New Era University

College of Engineering and Technology

Department of Electrical Engineering

EE572
MW 10:00-11:30AM
Electrical Machine Design

Design 1-A
Design of the Armature Winding and Core
Item 1 - 39
440kW, 450V

Name: Torrente, Arvin Joseph K.

Course: BS Electrical Engineer
Year: 5th year

Rating: __________
Date Started: July 1, 2015
Date Submitted: July 15, 2015

Engr. Reynaldo M. Dela Cruz

Specifications: 440kW, 450V

I. Objective:
- To follow the design procedure from item 1 - 39
II. Materials/Instruments:
- Drawing Materials
- Laptop
- Calculator
- Printer
- Boo
III. Procedure:
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,
=

6 1200
= 60
120

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 r=0.64
Item 3 and 4: Specific Loading and Air-Gap Density. Refer to Art. 2. From
the table on page 12, select q=900, and from the table on page 11,
select Bg=59000 . These are tentative selections and will be modified to suitable
values as the design proceeds.
Item 5: Line Current

= 977.78

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 0.5
percent, the full-load current in each armature conductor will be about
(1 + 0.005) =

1200
(1 + 0.005) = 201
6

Item 8, 9 and 10: Armature Diameter. Refer to Art. 2. By formula (7)

=

6.06 10
"

440000
6.06 10

= 6538.43
1200
59000 0.64 900

Using a rectangular pole face, where in Eq. (8) equals to 0.71

=

0.64

6 0.71

= 0.472

6538.43
= 24 .
0.472

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
=

12

24 1200
= 7539.82
12

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 ampereconductors 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.
=

24 1200
= 15079.64
6

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.
24 900
=
=
= 337.60
201
With 5 conductors per slot, this would mean a preliminary number of slots
337
:
= 67.4;
5
24
:
= 1.11
68
Calculating Slots per Pole:

= 11.33

Since it is desirable to have an odd integer if slots per pair odd poles. Slots
will be increased to 78
Final value of Z = 390
=

= 390

= 1039.68

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
900
= 6537.73
= 5659.39 (
)
1039.68
And
=

5659.39
= 9.83 (
24

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,
10
450 60 6 10
=
=
= 5.11 10

6 1200 440
Item 16, 17, and 18: Pole Pitch, Pole Arc, and Pole Area.

24
: =
=
= 12.56 .
6
: = 12.56 0.64 = 8.04 .
9.83
=
= 1.22
8.04
:
= 8.04 9.83 = 79 . .
The apparent air-gap flux density can now be computed and compared
with the assumed value in item 4.
Thus,

5.11 10
" =
=
= 64683.54
(
)
79
. .
Items 19 to 22: Dimensions of Slots and Armature Conductors. By formula
(17) on page 36, for a well-ventilated machine.
=

700,000 7550
+
= 2560
1039.68
4

Whence,
=

201
= 0.079 .
2560

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
=

24
= 0.967 .
78

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 + (450/30)=42 mils, and the cotton
4

covering on each conductor will add a total of about 20 mils to its thickness. The
space left for each of the eight conductors is, therefore,
0.4 (3 0.02) (2 0.042)
= 0.032 .
8
Since the copper area of two conductors is 0.08 sq in. it follows that each
conductor will have a depth of
=

2 0.032

0.079
= 1.23
2 0.032

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,
= 0.135 + (3 0.02) + (2 1.13) = 2.46 .
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
=

= 0967 0.4 = 0.567 .

The circumference of the circle through the bottom of the slots is

( 2 )=

24 2(2.46) = 59.91

And since the slots have paralleled sides, the width of tooth at the root is
59.91
0.4 = 0.368 .
78
The average tooth width is, therefore,
=

0.567 + 0.368
= 0.468 .
2

Items 24 and 25: Ventilating Ducts. Refer to Art. 16. Not more than four
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
=

3 0.375) = 0.97(11.5 3 0.375) = 10.06

Item 27. Net Cross Section of Teeth under Pole. The cross section of iron in
the teeth under one pole, at the midsection, is

0.64 = 10.06 0.468

78
0.64 = 39.17
6

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,
=

5.11 10
= 130,457.59 .
39.17

The computed
is more than the upper limit on page 40 for 60 cycles
which is 123,500, la should be adjusted to a satisfactory value.

After some preliminary calculations la = 12.5 is satisfactory.

Recalculating:
= 12.5 24 = 7200
5.11 10
=
= 55468.11
7.37 12.5
= 7.37 12.5 = 92.13
= 0.97(12.5 3 0.375) = 11.03
10.06
=
130,457.59 = 118,984.89
< 123,500
11.03
Item 29: Length per Turn of Armature Coil. Referring to Art. 16,
sin

1.15(0.4)
= 0.48;
0.967
cos = 0.866 = cos 30
=

1.15

By formula (18),
=

2
2 12.56
+4 +3 =
+ (4 2.46) + 3 = 41.85
cos
0.866

Therefore,

+2

= 41.85 + 25 = 66.85

, 67

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

2(0.032 1.23)
There being

67

=
10

2(0.032 1.23)

= 0.00067
10

cir mils in 1 sq in. With a total of

= 195 turns divided

into four parallel paths (a four-pole lap winding), the resistance per circuit will
be 0.00067
= 0.022, and the total armature resistance will be one-sixth of
this or 0.0037
The IR drop in the armature winding is 0.022 201 = 4.42 volts or 0.98
percent of the full-load terminal voltage. This compares favourably with the
approximate figures given in Art. 18. The watts lost in the armature winding
(item 33) are 4.42(201 6) = 5330.52
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
6

 = 450 + 2 + 4.42 + 2.21 = 458.63

The full-load flux must, therefore, be,

= 5.11 10

458.63
= 5.21 10
450

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,

73000 =
2
Whence, the radial depth Rd of the armature core below the teeth is,
=

5.21 10
= 3.24 . 3.25 .
2 11.03 73000

The internal diameter of the core stamping is, therefore,

24 (2 3.25) (2 2.46) = 12.58
Item 37: Weight of Iron in Core. The weight of a cubic inch of iron is 0.28lb,
and the total weight of iron in the core below the teeth will, therefore, be
0.28 11.03

[(24 4.92) (12.58) ] = 499.43

Item 38: Weight of Iron in Teeth.

0.28 2.46 (0.468 78) 11.03 = 277.33
Item 39: Total Weight off Armature Stampings.
500 + 277.33 = 777.33

500 .

V. Data and Results:

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
33
34
35
36
37
38
39

Specifications: 440kW, 450V

Symbol

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 (laD2)
Armature Diameter
Peripheral Velocity, fpm
Total number of face conductors
Number of slots
Number of conductors per slot
Axial length of armature; gross, in.
Flux per pole (open circuit)
Pole pitch, in.
Pole arc, in.
Area covered by pole face
(r la), sq. in.
Dimensions of armature conductors, in.
Slot pitch, in.
Slow width, in.
Slot depth
Foot width, in.
Top
Roof
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, @ 60C
Resistance of armature, ohms
IR drop in armature, volts
I2R loss in armature, volts
Estimated full-load flux per pole
Flux density in armature core below teeth
Internal diameter of core stampings, in.
Weight of iron core without teeth, lb
Weight of iron teeth, lb
Total weight of armature stampings, lb.

p
f
r
q
Bg
I
IC
D
v
z
S
la

Preliminary or
Assumed Values
6
0.64
900
59000
lap
201
6537.73
24
7550
337
11.50
5.11 10
12.56
8.04

79

92.13

s
d

10.06
39.17
130457
73000
-

2 (0.032 1.23)
0.967
0.4
2.46
0.567
0.368
0.468
4
0.375
11.03
42.95
118985
67
0.00067
0.0037
4.42
5331
5.21 10
71274.15
12.58
500
277.33
777.33

n
ln
Bt
-

Final Value
6
60
0.64
1040
55468
978
lap
7200
24
7550
390
78
5
12.50
-

VI. Question/Problems:
1. Given a dc-dynamo: developed volts=100; total number of slots = 53; number of
inductors per slot = 6; number of poles = 4; speed = 1000rpm; winding, series (or
wave). Calculate the flux per pole.
2. A certain four-pole simplex-lap-wound dc generator has 768 armature inductors and
revolves at 20 rps. If the flux per pole = 715,000 Maxwell, calculate the generated
voltage.
3. The lap-wound armature of a six-pole generator has 600 active conductors, the speed
is 1000rpm. The area of each pole face is 100 sq. in., and the average air-gap flux
density under the pole face is 8000gauss. Calculate the emf between positive and
negative brushes.
VII. Remarks: