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Alternative computational methods for electromagnetic circuits of disk-type

induction motors — comparison and verification

Conference Paper · April 2021

DOI: 10.1109/PEMC48073.2021.9432578

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 Alternative computational methods for
electromagnetic circuits of disk-type induction
motors – comparison and verification

Tomasz Wolnik,Ph.D.
Łukasiewicz Research Network – Institute of Electrical Drives and Machines KOMEL
Katowice, Poland
[email protected], ORCID ID 0000-0002-2636-8423

Abstract—Due to specific shape of electromagnetic circuit practise this may disqualify a particular design, since the
in disk-type motors, electromagnetic calculations should make time framework of the project is usually restricted. In
use of three-dimensional models. However, such calculations addition, time limitations occur, for example, at the stage of
are very time-consuming and this poses practical problems. submitting an offer to the customer. Alternative equivalent
The answer might be to use other alternative methods (not methods (other than FEM 3D) help to solve this problem,
based on 3D models), which would make it possible to obtain since they make it possible to obtain calculation results in a
appropriately accurate results. Comparison of calculation much shorter time.
results obtained with elaborated alternative computational Besides, in practise it’s also important that the input data of
methods for electromagnetic circuits of disk-type induction
the computational algorithm is based on the geometrical
motors is given in this paper. The results have been compared
with FEM 3D results and verified by lab test results (tests run
dimensions of the electromagnetic circuit. Then it is possible
with a physical motor model). When definite simplifications to analyze and monitoring the impact of design changes on
are adopted, the alternative computational methods make it the motor's operating parameters.
possible to reduce computational time in a significant way. The In [10,11] authors presents alternative calculation
achieved results are highly convergent with results acquired methods, but for axial flux permanent magnet motors
for real model. (AFPM), not axial flux induction motors (AFIM).
Keywords—disk-type motors, induction motors, In [6,12,13,14,15] authors presents the analytical method
computational methods. of calculating the electromagnetic circuit of the AFIM (Axial
Flux Induction Motor), but the input data are not the
I. INTRODUCTION geometric and winding data of the electromagnetic circuit.
In many applications disk-type motors present an Many physical quantities, such as electromagnetic force,
attractive alternative to cylindrical motors. Examples of efficiency, power factor etc. are assumed, not calculated on
specific disk-motor applications are lift drives, hoisting the basis of input data. This makes it impossible to analyze
machine drives as well as traction drives including vehicle the influence of design changes on motor parameters.
low-speed wheel drives etc. [1-6]. In most cases, brushless
In paper [13], the infinite permeability of the stator and
PM (Permanent Magnet) motors are used on account of their
rotor core was assumed, so the saturation of the magnetic
good parameters and resultant advantages [3,7]. The
circuit is not taken into account.
development trends in PM motors are strongly justified by
technical factors such as high efficiency, high torque An interesting approach is presented in [16]. For the
overload capacity, high power density coefficients. Apart calculations of the AFIM, the author used the
from all technical advantages, the PM motors possess two electromagnetic circuit of a classic radial flux induction
significant shortcomings: they are relatively expensive and motor (RFIM). However, the paper does not present the
the supply of main component (i.e. neodymium magnets) is method of converting the three-dimensional electromagnetic
strongly dependent on one monopolistic world source. In circuit to 2-dimensional and the obtained results were not
accordance with [8]c. 80% of neodymium magnet production compared with the test results on the physical model.
is centred in China. This is why even though PM disk motors
are being steadily developed, it’s important to research Comparison of the calculation results for single
simultaneously the construction of disk-type induction stator/single rotor disk-type induction motor (AFIM-11)
motors. obtained with alternative methods, i.e. the elaborated
analytical method and FEM (Finite Element Method) method
Due to specific flow of main magnetic flux in disk-type with 2D (2-dimensional) cylindrical model and standard
motors, where the length of magnetic path is subject to FEM 3D (3-dimensional) model is presented in this paper.
change when stator/rotor disk radii change, it is assumed that The developed alternative methods are based on geometric
electromagnetic circuits of these machines should be quantities of electromagnetic circuit and all winding data as
analysed with the help of three-dimensional models input quantities. These computational results have been
[1,5,9,10]. Then, the whole spectrum of different effects may verified by lab tests results (tests run with a real motor
be considered. However, the main drawback of such analysis model).
is long computational time. This is particularly true when
there is no possibility of limiting the computational model on
the basis of repeatable magnetic symmetry. Frequently in

XXX-X-XXXX-XXXX-X/XX/$XX.00 ©20XX IEEE

 II. MODEL AND DATA OF DISK-TYPE MOTOR
The analysis presented in this paper relates to design of
disk-type motor with a single stator and a single rotor
AFIM11 (Axial Flux Induction Machine 11). Model of the
electromagnetic circuit of this motor is shown in Fig.1. This
motor model was designed on the basis of the analytical
algorithm presented in detail in [17].

Fig. 2. Equivalent scheme of disk-type induction motor AFIM11

𝑈 = 𝑈 + 𝐼 ∙ 𝑅 + 𝑗𝐼 ∙ 𝑋 , (1)

𝑈 = 𝑗𝐼 ∙ 𝑋 + 𝐼 ∙ , (2)

𝐼 =𝐼 +𝐼 , (3)

where: U1 – stator phase voltage, I1 – stator phase current,

Rs – stator phase resistance, Xs – stator leakage reactance,
RFe – resistance representing stator iron core losses,
Xμ- magnetizing reactance, Uf – electromotive force (emf),
I0 – idle run current, Iμ – magnetizing current, IFe – active
Fig. 1. Three-dimensional model of the electromagnetic circuit of disk- component of idle run current, I'2 – rotor current, X'w – rotor
type induction motor [17] leakage reactance expressed in stator terms, R'w - rotor
resistance expressed in stator terms, s – slip.
The elaborated alternative methods are based upon
design data of the motor, this is used as input data in order to
analyse the impact of constructional changes in motor’s III. ALGORITHM OF ANALYTICAL CALCULATIONS
electromagnetic circuit on motor’s operational parameters. Algorithm of analytical calculations has been worked out
The basic data and parameters of the discussed disk-type and presented in detail in [17]. This analytical algorithm is
motor is given in Table I. aimed at providing possibilities of multiple and fast
calculations for the electromagnetic circuit of disk-type
TABLE I. DESIGN DATA – DISK-TYPE MOTOR
induction motors. The fundamental assumption is that it is
Rated power Pn 1.5 kW based upon original motor design data such as material
properties, stator/rotor winding data and dimensions of
Number of pole pairs pb 3 - different elements of electromagnetic circuit.
Rotational speed n 950 rpm The key issue in the elaborated algorithm is how to
Rated phase supply voltage U1 230 V calculate magnetizing current. Firstly, the magnetizing
current for idle run conditions is calculated. These
Number of phases m 3 - calculations are based upon iterative determination of flux
Rated frequency f1 50 Hz density distortion in the air-gap, this is represented by
correlation coefficient αi; then, main magnetic flux Φ and
Outer diameter – stator and rotor Dz 205 mm flux densities in different constructional elements of the
Inner diameter Dw 130 mm motor are calculated. Additionally, the algorithm takes into
account the impact of saturation (depending on current
Air-gap length δ 0.7 mm
value) on values of different leakage reactances of the motor
Number of stator slots Qs 36 - through the appropriately calculated Δκ factor.
Determination of magnetizing current value for idle run
Number of rotor slots Qw 40 mm
operation makes it possible to calculate parameters of the
Number of phase turns Z1 690 - transverse branch of the equivalent circuit.
The next stage of the calculations involves determination
Principle of operation of AFIM is the same as that of of remaining parameters of the equivalent scheme, dependent
standard induction cylindrical motor (RFIM); therefore, the on motor slip. On the basis of defined slip range and step Δs,
equivalent scheme is also identical (Fig.2) [17]. the algorithm calculates the values of equivalent scheme
parameters together with iterative recalculation of
magnetizing current for each slip value. When parameters are
calculated for defined maximum slip smax, the calculation
process is stopped and finished.
 In [1,16] the authors calculate the equivalent diameter as IV. EQUIVALENT FEM 2D METHOD AT CYLINDRICAL MOTOR
a half of sum Dz and Dw. In the opinion of the author of this PLANE
paper, the correct approach is to divide surface area of pole
This method is based upon FEM analysis of
pitch into half, not the diameter itself. The equivalent
electromagnetic circuit in the 2D plane of cylindrical motor -
diameter for the analytical calculations is determined with
2dRFIM model. Number of equations required for solution is
the help of Eq. (4). This is a geometrical diameter halving the
very significantly decreased if this approach is used and
area of motor’s pole pitch:
therefore calculation time is also considerably reduced. The
method has been detailed in [18]. The concept consists of
𝐷 = , (4) approximating three-dimensional model down to two-
dimensional model, while observing strict rules enumerated
in [17,18]. The several stages of conversion are graphically
where: Dsr – equivalent diameter, Dz – outer diameter, Dw – presented in Fig.4. It must be pointed out that conversion of
inner diameter. disk-type motor to 2D cylindrical motor is based upon linear
development of the cross-section (Fig.4b). For that reason,
The active length L of stator/rotor laminations is we assume that all geometrical dimensions of the model are
determined by: known.

𝐿= (5) The following key principles of converting model of disk

induction motor’s electromagnetic circuit to 2D model in
standard cylindrical motor plane have been established:
In classic cylindrical motors, part of winding protruding
away from the core is symmetrical at both sides; in disk-type
motors winding elements outside the core at outer diameter 1. Rotor’s outer diameter dzw of 2dRFIM model is equal to
differ from elements at inner diameter (Fig.3). That is why equivalent diameter Dsr.
the average turn length is calculated in accordance with (6)
as the sum of winding part protruding from the core at the 2. Active length L of 2dRFIM model is equal to
outer diameter, winding part protruding from the core at the (Dzs- Dzw)/2.
inner diameter and active part of the winding Ls. 3. Correction of rotor slot dimension is required, so that
width of rotor tooth bzw is constant and equal to real
∙ ∙ ∙ ∙ ∙ ∙
rotor tooth width at equivalent diameter Dsr.
𝑙 = 𝐿 + 4𝑙 + ∙𝑌 + ∙
4. Height of stator/rotor slot is equal to real slot height hqs
𝑌 + (𝜋 − 2) ∙ (𝑅 +𝑅 ) (6) and hqw of disk motor.
5. Height of stator/rotor yoke is equal to real yoke height
where: Ljs and Ljw of disk motor for machines with unsaturated
lczp – straight part of the winding protruding from the core.
laminations,
Rgz – radius of coil bend at the outer diameter, 6. Where stator or rotor core is saturated, it is necessary to
Rgw - radius of coil bend at the inner diameter, calculate lengths of main flux magnetic paths in
Ym – mechanical winding pitch. rotor/stator yokes of 2dRFIM with initially set
dimensions dzs and dww; these should be then corrected in
such a way, that magnetic voltage drop in rotor/stator
yokes of 2dRFIM model might be as close as possible to
values present in model of linear development of the
cross-section.
7. Correction of stator slot dimensions is required so that
stator tooth width bzs might be constant and equal to real
stator tooth width at substitute diameter Dsr.
8. Resistance of end-rings of 2dRFIM model is equal to
arithmetic mean of resistances of upper ring Dpn1 and
Dpn2.
9. On account of decreased cross-section of rotor slot in
2dRFIM model, the value of rotor bar conductance γpr
should be proportionately modified so that active
resistance of rotor bar might not be changed in relation
to real model.
Fig. 3. Stator winding coil of disk-type induction motor [17] 10. Air-gap length is equal to real air-gap length δ.
 V. FEM 3D MODEL
The final FEM 3D computational model of disk-type disk
induction motor AFIM-11 11 is shown in Fig.5.This model has
been prepared for computing different working points in
motor’s operational curve; that is, required rotational speed is
enforced for defined supply voltage/frequency values.
values In this
way we can simulate operation at a definite slip, i.e.
appropriate load torque.

a)

a) b)
Fig. 5. Calculation model of AFIM11 motor, FEM 3D algorithm a) Motor
with stator windings in place, b) stator core and rotor core including end
ring

FEM calculations
alculations make it possible to determine
distribution of flux density in different constructional
elements of electromagnetic circuit. On the basis b of this
information, the designer is able to assess the saturation rate
in the machine elements for a given working point. In disk-
type motor the value of flux density in different elements is
closely associated
ted with diameter, so application of 3D model
mod
in calculations is very helpful. Distribution of flux density in
b) selected elements of electromagnetic circuit of AFIM-11 is
shown in Fig.7.
The final results of FEM 3D calculations are waveforms
of such physical quantities as electromagnetic torque,
current, supply voltage, flux linkage and stator iron core
losses. Example of calculated electromagnetic torque
waveform for the discussed motor is
i shown in Fig.6.

c)
Fig. 4. Stages of converting electromagnetic circuit of disk model to 2D
plane of cylindrical motor: (a) core of disk motor, (b) linear development of Fig. 6. Electromagnetic torque time waveform for the model motor; speed
the stator/rotor cross-section at Dsr diameter, (c) 2D model at a plane of n=950 rpm. [17]
cylindrical motor. [18]
 The main comparison criterion adopted for assessment of
elaborated computational equivalent methods is accuracy of
calculations (in relation to real values obtained for the
physical model) as welll as time necessary for working out
the computational model together with actual calculation
time.
Computational models have been worked out using
computer equipped with Intel Core i7-4770K
i7 processor,
3.5 GHz, 32 GB RAM, licence restricted to a single core.
In order to compare the expenditure of time associated
with analysed methods, average calculation time for rated
working point of the motor for different FEM methods is
shown in Table II. Computational time for analytical method
is counted
ted in seconds and does not cover transient-type
transient time
analysis.

TABLE II. AVERAGE CALCULATION TIME

T FOR A SINGLE WORKING
POINT OF THE MOTOR, 2DRFIM AND 3DAFIM MODELS

FEM 2d FEM 3D -
Fig. 7. Flux density distribution in selected elements of electromagnetic -RFIM AFIM
circuit of AFIM11 motor
Average calculation time 2.5 h 80 h
VI. COMPARISON AND VERIFICATION
CATION OF COMPUTATIO
COMPUTATIONAL
Number of calculation periods 6 6
METHODS
Final calculation time 120 ms 120 ms
In order to verify the presented computational algorithms
and to evaluate the equivalentvalent computational methods, Time step 0.2 ms 0.4 ms
a physical model of the electromagnetic circuit of AFIM11
motor has been worked out and executed. Lab tests have
been run. This physical model is shown in Fig.
Fig.8. Comparison Data on number of finite elements used in 2dRFIM
of the methods has been performed for rated parameters of model of the equivalent method and 3D model of the
the motor and in the operational range. discussed disk-type
type motor AFIM-11
AFIM is presented in Table III.
Distribution of finite element mesh for both models
mode is shown
graphically in Fig.9.

TABLE III. NUMBER OF FINITE ELEMENTS

ELEM IN DIFFERENT FEM MODELS

FEM 2d FEM 3D -
-RFIM AFIM
Band (rotor surroundings) 1 120 32 900

Rotor cage 47 000 64 550

Stator winding 11 700 22 400

Rotor core 27 530 62 550

a) Stator core 37 120 41 730

Model surroundings 12 650 173 470

Total 143 140 407 320

b)
Fig. 8. Physical model of electromagnetic circuit of AFIM11 motor,
a) b)
a) stator with windings, b) rotor core with aluminium cage
cage. Fig. 9. Finite element mesh of computational model a) FEM 2dRFIM,
b) FEM 3D AFIM-11 [8]
 When we compare data set out in Tables II and III and As far as the rated parameters are concerned, we may argue
images shown in Fig.9, we may observe that even though that equivalent computational methods and analytical
total number of finite elements in FEM 3d AFIM model is method in particular, are characterized by very good
about 3 times higher, the density of finite element mesh is convergence with results obtained from physical model
significantly lower. Computational time for 3D model is tests. For this method relative error does not exceed 5% and
about 30 times longer even though computational time step this may be accepted as a very good result. In case of FEM
is twice as long as in 2D model (i.e. computational time step 2dRFIM method maximum relative error is 13.5% and this
is halved); we may state that it is about 60 times as long as relates to calculated load current I1. Still, at this error value
that of 2D model developed in equivalent plane of cylindrical
we may state that accuracy of calculations is good.
motor.
The remaining operational parameters of the motor are
Comparison of obtained results for different motor characterized by greater divergence from measured
parameters is shown in Table IV for all applied methods. The parameters. For FEM 2dRFIM method, the results in the
values of relative errors (calculated in accordance with operational range should be treated as rough estimates, since
Eq.(7) are given in Table V. relative errors for nearly all parameters attain 30 to 40%. In
| | case of analytical method this error is equal to 25%
δ[%] = ∙ 100 (7) maximum (this relates to slip corresponding to maximum
current). These differences are due to (among other things)
TABLE IV. COMPARISION OF RATED AND OPERATING PARAMETERS
FOR DIFFERENT MODELS
differences in calculated values of stator/rotor leakage
reactances and rotor resistance used in equivalent scheme
Rated and parameters.
Analytical FEM 2d FEM 3D
operational Tests
algorithm -RFIM -AFIM
parameters
T [Nm] 15 15 15 15.1 Apart from rated parameters and specific operational
parameters, operation of induction motor may also be
P1 [W] 1868 1832 1839 1882
described with selected curves. Comparison of
P2 [W] 1508 1514 1486 1520 computational methods for the most important curves is
I1 [A] 3.54 3.21 3.34 3.71 shown in Fig.10 [17].
n [rpm] 960 964 946 958
30
cosφ - 0.77 0.805 0.78 0.73
η % 80.7% 82.7% 80.8% 80.8%
25

Iμ [A] 1.91 1.77 1.67 1.87 20

Mk [Nm] 28.67 33.1 - 25.3
T [Nm]

15
sk - 0.163 0.17 - 0.13
Mr [Nm] 13.8 18.4 11.7 13.2 Lab tests
10
Ir [A] 13.7 15.1 11.6 11.5 Analytically
5 MES 2dRFIM
MES 3dAFIM
TABLE V. RELATIVE CALCULATION ERRORS FOR DIFFERENT MODELS 0
Rated and 900 920 940 960 980 1000
Analytical FEM 2d FEM 3D
operational n [ rpm]
algorithm -RFIM -AFIM
parameters
a)
T [Nm] 0.7% 0.7% 0.7%
P1 [W] 0.8% 2.7% 2.3% 6
P2 [W] 0.8% 0.4% 2.2%
I1 [A] 4.6% 13.5% 10.0% 5

n [rpm] 0.2% 0.6% 1.3%

4
cosφ - 4.8% 10.3% 6.8%
I1 [A]

η % 0.08% 2.4% 0.03% 3

Iμ [A] 2.1% 5.3% 10.7% 2 Lab tests

Mk [Nm] 13.3% 30.8% - Analytically
1 MES 2dRFIM
sk - 25.4% 30.8% -
MES 3dAFIM
Mr [Nm] 4.5% 39.4% 11.4% 0
Ir [A] 19.1% 31.3% 0.9% 0 5 10 15 20
T [Nm]
b)
 90 of elements compared to 2D model is c. 3 times greater and
amounts to more that 400 thou. finite elements.In case of
80 available computer hardware/software this was our limit,
where calculations were still possible. Software licence
70 restrictions are also of importance; they did not allow
calculations employing more processor cores than one
η [%]

60 (physically more cores could have been used). For the

defined 3D model mesh, calculation of single working point
50 lasted for c.80 hours and obtaining 4 points of operational
Lab tests
curve took c. 14 days. This sort of calculation time length is
Analytically
40 not acceptable outside research purposes. Moreover, it must
MES 2dRFIM
MES 3dAFIM
be taken into account that some technical designs are
30
obtained by iterations.
0 5 10 15 20
Therefore, in the discussed case we must consider that FEM
T [Nm] 3D method has proved to be the least accurate method
c) taking into account some external constraints such as
software limitations and licence restrictions.
0,9
The other two computational methods (equivalent methods)
exhibit good convergence of calculation results with lab test
0,8
results. For analytical method relative error does not exceed
in principle 15%, for most parameters it falls below 5%.
0,7 This testifies to correctness of the elaborated algorithm and
its assumptions. The least accuracy of this method (error
cos φ

0,6 within the range of 15 to 25%) has been obtained for

maximum torque and its corresponding slip and for start-up
0,5 Lab tests
torque.
Analitycally FEM 2D method also exhibits good convergence of
0,4 MES 2dRFIM calculation results, in particular where rated parameters and
MES 3dRFIM operational curves are concerned. The obtained FEM 2D
0,3 results for representative motor parameters such as start-up
0 5 10 15 20 current, maximum torque or start-up torque have been
T [Nm] burdened with error ranging from 30 to 40%. Therefore,
d) these results should be treated as rough estimate only.
Fig. 10. Comparison of computational methods and lab tests; a) torque
vs.speed, b) stator current vs. torque, c) efficiency vs. torque, d) power To conclude, from the viewpoint of designer
factor vs. Torque [17] undertaking the design of electromagnetic circuit in disk-
type induction motor, the elaborated equivalent method
VII. CONCLUSIONS basing on analytical calculations is most useful. It is
In practice, there is often a need to have a quick characterized by best convergence of calculation results and
information about motor parameters. Preparation of the lab test results, while computational time for complete
FEM 3D model and subsequent calculations are very time- motor curves is the shortest (seconds only). To verify the
consuming and therefore unacceptable. In this case, correctness of results obtained with this method, equivalent
alternative methods are helpful, which allow for calculate of FEM 2D method may be used. This is achieved using rules
electromagnetic circuit of AFIM in a much shorter time. The of model conversion to 2D plane formulated in this work.
paper presents a comparison of the proposed alternative Application of FEM 3D method for disk-type induction
methods with the FEM 3D method and the results obtained motors in industrial applications cannot be justified. The
for the physical model. computational analysis of the rated working point with FEM
The results presented in this paper are rather surprising, 3D method and computation step halved in relation to FEM
since worst (i.e. least) accuracy has been obtained for FEM 2D model took c. 32 times as much time. This sort of
3D calculations. This is in a way contrary to generally difference in computational process points directly to the
accepted assumptions, since only FEM 3D method takes rationality of elaborating equivalent methods, allowing
completely into account physical effects present in calculations, which are many times faster even though
electromagnetic circuit and represents physical object as iteration processes are used. We might suggest use of
closely to reality as possible. This assumption is of course computing units with much higher processings speeds and
correct. On the basis of results presented in this paper we software licences putting no restriction on use of multiple
should not draw a general conclusion saying that 3D FEM processor cores. However, the real technical and financial
calculations are the least accurate. This problem is more resources of the company or institution should also be
complex and relates mostly to hardware potential, that is considered. Use of external computing devices or purchase
preparation of appropriate finite element mesh. This aspect of unrestricted software licences is obviously possible, but
of the problem is admirably shown in Fig.9, where meshes it requires substatial financial outlay and it also prolongs the
for 2D and 3D FEM are pictured. Even though density of design process since some mediation in the information flow
3D FEM mesh model is significantly less, the total number becomes necessary.
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ACKNOWLEDGMENT
The project has been financed by the Narodowe Centrum
Nauki (National Science Centre) within the framework of the
research grant No. UMO 2012/07/B/ST8/04099.REFERENCES

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