Optimizing and manufacturing 2500 kW electric motor of Khuzestan Steel Company using reverse engineering method

Yousefian, Mahmoud; Shiayan, Abbas; Rahimi, Alireza; Mashhadi Zadeh, Mir Mohsen

doi:10.48301/kssa.2025.487671.3118

Optimizing and manufacturing 2500 kW electric motor of Khuzestan Steel Company using reverse engineering method

Document Type : Original Article

Authors

Mahmoud Yousefian ¹

Abbas Shiayan ²

Alireza Rahimi ³

Mir Mohsen Mashhadi Zadeh ⁴

¹ Department of Electrical Engineering, National University of Skills (NUS), Tehran, Iran

² Department of Electrical Engineering, Ferdowsi University, Mashhad, Iran.

³ Department of Mechanical Engineering, Islamic Azad University, Mashhad, Iran.

⁴ Department of Electrical Engineering, Shahid Chamran University, Ahvaz, Iran.

10.48301/kssa.2025.487671.3118

Abstract

More than 90% of industrial electric motors are three-phase induction motors. These motors have several advantages over DC and synchronous motors, including low maintenance requirements, cost-effectiveness, simple construction, mechanical robustness, and the ability to generate starting torque. Therefore, optimizing their design and manufacturing is crucial, as they constitute the majority of electric loads in industry. The application of modern techniques, particularly reverse engineering, can significantly enhance the performance and lifespan of electric motors. This article investigates the optimization manufacturing of a three-phase induction motor for the Khuzestan Steel Company using reverse engineering, based on the knowledge and expertise of the project team. The electric motor in question is 8-pole and 2500 kW for operating at 6600 volts and 50 Hz. All stages of development—from initial specification gathering to construction and final testing—were performed using reverse engineering methods. After validating the calculations and comparing the design parameters and limitations with existing models, adjustments were made at each stage to improve insulation, dimensional tolerances, and cooling performance. To enhance the bearing cooling system, a water-circulation cooling unit was designed and integrated, allowing for adjustable temperature and flow rate. The results indicate that the newly developed motor outperforms the original sample in certain aspects, including reduced cost and operating temperature, making it a competitive alternative.

Keywords

High-voltage electric motor

reverse engineering

optimization

Bearing cooling

genetic algorithm

Subjects

power engineering

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