Design of Wound

Rotor
Definition of Wound
Rotor..

 A type of three phase rotor that contains

windings and slip rings.

 This motor type permits control of rotor current

by connecting external resistance in series
with the rotor windings.
Terms used in Wound
Rotor
 Slip..
The difference between a motor's synchronous
speed and its speed at full load.

 Percent slip is a way to measure the speed

performance of an induction motor.

 Slip rings..
A conductive device attached to the end of a wound
rotor that conducts current to the brushes.
 Brush..
A device found inside a generator that is used
only in pairs to transfer power from a rotating
object.

 Brushes rest on the commutator of a DC motor.

 Ball bearing..
A friction-reducing device that allows one
moving part to glide past or rotate within
another moving part.
Design of wound
rotor
 Basic Requirements.
1.Variable speed
2.High Starting
torque

 Rotor consists of three phase winding to form

same no. of poles in stator .

 Rotor winding is connected in star and open

ends are connected to 3 slip rings mounted in
rotor shaft.
Schematic
diagram
Rotor winding are shorted through carbon brushes
riding on slip rings.

The existence of series resistances enable user

to modify speed characteristics of motor. They
are adjusted to control torque and starting
speed.
Rotor Resistance Effect on Torque &
Speed
 Placing resistance in series with the rotor windings
not only decreases start current, but also increases
the starting torque.

By increasing the rotor resistance from R0to R1to

R2, the breakdown torque peak is shifted left to
zero speed.
3 phase
winding
 If rotor resistance is increased the slip will
increase and hence speed regulation will be
poorer and also low efficiency.

 Speed of wound rotor motor can be controlled

from 50- 100% of rated speed by changing the
resistance
 Torque peak is much higher than the starting
torque available with no rotor resistance (R0).

 Slip is proportional to rotor resistance, and pullout

torque is proportional to slip. Thus, high torque is
produced while starting.
Properties of Wound
Rotor
 Constant speed-service requiring a heavy
starting torque than with a squirrel cage
rotor.

 Low starting current.

 Insertion of high external resistance alters the

starting torque to higher value
 The running efficiency could be achieved by
cutting out external resistance ,when motor
picks its speed.

 High staring torque and variable speed

control
 Advantages of Wound Rotor
induction motors
 The main advantage of a slip ring induction
motor is that its speed can be controlled
easily.

 It has a high starting torque when compared to

squirrel cage induction motor. Approximately 200
– 250 % of its full-load torque.

 A squirrel cage induction motor takes 600 % to

700 % of the full load current, but a slip ring
induction motor takes a very low starting current
approximately 250 % to 350 % of the full load
 Disadvantages of wound Rotor
Induction Motor
 Initial and maintenance cost is more compared to
squirrel cage motor because presence of slip rings,
brushes, short circuiting devices etc.

 Speed regulation is poor when operated with

external resistances in rotor circuit.

 Efficiency and power factor of slip ring motor is

lower compared to squirrel cage induction motor.

 Sensitivity to fluctuations in supply voltage

Other
applications
 Ball Mills
 Shredders
 Cement Mills
 Pumps - get varied
speed
The resistance in the rotor circuit is there to increase
the slip between the rotor magnetic field and the
rotating magnetic field on the stator without increasing
the stator current , so providing a fairly primitive
variable speed drive from a fixed frequency AC current.
The motors are noted for their ruggedness compared
to equivalent DC drives, which were the only
alternative for variable speed prior to the advent of the
electronic variable frequency drives which only became
available for regular industrial applications ( at high
p r i c e s ) i n t h e 1 9 8 0 ’ s .
 Design of wound
These are the typesRotor
of induction motors where in rotor
also carries distributed star connected 3 phase winding.
At one end of the rotor there are three slip rings
mounted on the shaft. Three ends of the winding are
connected to the slip rings. External resistances can be
connected to these slip rings at starting, which will be
inserted in series with the windings which will help in
increasing the torque at starting. Such type of induction
motors are employed where high starting torque is
required.
Number of rotor slots: The number of rotor slots
should never be equal to number of stator slots.
Generally for wound rotor motors a suitable value is
assumed for number of rotor slots per pole per phase,
and then total number of rotor slots are calculated. So
selected number of slots should be such that tooth
width must satisfy the flux density limitation. Semi-
Number of rotor Turns: The voltage between the slip
rings on open circuit must be limited to safety values. In
general the voltage between the slip rings for low and
medium voltage machines must be limited to 400 volts.
For motors with higher voltage ratings and large size
motors this voltage must be limited to 1000 volts. Based
on the assumed voltage between the slip rings
comparing the induced voltage ratio in stator and rotor,
the number of turns on rotor winding can be calculated.
Voltage ratio Er/ Es = (Kwr x Tr) / (Kws x Ts )
Hence rotor turns per phase Tr = (Er/Es)
(Kws/Kwr)Ts Er = open circuit rotor
voltage/phase
Es = stator voltage /phase
Kws = winding factor for stator
Kwr = winding factor for rotor
Rotor Current and conductor
section Assuming rotor mmf =
0.85* stator mmf 2x3xIr.Tr =
(0.85) 2x3xIs.Ts
Rotor current per phase Ir =
(0.85) Is.Ts/T Rotor conductor
area Ar = Ir/δr
The current density could be taken as 3
to 5 A/mm2
Types of Rotor
Windings
 Types of Rotor
Windings
For small induction motors of slip ring type ,mush
windings are used for rotor housed in semi –enclosed
slots. The coils are roughly formed outside the machine
and dropped into the slots through slot opening one by
one .

For large motors , a double layer bar type wave

winding is used .The winding has two bars per slot. The
bars are pushed through partially closed slots and are
bent to shape at the other end. The use of 4 bars per
slot is made to reduce the current handled by each slip
ring. The windings with more than 2 bars per slot is
called a barrel winding and is wave wound.
A type of winding used for ac
motors and generators in which
the conductors are placed one
by one into partially closed and
lined slots, the end connections
being subsequently insulated
separately,

Each coil is wound on a former,

making one coil side shorter
than the other.

It will be also observed that the

ends of coil situated in adjacent
slots cross each other. proceed
to left and right alternatively.

That is why sometimes it is

 Double Layer
Windings
In this type of winding, there are two conductors or
coil sides per slot arranged in two layers. Usually,
one side of every coil lies in the upper half of one slot
and other side lies in the lower half of some other
slot at a distance of approximately one pitch away .
The transfer of the coil from one slot to another is
usually made in a radial plane by means of a peculiar
bend or twist at the back end. Such windings in
which two coil sides occupy each slot are most
commonly used for all medium-sized machines.
 Rotor
Teeth
The width of rotor slot should be such that the flux
density in the rotor teeth does not exceed about 1.7
m2. The maximum flux density for rotor teeth at their
root as their section is minimum there.

Minimum width of rotor teeth Wtr ( min.) =

φm / 1.7 * ( Sr/p) * Li
Wtr = rotor slot pitch at the root – rotor slot width =
Π ( Dr- 2 dsr )/Sr – Wsr

Where, dsr = depth of rotor slot

Wsr = width of rotor slot
Sr = no. of rotor slots
 Rotor Core
The flux density in the rotor core is equal to stator
core density .
i.e. 1.2 –f 1.4 wb/m2
Depth of rotor d cr = m

core 2 ´ B cr ´ L i
Bcr = flux density in rotor
core
Inside diameter of rotor
lamination
D i = D r - 2 ( d sr + d cr )
Dr= rotor outer
diameter
dsr = depth of rotor slot
 Estimation of operating Characteristics

No load current: The noload current of

an induction motor has two
components magnetizing component, Im and iron loss
component, Iw.
Thus the no load current I0 = √(Im)2 + (Iw)2 amps

Magnetising current: Magnetising current of an induction

motor is responsible for producing the required amount of
flux in the different parts of the machine. Hence this
current can be calculated from all the magnetic circuit of
the machine. The ampere turns for all the magnetic circuit
such as stator core, stator teeth, air gap, rotor core and
rotor teeth gives the total ampere turns required for the
magnetic circuit. The calculation of magnetizing ampere
turn be based upon the value of flux density at 60 deg.
from the inter polar axis . Based on the total ampere turns
(i) Mmf for air gap can be calculated as ,

ATg=800,000 Bg60. Kg. lg

(ii) Mmf for stator teeth – The flux density is

uniform in the teeth when they are parallel sided
but when parallel sided slots are used ,the flux
density along the length of teeth is not uniform.
The value of mmf for teeth is found out by
finding flux density at the section 1/3 height of
tooth from narrow end. fm
B =
ts 1 / 3
( S s / p ) ´ W ts 1 / 3 ´ Li
Mmf required for stator teeth ATts =
atts x dss
(iii) Mmf for rotor teeth – Flux density in rotor teeth
at 1/3 height from narrow end
fm
B ts 1 / 3 =
( S r / p ) ´ W tr 1 / 3 ´ Li
Mmf required for stator teeth ATtr = Attr x dsr

(iv) Mmf for stator core – Corresponding to flux

density in the core ,the mmf per metre atcs can be
found .The length of path through the core can be
taken as 1/3 pole pitch at the mean core diameter.
Length of path throughP (stator
D + 2core
d +d )
l cs = ss cs
3p
Mmf for stator core = atcs x lcs
(V) Mmf for stator core – Corresponding to flux
density in the core ,the mmf per metre atcr can be
found .The length of path through the core can be
taken as 1/3 pole pitch at the mean core diameter.
Length of path through stator core
P ( D r - 2 d sr - d cs )
l cr =
3p
Total Mmf for rotor core ATcr= atcr x lcr

So, Total magnetizing mmf per pole for B60

At 60 = ATg + AT ts + AT tr + AT cs + AT cr
 Magnetising current Im= 0.427 *p*AT60 / (kws Ts )
where p – no of pairs of poles,
AT60 – Total ampere turns of the magnetic circuit at
600 from the centre of the pole,
Ts– Number of stator turns per phase.

Iron loss component of current: This component of

current is responsible for supplying the iron losses in the
m a g n e t i c c i rc u i t . H e n c e t h i s c o m p o n e n t c a n b e
calculated from no load losses and applied voltage.
Iron loss component of current Iw= Total no load losses /
(3x
phase
voltage)
No load Power Factor: No load power factor of an
induction motor is very poor. As the load on the machine
increases the power factor improves. No load power
factor can be calculated knowing the components of no
 Short Circuit ( Blocked Rotor ) Current
Calculation
For estimating the short circuit current , first estimate the
resistance and leakage reactance of the winding .
(i) Stator Resistance – The stator resistance per phase
is given by ;
L mts ´ T s
rs = r
as
Rs= stator resistance per phase
ρ= resistivity of copper
Lt= length of mean turn
Ts= Number of turns per phase of stator
winding
as= cross section area of stator winding copper
(ii)Rotor Resistance –The stator resistance per phase
is given by;
L mtr ´ Tr
rr = r
ar
(iv) Resistance of
bars
r Lb
rb =
ab

(v) Resistance of end rings

pD e
re = r
ae
 2
rp D e
=2 I e
Copper loss in two end rings
ae
 Leakage Reactance in
Induction Motor
Leakage reactance is the impedance/resistance offered by the
leakage
Leakage Inductor
inductor. is a hypothetical electrical component(not
actual, but somewhat to take the role of a inductor) used in
many cases where there is EMF production due to change of
flux . The leakage reactance is caused by the leakage fluxes
linking the armature conductors only because of the currents
in the conductors. These fluxes do not link with the field
winding and are therefore not mutual fluxes. As in an
induction motor, for convenience in calculation, the leakage
reactance is divided into
(1)end-connection leakage reactance
(2) slot-Leakage reactance
(3)tooth- top and zigzag leakage reactance
(4) belt-leakage reactance.
(i) The slot leakage reactance per
phase = lS
x s =8pf m0T ph L
2

qs p

(ii) Overhang leakage reactance

per phase lS
x 0 = 8pf m0T ph L
2

qs p
(iii) Zig zag leakage reactance per
phase
5 é 1 1 ù
x z = x m ê 2
+ 2 ú
6 ëq 1 q 2 û
(iv)
Differential leakage reactance per
phase
x h = x m ( k h 1 + k h 2 )
(v) Total per phase reactance of an induction motor referred t
X 1 = x 1 + x '2
xm= magnetizing reactance
Xh= harmonic or differential leakage reactance
 Circle Diagram of Induction
Motor

The “CIRCLE DIAGRAM” means that it is figure or curve

which is drawn has a circular shape. As we know, the
diagrammatic representation is easier to understand
and remember compared to theoretical and
mathematical descriptions. Actually, we do not have
that much time or patience to go through the writings
so we prefer diagrammatic representation. Also, it is
very easy to remember the things which are shown in
picture. As we know, “A PICTURE IS WORTH 1000
WORDS”. This also holds good here and we are to draw
circle diagram in order to compute various parameters
rather than doing it mathematically.
 Importance of Circle Diagram

A phasor diagram gives relation between current and

voltage only at a single circuit condition. If the condition
changes, we need to draw the phasor diagram again. But a
circle diagram may be referred to as a phasor diagram
drawn in one plane for more than one circuit conditions. On
the context of induction motor, which is our main interest,
we can get information about its power output, power
factor, torque, slip, speed, copper loss, efficiency etc. in a
graphical or in a diagrammatic representation.
STEPS:-
•The no load current and the no load angle calculated from no load test is
plotted. This is shown by the line OA, where Ɵ0 is the no load power factor
angle.
•The short circuit current and the angle obtained from block rotor test is
plotted. This is shown by the line OC and the angle is shown by Ɵ B . The
right bisector of the line AC is drawn which bisects the line and it is
extended to cut in the line AE which gives us the centre.
•The stator current is calculated from the equivalent circuit of the induction
motor which we get from the two tests. That current is plotted in the circle
diagram according to the scale with touching origin and a point in the circle
diagram which is shown by B.
•The line AC is called the power line. By using the scale for power
conversion that we have taken in the circle diagram, we can get the output
power if we move vertically above the line AC to the periphery of the circle.
The output power is given by the line MB.
•The total copper loss is given by the line GM.
•For drawing the torque line, the total copper loss should be separated to
both the rotor copper loss and stator copper loss. The line DE gives the
stator copper loss and the line CD gives the rotor copper loss. In this way,
the point E is selected.
•The line AD is known as torque line which gives the torque developed by
induction motor.
Maximum Quantities from Circle
Diagram
•Maximum Output Power

•When the tangent to the circle is parallel to the line then output power
will be maximum. That point M is obtained by drawing a perpendicular
line from the center to the output line and extending it to cut at M.

• Maximum Torque.

•When the tangent to the circle is parallel to the torque line, it gives
maximum torque. This is obtained by drawing a line from the center in
perpendicular to the torque line AD and extending it to cut at the circle.
That point is marked as N.

•Maximum Input Power.

•It occurs when tangent to the circle is perpendicular to the horizontal

line. The point is the highest point in the circle diagram and drawn to the
center and extends up to S. That point is marked as R.
Dispersion Coefficient:
Power factor is an important factor in designing of
induction motor.
Power factor depends upon two factors:
i) Magnetizing current (Im):a large value of the
magnetizing current
indicates poor power factor
ii) Ideal short circuit current (Isc): It is defined as
the current drawn by the motor at standstill
neglecting its resistance. A large value of ideal
short circuit current will be drawn for small value of
leakage reactance giving good power factor.
Dispersion coefficient defined as the ratio of
magnetizing current to ideal short circuit current.
Thus dispersion coefficient, σ = Im/Isci
=Im/(Es/Xs) Isci = Es/Xs
For small values of Im and Xs dispersion coefficient is
small and power factor is good. Thus for a small
value of dispersion coefficient power factor is good,
where as for large value of dispersion coefficient
power factor is poor.
Magnetizing current Im = P*AT60 / (2.34 kw Tph )
Where AT60 is the total mmf consumed by flux path,
out of which a
large part is consumed by air gap length.
AT air gap = 800000* 1.36*
Bav l’g Im α P * Bav l’g / Kws. Ts
Isci = Es/Xs
From equation , machine with a given L and D, the
dispersion coefficient is large for greater number of
poles, consequently making power factor poor. Thus
slow speed machine have poor power factor. To
improve ,decrease the length of air gap.
Effect of dispersion coefficient on induction
motor characteristics:
1. Effect on maximum power factor:
As shown in circle
diagram
OA=magnetizing
current
OB=ideal short circuit
current Dispersion
coefficient:
σ = OA/OB
 For σ = 0.05, maximum p.f. = 0.905
For σ = 0.10, maximum p.f. = 0.818
Hence there is a large decrease in
maximum p.f. when the dispersion
coefficient increases.
2. Effect on overload capacity:
Assuming, an induction motor is designed to have
maximum pf at full load
, its corresponding output will be DE. The maximum
output will be
corresponding to FC

For σ = 0.05 overload capacity =

2.348
For σ = 0.10 overload capacity =
Hence overload capacity decreases with increase in
1.740