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Computational and Experimental Analysis of Bridge Current Behavior in Induction Machines with Bridge-Structured Windings
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Keywords
Induction machines
bridge-structured winding
bridge current analysis
finite element modeling
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Abstract
Induction machines with bridge-structured windings present complex electromagnetic behaviors that significantly influence current distribution, torque production, efficiency, and thermal performance. This study provides a comprehensive computational and experimental analysis of bridge current behavior in such machines, integrating finite element modeling (FEM) and laboratory experimentation to address critical gaps in existing research. The computational framework models the bridge windings as coupled electrical circuits within the FEM environment, capturing localized current peaks, flux distortions, and mutual inductive interactions that are often overlooked in traditional analytical models. Multislice 2D modeling techniques are employed to resolve fine-grained variations in bridge currents under both steady-state and transient operating conditions, accounting for realistic material properties of copper conductors and non-oriented electrical steel laminations. Experimental validation is conducted on a laboratory-scale induction machine prototype equipped with bridge-configured windings, using high-precision current and torque sensors to quantify RMS deviations, flux ripple, and localized heating effects. The results demonstrate that bridge currents generate significant non-uniformity, particularly at junction points, which correlates with minor torque ripple and localized thermal hotspots. Comparative analysis between computational predictions and experimental observations confirms the accuracy of the FEM model, with deviations within 8% RMS across all measured parameters. The study further examines the implications of bridge current behavior for industrial automation applications, highlighting trade-offs between mechanical stability, electrical efficiency, and manufacturability. The findings also provide a foundation for predictive maintenance strategies and design optimization of non-standard winding configurations. Overall, this research advances the understanding of bridge current dynamics, offering an integrated methodology for both theoretical analysis and practical implementation, while providing actionable insights for engineers and researchers seeking to enhance the performance and reliability of induction machines in high-precision industrial systems (Michaelides, 2011).
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References
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