Optimal Design of Induction Motor Using Parametric Winding Optimization with FEA

This paper presents a comprehensive parametric optimization study of a three-phase squirrel cage induction motor to enhance its electromagnetic performance by systematically varying the number of conductors per slot and wire diameter. The analysis of 154 design cases was performed using ANSYS RMxprt. The number of conductors per slot ranged from 39 to 65, and the wire diameter varied from 0.60 mm to 0.70 mm. The original motor design, which had 40 conductors and a 0.67 mm wire diameter, showed significant performance issues. These included low efficiency (80.17%), a poor power factor (0.749), severe magnetic saturation (2.403 T), and a high magnetizing current (3.455 A). Conversely, the optimized configuration, which employed 49 conductors and a 0.66 mm wire diameter, demonstrated considerable advancements. The efficiency rose to 82.45%, reflecting a 2.28 percentage point improvement; the power factor was enhanced to 0.870; and the stator tooth flux density was reduced to 1.547 T. Furthermore, total losses were diminished by 75.9 W, and the stator phase current was lowered by 14.7%, from 5.38 A to 4.59 A. Transient finite element analysis, performed using ANSYS Maxwell 2D, supported these results, thereby confirming the smooth torque response, balanced sinusoidal currents, and stable power conversion. The strong correlation between RMxprt parametric trends and Maxwell time-domain validation reinforces the physical relevance of the observed performance gains. Consequently, this study demonstrates that a systematic optimization of stator winding parameters offers a cost-effective method for significantly improving induction motor efficiency, eliminating the necessity for modifications to magnetic materials or core geometry, and thus providing a valuable reference for both industrial motor design and energy efficiency enhancements.