Comparing Squirrel Cage and Wound Rotor Motors for Industry

In the vast landscape of industrial automation and power systems, induction motors serve as the backbone of mechanical power. Among various types, squirrel cage and wound rotor (slip ring) induction motors stand out with their distinct structures and performance characteristics. This article provides an in-depth analysis of these two motor types to guide optimal selection for different applications.

The squirrel cage motor features a rotor resembling its namesake—a cylindrical laminated iron core with evenly distributed aluminum or copper bars. These bars are permanently short-circuited by end rings, forming a closed circuit without brushes, slip rings, or external connections.

Key design features include:

• Skewed bars: Prevent magnetic locking between stator and rotor teeth
• Noise reduction: Minimizes magnetic hum and slot harmonics
• Improved starting torque: Ensures smooth torque output during startup

Wound rotor motors employ a three-phase winding similar to the stator. The rotor winding connects in a star configuration, with three terminals brought out through slip rings. Carbon brushes maintain constant contact with these rings, enabling external resistance connection to the rotor circuit.

• Starting torque: Squirrel cage (1.5-2x full load) vs. wound rotor (2-2.5x)
• Starting current: Squirrel cage (5-7x full load) vs. wound rotor (2.5-3.5x)

• Squirrel cage: Limited options requiring external devices like VFDs
• Wound rotor: Smooth speed control (50-100% of synchronous speed) via external resistance

• Squirrel cage: 90-95% efficiency due to minimal rotor losses
• Wound rotor: 85-90% efficiency affected by brush friction and copper losses

• Squirrel cage: 0.8-0.9 at full load
• Wound rotor: 0.6-0.8 due to additional reactance

• Squirrel cage: Aluminum/copper bars with laminated iron core
• Wound rotor: Insulated copper windings with slip ring assembly

The stator-rotor air gap affects excitation current, power factor, overload capacity, and cooling. Larger gaps improve cooling but increase excitation current requirements.

• Direct-on-line (DOL) for small motors
• Star-delta starting for medium motors
• Autotransformer starting for large motors

Rotor resistance starting provides high starting torque with limited current, gradually reducing resistance as the motor accelerates.

• Fans and blowers
• Centrifugal pumps
• Compressors
• Conveyor systems

• Cranes and hoists
• Elevators
• Ball mills
• Large pumps/fans requiring soft starts

• Squirrel cage: Minimal (bearing lubrication, vibration checks)
• Wound rotor: Frequent (brush replacement, slip ring maintenance)

Squirrel cage motors excel in constant-speed applications where simplicity and reliability are paramount. Wound rotor motors remain essential for applications requiring high starting torque, precise speed control, or soft-start capabilities, despite higher initial costs and maintenance requirements.