DESIGN SHEET FOR ARMATURE OF D-C GENERATOR- PART 1

Item
No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

24
25
26
27
28
29
30
31
32

Specification: 30kw; 230/250 volts;

900 rpm

Armature Core and Winding

Number of Poles
Frequency
Ratio of pole arc to pole pitch..
Specific Loading
Apparent air-gap flux density (open circuit)
Line Current (full load).
Type of Winding
Armature Current per Circuit
Output factor (
)..
Armature diameter, in..
Peripheral velocity, fpm
Total number of face conductors
Number of slots.
Number of conductor per slot.
Axial length of armature core; gross, in
Flux per pole (open circuit)..
Pole pitch, in..
Pole arc, in.
Area covered by pole face (
), sq in
Dimension of armature conductors, in. units
Slot pitch, in.
Slot width, in....
Slot depth in.
Tooth width, in.
At top
At root
Average
Number of radial ventilating ducts
Width of radial ducts, in.
Net length of armature core, in.
Net tooth section under pole, at center, sq in.
Apparent density in teeth under pole, at
center, sq in.
Length per turn of armature coil, in.
Resistance of one turn, ohms at 60C
Resistance of armature, ohms.
drop in armature, volts..

Symbol

D
v
Z
S
..

Preliminary
or
assumed
values

Final
Value

4
.
0.64
625
50,000

33.8667
1,683.33
14
3300
812
..
..

4
30
0.64
636
50,000
200
Lap
1,654
14
3540
826
118
7
8.439

11
7.04
..
..
s
d
t
..

n
..

.
.
.
.
.
.
.
.
...

2(0.02 X 0.124)

0.3
0.488

0.0467
0.06
3
0.375

.
.
..

.
..
.
..

63
0.0935
12.5

33
34
35
36
37
38
39

loss in armature winding, watts

Estimated full-load flux per pole
Flux density in armature core below
teeth.
Internal diameter of core stampings, in
Weight of iron in core (without teeth), lb..
Weight of iron in teeth, lb...
Total weight of armature stampings, lb

..
.

1693.335
84,600
85,000

..

DESIGN OF ARMATURE WINDING AND CORE

Item 1: Number of Poles and Frequency. Refer to Art. 3. Either four or six poles
might be suitable, but, since armature speed is fairly high, four poles will probably be
best for a trial design. The frequency is, therefore,

Item 2: Ratio of Pole Arc to Pole Pitch. Refer to Art. 2. Since the machine will be
provide with commutating poles, a suitable value for this ratio is
Item 3 and 4: Specific Loading and Air-Gap Density. Refer to Art. 2. From the
table on page 12, select
, and from the table on page 11, select
.
These are tentative selections and will be modified to suitable values as the design
proceeds.

Item 5: Line Current.

Item 6: Type of Winding. Refer to Art. 6. Since the current per path should no
exceed 250 to 300 amp it is clear that a lap winding must be used in this case. (A wave
winding with two parallel paths would make
200/2=100amp.)
Item 7: Armature Current per Circuit. The current in each armature circuit will be
one-fourth of the line current if the shunt-exciting current is neglected. A table giving
usual values of the shunt-field current, expressed as a percentage output current, will
be found on page 121. Assuming a shunt excitation of 1.6 percent, the full-load current
in each armature conductor will be about (120/6)(1+0.016)=33.8667 amp.
Item 8, 9 and 10: Armature Diameter. Refer to Art. 2.
By formula (7)

Using a rectangular pole face, where

in Eq. (8) equals to 0.71

Hence
=

A rectangular pole face, with the armature length equal to about 1.4 times the
pole arc, is desirable in this design because of the comparatively high speed. For the
diameter calculated, the peripheral velocity will be

Before proceeding with the design, it will be well to see whether or not a number
of poles different from the number selected from the trial calculation would be
satisfactory. The following numerical quantities should be checked against the usual
values found in commercial machine.
a. The frequency
is near the upper permissible limit: if four poles were
selected the frequency should be 80 cps, an excessive value.
b. The peripheral velocity
is reasonable from the standard point of
mechanical stresses and good ventilation.
c. The ampere-conductors per pole rarely exceed 25,000 (see p. 14). A large
pole pitch due to small number of poles, calls for a greater amount of iron in the
magnetic circuit and a larger air gap under the pole face to reduce the effect of armature
reaction on the flux distribution in the air gap. In this design, the approximate number of
armature ampere-conductors per pole

Which is well below the upper limit. The design may, therefore, proceed on the basis of
four poles.
Items 11, 12, and 13: Number of Inductors, Slots, and Conductors Per Slot. Refer
to Art 2.

With seven conductor per slot, this would mean a preliminary number of slots
and a slot pitch

; see Art. 12, and note that this is reasonable. Next,

calculating the number of slot per pole it is found to be

. However, since it is

desirable to have an integer of slots per pair of poles so that the slots per pole will be an
integer plus 1/2 , the total number of slots will be increased to 106; thus, slots per pair of
poles equal to 118/2=59, and slot per pole equal 29.5. Also note that the number of

slots embraced by each pole arc is an integer in this design;

29

0.64=19. With

the final value of Z=826, q is therefore 826 33.8667/14 =636

Item 14: Axial Length of Armature Core. This may be determined from the final
value of the output factor
; since this is inversely proportional to , it is equal to

and

This length is, however, subject to correction if later flux density calculations indicate
that this is desirable.
Item 15: Flux per Pole (Open Circuit). Using the value of Z, determined in item
11,

Item 16, 17, and 18: Pole Pitch, Pole Arc, and Pole Area.
Pole pitch
Pole arc =

. Note that

instead of the value 1.4,

originally assumed. Pole area =

The apparent air-gap flux density can now be computed and compared with the
assumed value in item 4.
Thus,

Note that this is less than the assume value as used in formula (7) for the calculation of
the output factor.
Items 19 to 22: Dimensions of Slots and Armature Conductors. By formula (17)
on page 36, for a well-ventilated machine

Whence

It is necessary now to find by trial the best arrangement of 875, item 11, in 214
slots, item 12.
The slot pitch (refer to Art. 12) is

In order to determine the actual dimensions of the armature conductors, it will

first be convenient to assume a width of slow. This should be about 0.3in., which makes

the ratio of tooth width to slot width 1.305., a reasonable value. Since a wire having an
area of 0.08 is rather light and easy to bend and shape, it will be desirable to use two
conductors in parallel in the winding copper and to arrange then shown in Fig. 17. This
arrangement suggest itself because there exists the possibility of having either twice as
many commutator segments as slots or the same number of segments as slots.
The width of each of the four side-by-side rectangular conductors will now be
determined. The slot insulation on each side of the slot, by formula (16), is 27 +
(250/30)=35 mils, and the cotton covering on each conductor will add a total of about 36
mils to its thickness. The space left for each of the eight conductors is, therefore,

Since the copper area of two conductors is 0.08 sq in. it follows that each conductor will
have a depth of
Finally, the slot depth can be determined. Allowing about one-third of the slot
width for the hardwood or fiber wedge, or 0.135in., and 35 mils for each of the insulation
spaces above, below and between the coils,
Thus, in Fig. 17,
and
.
Using the dimensions thus far calculated, it will be desirable to check and see if
the flux density in the teeth is not excessive (item 28).
Item 23: Tooth Dimensions. The width at the top of the tooth
. The circumference of the circle through the bottom
of the slots is
; and since the slots have paralleled sides, the
width of tooth at the root is (41/118)-0.3=0.0467in.
The average tooth width is, therefore, 0.06 in.
Items 24 and 25: Ventilating Ducts. Refer to Art. 16. Not more than three ducts
should be necessary in the armature 9 to 11 in. long, with each duct 3/8 in wide.
Item 26. Net length of Armature
Item 27. Net Cross Section of Teeth under Pole. The cross section of iron in the
teeth under one pole, at the midsection, is

Item 28: Flux Density in Teeth. Refer to Art. 17. The apparent flux density at the
center of the tooth, under open-circuit condition is,

Item 29: Length per Turn of Armature Coil. Referring to Art. 16,

By formula (18),

Therefore, the total length per turn

Item 30 to 33: Armature Resistance. Since the resistance of a conductor of a
given material at a given temperature is directly proportional to its length and inversely
proportional to its cross section, a very convenient and easily remembered rule is that
the resistance of copper is 1 ohm per cir-mil inch at a temperature of 60C. Therefore,
the resistance of one turn at 60Cwill be

There being ( )

cir mils in 1 sq in. With a total of 826/2=413 turns divided into

four parallel paths (a four-pole lap winding), the resistance per circuit will be 0.00362
(413/4) =0.374 ohm, and the total armature resistance will be one-fourth of this, or
0.0935
The IR drop in the armature winding is 0.374 33.8667= 12.5 volts or 1.14
percent of the full-load terminal voltage. This compares favorably with the approximate
figures given in Art. 18.
The watts lost in the armature winding (item 33) are 12.5(33.8667 4)=1693.335.
Item 34: Full load Flux. More flux must enter the armature at full load than no
load because the speed is assumed to be constant and the terminal emf is higher.
Moreover, in addition to the specified increase in terminal voltage from 230 at no load to
250 at full-load, it is necessary to develop (generate) enough voltage to overcome the
internal resistance. Assuming a brush-contact drop of 2 volts and a series-field a
commutating-field drop about one-half that in the armature winding, the total generated
voltage at full load must be
The full-load flux must, therefore be,

Item 35 and 36: Flux Density in Armature Core. Internal Diameter. Usual flux
densities for different frequencies are given in the table in Art. 17. A density of 85,000
will be suitable. Bearing in mind that the air-gap flux divides into two equal parts below
the teeth, the armature-core flux in one-half of the total flux. Therefore,

Whence the radial depth

of the armature core below the teeth is

The internal diameter of the core stamping is, therefore,

Item 37: Weight of Iron in Core. The weight of a cubic inch of iron is 0.28 lb, and
the total weight of iron in the core below the teeth will, therefore, be

Item 38: Weight of Iron in Teeth.

Where the figure 0.098 is the width of the tooth at the center.
Item 39: Total Weight of Armature Stampings.

DESIGN SHEET FOR ARMATURE OF D-C GENERATOR- PART 2

Item
No.

40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

Specification: 30kw; 230/250 volts;

900 rpm

Commutator and Brushes

Diameter of commutator, in.
Average volts per turn of armature winding..
Number of turns between bars.
Total number of commutator bars
Bar pitch, in.
Width of copper bar (on surface), in.
Radial depth bar, in.
Current density at brush-contact surface,
amp per sq in..
Contact area per brush set, sq in
Brush arc (circumferential width), in.
Axial brush length (total) per set, in
Number of brushes per set.
Axial length of commutator, in.
Brush-contact drop, volts..
Brush-contact loss, watts..
Brush-friction loss, watts.
Total brush loss, watts..
Drawing to scale giving leading dimensions
of armature and commutator..

Symbol

.
.
.
.
.
..

Preliminary
or assumed
values

Final
Value

.
.
.

11

40
1.693

....
.

Fig. 18

1
413
0.084
0.054
1.75
39.835
1.7
1.0
1.7
2
2.3
311.574

DESIGN OF COMMUTATOR AND BRUSHES

The design will now proceed with the calculation of the dimension of the
commutator and brushes, and other important information concerning them. For this
purpose the student will find it necessary to refer to Chap. 13 for details concerning
mechanical considerations.
Item 40: Diameter of Commutator. Refer to Art.14. A diameter of commutator not
exceeding 80 percent of the armature-core diameter is generally found practical,
although a reasonably good rule to follow is to make

Thus,

This is 78.57 percent of the core diameter and makes the peripheral velocity 0.7857
3300=2,592.85 fpm, near the upper limit. This dimension is subject to correction if the
thickness of the individual bars does not work out satisfactorily.
Items 41 to 43: Number of commutator bars. The potential difference between
adjacent commutator segments in a 250-volt machine might be anything between 4 and
12 volts. The average volts per turn of armature winding are

If the commutator is constructed with the same number of segments as slots there will
be four turns between adjacent segments; this will mean a potential difference of 21.12
volts between segments, because, for a lap winding and eight effective conductors per
slot, there will be four turns per element. The width of the commutator segment will,
moreover, be excessive, as a simple calculation should indicate. It will, therefore, be
desirable to use 413 commutator segments, with a resulting improvement in
commutation and more suitable, narrower, segment.
Items 44 and 45: Width of Commutator Segments. The bar pitch s
and, with mica 0.03 in thick, the bar width 0.084-0.03=0.054 in. at the
commutator surface.
Item 46: Radial Depth Segment. The proper depth of copper in the cross section
of the commutator bar is usually determined by mechanical considerations ( Chap. 13).
It must be sufficient to prevent appreciable machines (or bending) under the action of
centrifugal force. In large machines, with commutators of considerable length, the depth
of the bar, should, therefore, be considered in connection with peripheral velocity and
the (axial) distance between points of support. For peripheral velocities up to 2,500 fpm
the radial depth of the commutator segment should be about
; for
higher peripheral speeds the depth should be increased in proportion to the square of
the velocity. Thus,

Items 47 to 51: Dimensions of Brushes. Unless a very soft quality of carbon is

used, the current density over the brush-contact surface is about 30 to 50 amp per sq
in., (see Fig. 38). Taking 40 as a preliminary value, to be modified later if necessary to
accommodate a standard size of brush, the contact surface of one set brushes will be
(4 30.7)/(2 40)=1.693 sq in. A 1-in. width of brush, Art. 34, will cover a little over three
bars, which is reasonable for an armature with 428 segments and simplex-lap winding.
The total length of brushes per set, measured in a direction parallel to the axis of the
machine, will then be 1.693/1.0=1.693 (say) 1.7 in., which can be made up to two
brushes
1in. The surface density with thus be increased slightly to 40 (1.693/1.7)=39.835
amp per sq. in.
Item 52: Length of Commutator. In addition to 1.7 in. which be provided for the
two 1/2-in carbon brushes, the axial length if the commutator face must allow for the
following; (a) brush holders and clearances= 2 0.75/4=0.38 in.; (b) staggering (+) and
(-) brushes = 5/8 in. ; (c) end clearance for brushes = 1in.; (d) end play=3/8 in. The total
length will therefore, be
Items 53: Brush-Contact Drop. Referring to Fig. 38. The brush-contact drop for
hard carbon at about 40 amp per sq in. is 2.08. Allowing 10 percent for roughness,
chipping, and irregularities, this drop will be 2.3 volts.
Items 54 to 56: Brush Losses. The brush-contact loss will be
(2.3)(4 33.8667)=311.574 watts.
The brush friction loss may be calculated by using the formula (48), page 143,
where

using c=0.25 for hard carbon, P=1lb per sq in. for a peripheral velocity speed greater
than 3,000 fpm.

Total brush loss =

.
Items 57: The illustration (Fig. 18) gives the leading dimensions of armature and
commutator as worked out in this design. The diameter of the shaft supporting the
armature may be calculated by formula (160) in Chap. 13 treating the mechanical
features of the design of electrical machinery. This is

Another assembly of armature core and commutator, suitable for a machine of

small output, is shown on Fig. 19. This construction provides openings for ventilation
inside the armature core, but there is no provision of air circulation inside the

commutator. The construction here shown would be suitable for small armatures with
core stampings up to 16 in. in diameter

POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

College of Engineering
Electrical Engineering Department

ELECTRICAL MACHINE DESIGN

Design 1: DC Generator Armature Design

Submitted by
ABOGADIE, NICOLLE JAN A.
BSEE V-2

Submitted to
ENGR. LIBRADO S. GESALTA
Instructor

July 1, 2013