Design of DC Motor

% design of dc motor
pi=22/7;
P = input('enter value of the rated power of dc motor (KW)
:
V=input('enter rated voltage value');
Ia=P*1000/V;
A=2;
N = input('enter the speed of motor (RPM)
:
n=N/60;
eta1 = input('enter the efficiency of motor in terms of percentage:
eta=eta1/100;
shi=input('enter value of pole arc to pole pitch(0.64 to 0.72)
%specific magnetic loading
if(P<=5)
Bg=.58;
ac=15000;
elseif((P>=5)&&(P<=10))
Bg=.65;
ac=17500;
elseif((P>=10)&&(P<=50))
Bg=.78;
ac=25000;
elseif((P>=50)&&(P<=100))
Bg=.82;
ac=27500;
elseif((P>=100)&&(P<=200))
Bg=.87;
ac=31000;
elseif((P>=200)&&(P<=500))
Bg=.92;
ac=35000;
elseif((P>=500)&&(P<=1000))
Bg=.96;
ac=40000;
elseif((P>=1000)&&(P<=2000))
Bg=.98;
ac=43000;
elseif((P>=2000)&&(P<=5000))
Bg=1.05;
ac=49500;
elseif((P>=5000)&&(P<=10000))
Bg=1.15;
ac=51000;
elseif(P>=10001)
display('software can not design up to this much rating ');
end
Bav=Bg*shi;
%specific electric loading
Ki=.9
p=input('enter value of no. of poles
if (P >= 100)
Pa=P;
else
Pa=P*((1+2*eta)/(3*eta));
end;
');
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display('power developed by armature is (KW)

display(Pa);
f=p*n/2;
display('frequency of flux reversal is
(Hz)
display(f);
if (f<25)
p=input('please increase number of poles: ');
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
p=input('please decrease number of poles: ');
%
elseif((f>=25)&(f<=50))
%
display('number of poles is suitable.');
f=p*n/2;
end
elseif(f>50)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
p=input('please decrease number of poles:
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
elseif((f>25)&&(f<=50))
');
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
% display('number of poles is suitable.');
f=p*n/2;
end
end
if (f<25)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
');
:
')
f=p*n/2;
end
elseif(f>50)
f=p*n/2;
if (f<25)
p=input('please increase number of poles:
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
f=p*n/2;
end
% elseif((f>=25)&(f<=50))
%
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
f =p*n/2;
end
f=p*n/2;
end
if (f<25)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
f=p*n/2;
end
elseif(f>50)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
f=p*n/2;
end
% elseif((f>=25)&(f<=50))
%
if (f<25)
f=p*n/2;
elseif(f>50)
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%
%

elseif((f>=25)&(f<=50))
f=p*n/2;
end
f=p*n/2;
end
if (f<25)
f=p*n/2;
if (f<25)
elseif(f>50)
%
elseif((f>=25)&(f<=50))
f=p*n/2;
end
elseif(f>50)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
% elseif((f>=25)&(f<=50))
%
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
end
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if (f<25)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
elseif(f>50)

f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
%
elseif((f>25)&(f<50))
%
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
end
if (f<25)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
elseif(f>50)
f=p*n/2;
if (f<25)
f=p*n/2;
elseif(f>50)
%
elseif((f>=25)&(f<=50))
%
f=p*n/2;
end
% elseif((f>=25)&(f<=50))
%
if (f<25)
f=p*n/2;
elseif(f>50)
f=p*n/2;
elseif((f>25)&&(f<s50))
');
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f=p*n/2;
end
end
if (Ia>=400)
display('from the current rating for higher than 400A');
display('lap winding is used');
A=p;
elseif (Ia<=400)
display('from the current rating for less than 400A');
display('wave winding is used');
A=2;
end
Ib=2*Ia/A;
Co=(pi^2)*Bav*ac/1000;
display('output co-efficient is
display(Co);
product=Pa/(Co*n);
');
val1=(product*p)/(shi*pi);
D=(val1)^(1/3);
display('value of calculated diameter of armature core is (m)
:
display(D);
D=input('enter value of standardized diameter of armature core (m):
L=product/(D^2);
display('value of length of armature core is (m)
:
display(L);
L=input('enter value of standardized length of armature core(m)
:
tow=pi*D/p;
b=shi*tow;
Va=pi*D*n ;
%pole arc
display('peripheral speed of armature is(m/s):');
display(Va);
y=.01
duct
nd1=L/0.13;
nd=ceil(nd1);
display('number of ventilating duct is
display(nd);
%Li=Ki*(L-(nd*y));
%display('net iron length is (m)
%display(Li);
');
');
');
%width of ventilating
t=0.35;
display('the thickness of lamination used for machine is (mm)
display(t);
display('........calculation of length of airgap(lg).........')
%........calculation of length of airgap(lg).........
Kg=1.15;
display('assuming gap contraction factor (Kg)');
display(Kg);
ATa=ac*tow/2;
%mmf required for armature
display('armature mmf is (AT):');
');
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:
');
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display(ATa);
Lg=.5*ac*tow/(1600000*Kg*Bg);
%length of airgap
x1=.01*tow;
y1=1.015*tow;
if (Lg>=x1 && Lg<=y1)
display('length of airgap is suitable');
elseif (Lg<=x1)
Lg=.55*ac*tow/(1600000*Kg*Bg);
elseif (Lg<=x1)
Lg=.6*ac*tow/(1600000*Kg*Bg);
elseif (Lg<=x1)
Lg=.65*ac*tow/(1600000*Kg*Bg);
elseif (Lg<=x1)
Lg=.7*ac*tow/(1600000*Kg*Bg);
elseif (Lg<x1)
display('length of airgap is not in limit');
elseif (Lg>y1)
display('length of airgap is not in limit');
end
display('length of airgap is (m)');
display(Lg);
pqr=(Lg*800000*Kg*Bg)/ATa;
ATg=pqr*ATa;
%mmf required for airgap
display('mmf reqired for airgap is (AT)');
display(ATg);
%.......design of armature.....
display('...........design of armature...........')
phi=Bav*pi*D*L/p;
%flux per pole in weber
display('flux per pole in weber is (wb)');
display(phi);
E=.965*V;
display('generated EMf is (V)');
display(E);
Z=E*A*60/N*phi*p;
%number of armature conductors
Iz=Ia/A;
%current per parallel path
display('current per parallel path is (A):');
display(Iz);
display('for selection of current density:');
display('press 1 for large strap wound armatures with very good normal
ventilation,');
display('press 2 for small wire wound armatures with very good normal
ventilation');
selectdelz=input(' press 3 for high speed fan ventilated machines');
if (selectdelz==1)
delz=4.75*10^6;
elseif (selectdelz==2)
delz=5.35*10^6;
elseif (selectdelz==3)
delz=6.28*10^6;
end
az=Iz/delz;
%cross section area of armature conductor
display('cross section area of armature conductor is(mm^2)');
display(az);
Zc=Z/A;
%no. of armature conductors per parallel path
Lmta=(2*L)+(2.5*tow);
%.......design of armature core......
Li=Ki*(L-(nd*y));
display('internal length of core is (m):');
display(Li);
phi_c=phi/2;
%flux per pole in armature core
display('flux per pole in armature core is (wb):');
display(phi_c);
Bc=1.25;
%flux density in core in
display('flux density in core in wb/m^2');
display('Bc');
Ac=phi_c/Bc;
%area of armature core
display('area of armature core');
display('Ac');
wb/m^2
dc=phi_c/(Li*Bc);
%depth of armature core
display('depth of armature core is (m)');
display(dc);
%ds=?;
%
%Di=D-2*(dc+ds);
%internal diameter of core
%.......no. of armature slots........

%constraint code for selection of no.of slots in
%armature
pi=22/7;
u1=pi*D*10/25;
v1=pi*D*10/35;
u2=round(u1*100);
v2=round(v1*100);
n2=u2-v2;
for i=1:n2
v2(i+1)=v2(i)+1;
if rem(v2(i+1),3)==0
if rem(v2(i+1),2)~=0
a2(i+1)=Z/v2(i+1);
x2(i+1)=round(a2(i+1));
if rem(x2(i+1),2)==0
% display(x2(i+1));
display( v2(i+1));
tyu=v2(i+1);
%S=input('please select from above lesser no. of slots');
%zxc=x2(i+1)*S;
%display('final no of conductorsis:');
%display(zxc);
end
end
end
end
S=input('please select from above lesser no. of slots');
v3(i+1)=round(v2(i+1));
Z=v3(i+1)*S;
ZS=v3(i+1);
display('final no of conductors is:');
display(Z);
display(ZS);
coils=S;
Ra=E/Ia;
display(Ra);
S_pitch=pi*D/S;
%............design of the field system............
display('............design of the field system............');
%..........dimentions of poles
display('............diamentions of poles............');
if(P<=50)
%leakage coefficient for the field
Cl=1.20;
elseif(P>=50 && P<=100)
Cl=1.18;
elseif(P>=100 && P<=200)
Cl=1.15;
elseif(P>=200 && P<=500)
Cl=1.13;
elseif(P>=500 && P<=1000)
Cl=1.11;
elseif(P>=1000)
Cl=1.10;
end
Bp=input('please enter the value of flux density of field pole in range of 1.2
to 1.7 (wb/m^2)');
phi_p=Cl*phi;
%flux per pole
Ap=phi_p/Bp;
%cross section area of pole
Lp=L-.01;
%as per guideline lenth of pole
bp=Ap/Lp;
%width of pole
display('flux per pole with considering leakage factor (wb)');
display(phi_p);
display('cross section area of pole (m^2)');
display(Ap);
display('lenth of pole (m)');
display(Lp);
display('width of pole(m)');
display(bp);
%...........magnetic circuit
%calculation for field

if(D<=.2)
%leakage coefficient for the field
df=.03;
elseif(D>=.2 && D<=.35)
df=.035;
elseif(D>=.35 && D<=.5)
df=.04;
elseif(D>=.5 && D<=.65)
df=.045;
elseif(D>=.65 && D<=1.0)
df=.050;
elseif(D>=1.0)
df=.055;
end
ATfl=1.6*ATa;
row=2*10^-8;
Lmt=pi*(Lp+bp)+4*df;
(m)
Ef=.85*V/p;
per pole(V)
af=ATfl*row*Lmt/Ef;
winding(m^2)
dia_field_wdg=(4*af)/pi;
delta_f=2*10^6;
If=delta_f*af;
Tf=ATfl/If;
Rf=Tf*row*Lmt/af;
Sf=.75;
qf=700;
hf=Tf*af/(Sf*df);
hpl=(hf+.13*tow)/0.85;
hs=.15*hf;
Qf=If^2*Rf;
c=.15;
cs=2*Lmt*(hf+df);
thetac=(Qf*c)/cs;
%mmf for field winding(AT)

%resistivity(A*m)
%lenth of mean turn of field winding
%voltage across shunt field winding
%cross section area of field
%diameter of field winding
%current density in field winding
%current in the field winding
%turns of field winding
%resistance of the field winding
%space factor
%permissible loss watt per (m^2)
%height of the field winding
%height of the field pole
%height of the field pole shoe
%copper losses in field winding
%cooling coefficient
%cooling surface area(m^2)
%temperature rise inn machine
%......design of yoke.......
phi_y=phi_p/2;
By=1.4;
Ay=phi_y/By;
Ly=1.5*L;
dy=Ay/Ly;
Dyi=D+Lg+hpl;
Dyo=Dyi+dy;
%.....design of inter poles.......
%flux in yoke
%flux density in yoke
%cross section area in yoke
%lenght of yoke
%depth of yoke
%internal diameter of yoke
%outer diameter of yoke
Lpi=.62*L;
Lgi=1.625*Lg;
hpi=((Dyi-D)/2)-Lgi;
Dip=pi*D/S;
%lenth of interpole
%lenth of interpole airgap
%height of intter pole
%diameter of interpole
kgi=.13;
%gap contraction factor
Bgi=.5;
%flux density of interpole
ATi=(800000*kgi*Bgi*Lgi)+((ac*tow)/2); %mmf for interpole
Ii=Ia;
%current of interpole winding
Ti=ATi/Ii;
%turns of interpole
delta_i=3.25*10^6
%current density of interpole winding
ai=Ii/delta_i;
%cross section area of interpole
winding
Lmti=pi*(Dip);
Ri=Ti*row*Lmti/ai;
%resistance of interpole winding
Pcui=Ii^2*Ri;
%copper loss in interpole winding
%.....DESIGN OF WINDING.....
%coil=(E*p)/15;
coils=S;
if (Ia>=400)
Yb1=(2*coils/p);
Yb=round(Yb1);
if rem(yb,2)==0
Yb=Yb+1;
end
Yf=Yb-2;
Y=Yf-Yb;
Yc=1;
display('closed type simplex progressive lap winding is used');
%design of equalizers connection
Yeq1=(2*coils/p);
Yeq=round(Yeq1);
no_eqrings=12;
no_tappings=(no_eqrings*p)/2;
Yph=2*coils/(no_eqrings*p);
elseif (Ia<=400)
Y=((2*coils+2)/(p/2));
Yc=Y/2;
if rem(Y/2,2)~=0
Yf=Y/2;
Yb=Yf;
else
Yb=(Y/2)+1;
Yf=(Y/2)-1;
end
display('closed type simplex progressive wave winding is used');
display(Yf);
display(Yb);
end
%.........design of commutator and brushes........
commu_s=coils;
if(V<=200);
Dc=.75*D;
elseif((V>=200)&&(V<=300))
Dc=.68*D;
elseif(V>=300)
Dc=.62*D;
end
Vc=pi*Dc*n;
beta_c=pi*Dc/commu_s;
%no of commutator segments
display('please select type of material for brush');

display('press 1 for natural graphite');
display('press 2 for Hard carbon');
display('press 3 for electrographitic');
display('press 4 for metal graphitic');
brush_material_type=input('press =
');
if(brush_material_type==1)
Vbcd=.9 ;
%brush contact drop(V)
delta_brush=.1*10^6;
%current density in brush(A/m^2)
Pb=14000;
%brush pressure in N/m^2
mu=.15;
%coefficient of friction
elseif(brush_material_type==2)
Vbcd= .13;
delta_brush=.075*10^6 ;
Pb=17000;
mu=.2;
Vbcd=.14;
delta_brush=.095*10^6;
Pb=19000;
mu=.15 ;
Vbcd=.6 ;
delta_brush=.15*10^6 ;
Pb=19000;
mu=.15;
end
Ab=Ib/delta_brush;
%cross section area of brush arm
AB=p*Ab;
%total cross section area of brush
tb=2.5*beta_c;
%thickness of brush
nb1=Ib/70;
nb=round(nb1);
%no. of brushes in brush arm
ab=Ab/nb;
%cross section area of each brush
wb=ab/tb;
%width of each brush
Wcf=mu*Pb*AB*Vc;
%total brush contact friction loss
Wcc=Ia*Vbcd;
%brush contact drop
WCL=Wcc+Wcf;
%total commutator loss
Lc=(nb*(wb+.005))+.02;
%length of commutator
%..........losses and efficiency...........

%windage and bearing friction
%losses according to peripheral
%speed
if(Va<=10)
Pwb=.002*P*1000;
elseif((Va<=20)&& (Va>=10))
Pwb=.004*P*1000;
elseif((Va>=20)&& (Va<=30))
Pwb=.006*P*1000;
elseif((Va<=40)&& (Va>=30))
Pwb=.009*P*1000;
elseif((Va<=50)&& (Va>=40))
Pwb=.012*P*1000;
end
%ironloss
%I^2R losses
Pcu=Ia^2*Ra;
%armature copper loss
Qf;
%shunt field winding loss
Pcui;
%copper loss in interpole
WCL;
%total commutator loss
Pwb;
%friction and windage losses
Ptotal_loss=Pcu+Qf+Pcui+WCL+Pwb;
efficiency=(1-(Ptotal_loss/(Ptotal_loss+(P*1000))))*100;
display(efficiency);
display(Ptotal_loss);
%......design sheet......
display('
');
display('..........................design
sheet................................');
display('rating (KW)');
display(P);
display('voltage (V)');
display(V);
display('speed in rpm');
display(N);
display('output (KW)');
display(P);
display('armature power (KW)');
display(Pa);
display('armature diameter(m)');
display(D);
display('speed (rps)');
display(n);
display('armature peripheral speed (m/s)');
display(Va);
display('output coefficient');
display(Co);
display('average flux density (wb/m^2)');
display(Bav);
display('ampere conductors per meter');
display(ac);
display('gross core length (m)');
display(L);
display('number of poles');
display(p);
display('frequeny of reversals (Hz)');
display(f);
display('pole pitch(m)');
display(tow);
display('pole arc(m)');
display(b);
display('number of ducts');
display(nd);
display('width of each duct (m)');
display(y);
display('net iron (m)');
display(Li);
display('
');
display('.........................design of
winding............................');
display('generated emf(V)');
display(E);
display('max flux density of airgap(wb/m^2)');
display(Bg);
display('ratio of pole arc to pole pitch');
display(shi);
display('flux per pole(wb)');
display(phi);
display('armature current (A)');
display(Ia);
display('parallel path');
display(A);
display('armature conductors');
display(Z);
display('number of slots');
display(S);
display('conductors per slots');
display(ZS);
display('coils');
display(coils);
display('back pitch (m)');
display(Yb);
display('front pitch(m)');
display(Yf);
display('slot pitch(m)');
display(S_pitch);
display('area of conductor (m^2)');
display(az);
display('length of mean turn of armature (m)');
display(Lmta);
display('armature resistance(ohm) ');
display(Ra);
display('voltage drop');
display(Ia*Ra);
display('
');
display('............................design of magnetic
circuit....................');
display('armature mmf per pole (AT)');
display(ATa);
display('height of pole (m)');
display(hpl);
display('air gap density (wb/m^2)');
display(Bg);
display('lenth of airgap(m)');
display(Lg);
display('gap contraction factor');
display(Kg);
display('mmf for gap');
display(ATg);
display('depth of core (m)');
display(dc);
display('area of core(m^2)');
display(Ac);
display('flux density in core (wb/m^2)');
display(Bc);
display('leakage factor');
display(Cl);
display('area of pole(m^2)');
display(Ap);
display('width of pole(m)');
display(bp);
display('length of pole');
display(Lp);
display('flux density of pole (wb/m^2)');
display(Bp);
display('mmf for pole per pole');
display(ATfl);
display('length of yoke(m)');
display(Ly);
display('depth of yoke (m)');
display(dy);
display('area of yoke(m^2)');
display(Ay);
display('flux density in yoke(wb/m^2)');
display(By);
display('
');
display('.............................main field
winding......................... ');
display('mmf required ');
display(ATfl);
display('number of turns per pole');
display(Tf);
display('conductor area (m^2)');
display(af);
display('diameter of field winding(m^2)');
display(dia_field_wdg);
display('depth of winding(m)');
display(df);
display('resitance of field winding(ohm)');
display(Rf);
display('field current(A)');
display(If);
display('copper loss (watt)');
display(Qf);
display('temperature rise (degree c)');
display(thetac);
display('current density (A/m^2)');
display(delta_f);
display('
');
display('..........................design of
interpole.........................');
display('length inter pole gap(m) ');
display(Lgi);
display('flux density of interpole(wb/m^2)');
display(Bgi);
display('mmf of interpole');
display(ATi);
display('turns of inter pole');
display(Ti);
display('conductor area (m^2)');
display(ai);
display('resistance of each interpole winding(ohm)');
display(Ri);
display('
');
display('..........................design of
commutator........................');
display('commutator diameter');
display(Dc);
display('no. of commutator segments ');
display(commu_s);
display('pitch of segments');
display(beta_c);
display('peripheral speed');
display(Vc);
display('current density in brush (A/m^2)');
display(delta_brush);
display('tottal area of brush arm(m^2)');
display(AB);
display('area of each brush arm (m^2)');
display(Ab);
display('area of each brush in brush arm (m^2)');
display(ab);
display('no. of brushes in each brush arm');
display(nb);
display('width of each brush(m)');
display(wb);
display('length of commutator(m)');
display(Lc);
display('brush contact loss (W)');
display(Wcc);
display('brush friction loss (W)');
display(Wcf);
display('
');
display('...........................losses....................................
..');
display('armature copper loss(W)');
display(Pcu);
display('field copper loss(W)');

display(Qf);
display('friction and windage loss(W)');
display(Pwb);
display('interpole copper loss(W)');
display(Pcui);
display('brush contact loss(W)');
display(Wcc);
display('total loss(W)');
display(Ptotal_loss);
display('efficiency at full load');
display(efficiency);

Design of DC Motor

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Design of DC Motor

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% design of dc motor

display('power developed by armature is (KW)

p=input('please decrease number of poles:

p=input('please decrease number of poles:

%number of armature conductors

%.......no. of armature slots........

%calculation for field

%mmf for field winding(AT)

%.........design of commutator and brushes........

%no of commutator segments

display('please select type of material for brush');

%..........losses and efficiency...........

display('field copper loss(W)');

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