 space
space
q

Figure 9.20 Thermal circuit of the stator of an open-circuit cooling machine

9.3.5 Solution of Equivalent Circuit

Let us examine the solution of an equivalent circuit. To decrease the number of equations,
only the stator circuit of Figure 9.9 is considered. The example circuit is presented in
Figure 9.20. There are 11 nodes in the circuit. The line connecting the nodes 9, 10 and 11
indicates the circulation of the cooling air.
The nodal point method known from circuit theory is used in solving the circuit. The circuit
equations written in matrix form are

 
G 1,2 −G 1,2 0 0 0 0 0 0 0 0 0
 
 −G 1,2 G 1,2 + G 2,3 + G 2,10 −G 2,3 0 0 0 0 0 0 −G 2,10 0 
 
 0 −G 2,3 G 2,3 + G 3.4 −G 3.4 0 0 0 0 0 0 0 
 
 
 0 0 −G 3,4 G 3,4 + G 4,7 0 0 −G 4,7 0 0 0 0 
 
 0 0 0 0 G 5,8 + G 5,9 0 0 −G 5,8 −G 5,9 0 0 
 
 
 0 0 0 0 0 G 6,8 + G 6,11 0 −G 6,8 0 0 −G 6,11 
 
 0 0 0 −G 4,7 0 0 G 4,7 + G 7,8 −G 7,8 0 0 0 
 
 
 0 0 0 0 −G 5,8 −G 6,8 −G 7,8 G 5,8 + G 6,8 + G 7,8 0 0 0 
 
 0 0 0 0 −G 5,9 0 0 0 G 5,9 0 0 
 
 
 0 −G 2,10 0 0 0 0 0 0 0 G 2,10 0 
0 0 0 0 0 −G 6,11 0 0 0 0 G 6,11
   
Θ1 PFey
   
 Θ2   0 
   
 Θ   0 
 3   
   
 Θ4   PFed 
   
 Θ5   PCuw 
   

×  Θ6
 
 =  PCuw

.
(9.104)
   
 Θ7   P 
   Cuu 
   
 Θ8   0 
   
 Θ9   −Φ5,9 
   
   
 Θ10   −Φ2,10 
Θ11 −Φ6,11

The conductance G n,m refers to the conductance between nodes n and m. For instance,

1 1
G 1,2 = , G 2,3 = , ....
R3 R2 + R4
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494 Design of Rotating Electrical Machines

On the diagonal of the matrix in (9.104) there is the sum of the conductances, which are
connected to the node under consideration. Everywhere else, there are the conductances be-
tween the nodes with a minus sign. For instance, the three conductances G 1,2 , G 2,3 and G 2,10
are connected to node 2 and their sum G 1,2 + G 2,3 + G 2,10 is on the diagonal. On the same
row, −G 1,2 is in the first column, −G 2,3 in the third column and −G 2,10 in the tenth column.
Between the other nodes, node 2 does not have a connection, and these elements are zero in
the matrix.
Equation (9.104) can be written in short form as

     
P P [0]
[G] · [Θ] = = − , (9.105)
[−Φ e ] [0] [Φ e ]

where
 
PFey
 0 
 
 0 
 
 PFed 

[P] =  , (9.106)

 PCuw 
 PCuw 
 
 PCuu 
0

 
Φ5,9
[Φ e ] =  Φ2,10  . (9.107)
Φ6,11

In Equation (9.105) there are eleven unknown temperature rises and three unknown heat
flows Φ 5,9 , Φ 2,10 and Φ 6,11 or [Φ e ], thus we need three more equations. These are obtained
from the temperature rise of the coolant. According to Equations (9.95), (9.98) and (9.99), the
temperature rises in nodes 9, 10 and 11 are

Θ9 = Rq (Φ5,9 + Pρ1 ), (9.108)

Θ10 = 2Rq (Φ5,9 + P ρ1 ) + Rq Φ2,10 , (9.109)
Θ11 = 2Rq (Φ5,9 + Pρ1 ) + 2Rq Φ2,10 + Rq (Φ6,11 + Pρ2 ), (9.110)

where Pρ1 and Pρ2 are the friction losses in the end winding spaces and Rq the thermal
resistance (9.94). In matrix form

       
Θ9 Rq 0 0 Φ5,9 Rq Pρ1
 Θ10  = 2Rq Rq 0  ·  Φ2,10  +  2Rq Pρ1 , (9.111)
Θ11 2Rq 2Rq Rq Φ6,11 2Rq Pρ1 + Rq Pρ2
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Heat Transfer 495

or in short

[Θ e ] = [Re ] · [Φ e ] + [Θ ρ ]. (9.112)

The unknown heat flows are solved from Equation (9.112)

[Φ e ] = [Re ]−1 · [Θ e ] − [Re ]−1 · [Θ ρ ]. (9.113)

Substituting Equation (9.113) for [Φ e ] in Equation (9.105) we obtain

   
P 0
[G] · [Θ] = −  , (9.114)
0 [Re ]−1 · [Θ e ] − [Re ]−1 · [Θ ρ ]

and further
     
0 0 [P] [0] 
[G] + · [Θ] = + , (9.115)
0 [Re ]−1 [0] [Re ]−1 · Θ ρ

from which the solutions for the temperature rises in 11 nodes are obtained
  −1  
0 0 [P] 
[Θ] = [G] + · . (9.116)
0 [Re ]−1 [Re ]−1 · Θ ρ

9.3.6 Cooling Flow Rate

The required cooling flow rate can be solved from the equation

Ptot = ρcp qΘ, (9.117)

where Ptot is the sum of losses in the machine, ρ the density, cp the specific heat capacity of
the cooling fluid, q the volume flow rate and Θ the permitted temperature rise of the coolant.
The required volume flow rate of the coolant is, according to Equation (9.117),

Ptot
q= . (9.118)
ρc p Θ

For air ρ = 1.146 kg/m3 (35 ◦ C), cp = 1.0 kJ/kg K and

 
Ptot m3
q = 0.865 , (9.119)
Θ s

where Ptot is given in kW and Θ in K. For instance, for Θ ≈ 15 K

 
m3
q = 0.06 · Ptot . (9.120)
s
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496 Design of Rotating Electrical Machines

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SKF (1994) General catalogue from SKF. Catalogue 4000/IV E.
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Appendix A

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
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Table A.1 Magnetic sheets: Typical peak magnetic field strength, A/m at 50 Hz. Reproduced by permission of Surahammars Bruk AB

Peak magnetic field strength A/m at 50 Hz and peak magnetic polarization J/ T of:
Grade EN Thickness
10106 (mm) 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80
M235-35A 0.35 24.7 32.6 38.1 43.1 48.2 53.9 60.7 68.8 79.3 93.7 115 156 260 690 1950 4410 7630 12 000
M250-35A 0.35 26.8 35.7 41.8 47.5 53.4 60.0 67.9 77.5 90.0 107 133 179 284 642 1810 4030 7290 11 700
November 18, 2008

M270-35A 0.35 30.0 39.6 46.0 52.0 58.2 65.2 73.3 83.1 95.5 112 136 178 272 596 1700 3880 7160 11 600
M300-35A 0.35 30.9 40.2 46.4 52.1 57.9 64.4 72.0 81.1 92.6 108 130 168 250 510 1440 3490 6700 11 300
M330-35A 0.35 31.4 41.4 48.2 54.3 60.4 67.1 74.9 84.2 96.3 113 137 179 266 521 1380 3400 6610 11 100
20:41

M700-35A* 0.35 70.2 89.1 98.8 106 113 120 127 135 144 155 169 192 237 342 681 1890 4570 8580

© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6

M250-50A 0.50 30.6 40.7 47.9 54.5 61.3 69.0 77.8 88.6 102 120 145 186 278 584 1600 3680 6890 11 600
M270-50A 0.50 31.5 42.0 49.4 56.1 63.1 70.7 79.5 90.1 103 121 145 185 273 557 1520 3560 6730 11 400
M290-50A 0.50 32.2 42.9 50.3 57.1 63.9 71.4 79.9 89.9 103 119 144 184 271 549 1500 3520 6700 11 400
M310-50A 0.50 33.3 43.9 51.2 57.7 64.2 71.2 79.1 88.4 100 116 139 175 251 470 1230 3070 6150 10 700
M330-50A 0.50 33.2 44.3 52.0 58.9 65.9 73.4 82.0 92.2 105 122 145 183 259 470 1190 3030 6120 10 700
M350-50A 0.50 34.8 46.0 53.7 60.6 67.4 74.6 82.6 91.8 103 119 141 178 250 455 1180 3020 6100 10 700
M400-50A 0.50 40.1 52.5 60.8 68.1 75.2 82.5 90.4 99.3 110 125 146 181 251 443 1110 2900 6020 10 600
M470-50A 0.50 48.8 64.8 74.3 82.4 90.2 98.2 107 117 129 146 170 209 284 475 1100 2850 5980 10 500
Printer Name: Yet to Come

M530-50A 0.50 51.5 68.1 77.6 85.6 93.3 101 110 120 132 147 170 208 282 470 1080 2790 5890 10 400
M600-50A 0.50 65.6 83.8 94.1 103 110 118 127 136 147 159 177 205 255 370 718 1840 4370 8330
M700-50A 0.50 67.8 88.3 99.2 108 116 124 132 142 152 164 180 206 254 363 690 1760 4230 8130

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
(Continued)
Design of Rotating Electrical Machines
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Appendix A

M800-50A 0.50 84.5 107 121 133 145 156 168 180 194 209 228 254 304 402 660 1480 3710 7300
M940-50A 0.50 102 129 146 161 171 181 192 203 217 228 243 267 311 400 645 1440 3590 7090
M530-50HP* 0.50 57.7 74.9 85.2 93.7 102 109 118 127 137 148 164 189 232 326 594 1460 3620 7320
November 18, 2008

M310-65A 0.65 25.8 35.5 42.9 49.7 56.7 63.8 71.7 80.6 91.5 107 130 169 257 545 1490 3540 6800 11 600
M330-65A 0.65 26.5 36.2 43.7 50.6 57.6 64.8 72.7 81.8 93.3 109 133 174 261 530 1410 3350 6500 11 200
M350-65A 0.65 27.3 37.7 45.9 53.1 59.9 66.8 74.2 82.5 90.1 101 121 155 230 441 1210 3020 6040 10 600
20:41

M400-65A 0.65 29.5 40.1 48.4 56.2 64.2 72.6 81.9 93.0 108 127 155 197 278 484 1140 2820 5830 10 300
M470-65A 0.65 31.2 42.0 50.2 57.8 65.5 73.5 82.1 91.6 103 118 140 175 242 426 1060 2700 5670 10 100
M530-65A 0.65 44.0 59.5 69.6 78.2 86.6 95.0 104 113 125 138 159 196 270 454 1040 2630 5620 10 100
M600-65A 0.65 48.8 65.1 75.6 84.9 93.8 103 112 122 133 147 169 205 273 444 991 2550 5540 9980
M700-65A 0.65 57.4 75.8 87.6 98.0 108 118 129 140 153 167 185 211 265 379 688 1630 3920 7760
M800-65A 0.65 74.7 97.5 110 120 130 140 150 162 175 190 208 227 265 366 633 1490 3670 7420
M1000-65A 0.65 83.3 107 119 130 140 150 160 172 185 200 218 237 275 368 604 1360 3370 7010
M600-65HP* 0.65 63.6 82.6 93.9 103 113 122 131 142 153 167 182 202 244 337 587 1360 3370 7010
M600-100A 1.00 29.0 44.1 57.1 70.2 84.1 99.2 116 134 153 176 212 281 401 646 1250 2740 5560 9980
M700-100A 1.00 29.3 44.8 58.4 72.2 87.0 103 121 140 161 185 225 294 412 649 1220 2630 5370 9710
Printer Name: Yet to Come

M800-100A 1.00 49.3 69.2 85.1 101 117 135 154 174 196 221 261 332 450 675 1190 2550 5360 9770
M1000-100A 1.00 56.0 80.8 100 119 139 161 183 208 233 257 291 348 444 576 847 1610 3760 7520
* This grade does not appear in EN 10106.
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Appendix B

Table B.1 Technical data: DAMID, DAMID PE and DASOL according to IEC 60317-0-1.
Reproduced by permission of AB Dahréntråd
Diameter/ Grade 1/mm Grade 2/mm Filling/
mm (conductors/cm2 ) Length/m/kg
Min. Max. outer Min. Max. outer
Rated resin diameter resin diameter Grade 1 Grade 2 Grade 1 Grade 2
0.200 0.014 0.226 0.027 0.239 2251 2012 3354 3247
0.212 0.015 0.240 0.029 0.254 1996 1784 2990 2900
0.224 0.015 0.252 0.029 0.266 1813 1623 2682 2600
0.236 0.017 0.267 0.032 0.283 1615 1434 2419 2354
0.250 0.017 0.281 0.032 0.297 1455 1303 2188 2137
0.265 0.018 0.297 0.033 0.314 1303 1165 1949 1906
0.280 0.018 0.312 0.033 0.329 1180 1060 1750 1713
0.300 0.019 0.334 0.035 0.352 1059 927 1524 1493
0.315 0.019 0.349 0.035 0.367 943 852 1385 1358
0.335 0.020 0.372 0.038 0.391 830 752 1224 1200
0.355 0.020 0.392 0.038 0.411 748 679 1093 1072
0.375 0.021 0.414 0.040 0.434 669 608 979 961
0.400 0.021 0.439 0.040 0.459 594 544 862 846
0.425 0.022 0.466 0.042 0.488 528 481 765 748
0.450 0.022 0.491 0.042 0.513 477 434 683 670
0.475 0.024 0.519 0.045 0.541 426 391 613 602
0.500 0.024 0.544 0.045 0.566 387 357 553 544
0.530 0.025 0.576 0.047 0.600 346 318 493 484
0.560 0.025 0.606 0.047 0.630 312 289 442 435
0.600 0.027 0.649 0.050 0.674 271 252 385 379
0.630 0.027 0.679 0.050 0.704 247 230 350 345
0.650 0.028 0.702 0.053 0.729 232 215 328 324
0.670 0.028 0.722 0.053 0.749 219 204 309 305
0.710 0.028 0.762 0.053 0.789 197 183 276 273
(Continued)

Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
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502 Design of Rotating Electrical Machines

Table B.1 (Continued)

Diameter/ Grade 1/mm Grade 2/mm Filling/
mm (conductors/cm2 ) Length/m/kg
Min. Max. outer Min. Max. outer
Rated resin diameter resin diameter Grade 1 Grade 2 Grade 1 Grade 2
0.750 0.030 0.805 0.056 0.834 176 164 247 244
0.800 0.030 0.855 0.065 0.884 155 146 218 215
0.850 0.032 0.909 0.060 0.939 137 128 193 191
0.900 0.032 0.959 0.060 0.989 124 116 172 170
0.950 0.034 1012 0.063 1044 110 104 154 153
1000 0.034 1062 0.063 1094 100 95 140 138
1060 0.034 1124 0.065 1157 89 84 124 123
1120 0.034 1184 0.065 1217 80 76 111 110
1180 0.035 1246 0.067 1279 73 69 100 100
1250 0.035 1316 0.067 1349 65 62 90 89
1320 0.036 1388 0.069 1422 59 56 80 80
1400 0.036 1468 0.069 1502 52 50 72 71
1500 0.038 1570 0.071 1606 45 43 62 62
1600 0.038 1670 0.071 1706 40 38 54
1700 0.039 1772 0.073 1809 36 34 48
1800 0.039 1872 0.073 1909 32 30 43
1900 0.040 1974 0.075 2012 29 27 39
2000 0.040 2074 0.075 2112 26 25 35
2120 0.041 2196 0.077 2235 23 22 31
2240 0.041 2316 0.077 2355 20 19 28
2360 0.042 2438 0.079 2478 19 18 25
2500 0.042 2578 0.079 2618 16 16 22
2650 0.043 2730 0.081 2772 15 14 20
2800 0.043 2880 0.081 2922 13 13 18
3000 0.045 3083 0.084 3126 11 11 16
3150 0.045 3233 0.084 3276 10 10 14
3350 0.046 3435 0.086 3479 9 9 13
3550 0.046 3635 0.086 3679 8 8 11.2
3750 0.047 3838 0.089 3883 t 7 10.0
4000 0.047 4088 0.089 4133 6 6 8.8
4250 0.049 4341 0.092 4387 5 5 7.8
4500 0.049 4591 0.092 4637 5 5 7.0
4750 0.050 4843 0.094 4891 4 4 6.3
5000 0.050 5093 0.094 5141 4 4 5.7
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Index
Absolute overlap ratio, 420 Armature reaction, 47, 145, 153, 166, 298,
Absorptivity, 466, 468 303, 358, 371, 409. See also armature
AC-to-DC rectification, 404 current linkage
Admittance, 389 Armature yoke, 15
Ageing Arrhenius equation, 443
electrical, 444 Asynchronous generator, 352
thermal, 443 Asynchronous machine, 170, 177, 283, 358
Ageing of insulation, 442 Auinger, H., 351
Aho, T., 147
Air gap, 15, 159, 164, 297, 430 Balancing connector, 140. See also equalizer
length bar
equivalent air-gap, 476 Barkhausen jump, 185. See also magnetic
length, 474, 476 material
effective air-gap, 169 Barkhausen noise, 185. See also magnetic
Air-gap diameter, 301 material
Air-gap flux, 16, 225 Base value, 40
Air-gap flux density, 91, 282 Becker, K. M., 474
Air-gap flux distribution, 145 BH curve, 16, 159, 175, 186
Air-gap flux linkage, 360 Black body, 467
Air-cooled machine, 295 Bloch wall, 183
AlNiCo magnet, 200, 201. See also Boundary layer, 470
permanent magnet concentration, 470
Amide-imide, 435 thermal, 470, 472
Amorphousity, 435 velocity, 470, 472
Ampère’s law, 3, 5, 58, 153, 156, Braided conductor, 151
205, 256, 366, 367 Breakdown strength, 444
Anisotropic, 6, 190, 202 Breakdown voltage, 429, 440
Anisotropy, 204 Breakthrough field strength, 440
Aplac (circuit analysis), 488 Brush, 48, 128, 137, 394, 404, 409, 459
Apparent power, 281, 285, Brush rocker, 412
418 Brushless synchronous generator, 396
Aramid fibre, 434
Aramid paper, 431 Capacitance, 357
Arkkio’s method, 34 electric, 477
Armature current, 287, 308, 404 of insulation, 443
Design of Rotating Electrical Machines Juha Pyrhönen, Tapani Jokinen and Valéria Hrabovcová
© 2008 John Wiley & Sons, Ltd. ISBN: 978-0-470-69516-6

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504 Index

Capacitive load, 373 Corona protection, 447

Capacitor, 370, 451 Couette Reynolds number, 461
Carter factor, 160, 369 Coulomb’s condition, 9
Carter, F.W., 160 Coulomb’s Virtual Work method, 32
Characteristic length of surface, 471 Counterrotating field, 362, 386, 387
Circulating current, 261 Creepage current, 430, 432, 444
Clearance in air, 429 Creepage distance, 430, 444, 449
Coenergy, 29, 31, 416 Critical angular speed, 296
Coercive force, 5, 202 Critical conductor height, 266
Coercivity, 187, 189, 200 Cross-linking agent, 436
Coil, 50, 370, 382 Crystallinity, 435
Coil group, 50, 109 Curie temperature, 204
Coil span, 54, 73, 229, 247, 405 Current density, 1, 256, 271, 293, 308, 412,
average, 256 465
Coil turn, 306 armature linear, 145
Commutating pole, 146, 283, 405, 446 linear, 316, 388
Commutation, 411, 413 linear, 23, 143, 293, 326
Commutation period, 411 Current linkage, 5, 153, 158, 180, 209
Commutator, 394, 404, 405 armature, 47, 145, 409
Commutator machine, 47, 122, 127, 193 asynchronous machine, 315
Comparative Tracking Index (CTI), 430 cage winding, 320
Condition monitoring, 449 commutator armature, 144
Conductance commutator winding, 142
electric, 476 cosinusoidal distribution, 52
thermal, 476, 479 direct component, 144
Conduction, 462, 463 harmonic stator, 366
Conductivity, 6, 255, 429 pole winding, 312
electric, 465 quadrature component, 144
thermal, 463, 471, 477, 480 rotor bar, 325
Conductor height, 258, 262 salient-pole winding, 51
critical, 265 sinusoidal, 301
reduced, 259, 264 slot winding, 81
Conductor transposition, 266 stator, 360
Conservation of charge, 2 symmetrical three-phase, 359
Contact heat transfer coefficient, 475 three-phase winding, 58
Continuous running duty, 346 Current linkage harmonic, 315
Continuous-operation periodic duty, 347 Current ripple, 425
with electric braking, 348
with related load/speed changes, 348 Dacron
R
, 431
Convection, 462, 470 Damper bar, 362
heat transfer coefficient, 471 Damping, 361
Coolant, 487 Davidson, R., 414
flow rate, 495 DC link, 426
Cooling, 189, 282, 462 DC machine, 15, 156, 283
open-circuit, 492 Demagnetization curve, 207
Cooling flow rate, 495 Density, 464
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Index 505

Depth of penetration, 258 Equivalent circuit, 363

Dielectric loss, 450 of a three-phase asynchronous motor, 335
Dielectric loss factor, 450 of a conductor, 274
Dielectric strength, 429, 432, 440 of a slot, 275
Diolen
R
, 431 of a synchronous machine, 363
Dip and bake method, 447 of an asynchronous machine, 327
Direct-on-line (DOL), 400 of an end winding, 486
Dirichlet’s boundary condition, 11, 12, 21 of an insulation construction, 451
Displacement current, 5 of capacitor motor main and auxiliary
Dissipation power, 47, 194, 312 windings, 356
Distribution factor, 66, 90 of transients, 364
Double-salient reluctance machine, 50, 157, thermal, 476
291, 413, 414 Ester-imide, 435
Double-salient reluctance motor, 420 Euler’s number, 326. See also Napier’s
Drain, 6 constant
Duty cycle, 281, 347 Excitation, 394
Duty type, 346 brushless, 395

Eddy current, 3, 10, 147, 187, 275, Fanning friction coefficient, 472
362 Faraday’s induction law, 3, 63, 168, 230,
Effective torque zone, 420 257, 303. See also induction law
Efficiency, 307, 312, 343, 421, 427 FEP fluoropolymer, 436
of totally enclosed four-pole induction Ferraris rotor, 147
motors, 352 Ferrite magnet, 201. See also permanent
Efficiency class, 352 magnet
Electric capacitance, 477 Ferromagnetic metal, 187
Electric charge, 10, 477 Fibre insulator, 454
Electric charge density, 1 Field
Electric field density, 438 electric, 1, 3, 429
Electrical stress, 440 magnetic, 1, 47, 226
Electromotive force (emf), 16, 43, 63, 153, Field diagram, 24, 161, 165
250, 285, 302, 322, 377 orthogonal, 18, 19, 20, 21, 164, 171, 427
stator, 376 Field Effect Transistor (FET), 423
Emissivity, 468 Field strength, 309, 310, 311, 366
relative, 467 air-gap, 317
EN 10106, standard, 192 effective, 441
Enclosure class, 281, 343, 346 electric, 1, 10, 432, 438
Energy conversion, 225 magnetic, 1, 3, 153, 256, 286
Energy conversion loop, 418 tangential, 367
Energy conversion ratio, 419 Field winding current, 370, 394
Energy density, 28, 185 Finite Element Analysis (FEA), 365
Energy product, 202, 204, 205 Flange mounting, 343
Epoxy resin, 437, 448 Fluoropolymer, 436
Equalizer bar, 140. See also balancing Flux
connector electric, 3
Equivalent air-gap length, 476 magnetic, 3, 154, 421
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506 Index

Flux barrier, 401 diffusion, 457

Flux density, 15, 163, 283, 294 flow, 483
air-gap, 302 flow density, 467, 472, 476
air-gap magnetic, 51 flow rate, 463
apparent, 174 heat-flow-controlled temperature source,
electric, 1, 6 488, 490, 491
magnetic, 1, 153, 159, 165, 275, 318, 360 quantity of heat, 476
remanence, 187 specific heat capacity, 471, 477
saturation, 187 transfer, 457
Flux density distribution, 63 transfer area, 463
sinusoidal, 301 transfer coefficient, 468, 472, 474
Flux diagram, 18, 158 transfer properties, 464
Flux guide, 401 Heck, C., 189
Flux leakage, 225, 361 Heikkilä, T., 399
air-gap, 229, 230 Heller, B., 163
Flux linkage, 4, 168 Hot pre-wedging, 448
air-gap, 169, 225, 285, 303 Hot-spot allowance, 442
Flux tube, 17 Huppunen, J., 147
Fourier’s law, 463 Hysteresis loop, 189
Friction coefficient, 472
Fundamental component IC class, 346
of stator current linkage, 367 IEC 600112, 430
Fundamental harmonic IEC 60034, 441
of linear current density, 316 IEC 60034-1, 315, 432
Fundamental wave, 315 IEC 60034-4, 383
IEC 60034-5, 346
Galvanic contact, 431 IEC 60034-6, 346
Gardiner, S., 474 IEC 60034-7, 343
Gauss’s law, 3, 7 IEC 60034-8, 343
Generator IEC 60050-411, 47
asynchronous machine, 351 IEC 60085, 432
Generator logic, 43, 376, 382 IEC code, 344
Geometrical factor, 474 Impedance, 366
Gliding discharge voltage limit, 444 AC, 271, 272
Goss texture, 191 cage winding, 320
characteristic, 453
Haataja, J., 352 measuring, 451
Haefely Trench Tettex partial discharge negative-sequence, 353
measurement unit, 452 phase, 321, 322
Hamata, V., 163 positive-sequence, 353
Hard chopping, 425 rated, 40
Harmonic factor, 389, 390 rotor, 320, 368
Heat synchronous, 385
capacity, 477 Impregnating resin, 431, 439
contact heat transfer coefficient, 475 Impregnating varnish, 431, 436, 437
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Index 507

Impulse voltage, 442 Insulation coordination, 430

Inception voltage, 440 Insulation distance, 429
Indifference point, 24 Insulation resistance, 449
Inductance, 4, 168, 278. See also leakage Insulator, 429
inductance Intermittent periodic duty, 347
air-gap, 230 with electric braking, 347
direct-axis subtransient, 365 with starting, 347
direct-axis synchronous, 360, 397 IP class, 462
direct-axis transient, 364 Isotropic, 6, 202
leakage, 216, 227, 359
magnetizing, 154, 221, 252, 285, 387 Kapton polyimide, 435
mutual, 36, 217, 226 Kapton
R
, 431
phase, 321 Kaye, J., 474
qudrature-axis subtransient, 365 Key fitting, 220
saturating reluctance machine, 417 Key-closed slot, 446
self-inductance, 36, 216, 226 Kirchhoff’s 1st law, 321
skew, 252 Küpfmüller, K., 259
stator, 359 Kurronen, P., 399
stator magnetizing, 336
subtransient, 362 Law of energy conversion, 26
synchronous, 361 Lawrenson, P.J., 291
transient, 225, 363 Leakage factor, 207, 232, 233, 389, 390
winding, 226 Leakage flux, 225, 227, 256
Inductance ratio, 400, 402 end winding, 227
Induction law, 3. See also Faraday’s pole, 227
induction law slot, 225, 227
Induction motor, 15, 288, 302 tooth tip, 227
Inductive load, 373 Leakage inductance, 267, 322, 349. See also
Insulated-Gate Bipolar (IGB) transistor, inductance
423 air-gap, 230
Insulating film, 432 end winding, 230, 246
Insulating foil, 433 skew, 230
Insulating material, 429 slot, 230, 234, 247
Insulating resin, 429 tooth tip, 230, 245
Insulating strength, 429 Lenz’s law, 276
Insulating varnish, 439 Levi, E., 249
Insulation, 429, 457 Lindström-Dahlander connection,
conductor, 431, 435 126
groundwall, 431 Linear polymer, 436
lifetime, 458 Liner
phase coil, 434 slot insulation, 445
phase-to-phase, 431 Lipo, T. A., 259, 460
pole winding, 431 Litz wire, 266
slot, 431, 434 Load angle, 402, 403
Insulation capacity, 449 Load angle equation, 375
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508 Index

Loadability, 426 Maxwell

electrical, 293 displacement current, 5
magnetic, 294 equation, 1, 2
mechanical, 291 stress tensor, 33
Lorentz force, 1, 320, 405, 441 Maxwell, J. C., 5
Lorentz force equation, 318 Mechanical strength
Lorentz law, 68 insulation, 431
Loss Mechanical stress, 291, 440
additional, 458, 460 Mica, 429, 431
bearing, 460, 462 Mica insulator, 433
copper, 458 Mica paper, 432
dielectric, 430, 432, 449, 451 Mica tape, 448
eddy current, 193, 197, 261, 297 Miller, T. J. E., 472
electromagnetic, 460 Monomer, 436
end winding, 426 Moody diagram, 472
friction, 313, 327, 328, 346, 461, 476, 488 Moody friction factor, 472
hysteresis, 193, 194, 423 Moody, L. F., 472
iron, 192, 294, 307, 311, 327, 401, 458, Morgan, J. D., 355
476 Motor logic, 43, 376, 379
mechanical, 458, 460 Motor supply cable, 453
resistive, 255, 293, 308, 313, 327, 343, Mylar polyester, 434
354, 458, 476, 479, 486 Mylar
R
, 431
surface, 199
ventilator, 462 Napier’s constant, 326. See also Euler’s
windage, 313, 328, 461, 462, 476 number
Loss angle, 451 NdFeB magnet, 399. See also permanent
magnet
Magnetic circuit, 153, 226, 283, 312, 327, Neodymium iron boron magnet, 397. See
358, 375, 404, 430 also NdFeB magnet, permanent
Magnetic energy, 185, 194, 235 magnet
Magnetic equipotential surface, 18 Neodymium magnet, 202. See also
Magnetic force, 28 permanent magnet
Magnetic material, 183 Nerg, J., 33
Magnetic potential difference, 154, 305 Neumann’s boundary condition, 11, 12
Magnetic voltage, 156, 250, 309, 311 Newton’s law of cooling, 472
Magnetizing, 312 Niemelä, M., 349
Magnetizing current method, 34 No-load curve, 384
Magnetizing inductance, 349 Nomex
R
, 434
direct, 359 Nonsalient pole machine, 15, 169, 358, 362
quadrature, 359 Nonsalient pole synchronous machine, 159,
Magnetomotive force (mmf), 159 283, 308
Main dimension, 282, 302 Normal system, 97
Mass density of fluid, 474 Nusselt number, 471, 474
Mass flow rate, 472
Mass transfer coefficient, 471 Ohm’s law, 255
Matsch, L. D., 355 Open-circuit cooling, 488, 492
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Index 509

Overexcitation, 370 Poisson’s ratio, 291

Overhang, 445 Polarization, 10
Polarization curve, 207
Partial discharge, 429, 443, 447, 450 Pole body, 15, 50, 164, 177
Partial discharge measurement, 451, 452 Pole shoe, 15, 165, 199, 362, 380, 388, 404
Partial discharge strength, 431 Pole-Amplitude-Modulation (PAM), 127
Paschen curve, 429, 430 Polyamide-imide, 435
Paschen law, 429 Polyester film, 431, 434
Per unit value, 40 Polyester resin, 431, 437
Permanent magnet, 153, 183, 200, 285, Polyether-etherketone (PEEK), 436
312, 358 Polyethyleneterephthalate (PETP), 434
Permanent magnet excitation, 395 Polyimide film, 431, 434
Permanent magnet machine, 154, 395, 397 Poly-phase induction machine, 155
Permanent magnet synchronous generator, Position sensorless control, 425
302 Power balance
Permanent magnet synchronous machine, of an induction motor, 458
303 Power factor, 281, 283, 287, 302, 307, 350,
Permanent magnet synchronous machine 402
(PMSM), 358 of totally enclosed induction motors, 351
Permeability, 6, 191, 235, 256 synchronous reluctance machine, 403
Permeance, 4, 18, 161, 166 Poynting’s vector, 369
magnetic, 38, 235 Prandtl number, 471
magnetic circuit, 336 Protective paint, 431
mutual, 37 PTFE fluoropolymer, 436
Permeance factor, 235, 369, 392 Pull-out torque, 348
slot, 237, 238
Permeance harmonics, 193 Radial flux electrical machine, 473
Permittivity, 6, 429 Radiation, 462, 466
Phase voltage, 360 electromagnetic, 466
Phasor diagram, 372 heat transfer coefficient, 469
current, 321 Rao, K., 474
of a nonsalient pole synchronous Rated output power, 313
generator, 378 Reactance, 41, 226
of a nonsalient pole synchronous motor, magnetizing, 42, 353, 361
380 RECo magnet, 202. See also permanent
of a steady-state short-circuit nonsalient magnet
pole generator, 385 Reduced contactor height, 258
of a steady-state, salient-pole generator, Reduced system, 97
374 Reflection factor, 454
of a synchronous generator, 378 Reflectivity, 466
of a synchronous reluctance machine, 402 Relative value, 41
of currents in a conductor, 271 Reluctance, 4, 154, 304
of subconductor currents, 279 Reluctivity, 11
Phasor diagram of a capacitor Remanence, 352
of a capacitor motor, 357 Remanence flux density, 154
Pitch factor, 66, 90, 322 Resin Rich (RR) method, 448
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510 Index

Resistance, 25, 255, 321, 322 Short-circuit ring, 220, 249, 322, 323, 358,
AC, 259, 458 362, 461
DC, 259, 333, 460 Short pitching, 73
DC, field winding, 365 Silicone resin, 431
electric, 476 Skewing, 220, 228, 339, 362
junction thermal resistance, 475 Skewing factor, 66, 250, 322
phase, 323 Skin effect, 3, 151, 225, 256, 266, 267, 271,
thermal, 477 334
thermal resistance of convection, 472 stator winding, 287
thermal resistance of radiation, 468 Skin effect factor, 458
winding, 458 Slip, 147, 193, 243, 322, 328, 386
Resistance factor, 259, 260, 264 fundamental, 368
Resistivity, 188, 197, 269, 464 Slip ring, 48, 147, 394
Reynolds number, 471 Slip-ring machine, 329
critical, 471 Slot, 237, 334, 404, 479
tip, 462 Slot angle, 53, 250
Richter, R., 199, 237, 238, 259, 370 Slot closer, 431
RMS value, 283, 285, 303 Slot filling, 448
Roebel bar, 151, 266, 267 Slot key, 445
Rotating-field machine, 182 Slot number
Rotor bar, 334 cage winding, 340
Rotor field winding current, 358 Slot pitch, 53, 158, 252, 285, 302, 377
Rotor stack, 475 rotor, 362
Rotor teeth, 181, 304 stator, 340
Rotor yoke, 15, 154, 177, 181, 283, 311 Slot separator, 445
Solid rotor, 295, 298
Saari, J., 461 Solid-rotor construction, 366
Saber (circuit analysis), 488 Solution of a thermal equivalent circuit,
Sabersky, R., 474 493
Saliency, 154, 387 nodal point method, 493
Salient-pole machine, 14, 358, 362 Solvent, 436
Salient-pole synchronous machine, 156, Source, 6
283, 359 Source current, 10
Salminen, P., 399 Space factor, 308
Sankey diagram, 459 Sparking, 444
Sastri, V., 474 Specific heat capacity, 464
Saturation, 147, 179, 238, 304, 416, Spice (circuit analysis), 488
427 Squirrel cage induction motor, 323,
Saturation factor, 305 475
Saturation magnetization, 185 Squirrel cage rotor, 48
Saturation polarization, 185 Stack, 219. See also stator stack
Schering bridge, 451 Stamping, 348
Schuisky, W., 387, 389, 462 Stator slot, 158, 164, 282, 447
Shaded-pole motor, 358 Stator slot insulation, 445
Shearing stress, 441 Stator stack, 250, 256, 282, 447, 475
Short-time duty, 347 Stator teeth, 181, 309
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Index 511

Stator yoke, 154, 177, 181, 283, 309, 311, Temperature rise allowance, 442
489 Tensile strength, 440
Stefan-Boltzmann constant, 467 Terminal voltage, 330, 352, 377
Stefan-Boltzmann equation, 467 fundamental, 303
Stoke’s theorem, 12 stator, 376
Stoll, R., 259 Terylene
R
, 431
Stress tensor, 33 Thermal class, 442, 458
Stroke angle, 420 Thermal conductivity, 463
Subconductor, 259, 260, 261 Thermal equilibrium, 348
Surahammars Bruk, 192, 195 Thermal equivalent circuit
Surge (impulse) wave, 453 of a winding, 479
Surge comparison testing, 449 of an electrical machine, 479
Switched reluctance (SR) machine, 15 solution of, 493
Switched reluctance machine (SR machine), Thermal network, 488
414, 415 of coolant flow, 490
Switching overvoltage, 441 Thermal resistance, 282, 293, 431, 434, 442,
Symmetry condition, 99 443, 465
Synchronous inductance of convection, 472
direct-axis, 363. See also Inductance of junction, 475
quadrature-axis, 363. See also of radiation, 468
Inductance per unit length, 477
Synchronous machine, 15, 358 Thermal stress, 440, 443
permanent magnet, 358 Thermoplastic, 431, 435
separately excited, 358 Time constant, 365
Synchronous reluctance machine, 154, Time-harmonic field strength vector
155 amplitude, 367
Synchronous reluctance machine (SyRM), Tooth, 15, 173, 283
358, 400 Torque, 1, 30, 34, 50, 157, 284, 301, 312,
319, 476
Tangential stress, 23, 33, 283, 284, 301. asynchronous, 387
See also Maxwell braking, 399
tanδ curve, 450 cogging, 399
tanδ measurement, 442, 449, 451 drag, 461
tanδ measurement circuit, 451 electromagnetic, 329, 416
tanδ value, 450 pull-out, 330, 399, 402
Taylor number, 474 reluctance, 361, 376
modified, 474 SR machine, 415
Taylor vortex flow, 474. See also starting, 147, 331, 386, 388, 391
Taylor-Couette flow synchronous, 338
Taylor-Couette flow, 474 Torque coefficient, 461
Teeth, 128, 486 Torque production, 34, 147, 156, 171, 284,
Teflon, 436 303, 402. See also torque.
Temperature gradient, 463 asynchronous machine, 315
Temperature index, 442 Torque ripple, 425
Temperature rise, 291, 312, 320, 347, 442, Totally enclosed fan-cooled induction motor
457, 481 (TEFC), 491
XYZ PQR
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512 Index

Track resistance, 430, 438 Dahlander, 127

Transmissivity, 466 damper, 150, 362, 366, 386
Trickle Impregnation, 447 diamond, 54, 71, 73, 92. See also lap
winding
Underexcitation, 370 double-layer, 98, 137, 239
double-layer fractional slot, 106
V curve, 394 drum armature, 137
Vacuum Pressure Impregnation (VPI), 440, end, 228, 264, 486
447 excitation, 312
Varnish field, 14, 47, 153, 396, 404, 405, 446
alkyd-based, 437 fractional slot, 55, 72, 92, 93, 182, 393
oil-based, 436 frog-leg, 138
polyester, 437 full-pitch, 66, 73, 74, 228, 338, 405
polyester-based, 437 integral slot, 55, 72, 93, 182
surface, 438 integral slot stator, 340
Ventilating duct, 171, 172 lap, 129, 131, 132, 136. See also diamond
Virtual work, 25, 159 winding
Viscosity magnetizing, 15, 23, 47, 153, 170, 308,
dynamic, 461, 471 343
kinematic, 471 phase, 48, 54, 285, 303, 306, 360
Vogt, K., 259 pole, 446
Voltage phasor diagram, 63, 80 poly-phase, 84, 154, 301
Voltage strength, 430, 431, 444, 449 poly-phase slot, 54
rotating-field, 47
Weibull exponential distribution, 444 rotor, 248
Weiss domain, 183 salient-pole, 48
White body, 467 short-pitch. See also chorded winding
Wiart, A., 296 short-pitched double-layer, 338
winding shunt, 404
random-wound, 446 single-layer, 98
Winding single-layer fractional slot, 106
armature, 47, 127, 153, 273, 302, 309, single-layer stator, 71
362, 396, 404, 405 slot, 48, 179, 228, 255, 301, 308, 366
base, 102, 182 stator, 154, 232, 248, 353, 360, 366, 421,
cage, 148, 232, 308, 309, 321, 362, 369, 486
386 two-plane, 53
cage, asymmetric, 388 wave, 137. See also commutator winding
chorded. See also short-pitch winding Winding current, 10, 226
coil, 228 Winding factor, 4, 63, 77, 301, 302, 389
commutating, 47 distribution, 61
commutating pole, 404, 410 of a salient-pole field winding, 366
commutator, 48, 122, 128, 129 Wound rotor, 48
compensating, 47, 145, 405, 409, 410
concentrated, 446 Yoke, 404
concentrated pole, 14
concentric, 54, 92 Zones of windings, 98