Abstract

Introduction: This research presents an innovative contribution to the field of induction motor efficiency optimization by analyzing the complex interactions between copper and iron losses in a 15 kW three-phase induction motor under variable operating conditions (10–60 Hz). While previous studies—such as Li et al. (2024) [16]—focused on simplified two-dimensional models or purely theoretical analyses, this study employs an integrated approach that combines advanced modeling with experimental validation, the main objective is to establish a reliable, accurate framework for quantifying and understanding loss mechanisms across a range of frequencies and thermal environments. Methodology: The study utilizes both 2D and 3D finite element analysis (FEA) in conjunction with high-precision experimental measurements to evaluate the effects of copper and iron losses under real-world dynamic conditions. A novel aspect of this methodology lies in accounting for manufacturing-induced variations, such as changes in the magnetic B−HB-H curve due to lamination processes. Additionally, the analysis incorporates loss measurement in end-winding regions due to magnetic leakage—often neglected in conventional simulations—and performs sensitivity analysis on winding arrangements and lamination thickness to extract industrially viable design recommendations. Results: The results demonstrate a significant rise in both copper and iron losses with increasing frequency. Copper losses were predominantly influenced by proximity and skin effects, leading to increased AC resistance and localized heating in active windings, iron losses, on the other hand, were found to be heavily dependent on magnetic flux density, lamination quality, and the presence of manufacturing defects. Notably, neglecting production-induced changes in core material properties resulted in substantial errors in conventional modeling. By optimizing wire layout, adopting thinner laminations (0.3 mm), and implementing advanced cooling systems, the total loss was reduced by up to 20%, these improvements enhance energy efficiency, extend motor lifespan, and reduce operational costs. Conclusion: This study provides a robust framework for understanding the coupled behavior of copper and iron losses in induction motors and highlights the importance of selecting appropriate materials, modeling manufacturing effects, and improving thermal management strategies, the integration of experimental and numerical methods represents a substantial advancement over prior work and provides actionable insights for optimizing industrial motor design to achieve higher efficiency and sustainability.