Deep bar vis--vis Double cage rotor design for large MV motors

Usually, large MV motors are designed with either Al die cast or, Cu cage rotor. Aluminium
die cast machine for the casting of large rotors is very expensive & maintaining the quality is
also difficult. Also, casting of rotor with Aluminium become non-feasible beyond certain
diameter and core length, because of Die cast machine constraint. Some customer &
consultants also do not purchase motors with Aluminium die cast rotor beyond certain
rating. Hence, manufacturers prefer to design rotors of large motors with Copper bar with
brazing at both ends.

Copper cage rotor design may of two varieties - either with Double cage or with Deep bar
design. Both Double cage and Deep bar design are used to control starting torque and
starting current of A.C induction motors to the desired level. The shape of rotor slot is so
chosen that the overall reactance is smaller resulting in higher starting torque. In case of
Double cage rotor design, high resistance conductor is used in outer cage to increase motor
starting torque.

1. Deep bar rotors: In deep bar rotor construction, the shape of rotor slots are usually of
higher depth, smaller width & the shape are properly designed to meet the torque
requirement of the motor application. Usually, L, rectangular or, inverted T shaped half-
hard rotor bars are used for the slot. Copper bars are inserted in the slots generally with
interference fitting in slot on height and 2nos. Copper rings are brazed at the two ends of
rotor bars. These copper bars as per designed section can be manufactured at a good
vendors place by cold drawn process. End ring material is available in market and can be
shaped as per need by a vendor. Both manufacturing & repairability of such rotors are
simple.

2. Double cage rotors: Double Cage Induction motor is that type of motor in which a double
cage or two rotor cages are used. The outer cage is generally designed with high resistance
conductor like Brass, Bronze etc., whereas for the inner cage, half hard copper having lower
resistance is used. The material for the outer rotor bar copper alloy is not randomly
available in market. Hence, both manufacturing of new rotor and its repairability is difficult.
As the resistance of the outer cage alloy material is much higher compared to copper, it
causes higher copper losses and thereby reduces motor efficiency. Higher rotor copper loss
in rotor of outer cage also results in higher motor temperature and to bring down the higher
temperature, additional active material has to be provided, both in stator & rotor and thus
increasing motor price. Therefore, the efficiency of a motor with double cage rotor is much
lower compared to motor with deep bar design. In case of double cage rotor, the pull out
torque is also lower, because one cage produces the maximum torque at a speed is different
from the other cage.
Comparing the above two rotor design, the superiority of single cage rotor design with deep
bar over double cage can be clearly established, particularly efficiency, price & repair point
of view. Further, the chance of rotor bar/ring joint failure (which is the most common
failure for rotor) doubles in case of Double cage rotor design. Despite all these fact,
customers often insist for similar design in case replacement of old motors with Deep bar
rotor design. In such cases, manufacturers have to clarify technically the drawback of such
design to customer.

Moreover, although expensive, the introduction of VSD along with motor with single cage
design can achieve any starting torque up to POT & thus can eliminate higher starting
torque requirement.