{"id":14169,"date":"2022-07-19T11:22:15","date_gmt":"2022-07-19T09:22:15","guid":{"rendered":"https:\/\/came-italy.com\/?p=14169"},"modified":"2023-09-10T16:43:13","modified_gmt":"2023-09-10T14:43:13","slug":"the-benefits-of-the-came-service-for-optimisation-of-a-wound-stator","status":"publish","type":"post","link":"https:\/\/came-italy.com\/en\/the-benefits-of-the-came-service-for-optimisation-of-a-wound-stator\/","title":{"rendered":"The benefits of the Came service for optimisation of a wound stator"},"content":{"rendered":"<p>Is it possible to optimise the wound stator design in a high efficiency motor? And how far can this process go? To what end?<\/p>\n<p>These are the questions that I asked myself when faced with a request from the Came Production Manager. The request was clear: come up with a substantial change to a historical customer&#8217;s product, indeed a family of products, in order to reduce the cycle time and thereby <a href=\"https:\/\/came-italy.com\/it\/i-servizi-came-per-dare-soluzioni-al-cliente\/\" target=\"_blank\" rel=\"noopener\">increase production efficiency, of course with the same motor performance and product cost<\/a>.<\/p>\n<p>Today we are looking at a new key service that the <a href=\"https:\/\/came-italy.com\/it\/i-benefici-per-i-clienti-del-servizio-came-rd-presentati-nel-nostro-nuovo-video\/\" target=\"_blank\" rel=\"noopener\">Came Research and Development Department<\/a>&nbsp;provides to its customers and internal bodies:&nbsp;<a href=\"https:\/\/came-italy.com\/it\/servizi\/\" target=\"_blank\" rel=\"noopener\">the optimisation service<\/a>.<\/p>\n<p>The aim of this service is to find a solution that can optimise a product, and it is divided into two processes:<\/p>\n<ul>\n<li>Optimising product consumption (electrical efficiency)<\/li>\n<li>Optimising the product through industrialisation (product efficiency)<\/li>\n<\/ul>\n<p>&nbsp;<br \/>\nIn this article, I will focus on the study of an IE3 three-phase motor winding:<br \/>\nMec 90S\/B5 1.1kW 230\/400V 50Hz IE3 motor<\/p>\n<ul>\n<li style=\"list-style-type: none;\">\n<ol>The project was divided into two phases:<\/p>\n<li>Winding design specifications<\/li>\n<li>CAD simulation of the motor and study of an alternative<\/li>\n<\/ol>\n<p>&nbsp;<br \/>\n<strong>1. Winding design specifications<\/strong><br \/>\nThe stator consists of a classic 135\u00d780-36c 4-pole three-phase asynchronous winding.<br \/>\nThe most critical design choice was the winding pattern (1-8-10-8 pitch), which offers an electrical efficiency benefit because of its lower phase resistance.<br \/>\n<img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-14226 size-full\" src=\"https:\/\/came-italy.com\/wp-content\/uploads\/2022\/07\/1-Retrogressive-short-coil-1-8-10-8.jpg\" alt=\"\" width=\"643\" height=\"195\"><br \/>\nThe main disadvantage of this distribution is unfortunately that it is more difficult to make than the better-known concentric winding pattern (1-8-10-12 pitch), especially the phase insulation, resulting in approximately 15% lower production efficiency.<br \/>\nThe aim of this study was to assess the possibility of developing a concentric pitch motor with the same performance while not increasing the final product cost.<br \/>\n&nbsp;<br \/>\n<strong>2.<\/strong> <strong>CAD simulation of the motor and study of an alternative<\/strong><br \/>\nIn this second phase, collaboration with SPIN Applicazioni Magnetiche and CAD simulation with FluxMotorTM allowed us to characterise the current model and verify the efficiency loss with the classic pattern shown below, for the same data and materials.<br \/>\n<img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-14230 size-full\" src=\"https:\/\/came-italy.com\/wp-content\/uploads\/2022\/07\/2-Concentric-1-8-10-12.jpg\" alt=\"\" width=\"643\" height=\"198\"><br \/>\nThe simulation results are shown below, and indicate an efficiency loss of 1%.<\/p>\n<table class=\"tg\" style=\"border-collapse: collapse; border-spacing: 0;\">\n<thead>\n<tr>\n<th style=\"background-color: #ff5a00; color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; font-weight: bold; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid inherit;\">&nbsp;<\/th>\n<th style=\"background-color: #ff5a00; color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; font-weight: bold; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid inherit;\"><strong>Bundle length<\/strong><\/th>\n<th style=\"background-color: #ff5a00; color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; font-weight: bold; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid inherit;\"><strong>Efficiency<\/strong><\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid inherit;\">Standard motor<\/td>\n<td style=\"color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid inherit;\">110 mm<\/td>\n<td style=\"color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; font-weight: bold; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid inherit;\">84.3%<\/td>\n<\/tr>\n<tr>\n<td style=\"color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid black;\">Motor with concentric winding<\/td>\n<td style=\"color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid black;\">110 mm<\/td>\n<td style=\"color: #000000; font-family: Arial, Helvetica, sans-serif !important; font-size: 14px; font-weight: bold; overflow: hidden; padding: 10px 10px; text-align: left; vertical-align: top; word-break: normal; border: 1px solid black;\">83.7%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<br \/>\n<img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-14210 size-full\" src=\"https:\/\/came-italy.com\/wp-content\/uploads\/2022\/07\/3-graph.jpg\" alt=\"\" width=\"800\" height=\"302\"><\/li>\n<li style=\"list-style-type: none;\">The efficiency reduction with the new winding pattern could be recovered in several ways:\n<ul>\n<li>Using laminations with lower losses<\/li>\n<li>Increasing the copper fill factor<\/li>\n<li>Increasing the bundle height<\/li>\n<\/ul>\n<p>&nbsp;<br \/>\nWe ruled out using laminations with lower losses due to price and availability, and focused on changing the other two aspects of the design. After some simulations, this resulted in:<\/p>\n<ul>\n<li>Increasing the copper volume by +5%<\/li>\n<li>Increasing the bundle height by +4,5%<\/li>\n<li>Restoring the efficiency to its original value of 84,3%<\/li>\n<\/ul>\n<p>&nbsp;<br \/>\n<strong>Conclusions<\/strong><br \/>\nThe higher raw material cost is largely offset by the higher production efficiency, with net final winding cost savings estimated to be approximately 2,5%.<br \/>\nThe result might seem insignificant, but it has a great impact in terms of increased production capacity. This allows Came to respond more effectively to the ever-increasing market demands with alternative solutions without increasing the product cost.<br \/>\nTeamwork, availability of internal and external expertise and professionalism: these are the key factors that have successfully led to the required goal.<\/p>\n<div style=\"width: 100%; float: left;\">\n<div style=\"float: left;\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-4129 alignleft\" style=\"border: 1px solid #f4792d;\" src=\"https:\/\/came-italy.com\/wp-content\/uploads\/2018\/11\/FabrizioBardelli.jpg\" alt=\"\" width=\"150\" height=\"173\"><\/div>\n<div style=\"float: left; margin-left: 20px;\">Article by:<br \/>\n<a href=\"mailto:consulting@came-italy.com\">Fabrizio Bardelli<\/a><br \/>\nCame Research and Development Expert<br \/>\n<a href=\"mailto:consulting@came-italy.com\">consulting@came-italy.com<\/a><br \/>\n<a href=\"tel:+39 0444 488282\">+39 0444 488282<\/a><\/div>\n<\/div>\n<\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Is it possible to optimise the wound stator design in a high efficiency motor? And how far can this process go? To what end? These are the questions that I asked myself when faced with a request from the Came Production Manager. The request was clear: come up with a substantial change to a historical [&hellip;]<\/p>\n","protected":false},"author":13,"featured_media":14222,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"ngg_post_thumbnail":0,"footnotes":""},"categories":[178,165],"tags":[840,842,845,846,841,843,844,847,839],"class_list":["post-14169","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-products","category-research-development","tag-2-5-saving-in-the-winding","tag-came-optimisation-service","tag-came-rd","tag-electrical-efficiency","tag-high-efficiency-motor","tag-increased-production-efficiency","tag-lower-product-cost","tag-product-efficiency","tag-wound-stator-design"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>The benefits of the Came service for optimisation of a wound stator - Came Spa<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/came-italy.com\/en\/the-benefits-of-the-came-service-for-optimisation-of-a-wound-stator\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"The benefits of the Came service for optimisation of a wound stator - Came Spa\" \/>\n<meta property=\"og:description\" content=\"Is it possible to optimise the wound stator design in a high efficiency motor? And how far can this process go? To what end? These are the questions that I asked myself when faced with a request from the Came Production Manager. 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