4088 IEEE TRANSACTIONS ON MAGNETICS, VOL. 49, NO.

7, JULY 2013

Development of a High Speed Induction Motor for Spindle Systems

Do-Kwan Hong, Jae-Hak Choi, Dong-Jun Kim, Yon-Do Chun, Byung-Chul Woo, and Dae-Hyun Koo
Electric Motor Research Center, Korea Electrotechnology Research Institute, Changwon 641-120, Korea

This paper deals with the analysis techniques of a high speed and high efficiency 10 kW, 30 000 rpm rated induction motor. The in-
duction motor has been analyzed by the time-varying magnetic finite element method and the test results show that there is a possibility
that the motor could be used in a high speed spindle system application. All performances of the prototype are successfully verified. All
analysis techniques are introduced to develop a high speed and high efficiency induction motor made by copper die casting. The analysis
techniques are composed of magnetic analysis, structural analysis, critical speed analysis, unbalance response analysis and computa-
tional fluid dynamics (CFD). CFD simulation results are compared with the experiment, and are within a 5% deviation.
Index Terms—Computational fluid dynamics (CFD), copper die casting, critical speed analysis, high speed induction motor for spindle
systems, response surface methodology (RSM), structural analysis, unbalance response analysis.

I. INTRODUCTION

T HIS PAPER presents the development of a high speed and

high efficiency three-phase copper die casting induction
motor for spindles and electric vehicles. Multi-pin gate copper
die casting can improve the filling ratio of copper bars, and can
directly manufacture the die casting of each conductor bar. For-
merly, the pin gate method has been widely used in aluminum
die casting and copper die casting. The aim is that copper die
casting technology can be applied to high speed and high ef- Fig. 1. Configuration of prototype, rotor made by die casting, stator, and sev-
eral parts (pole/slot:4/24, stack length:100 mm, rated torque:3.25 Nm, rated-
ficiency induction motors under 30 kW. The introduction of power:10 kW, stator outer dia.:83 mm, rotor outer dia.:49.5 mm).
new material techniques which have a low loss steel sheet and
copper die casting rotor are essential for the development of
high speed and high efficiency induction motors. A copper die
Fig. 1 shows the dimension and the specification of the proposed
casting induction motor can obtain an energy saving effect of
three-phase induction motor.
about 2–3% compared to previous aluminum die casing induc-
tion motors. In addition, copper die casting motors can reduce
B. Magnetic Analysis Considering Losses
the size of motors and reduce material costs [1]–[3]. To develop
a three-phase high speed and high efficiency induction motor, In a 2-D Cartesian coordinate system, the finite element anal-
the focus is placed on the design tendency between the bridge ysis of the induction motor is performed with the following as-
of the rotor core and copper bar diameter considering magnetic sumption: 1) the current density and magnetic vector potential
analysis and structural strength analysis caused by centrifugal have only a z-axis component and the displacement current can
force. The developed induction motor performance (torque, ef- be ignored at the quasi-steady state, 2) the core is ideally lami-
ficiency) is evaluated by magnetic analysis. Meanwhile, the crit- nated, 3) the magnetic permeability of core is isotropic, and 4)
ical speed analysis and unbalance response analysis are per- the conductivity of the conductor (winding and rotor bar) has
formed for dynamic stability. Also, the generated loss of the equivalent value. From the above assumptions, the governing
high speed motor is used as the heat source of the thermal-fluid. equation for the induction motor can be expressed in a magnetic
The 3-D thermal-fluid analysis results are compared with the vector potential as follows:
experiment, and are within a 5% deviation of each other.
(1)
II. ANALYSIS TECHNOLOGY AND RESULT
where is the magnetic permeability, is the magnetic vector
A. Proposed Machine Description potential, is the equivalent conductivity of rotor bar, is the
input current density.
Fig. 1 shows the configuration of the copper diecasting induc-
In case of core losses, the total losses are commonly ex-
tion motor for a high speed spindle system. The rotor is manu-
pressed by (2) for sinusoidally varying magnetic flux density B
factured by a multi-fin gate die casting method and the winding
with frequency and are divided into hysteresis loss and eddy
of the stator is moulded by epoxy compound material. Also,
current loss. Each of the losses is calculated by (2)

Manuscript received November 05, 2012; revised January 07, 2013; accepted (2)
January 14, 2013. Date of current version July 15, 2013. Corresponding author:
D.-K. Hong (e-mail: dkhong@keri.re.kr).
Color versions of one or more of the figures in this paper are available online
where : maximum flux density, : hysteresis loss coeffi-
at http://ieeexplore.ieee.org. cient, : Steinmetz coefficient in the range 1.5 to 2.5, : fre-
Digital Object Identifier 10.1109/TMAG.2013.2241033 quency, : eddy current loss coefficient.

0018-9464/$31.00 © 2013 IEEE

HONG et al.: DEVELOPMENT OF A HIGH SPEED INDUCTION MOTOR FOR SPINDLE SYSTEMS
Fig. 2. Design variables (2-D 1/2 symmetry condition).
TABLE I
DESIGN VARIABLES AND ITS LEVELS
TABLE II
MAGNETIC ANALYSIS RESULT USING CENTRAL COMPOSITE DESIGN
(Yield strength: S7(385 MPa), Copper (69 MPa), SM45C (505 MPa))
Eddy current loss and hysteresis loss can be calculated by
using the distribution of time-varying magnetic flux density.
The hysteresis loss has been influenced by major hysteresis loop
from fundamental and minor hysteresis loop from harmonic.
The both loop have to be calculated from the time-varying mag-
netic flux density.
Fig. 2 shows three design variables in the 2-D model applied
symmetry condition. Table I and Table II represent design vari-
ables, its levels and Central Composite Design (CCD), sampling
to determine stator tooth width (Tw_s) the copper bar diameter
(Dbar), and the bridge distance (Pbar) as design variables using
response surface methodology (RSM) [4].
C. Structural Analysis
The von Mises criterion is also known as the maximum dis-
tortion strain energy criterion. The von Mises stress, , is
computed with the principal stresses as follows:
(3)
4089
Fig. 3. von-Mises stress distribution of core and PM (36,000 rpm,
100 ).
Fig. 4. Contour plots of efficiency, WCuR (eddy current loss of rotor bar),
stress of bar and stress of core (Tw:2.38 mm).
The structural analysis is well performed by the 2-D
cross-section model (symmetry condition) [5]. Fig. 3 shows the
maximum equivalent stress distribution of rotor (36,000 rpm,
100 ). The generated maximum von-Mises stress of each
part is within a sufficient allowable range considering the yield
strength of each material used.
D. Response Surface Methodology (RSM)
Fig. 4 shows the contour plots of efficiency, WCuR (rotor
copper loss), stress of bar and stress of core between Dbar and
Pbar. Efficiency and WCuR are countertrends varying Dbar and
Pbar. As Dbar increases, efficiency and copper loss of the rotor
is improved. But, as Pbar decreases, the generated stresses of
the bar and core increase. In spite of the lower yield strength
of the copper material, the mechanical safety factor is sufficient
according to the variation of the diameter of the bar and bridge
of the rotor core.
The optimization formulation of theinductionmotorcan be de-
fined as follows:
In this paper, two fitted second order polynomials having
three design variables for each objective function, efficiency,
4090
TABLE III
VERIFICATION RESULT OF OPTIMUM MODEL
Fig. 5. Campbell diagram (critical speed).
WCuR, stress of bar and stress of core, are determined. The ad-
justed coefficients of multiple determinations which shows
the reliability of the metamodel are 99.8%, 99.9%, 96.4% and
96.2% for each objective function, efficiency, WCuR, stress of
bar and stress of core, respectively. Table III shows a com-
parison of the optimum result (consideration of the electrical
characteristics) and the optimum result (consideration of elec-
trical-mechanical characteristics) [4]. In consideration of me-
chanical characteristics, the efficiency is decreased and WCuR
is increased by comparison with consideration of the electrical
characteristics.
E. Critical Speed and Separation Margin
The rotor of the three-phase induction motor consists of a
shaft, copper bar, end rings and lamination core as shown in
Fig. 1. 2-D FEM rotor dynamic analysis is performed [5], [6].
The critical speed of the rotor considering rotation and gyro-
scopic effect should be above the operating speed, 30,000 rpm,
and have a sufficient separation margin, 119.0%, as shown in
Fig. 5. The 1st forward whirling critical speed (65,708 rpm) of
the developed model is higher than the operating speed (30,000
IEEE TRANSACTIONS ON MAGNETICS, VOL. 49, NO. 7, JULY 2013
Fig. 6. Unbalance response result considering bending mode.
rpm). An appropriate separation margin is typically 20 30%
between the operating speed and the bending forward whirling
critical speed.
F. Unbalance Response Analysis
Unbalance vibration response analysis enabled the prediction
of the expected vibration amplitude by unbalance in high speed.
The calculated unbalance is as shown below [5]
(4)
where, G is G grade (2.5), M is the weight of the rotor (4 kg), N
is rotational speed and is unbalance (3.183).
Four times the unbalance magnitude is applied to the rotor in
this paper [6]. The applied unbalance location at maximum dis-
placement by 1st bending mode and response position to check
generated maximum vibration displacement should be within
the allowable vibration displacement
(5)
where, A is allowable vibration displacement, N is rotational
speed. The unbalance vibration responses are satisfied with al-
lowable vibration displacement (16.06 ) of API 611 stan-
dard, as shown in Fig. 6.
G. 3-D CFD
3-D CFD is performed by CFX. The water jacket cooling and
a simplified model of topology are considered [7], [8]. The heat
sources of the CFD model are determined from magnetic anal-
ysis considering PWM current wave by inverter analysis and
switching frequency. The numerically determined temperature
distributions of the machine are compared with measurement
results from the thermo-couple located at the end of winding.
Fig. 7 shows the CDF input condition and heat source. The high
speed operating of the rotor generates air flow inside the ma-
chine. Consequently, temperature distributions of the winding,
copper bar, end ring and stator are shown in Fig. 7. CFD simu-
lation results are compared with the experiment, and are within
a 3.2% deviation.
H. Performance Test
Fig. 8 shows the dynamo-system for the induction motor
performance test including efficiency, voltage, current, output
HONG et al.: DEVELOPMENT OF A HIGH SPEED INDUCTION MOTOR FOR SPINDLE SYSTEMS 4091

Fig. 9. Saturated temperature at the end of winding and efficiency.

The standard of judgment for temperature saturation is

over 40 minutes. The temperature of the induction motor is
saturated by around 110 on the rated load. Fig. 9 shows that
the efficiency between the analysis and test is well matched with
an error of 6.5%. CFD Simulation results are compared with the
experiment, and are within a 5% deviation.

III. CONCLUSION
The three-phase high speed and high efficiency induction
motor is developed by design, several analysis techniques,
manufacture and evaluation. The analysis techniques are
composed of magnetic analysis considering losses, structural
analysis, critical speed, unbalance response analysis and 3-D
CFD. Thethree-phase high speed and high efficiency induction
motor which is rated at 10 kW, 30,000 rpm for its spindle made
by copper die casting, has been developed successfully using
several design, analysis, and manufacturing techniques, as well
as performance tests. All performances of the prototypeare
successfully verified.

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Fig. 7. CFD input condition and temperature distribution result.
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