Design and Development of Energy Efficient Single Phase Induction Motor For Ceiling Fan Using Taguchi’s Orthogonal Arrays

The content of this introduction paper is based on the article 'Design and Development of Energy Efficient Single Phase Induction Motor For Ceiling Fan Using Taguchi's Orthogonal Arrays' published by ['IEEE International Conference on Computing, Power and Communication Technologies (GUCON)'].

Fig. 1 Cross section of ceiling fan SPIM
Fig. 1 Cross section of ceiling fan SPIM

1. Overview:

  • Title: Design and Development of Energy Efficient Single Phase Induction Motor For Ceiling Fan Using Taguchi's Orthogonal Arrays
  • Author: Utkarsh Sharma, Bhim Singh
  • Year of publication: 2020
  • Journal/academic society of publication: 2020 IEEE International Conference on Computing, Power and Communication Technologies (GUCON)
  • Keywords: AC Fans, Taguchi's Orthogonal Array, Single Phase Induction Motor, Home Appliances.

2. Abstract:

The conventional single phase induction motor (SPIM) based ceiling fans are difficult to design using the analytical procedure because of inherent non-linearities in the electromagnetic construction. The high skew of rotor bars to eliminate the effect of low order harmonics, makes the analytical solution based on 2D magnetic circuit, quite inaccurate. This paper deals with the systematic design and experimental validation of the energy-energy efficient SPIM for ceiling fan application. A systematic approach starting from the existing SPIM is presented for improvement in the efficiency of the motor using 2D finite element analysis. The process involves the design validation of the existing ceiling fan motor followed by a set of design of experiments (2D multi slice time stepping transient finite element analysis) to obtain the energy efficient motor. Taguchi's orthogonal arrays are used for the improvement in the performance of the motor.

3. Introduction:

Ceiling fans, invented by Philip Diehl in 1895, primarily circulate air to provide cooling. Permanent capacitor single-phase induction motors (PCSPIMs) are commonly used due to their ease of manufacture, good power factor, and long lifespan. Designing these motors, especially outer rotor types used in ceiling fans, is complex due to constraints like winding placement, stator saturation, rotor slot size, and material volume compromise. Existing design literature primarily focuses on inner rotor SPIMs. Accurate analytical modeling of ceiling fan SPIMs is difficult due to unequal magnetic circuit lengths, high rotor bar skew, and prominent winding overhang.

4. Summary of the study:

Background of the research topic:

Ceiling fan design using Single-Phase Induction Motors (SPIMs) is challenging due to inherent non-linearities and the need for high rotor bar skew.

Status of previous research:

Existing literature mainly focuses on inner rotor SPIMs, with limited research on outer rotor designs used in ceiling fans. Analytical modeling is complicated by factors like unequal magnetic circuit lengths and high rotor skew.

Purpose of the study:

To present a systematic design and experimental validation of an energy-efficient SPIM for ceiling fan applications.

Core study:

Improvement of SPIM efficiency using 2D Finite Element Analysis (FEA) and Taguchi's orthogonal arrays.

5. Research Methodology

Research Design:

A multi-level robust design process using five stages, employing Taguchi's orthogonal arrays to minimize the number of FEA simulations.

Data Collection and Analysis Methods:

2D multi-slice time-stepping transient FEA simulations. Taguchi's method was used to analyze the effect of design variables on motor efficiency. Statistical relations were used to predict optimal levels for each design variable.

Research Topics and Scope:

Validation of an existing commercial SPIM ceiling fan. Optimization of stator and rotor parameters using orthogonal matrices. Further tuning of parameters for performance improvement.

6. Key Results:

Key Results:

  • The existing commercial ceiling fan motor was validated using FEA.
  • Stator and rotor parameters were optimized using Taguchi's L18 orthogonal arrays.
  • Further refinement was performed using L4 and L8 arrays.
  • A final design with significantly improved efficiency was achieved.
  • The improved design showed reduced saturation levels in the flux density plots.
Fig. 2 (a) Airgap flux density (b) Air gap MMF in a 16 Pole ceiling fan SPIM
Fig. 2 (a) Airgap flux density (b) Air gap MMF in a 16 Pole ceiling fan SPIM
Fig. 3 Commercial ceiling fan stator (b) rated performance of the motor
Fig. 3 Commercial ceiling fan stator (b) rated performance of the motor
Fig. 5 Stages of formation of Orthogonal Arrays of Runs
Fig. 5 Stages of formation of Orthogonal Arrays of Runs
Fig. 6 Analysis of averages plot for (a) First L18 OA (b) Second L18 OA
Fig. 6 Analysis of averages plot for (a) First L18 OA (b) Second L18 OA
Fig. 9 (a) Flux density plot for the improved design motor (b) flux lines plot for the improved design motor.
Fig. 9 (a) Flux density plot for the improved design motor (b) flux lines plot for the improved design motor.
Fig. 10 (a) Air gap radial flux density plot wrt mechanical angle (b) Harmonic spectrum of the air gap flux density (c) winding currents (d) Torque vs Speed characteristics of motor and load for improved design
Fig. 10 (a) Air gap radial flux density plot wrt mechanical angle (b) Harmonic spectrum of the air gap flux density (c) winding currents (d) Torque vs Speed characteristics of motor and load for improved design

Figure Name List:

  • Fig. 1 Cross section of ceiling fan SPIM
  • Fig. 2 (a) Airgap flux density (b) Air gap MMF in a 16 Pole ceiling fan SPIM
  • Fig. 3 Commercial ceiling fan stator (b) rated performance of the motor
  • Fig. 4 Flux density plot of the existing ceiling fan motor at rated loading
  • Fig. 5 Stages of formation of Orthogonal Arrays of Runs
  • Fig. 6 Analysis of averages plot for (a) First L18 OA (b) Second L18 OA
  • Fig. 7 Analysis of averages plot for (a) L4 OA (b) L8 OA
  • Fig. 9 (a) Flux density plot for the improved design motor (b) flux lines plot for the improved design motor.
  • Fig. 10 (a) Air gap radial flux density plot wrt mechanical angle (b) Harmonic spectrum of the air gap flux density (c) winding currents (d) Torque vs Speed characteristics of motor and load for improved design

7. Conclusion:

A single-phase induction motor for ceiling fan applications was designed, developed, and tested. Taguchi's orthogonal arrays were used to handle the complex nonlinear behavior and discrete design variables. Stator and rotor were tuned through simulations.

A single phase induction motor for ceiling fan application with improvement in efficiency and service factor has been designed, developed and tested with satisfactory performance. The improved design of the motor is approached using the Taguchi's orthogonal arrays because of complex nonlinear behavior of the motor and discrete nature of the design variables for feasible manufacturing. The stator and rotor are broadly tuned with set of simulations with higher number of simulations runs. Further, they are fine tuned for improvement in the performance. The input wattage is much lower than the existing fan. Thus, a feasible improved design for ceiling SPIM is achieved.

8. References:

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9. Copyright:

  • This material is a paper by "Utkarsh Sharma, Bhim Singh". Based on "Design and Development of Energy Efficient Single Phase Induction Motor For Ceiling Fan Using Taguchi's Orthogonal Arrays".
  • Source of the paper: [DOI: Not provided in the paper, but it is an IEEE conference paper.]

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