Optimal design of electric motors

7.5 kW, 380 V, 50 Hz, 4 poles, three-phase

Optimal design of electric motors

Electric motors are widely used in
industrial and domestic applications

+
Optimized design can improve the
efficiency of the motors

Reduction of energy consumption

Independent Variables Design Parameters

Stator outer diameter
x2

x1

Stator slot
Stator inner diameter

Independent Variables Design Parameters

Stator outer diameter
x2

Stator teeth width

Stator wire size

x5

x3

Stator slot height

x4

x1

x6

Stator slot
Stator inner diameter

Air-gap length

Independent Variables Design Parameters

Rotor slot height :

x9

Stack length

Rotor teeth width

x8

x7

Rotor slot

Independent Variables Design Parameters

Stator inner diameter :

120.0mm x1 130.0mm

Stator outer diameter :

180mm x2 220mm

Stator teeth width :

4.5mm x3 6.5mm

Stator slot height :

16mm x4 19mm

Stator wire size :

1.4mm 2 x5 4.0mm 2

Air-gap length :
Rotor teeth width :
Rotor slot height :
Stack length :

0.3mm x6 0.5mm
3.5mm x7 5mm
16mm x8 18.5mm

140mm x9 190mm

Simulation and Performance Evaluation

x1
x2
x3

Simulation
Program

x9

feas

0 : design infeasible
1 : design feasible

Performances/features
Manufacturing cost
Operating cost
Rated efficiency
Rated power
Power factor at rated load
Starting current
Starting torque

Breakdown torque
Stator slot fullness
Stator winding temperature
Rotor bars temperature
Induction in the stator and rotor teeth
Rated slip

Nonlinear Constraints
Rated power:
Power factor at rated load:

pwi 7560W
cos 0.8

Starting current: I st 67 A
Starting torque: Tst 97 Nm
Breakdown torque: Tmax 140 Nm
Stator slot fullness: k ssf 0.55
o
Stator winding temperature: Tcu 130 C

Rotor bars temperature: Tal 150 o C

Induction in the stator teeth:

1.2T H st 1.8T

Induction in the rotor teeth:

1.2T H rt 1.8T

Rated slip: RS 0.05

Initial Feasible Design

Existing motor having

a Rated Efficiency of 88.38%

(Real Measured Efficiency of 84.2%)

x1 = 126.6mm
x2 = 200mm
x3 = 5.5mm
x4 = 17.5mm
x5 = 1.5727 mm 2
x6 = 0.4mm
x7 = 4mm
x8 = 17.8mm
x9 = 160mm

Problem Statement

( )

x
find such that f x f ( x )

for all x {x : l x u , g ( x ) 0}

arg min f ( x )
s.t.

g (x ) 0
l xu

Problem Statement

arg min f ( x )
s.t.

l xu

g (x ) 0
l xu

Simulation
Program

feas

f (x )
g (x )

Problem Properties

- Nonlinear objective and constraints

- Analytical expression of f ( x ) and g ( x ) not available:
No Derivative Knowledge
- Presence of so-called hidden constranits
- Computation of f ( x ) and g ( x ) affected by
numerical errors

A difficult Global Optimization problem

Induction Motor Optimal Design

optimal design:
Stator inner diameter : x1 = 129.94mm
Stator outer diameter : x2 = 220mm
Stator teeth width : x3 = 4.53mm
Stator slot height : x4 = 19mm
Stator wire size :

x5 = 2.635mm 2

Air-gap length : x6 = 0.3mm

Rotor teeth width : x7 = 3.543mm
Rotor slot height : x8 = 18.5mm
Stack length : x9 = 187.1mm

(initial design:)

(126.6mm )
(200mm )
(5.5mm)
(17.5mm )

(1.573mm )
2

(0.4mm )
(4mm )
(17.8mm )
(160mm)

Optimized design

Induction Motor Optimal Design

optimal design:
Rated Efficiency of 91.9%

initial design:
Rated Efficiency of 88.38

Real Measured Efficiency 90.2% Real Measured Efficiency 84.2%

Optimal design of electric motors

Associazione Nazionale Industrie Elettromeccaniche

il parco motori nazionale relativo alla taglia da 7.5 kW - 4 poli
si aggira intorno ai 30000 motori
(per usi industriali: nastri trasportatori, ventilatori,)
luso dei motori ottimizzati implicherebbe un risparmio annuo di
35 GWh/anno pari a circa 3.5 Milioni di /anno