Core Loss Testing
Core Loss Testing
Flux Density B
a Saturation
Retentivity
b
Coercivity
–H c f H
Magnetizing Force Magnetizing Force
in Opposite Direction
e
d (b)
Flux Density
Saturation in –B 2
in Opposite Direction
Opposite Direction (a) The right-hand rule. (b) Flux travels circumferentially
1 around the core, inducing voltage between the
58
Hysteresis loop (B-H curve). laminations. (Photo courtesy of EASA.)
amperage component. This high cur- much less sensitive to eddy-current
rent causes localized heating of the losses. Table 1 illustrates that the
shorted laminations, thus extending THE ONLY BENEFIT lamination thickness decreased as
damage to the interlaminar insulation. the operating frequencies increased,
This cycle of damage continues, even- OF USING A CORE and the manufacturers strove to max-
tually leading to a failure of the wind- imize the effective use of active
ing insulation, laminated core, or the TESTER TO CHECK materials and further improve the
rotor cage. efficiency of electrical equipment.
The loop test is a procedure for SCIM ROTORS IS This is applicable to motors, genera-
energizing the stator core with an TO DETECT ROTOR tors, and transformers.
external source of magnetic flux den- The well-known 10° rule [5] pos-
sities to simulate operating condi- CAGE tulates that the expected insulation
tions. The test models a transformer life is halved for every 10 °C
turn ratio on a single phase–single ANOMALIES. increase in temperature. A 50 °C
coil basis for convenience. Depending increase in temperature reduces the
on the available power supply (espe- expected insulation life from 30
cially current limitations), the loop years to less than a year. A hot spot
turns and voltage are changed in direct proportion, and does not have to be very large to wreak havoc with
the current varies inversely, thus providing the same kil- insulation life.
ovoltamperes. The test can be performed using multiple
loop turns, as described in IEEE Standard 432, or with a
single loop turn with a power supply capable of supply- Factors Affecting Core Losses
ing the high current required for the low excitation volt- Core losses are comprised of hysteresis and eddy-current
age [2], [3]. For example, a 100-turn, 250-V test is losses at approximately 2:1 ratio in a new core. Hysteresis
equivalent to a one-turn, 2.5-V test. However, the one- losses occur within the steel and are influenced by the type
turn test would require 100 times the current as the 100- of steel (carbon steel versus silicon steel) used and are pro-
turn loop test. portional to the lamination thickness, grain size, and oper-
Whether caused by a rotor–stator rub from bearing ating system frequency.
failure or core plate deterioration due to excessive burn- Eddy-current loss is given by
out temperatures, shorting of the laminations produces
higher eddy-current losses [4]. The stator core test
should be performed before and after the burnout Pe ¼ 7:47 3 1014 (B2 f 2 t2 )(qd), (1)
evaluated. 72
63
54
Rotor and Armature 45
Operating Frequency 36
The operating frequency of a rotating core is directly 27
determined by the operating and synchronous speeds of 18
9 Hysteresis Loss
the machine. The high slip designs result in a higher 0
operating frequency for a rotor core, when compared 30 50 60 100 200 400
Frequency
7
Effect of frequency on losses, 0.6-mm lamination thickness.
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Eddy-Current Loss
70
60
50
40
30
20 Hysteresis Loss
10
0
30 50 60 100 200 400 800 1,000
6 Frequency
ODP type frame with minimal core contact. (Photo courtesy 8
61
of EASA.) Effect of frequency on losses, 0.8-mm lamination thickness.
effectively, multiply the percent slip 13 kilolines/cm 2 (85k/in 2 ) normally
times the line frequency to determine used for testing stator cores. In addition,
the rotor frequency. Note that even the
HIGH- infrared thermography (Figure 9) can
high slip design D rotor is only PERMEABILITY be useful for detecting partial open cir-
exposed to 9–15 Hz during normal cuits in the rotor cage. There are re-
operation. STEEL REQUIRES ported cases of rotor core testing, at the
Because the rotor frequency is so IEEE Standard 432 test levels, at which
low, eddy-current losses are not a ELEVATED the heat generated by current passing
significant concern for most induction through a shaft-to-core weld actually
rotors. The core test, performed using MAGNETIC FLUX bent the shaft.
50- or 60-Hz power, is not a useful
test for most squirrel cage rotors. A DENSITIES TO Armature Frequency
possible exception is the two-pole DETECT SHORTED Evaluation of dc armature core test
rotor, where the test might reveal results must also consider the role of
localized hot spots that might contrib- LAMINATIONS. frequency. DC machines are designed
ute to thermal bowing and increased to operate at a wide range of speeds,
vibration levels. with the operating frequency being
Thus, the only benefit of using a core tester to check dependent on the revolutions per minute (r/min) and
SCIM rotors is to detect rotor cage anomalies. An open poles [6].
rotor bar can force the current, normally carried by the Knowing that eddy currents are an ac phenomenon,
bar, to pass through the laminations in the vicinity of some are surprised to learn that a dc armature is subject
the break, generating heat. When used in conjunction to ac; each coil reverses polarity as it passes from pole to
with magnetic imaging paper or iron filings to check pole (Figure 10) while rotating. Unlike ac machines, the
the integrity of the rotor cage, the core loss tester can relationship between r/min and number of poles for dc
be useful. machines is not fixed; therefore, the actual r/min affects
To avoid overheating of the rotor core, the magnetic the eddy-current losses in dc armatures. The operating
flux densities should be 1.8–2.3 kilolines of flux/cm 2 frequency of the armature should be a factor in evaluat-
(12–15 kilolines of flux/in 2 ) as opposed to the ing the condition of the armature core.
To calculate the frequency of an armature, use the r/min
and number of poles:
TABLE 2. ROTOR OPERATING FREQUENCY FOUR-
POLE MOTOR, 60 HZ (50 HZ) Armature frequency ¼ poles 3 r=min=120: ð3Þ
IEEE INDUSTRY APPLICATIONS MAGAZINE JAN j FEB 2011 WWW.IEEE.ORG/IAS
Pole Iron
Field Coil
FLIR 1 87.8
117
74
°F
9 Interpole Armature
Thermal image of SCIM rotor under test. (Photo courtesy of 10
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EASA.) DC armature polarity reverses to ac.
operating frequency on core losses for Spindle Motors, Frequency,
a four-pole armature at different oper- and Lamination Thickness
ating speeds. When high frequencies are discussed,
When a loop test or traditional EDDY-CURRENT the spindle motor, often operating at
tester is used for armature or rotor LOSSES WITHIN 240 Hz or more, is another special
cores, several drawbacks exist. The case. Eddy-current losses vary in
search coil must fully encompass the THE LAMINATIONS proportion to the square of the lami-
back iron. If the core has vent open- nation thickness, so thinner lamina-
ings (Figure 11) in the back iron PRODUCE tions (0.25 mm) are used to control
and the search coil lead is passed the eddy-current losses. Thinner
through a vent opening, only part of RESISTIVE laminations have a lower stacking
the back iron is an active part of the factor because of the higher propor-
circuit. HEATING. tion of insulation to steel lamination.
The transformer ratio of the one- Generators and electric motors as-
turn current path and the search coil sociated with the aircraft industry
assumes the same active iron for both.
When the amount of active iron is changed, such as by
routing the sensing leads through a vent opening, the
sensed voltage will not be the same as when the search
coil encompasses the entire back iron.
Why a one-turn coil? Physical arrangement of the
stator core allows full access inside and outside the stack,
varying with only the inclusion of the frame material (as
noted earlier), whereas with many rotors or armatures,
there is no free internal space to pass a cable. The only
means of passing a current through the center of the
rotor or armature assembly is through the shaft; thus,
the test leads attach directly to the shaft ends. (Note that
the only exception to this would be for a vertical hollow-
shaft-type machine.) When the sensing leads are con-
nected to the shaft, the tester can only read the voltage
drop across the shaft. This bears emphasis. The sensing
11
TABLE 4. ADJUSTMENT FACTORS FOR DIFFERENT OPERATING FREQUENCY AND CORE LOSS.
Hz 25 50 60 120 240 400
Base 1.02 (1.5) 2.04 (3) 2.45 (3.6) 4.9 (7.2) 9.8 (14.4) 16.3 (24)
Watts loss/lb (kg) 1.04 (2.25) 4.17 (9) 6.0 (13) 24.0 (51.8) 96.0 (207) 267 (576)
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commonly operate at 400 Hz, Common sense should be applied
requiring thinner laminations. when evaluating a core. NEMA T-frame
motors generally use lower loss steel
Importance of Frequency HYSTERESIS than older U frame and pre-NEMA
To factor in the effect of frequency LOSSES ARE motors. Energy-efficient motors with
on core testing, consider the relative conservative densities and better grades
watts loss/lb for the same core at vari- HIGHER FOR of steel have lower losses than many
ous applied frequencies (Table 4). metric design motors. Vintage 25- or
Because eddy-current losses are propor- CARBON STEEL 40-Hz motors are more likely to have
tional to the square of the frequency, thicker laminations, so a core test will
it is logical to apply the square root of THAN SILICON report higher eddy-current losses than
the 6 W loss/kg limit (3.6) and change for a more recently manufactured 60-
that in proportion to other operating STEEL. or 50-Hz core. Finally, since eddy-
frequencies. current losses are proportional to the
For example, to determine the equiva- squared frequency, the core losses
lent losses for 120 Hz, double the 3.6 during a test applied at 60-Hz
value, and square it. If a 60-Hz core loss test of a 120-Hz should be carefully evaluated for motors that operate at
core results in a good value of 13 W/kg (6 W/lb), the higher frequencies.
expected eddy-current losses operating at 120 Hz would be The material of the frame itself (steel, aluminum, cast
51.8 W/kg (24 W/lb). See (4) and (5). Reasonable limits for iron) can influence the core test results. Although the
frequencies other than 60 Hz should be determined by col- frame does not affect the running core losses, this can
lecting actual data. greatly skew the interpretation of the core test. Frame
Expected loss is estimated by construction has a lesser effect, as it affects stack pres-
p 2 sure. If the core is in full circumferential contact with
W=lb ¼ ½ðf =60Þ 6 ð4Þ the core (as in a TEFC machine), the effect is much
greater than if the core is in intermittent contact (as in
an ODP design). Ideally, if the core test results are in
or question, the stator should be removed from the frame
p to avoid conflicting results.
W=kg ¼ ½ðf =60Þ 132 ; ð5Þ Rotor cores function at comparatively minimal frequen-
cies. Application of the stator core loss testing method is
generally inappropriate and except for minor, coincidental
IEEE INDUSTRY APPLICATIONS MAGAZINE JAN j FEB 2011 WWW.IEEE.ORG/IAS
where f is the frequency applied. rotor bar appearance, yields misleading information.
Note: Although IEEE Standard 432 was administra-
Conclusions tively withdrawn in 2004, work in the IEEE Power &
For core loss testing of stators operating on 60-Hz (or Energy Society continues toward merging 432 and IEEE
50 Hz) sinusoidal power, IEEE Standard 432-1992 is the Standard 56, both of which pertain to insulation mainte-
source document. Reference [4] builds upon the document nance. When this article was submitted, the work was in
to establish procedures based on the core dimensions, draft 18.
weights, and standardized magnetic flux densities.
IEEE Standard 432 recommends core loss testing at References
5% over the magnetic flux density of the winding [1] Guide for Insulation Maintenance for Rotating Electrical Machinery (5 hp to
than 10 000 hp), IEEE Standard 432, 1992.
design. Industry practice adopted a value of 1.3 T, or [2] less J. A. Britton, Recommendations for Core Loss Testing on Cage Type Induction
85 kilolines/in2, corroborated by major manufacturers of Motors. Accident, MD: Phenix Technologies.
commercial core testers. Some evidence suggests using [3] Core Loss Testing in the Practical Motor Repair Environment. Louisville,
1 T (64.5 kilolines) as the target saturation level might KY: Lexseco, 1989.
result in greater repeatability of results. The higher the [4] Stator Core Testing. EASA, Tech Note 17, 1992.
[5] Standard Test Procedure for Evaluation of Systems of Insulating Materials for
magnetic flux density, above the knee of the saturation Random-Wound AC Electric Machinery. IEEE Standard 117.
curve, the greater the margin for error. [6] Core Loss Testing: Tips for Special Cases. EASA Currents, Feb.2002.
As measured using a static core test, the losses of a [7] Recommended Practice for the Repair of Rotating Electric Machinery, ANSI/
good 50- or 60-Hz stator range between 2 and 9 W/kg EASA AR1002006.
(1 and 4 W/lb) depends on steel grade; higher losses
usually indicate a defective core and require corrective
measures. As eddy-current losses vary as the square of Chuck Yung (cyung@easa.com) is with EASA in St. Louis,
the applied frequency, the importance of core loss test- Missouri. Travis Griffith is with GE Oil & Gas in Houston,
ing increases with the frequency of the equipment Texas. Yung and Griffith are Senior Members of the IEEE.
under consideration. Spindle motors and armatures that This article first appeared as “Core Loss Testing: A Good
operate at higher frequencies are far more critical than Procedure Gone Astray?” at the 2009 Petroleum and Chemical
induction rotors. Industry Conference.
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