Quality Assurance Testing for Screening Defective Aluminum Die-Cast Rotors of Squirrel Cage Induction Machines

Myung Jeong, Jangho Yun, Yonghyun Park, Sang Bin Lee*, Konstantinos N. Gyftakis

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

Abstract / Description of output

The recent trend in squirrel cage induction motor manufacturing is to replace fabricated copper rotors with aluminum die-cast rotors to reduce manufacturing cost to stay competitive in the global market. Porosity in aluminum die-cast squirrel cage rotors is inevitably introduced during the die cast process. Porosity can cause degradation in motor performance and can lead to a forced outage causing irreversible damage in extreme cases. Many offline and online quality assurance test methods have been developed and applied for assessment of rotor quality. However, years of experience with the existing test methods revealed that they are not suitable for quality testing or capable of providing a quantitative assessment of rotor porosity with sufficient sensitivity. In this paper, a new offline test method capable of providing sensitive assessment of rotor porosity is proposed. It is shown that rotors with minor and distributed porosity that are difficult to detect with other tests can be screened out during manufacturing. The proposed method is verified through a 3-D finite element analysis and experimental testing on closed and semiopen slot aluminum die cast rotors of 5.5 kW induction motors with porosity.

Original languageEnglish
Pages (from-to)2246-2254
Number of pages9
JournalIEEE Transactions on Industry Applications
Issue number3
Early online date12 Feb 2018
Publication statusPublished - 1 May 2018

Keywords / Materials (for Non-textual outputs)

  • Aluminum die-cast rotor
  • fault detection
  • fill factor
  • induction machines
  • porosity
  • quality assurance
  • squirrel cage rotor


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