On Inter-bar Currents in Induction Motors with Cast Aluminium and Cast Copper Rotors

Abstract: This thesis presents a study of the effects of inter-bar currents on inductionmotor starting performance and stray-load losses. The work is focused on theperformance differences between aluminium and copper casted rotors.A method to predict the stator current when starting direct-on-line isdeveloped. This includes modelling of skin-effect, saturation of the leakageflux paths and additional iron losses. The results are verified by measurements.An analytical model accounting for inter-bar currents is derived, andthe dependency of the harmonic rotor currents on the inter-bar resistivity isinvestigated. It is found that the inter-bar currents can have considerableeffect on motor starting performance and stray-load losses, the amount beingstrongly dependent on the harmonic content of the primary MMF.Based on measurements of inter-bar resistivity, the starting performanceof an aluminium and a copper casted rotor is simulated. The results indicatea higher pull-out torque of the aluminium rotor than for the equivalent copperrotor. This is rather due to an increase of the fundamental starting torque ofthe aluminium rotor, than due to braking torques from the space harmonicsin the copper rotor. The results are verified by measurements. It is foundthat the difference between the pull-out torques is even larger than calculatedfrom the model. Thereby, it can be concluded that the inter-bar currents havea considerable effect on motor starting performance.At rated speed the braking torques are larger in the aluminium rotor thanin the copper rotor. This is seen as increased harmonic joule losses in the rotorcage. Simulations have shown, that these losses can be as large as 1% ofthe output power for the studied machine.