Unit IIDesign of DC Machines

ByDr. R.KarthigaivelAssociate ProfessorDepartment of Electrical and Electronics

EngineeringPSNA College of Engineering and Technology, DindigulTamil Nadu
6040_b

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Parts of DC machine

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Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul
Output Equation of DC Machines
OutputEquationgivesarelationbetweenthemachineratinganditsarmaturedimensionsinter
msofarmaturediameter,corelength,speed,specificelectricandspecificmagneticloading
s.
Let
Pa=powerdevelopedbyarmatureinkW
Pa=generatedemfarmaturecurrent10-3
Pa=EIa10-3(1)
Generatedemfinadcmachine,
.E
aZnpE
.
.(2)

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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. flux per pole in Wb
Z total number of armature conductors
n motor speed in rps(n=N/60)
N speed in rpm
a number of parallel paths
Number of parallel path, a = 2(for wave winding)
a = no. of poles=p(for lap winding)
Substitute (2) in (1)
310....aaIaZnpP
.
Let current in each conductor
aIIaZ.(3)
310)()(.....nZIpPZa.(4)

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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DLpBav.
.
.Specific magnetic loading,
DLBpav...(5)
Specific electric loading,
DZIacZ
.
.
DacZIZ..(6)
WhereD

armature diameter

L armature core length

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Substitute (6), (5) in (4)
310.....nDacDLBPava..
32210....nLDacBav.
kWinnLDCPoa..2
Where
Output co-efficient,
3210...acBCavo.
(7)
(8)
for motor
.
PPa.
PPa.
for generator
Power developed by the armature
{Pa= i/p -losses}
{Pa= o/p + losses}
{P = o/p}

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Let
Kf form factor
Bav average gap density
Bg(or)Bm maximum gap density
Form factor ,
.
.
...
bBBKgavf
Where
b pole arc
pD.
.. Pole pitch
. Pole pitch

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Main Dimensions
a.Armature diameter (D)
b.Armature core length (L)
(i)Specific magnetic loading is related with D and L
(ii)Specific electric loading is related with D
(iii)The output coefficient depends on the value Bavand ac
The choice of specific magnetic loading depends on :
a. Teeth flux density
b. Frequency of flux reversal
c. size of the machine

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul9

Teethfluxdensity
Fluxdensityintheairgapishigh,itmayincreaseahighfluxdensityinthearmatureteethbeyo
ndthelimit.Thevalueoffluxdensityintheteethataminimumsectionshouldnotexceed2.2Wb/
m2.
Thehighvalueoffluxdensityintheteeth
(i)Causesmoreironlosses
(ii)Requireshighermmfforpassingthefluxthroughtheteeth.Itcanleadtoincreasedfieldc
opperlossesandhighercostofcopper.
Frequencyoffluxreversal
f=(np/2)
Higherfrequencyoffluxreversalresultsinincreasedironlossesinarmaturecoreandteeth.
Thereforeweshoulduseasmallvalueoffluxdensityintheairgapfoeamachinehavinghigherfr
equency.
Sizeofmachine
Ifsizeofthemachineincreases,thewidthofthetoothalsoincreasesduetoanincreaseindiam
eterofthearmature.Butthiswillnotcausethesaturationofmachinewhenthereisincreasedv
alueofgapfluxdensity.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Choice of specific electric loading (or)
Ampere conductors per metre (ac)
Temperaturerise
Speed
Voltage
Sizeofmachine
Armaturereaction
commutation

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Theventilationofthemachineisbetterwhenamachinerotatesathighspeedandgraterlossesc
anbedissipated.Forahighspeedmachine,itispossibletouseahighvalueof ac .
.Heatdissipatedinthemachineincreaseswhenchoosingahighvalueof ac duetouseofmorearmatu
reconductors.
.Ahighvalueof ac canbeusedformachinesusinginsulatingmaterialswhichcanwithstandatempe
raturerise.
.Thechoiceofvaluefor ac dependsupontypeofenclosureandcoolingtechniquesemployedinthem
achine.
Temperature rise
Speed
Voltage
.Thechoiceof ac valuedependsonnumberofarmatureconductorswhichinturnsdependsonspaceav
ailabilityfortheprovisionofconductors.
.Inhighvoltagemachines,thethicknessofinsulationshouldbelarge,
thereforethereislessspaceforconductorsresultsinlowvalueof ac

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Size of machine
.Inlargesizemachinethereismorespaceforaccommodatingtheconductors.Soitcanbepossib
letousehigher ac .
Armature Reaction
.Forhigher ac armaturereactionwillbesevere.
.Inordertopreventthis,thefieldshouldbemadestronger.Themmfrequiredforthefieldhave
tobeincreasedtopreventdecreaseinflux.
.Thisincreasethecostofconductorsused
Commutation
ac a(Z/D)
.Forhighvalueof ac ,eitherincreasetheconductorsordecreasethearmaturediameter.
. ac areactancevoltageincoilainductanceinthecoil
.Highvalueof ac resultinincreasedreactancevoltagewhichdelaythecommutationcondition.( a
c liesbetween15000to50000)

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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SeparationofDandLinDCmachines
ThefactorswhichinfluencetherelativevalueofDandLindcmachinesare
i.Machineproportions
ii.Peripheralspeed
iii.Momentofinertia
iv.Voltagebetweenadjacentcommutatorsegments

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Machineproportions
.Thedimensionsofthemachinearedecidedbythepolecriterion
.Thecrosssectionofpolemayberectangularofsquare
..
.Inasquaresection,widthofthepolebodyisequaltolengthofthemachine.But,thewidthofth
epolebody(b)isabout0.45to0.55timesofpolepitch.
L=b=(0.45to0.55)
.Inrectangularpoleconstruction,thelengthofthemachineisequaltotwicethewidthofpole
bodyL=bto2b
.Forsquarepolefaceconstruction,L=b(or)L/b=1
.
.)1.145.0(to.C:\Users\god\Desktop\DEM\Karthi11\7.jpg

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Peripheralspeed
Peripheralspeedofarmature,smnDVa/..
Peripheralspeedofarmatureislimitingfactortothevalueofdiameter.
Therefore,thePeripheralspeedofarmatureshouldnotexceedabout30m/sec.
Moment of inertia
.Machinesusedforcontrolsystems,asmallmomentofinertiaisdesirableanditcanbeobtaine
dbyselectinglowvalueofdiameterforarmatureconstruction.
.Ifmachinesaredesignedforimpactloadapplications,thenselectionofarmaturediameters
houldbelarge.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul16

Voltage between adjacent commutator segments
ThemaximumcorelengthofmachineisdecidedbymaximumallowableVoltagebetweenadjacentco
mmutatorsegments.
Maximum Voltage between adjacent commutator segments,
cagmcmTLVBE2.
Where
Bgm-maximum gap density under load condition
L -Core length of machine
Va-peripheral speed in m/sec
Tc-number of turns/coil

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul17

A5kW,4pole,250V,1500rpmshuntgeneratorisdesignedtohaveasquarepoleface.Theloadings
are:averagefluxdensityinthegap=0.42Wb/m2andampereconductorspermetre=15000.findth
emaindimensionsofthemachine.Assumefullloadefficiency=0.87andratioofpolearctopole
pitch=0.66.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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L = 0.1 m
Ans.
D=0.193mL=0.1m

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Adesignisrequiredfora50kW,4pole,600rpm,dcshuntgenerator,
thefullloadterminalvoltagebeing220V.Ifthemaximumgapdensityis0.83Wb/m2andthearmat
ureconductorspermetreare30000.
calculatesuitabledimensionsofarmaturecoretogiveasquarepoleface.
Assumethatthefullloadarmaturevoltagedropis3%oftheratedterminalvoltage,andthatthe
fieldcurrentis1%ofratedfullloadcurrent.Ratioofpolearctopolepitchis0.67.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul22

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Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul26

Selection of Number of Poles
Factors which affect the Selection of suitable Number of Poles are
(i)Frequency
(ii)Weightofironpart
(iii)Weightofcopper
(iv)Lengthofcommutator
(v)Labourcharges
(vi)Flashoverbetweenbrushes
(vii)Distortionoffieldform
Frequency of flux reversal apoles airon losses

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Weightofironpart
.Ifthenumberofpolesisdoubled,thenthefluxintheyokeishalved.
.Tokeepyokefluxdensitysame,theweightofironinyokecanreducedinproportiontoincrease
innumberofpoles.
.Increasingtheno.ofpolesincreasesthefrequencyoffluxreversalinthearmaturecorewhic
hresultsincreasecorelosses.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Weight of copper
The weight of copper can be divided into
i.Armature copper
ii.Field copperDue to increase in no. of poles decreases armature and field copp
er.
Length of commutator
Whenno.ofpolesincreasesitresultsinreductioninthelengthofcommutator.
2 pole m/c4 pole m/c
Current per parallel path
Ia/2
Ia/4
Current per brush arm
Ia
2Ia/4=(Ia/2)

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Labour Charges
Thelabourchargeswillincreaseastheno.ofpolesincreasesduetomorearmaturecoilstowind
,insulateandsoldertocommutatoranddesignoffieldwindingsFlash over between brushes
Distortion of field form
pZIATza2
.
.Forasmallerno.poles,ATaincreasesresultsindistortionoffieldformandreductioninflu
xunderloadconditions.
.Toavoidthedistortionoffieldform,itisnecessarytoprovidecompensatingwindingforama
chineshavingsmallno.ofpoles.
.Itcomplicatestheconstructionandincreasesthecostofmachine.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul30

Advantages of having more number of poles
Increasing the number of poles, will reduces the following
.Weight of iron parts
.Weight of copper
.Length of commutator
.Distortion of field form
Disadvantages of increasing number of poles
.Frequency of flux reversal is more
.High labour charge
.Increase the flash over between brush arms

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul31

Guideline for selecting number of poles
i.Frequency of flux reversal
Frequency lies between 25 to 50 HzLower frequency is preferred for large machine
sii.Thevalueofcurrentperparallelpathshouldbelimitedto200Aandcurrentperbrusharmsh
ouldbelimited400A.
2npf.
Wave windingLap winding
Current per parallel path
Ia/2
Ia/p
Current per brush arm
Ia
2Ia/p

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul32

iii. The value of armature mmf per pole should not be excessively
large.
Armature mmf/pole
2
.acATa.
pDacATa2
.
.
Output (kW)
ATa(amp turns/m)
Upto100
5000 or less
100-500
5000 to 7500
500 -1500
7500 to 10000
Over 1500
upto12500

iv.Ifmorethanonechoiceofpolessatisfiestheabovethreeconditions,thenselectlargeno.
ofpoles.Thisresultsinreductioninironandcopper.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul33

Findthesuitablediameter,corelengthandnumberofpolesofa400kW,550V,900rpmdcgenerato
rhaving92%efficiency.Assumeanaveragefluxdensityintheairgapofabout0.6Wb/m2andampe
reconductorspermetretobe35000.C:\Users\god\Desktop\DEM\Karthi11\14.jpg
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Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul38

Findthemaindimensions,numberofpolesandlengthofairgapofa600kW,500V,900rpmgenerato
r.Assumeaveragegapdensityis0.6Wb/m2andampereconductorspermetre35000.Theratioofpo
learctopolepitchis0.75andtheefficiencyis85%.
The following are the design constraints : peripheral speed 40 m/s,
frequency of flux reversal 50 Hz, current per brush arm
400A, armature mmfper pole 7800 AT. The mmfrequired for air
gap is 60 percent of armature mmfand gap contraction factor 1.15.

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Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul46

Magnetic circuit calculations
Magnetic circuit calculation involves two types of problems
i.Itisrequiredtodeterminethemmfneededtoestablishadesiredfluxatagivenpointinamagn
eticcircuit.
ii.Thefluxorfluxdensityisunknownandisrequiredtobedeterminedforagivengeometryofth
emagneticcircuitandspecifiedmmf.
Themagneticcircuitissplitupintoconvenientpartswhichmaybeconnectedinseriesparalle
l.
Thecalculationofmmfinthemagneticpartsaresimplewhereasincaseofairgapandtaperedtee
th,thecalculationsarecomplex.

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul47

MMF calculation of air gap
Let
lg length of air gap
ys slot pitch
Ws slot width
Wt tooth width
L Length of core
nd number of radial ventilating ducts
Wd width of each duct
H = atg= mmf per unit length
Atg = atglg total mmf required in the air gap
Bgor Bav average gap flux density or specific magnetic loading
Wb/m2

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul48

Reluctance of air gap with smooth armature surfaceC:\Users\god\Desktop\DEM\Karth
i11\1.jpg
The reluctance of air gap for one slot pitch
sgggLylAlS00
.
.
.
.
70104.....Permeability of free space
A = Lys= area of cross section of air gap over one slot pitch
AlAlSr...0
..

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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Reluctance of air gap for slotted armature
The area of cross section of the air gap through which the flux passes is
Lys (or) LWt.
Effective or contracted slot pitch
tsssWWyy....
)(000ssgsgggWyLlyLlAlS
.
.
.
..
.
..C:\Users\god\Desktop\DEM\Karthi11\2.jpg

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul50

ReluctanceofairgapwitheffectsofbothslotsandventilatingductsC:\Users\god\Desktop\
DEM\Karthi11\5.jpg
Effective or concentrated axial length
ddcdwnKLL...
Kcd Carter co-efficient for ducts
which depends on the ratio of
gdlwlengthgapwidthduct
.
sddcdgsgggywnKLlyLlAlS)(000.
.
.
..
...

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul

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gap contraction factor for ducts is defined as
)(tanRetanRecasesmoothductswithoutgapairofcelucductswithgapairofcelucKgd.
LLwnKLLKLylwnKLlddcdgdsgddcdg
.
.
.
.
.
.
00/
)(/
.
.
Nowconsidertheeffectofbothslotandventilatingducts,reluctanceofthiscasegivenby
sgggyLlAlS
...
..
00..

52Picture1
Clarifications ?

Picture1
Thank you
53

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul54

Design of Armature (Armature winding)
i.Choice of armature winding
ii.Number of armature conductors
iii.Number of armature coils
iv.Number of armature slots
Choice of armature winding
(a)Labwinding
.No.ofparallelpathisequaltoNo.ofpoles(a=p)
.Thecurrentineachparallelpathsis(1/p)timesofratedarmaturecurrent
(b)Wavewinding
.No.ofparallelpathsisequalto2.
.Theconductorshavetocarryhalfoftheratedarmaturecurrent

Dr. R.Karthigaivel, Associate Professor/EEE, PSNA CET, Dindigul55

Number of armature conductors
Generated emf (or) back emf,
Total no.of armature conductors,
aZnpE
.
.
npEaZ
.
.
E= V+Iarm(for generator)
E= V-Iarm(for motor)
rm-internal resistance
Iarm-internal voltage drop

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Number of armature coilsThemaximumvalueofvoltagebetweenadjacentsegmentsatloadsho
uldnotexceed30V.
Singleturnhastwoconductors,sinceNo.ofcoilsforsingleturnwinding=(Z/2)