How to optimize the space in end-winding of a three-phase induction motor

[ed76]

Hi Guys,

I want to reduce the area taken by the end-winding to optimize an AC induction motor. My questions are the following:

1) Can changing the winding from lap to concentric save space for the end-winding assuming a single-layer winding or a double layer?
2) How about changing the number of turns per slot, for example from 2 to 3? I know this changes the performance and operation of the motor but I know how to deal with that. I'm assuming here having a smaller bundle of strands might be easier to arrange at the end-winding but I'm not sure.
3) How about changing the number of poles from 4 to 6 assuming we have 72 stator slots? Again I know that design will change for the motor and I need to choose the optimal number of poles not only based on the end-winding but the overall performance. However, my question are only here related to the end-winding and how I can reduce the area they occupy.

Any other tips are welcome.

Thanks

 

[zlatkodo]

Obviously, end winding should be reduced, but what exactly: height or width?
Attach some photos illustrating the original winding and housing.
A little strange is that HP and/or rpm of your motor can be reduced so significantly. Note, some changes proposed by you will cause approximately a twice lower HP ?!?!
You need to be more specific about what you want. Is it about designing a new motor or repairing the old one? What are a nameplate data? Tell us all the winding data, ( if they are known) in order to suggest you the feasible redesign ?
Read more about the general limitations in case of winding redesign:
Winding Redesign

 

[ed76]

Hello, thanks for the interaction.

The motor is new. I have the freedom to manipulate several machine parameters to come up with the right HP and speed etc. My questions are directly related to the reduction of the end winding height. Any general tips regarding this are appreciated.

 

[theode]

When winding coils,the excess at the ends is to allow fitting into the slots.
Also the coils need shaping to allow each phase to fit in.
You could try winding each coil a slot at a time in the stator and pull the ends tighter.
When winding,the wire is quite soft.This makes it easy to shape the coil ends with a mallet.
Depends how small you want them.
It's the wire in the slots that do the work,so the ends can be any size.
Just take care with the insulation.