Item 24 25: Ventilating Ducts Not more than three(3) ducts should be necessary in an armature 9 to 11 inches long with

h each ducts 3/8 inch wide. Item 26: Net length of the armature ln = 0.92(la lv) where: la = axial length of the armature core lv = total width of all vent ducts ln = 0.92( 8.52 3 x 3/8) ; ln = 6.8 inches

Item 27: Net cross section of teeth under pole Net cross section of teeth under pole = Where: ln = net length of armature Atw = average tooth width r = ratio of pole arc to pole pitch Net cross section of teeth under pole = 6.8 x 0.150 x ( 201 / 6 ) x 0.64 Preliminary Net cross section of teeth under pole = 21.87 sq. inches Final Net cross section of teeth under pole = 6.84 x 0.150 x ( 201/ 6 ) x 0.64 Final Net cross section of teeth under pole = 22 sq. inches Item 28: Flux density in teeth Flux density in teeth = / Net cross section of teeth under pole =2,712,700 / 21.87 Flux density in teeth = 124,037.49 lines/ sq.inch By formula: laD2 = (P/N)(6.06 x 108 / (Bg x q x r)) = (160,000 / 1200)( 6.06 x 108 / (51,100 x 781.12 x 0.64)) laD2 = 2933.34 ln x Atw x ( slots / pole) x r

laD2 = 3014.85 / D2 = 3014.85 / 18.552 = 8.76

Bg = 2,712,700 / (6.21 x 8.76) = 49866.18 lines/ sq.inch lar = 6.21 x 8.76 = 54.40 sq.inch ln = ( 8.76 1.125 ) x 0.92 ln = 7.02 inches Bt = ln old / ln
new

x teeth

Bt = ( 6.34 / 7.02 ) x 124,037.49 Bt = 112,022.46 line/ sq.inch Item 29: Length per turn of armature core sin = (1.15 x s) / sin = (1.15 x 0.1160) / 0.2899 = 27.4 By formula: lc = ( 2 / cos + 4d + 3) lc = ( 2 x 9.71)/ cos 27.4 + (4 x 1.53) + 3 lc = 31.54 inches total length per turn = lc + 2la = 31.53 +( 2 x 8.76) total length per turn = 49.05 inches Item 30: Resistance of one turn, ohm at 60oC R = total length per turn / (2 x Ls x dc x (4/)x106 ) Where: Ls = space for each conductor Dc = depth of each conductor R = 49.05 / (2 x 0.0665 x 0.6015 x (4/) x106 ) R = 481.55

Item 31: Resistance of armature With a total of 415 / 2 = 208 turns divided into six parallel paths, the resistance per ckt. will be 481.55 x ( 811 / 2(6)) = 0.0325 and the total armature resistance will be 1/6 of 0.0325 / 6 = 5.42 ohms. R = (481.55 )(2 / 2P) = 481.55 (811 / 2(6)) = 0.0325 ohms Ra = 0.0323 / 6 = 5.42 Item 32: IR drop V = IR Where: V = is the voltage drop across the winding I = current at full load R = resistance per ckt. V = (0.0325)(56.13) = 1.82 V Item 33: Wattage loss in armature winding W = I2R = 56.13 x 1.82 x 6 = 612.94 watts Item 34: Full load flux In addition to the specified increase in terminal voltage from 220 to 240 volts, it is necessary to develop enough voltage to overcome internal resistances. Assuming a brush contact drop of about that of the voltage drop in the armature winding, the total generated voltage at the full load must be: 480 + 2 + 1.82 + (0.94 / 2) = 484.29 volts

The full load flux therefore is: 2,712,700 x ( 484.29/ 440) = 2,985,757.92 maxwells Item 35 36: Flux density in armature core and Internal Diameter Assume a density of 73000 from the table of upper limits of flux density in dynamo armatures is suitable. By formula: Rd x ln x 73,000 = (/2) Where: Rd = radial depth ln = net length of the armature = full load flux

Rd = 2,985,757.92 / ( 2 x 7.02 x 73,000 ) Rd = 2.91 inches The internal diameter(di ) of the core stamping is therefore: di = D ( 2 x Rd ) ( 2 x d) where: D = armature diameter d = slot depth di = 18.55 (2 x 2.91) ( 2 x 1.53) di = 9.67 inches Item 37: Weight of Iron in Core The weight of iron in cubic inch is 0.28, then the total weight of iron in core below the teeth will be: =0.28 x ln x (/4)( (D 2xd)2 - di 2) = 0.28 x 7.02 x (/4)[ ( 18.55 2 x 1.53)2 (9.67)2 = 230 lbs. Item 38: Wight of iron in teeth 0.28 x d x Atw x s x ln

= 0.28 x 1.53 x 201 x 0.15 x 7.02 = 90.67 lbs. Item 39: Total weight of the armature stamping Total weight of the armature stamping = Wic + Wit Total weight of the armature stamping = 230 + 90.67 Total weight of the armature stamping = 320.67 lbs.

B.)Design of commutator and brushes

Item 40: Diameter of the commutator Diameter of the commutator = (armature diameter / 2) + 4 Diameter of the commutator = (18.55 / 2) + 4 Diameter of the commutator = 13.28 inches

Item 41- 43 : Average voltage per turn of armature winding, Number of turns of armature winding, total number of commutator bars. As shown in the table of Volts between commutator segment, a 480volts machine can operate from 4 to 12 volts. Therefore: E/ ( Z/ 2P) = 480 / ( 811 / 2(6)) = 7.1 V C = 811 / 2 Number of turns of armature winding = 1 Total number of commutator bars = 405.5 commutator segments Item 44 45: Bar pitch and Bar width Bar pitch = ( x 13.28) /405.5 = 0.103 inch With mica 0.03 thick in inch, the bar width is 0.103 0.03 = 0.073 inch

Item 46: Radial depth of segment (h) h = (Diameter of the commutator +15) / 15 x (4700/4500)2 h = ( 13.28 + 15) / 15 x (4700/4500)2 h = 2.05 (assume) Item 47 - 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 ampere/ inch. Use 40 amperes/ inch as a preliminary value. Contact area per brush set = ( 6 x 56.13) / (3 x 40) = 2.81 sq.inch Assume brush arc (Circumferential width) = 1 inch Axial length per set = Contact area per brush set / brush arc Axial length per set = 2.81 sq.inch / 1 inch Axial length per set = 2.81 inches say 3 inches The current density will then be increase to: ( 40 x 281 ) / 3 = 37.47 amperes/ inch Assume the number of brushes as indicated up to eight(8) 1 by 1 inch In addition to the 8.8 inches which must be provided for eight(8) 1 by 1 inch carbon brushes, the axial length of the commutator face must allow for the following:

a. brush holder clearance = 8 x 5/16 = 2.5 inches b. stage ring of positive(+) and negative(-) brushes = 5/8 inch c. end clearance for brushes = 1inch d. end play = 3/8 inch total axial length = 3 +2.5 + 5/8 + 1 + 3/8 total axial length = 7.5 or 8 inches Item 53: Brush contact drop

Referring to the figure of Potential drop due to surface resistance of carbon brushes, the brush contact drop for hard carbon at about 40 amperes/ sq.inch is 2.08. allowing 10% for roughness, chipping and irregularities, this drop will be about: 2.08 + 2.08 x 10% = 2.29 volts Item 54 56: Brush Losses Brush contact loss = 2.29 x 6 x 56.13 = 771.23 watts Brush friction loss(Wf) = cPAND x x 746 / ( 12 x 33,000) Where: c = coefficient of friction with carbon brushes = 0.23 for hard carbon P = pressure of the brush in the commutator, use 2 lbs/sq.inch of contact pressure. N = speed D = commutator diameter A = total area of the brush surface Brush friction loss = ( 0.25 x 2 x 2.81 x 6 x 1,200 x 13.28 x x 746) / (12 x 33,000) Brush friction loss = 795.06 watts Total brush losses = 771.23 watts + 795.06 watts Total brush losses = 1566.29 watts

Item 57: Diameter of the shaft supporting the armature Diameter = ( output power / speed)1/3 Diameter =0.84 x ( 160,000 watts / 1200 rpm) 1/3 Diameter = 4.29 inches

C) Design of Pole cores, Frames and Windings

Item 1: Number of Poles Number of Poles = 6 poles Item 2: Number of commutating poles Number of Commutating poles = 6 poles Item 3: Diameter of armature core Diameter of armature core = 19 inches Item 4: Axial length of Armature core, gross Axial length of Armature core = 8.56 inches Item 5: Ratio of pole arc to pole pitch r = 0.64 Item 6: Air Gap under center of pole() = ( Z x Ic) / ( P x Bg ) where: Z = Total number of face conductor Ic = load current P = Number of poles Bg = total apparent air gap density = ( 415 x 112.31 ) / ( 6 x 48,620) = 0.16 inch By using formula: t = 0.04 x ( D + 3)1/2 t = 0.04 x ( 19 + 3 )1/2 t = 0.19 inch

Item 7: Leakage factor In the table of leakage factor, by interpolation: ( 200 100) / ( 200 160) = ( 1.22 1.11) / (1.22 lf) Lf = 1.18

Item 8: Maximum Flux The flux estimated in item 34 of this design is 2,983,219 maxwells. From the B-H curve it appears that 95,000 lines/sq.inch will not require as excessive number of ampere-turns. Item 9: Cross section of the pole core Cross section of the pole core = (e x lf) / m where: e = estimated flux lf = leakage factor

m = maximum flux Cross section of the pole core = (2,983,219 x 1.18) / 95000 Cross section of the pole core = 37.05 sq.inch Item 10: Length of winding space Lcore = la 1.5 where: la = axial length Lcore = length of the core = total air gap Lcore = 8.56 1.5(0.19) Lcore = 8.28 inches The width of the pole core should therefore be: = 37.05 / 8.28 = 4.475 inches The dimension will tentatively be made 6 . Item 11: Flux Density in Frame Select 90,000 lines/sq.inch

Item 12: Cross-Sectional Area of the Yoke Cross-Sectional Area of the Yoke = (e x lf ) / ( 2 x 90,000)

Cross-Sectional Area of the Yoke = ( 2,983,219 x 1.18 ) / ( 2 x 90,000 ) Cross-Sectional Area of the Yoke = 20 sq. inch Assumed yoke overhang of 2 inches per end, axial length of the yoke = 8.56 + ( 2x2) = 12.56 inches Width of the yoke = 19.56 / 12.56 Width of the yoke = 1.56 inches say 2 inches Item 13: Outside diameter of Frame AB = ( r pole width) AB = ( 6.37 4.29) inch AB = 2.08 inch Flux passing at portion of X: x = ( lf -1) x fl / 4 + ABx fl / r x = (( 1.18 -1) x 2,983,219 / 4) + (2.08x 2,983,219 / 6.37) x = 1,108,357,182 maxwells x = 1,108,357.182 / ( 8.28 x 90000) = 1.49 inches

Item 14 - 17: Ampere turns per pole for Total Magnetic Circuit. Plotting the Open circuit. saturation curve.

e = equivalent air gap = 0.5685 / ( 0.1685 / 0.19 + 2ln ( 0.5 x 0.4/0.19 + 1)) e = 0.2445 inch de = equivalent slot depth de = 0.905 + 0.19 0.2445 de = 0.4705 From Item 23 of Design 1 t = 0.1685 inch tr = 0.1143 inch tave = 0.1414 inch From formula 40: Bg = Bt (de + e) + de de a tmln Bg = Bt [1.3965 + 0.3965/] tmln + e a - 1

Table 1: Bt at tm assumed 12, 000 13, 000 14, 000 16, 000 Table 2: Bg At the middle Bt 16, 000 14, 000 13, 000 12, 000 Hm 60 23 15 9 At root Bt 19,79 4 17,31 9 16,08 2 14,84 5 Hr 130 34 22 14 At top Bt 15,87 7 13,89 2 12,90 0 11,90 7 He 15 9 7 6 H (TI)t H, magnetizing force 8 12 21 58 Bt/H 1, 500 1, 083.33 667 276 Bg Formula 40 16,755 18,150 19,543 22,321

22,321 19,543 18,150 16,755

172. 5 22.5 14.8 3 9.33 3

164.0 5 21.4 14.1 8.88

te =

de(t - tr)/d + tr

= [ 0.4705( 0.1685 - 0.1143)/0.905 ] 0.1425 inches

+ 0.1143te =

For Column 1: Value of Bg in Table 1 For Column 2: Bt at middle corresponding to Bg(Base on Curve No. 1) For Column 3: Base on the graph (Fig 47 & 48) corresponding to Bg at middle For Column 4: Bt at root = Bt at middle x tm/tr Bt1 = 16, 000 x ( 0.1414 / 0.1143 ) = 19,784 gauss Bt2 = 14, 000 x ( 0.1414 / 0.1143 ) = 17,319gauss Bt3 = 13, 000 x ( 0.1414 / 0.1143 ) = 16,082 gauss Bt4 = 12, 000 x ( 0.1414 / 0.1143 ) = 14,845 gauss For Column 5: Corresponding Hr for Bt at root (Base on graph Fig 47 & 48) For Column 6: Bt at top = Bt at middle x tm/te Bt1 = 16, 000 x ( 0.1414/0.1425) = 15,877 gauss Bt2 = 14, 000 x ( 0.1414/0.1425) = 13,892 gauss Bt3 = 13, 000 x ( 0.1414/0.1425) = 12,900 gauss Bt4 = 12, 000 x ( 0.1414/0.1425) = 11,907gauss For Column 7: He for Bt at top (base on the graph Fig 47 & 48) For Column 8: Average H H = 2/3Hm + (Hr + He)/6 H1 = (2/3)(60) + (130 + 15)/6 = 172.5 Gilberts/cm H2 = (2/3)(23) + (34 + 9)/6 = 22.5 Gilberts/cm H3 = (2/3)(15) + (22 + 7)/6 = 14.83 Gilberts/cm H4 = (2/3)(9) + (14 + 6)/6 = 9.333 Gilberts/cm For Column 9: Ampere-turns at teeth, (TI)t (TI)t = ( Hde x 2.54)/0.4 TI1 = (172.5 x 1.224 x 2.54)/ 0.4 = 164.05 A-t

TI2 = (22.5 x 1.224 x 2.54)/ 0.4 = 21.4 A-t TI3 = (14.83 x 1.369 x 2.54)/ 0.4 = 14.1 A-t TI4 = (9.333 x 1.369 x 2.54)/ 0.4 = 8.88 A-t

Ampere turn required for air gap: TIg = ( Bg x e x 2.54)/ 0.4 TIg = ( Bg x 0.2445 x 2.54)/ 0.4 = 0.4942 Bg Bg (gauss) 22,321 19,543 18,150 16,755 TI
g

11,031 9,658 8,970 8,280

ITEM 14. TI per pole for total magnetic circuit (no load) Intersection at 220 V and DC curve = 2490.37 A-t ITEM 15. TI per pole on shunt field(full load) Intersection at 240 V and resistance line = 3231.12 AITEM 16. TI per pole total at full-load Intersection of 247.57V and DC curve = 4378.5 A-t ITEM 17. TI per pole in series winding 4378.5 A-t - 3231.12 A-t = 1147.38 A-t Curve N o L o 280 a d 260 V o 240 l t a g e s

220
Shunt field-open circuit Shunt field-full load Series field

200
Shunt & series full load

Ampere-turn (x1000)
Table 3
No load voltage Flux entering armature per pole, maxwells Flux density: lines/in2 Armature core Pole core Yoke ring Air gap Ampere turn per inch Armature Pole core Yoke ring Ampere turn Armature Pole core Yoke ring Air gap and teeth Total 38 119 250 3,200 3,607 36.52 136.5 285 2032.35 2,490.37 43.12 175 350 2,663 3,231.12 61 266 520 4,250 5,097 10 17 25 11 19.5 28.5 13 25 35 16 38 52 59,509 76,200 71,900 42,700 45,100 57,700 54,440 32,410 50,735 64,920 61,300 36,500 73,700 94,200 89,000 53000
210 3,500,000 220 2,651,000 240 2,983,219 260 4,330,000

For 210V Flux entering armature per pole = 3,500,000 Flux density At armature =
= 3,500,000 = 59,509 lines/in2

2 x At

2 x 29.4

At pole core = [1.125] / 51.7 = 76,200 lines/in2

At yoke ring = 1.15(3,500,000) = 71,900lines/in2

2 x 28.06 At air gap = 3,500,000 81.8 = 42,700lines/ in2 Ampere turn per inch Armature: Annealed = 10

Pole core: Annealed = 17 Yoke ring: Magnet = 25

At armature = 10 A-t x 3.8 in = 38 A-t inches At pole core = 17 A-t x 7 in = 119 A-t inches At yoke ring = 275A-t x 10 in = 250 A-t inches Air gap and teeth = 3,200 A-t inches Total = 3,607A-t inches

For 220 V Flux entering armature per pole = 2,651,000 Flux density At armature =
/2x At = 45,100 lines/in2

At pole core = [1.125] / 51.7 = 57,700 lines/in2 At yoke ring = 1.15()/2x28 = 54,440 lines/in2 At air gap = 2,651,000/81.8 = 32,410 / 6.44 = 5,032.35 Ampere turn per inch Armature: Annealed = 11 Pole core: Annealed = 19.5 Yoke ring: Magnet = 28.5

Amp-turns At armature = 11 A-t x 3.32 in = 39.6 A-t inches At pole core = 19.5 A-t x 7 in = 149.5 A-t inches At yoke ring = 28.5 A-t x 10 in = 275.9 A-t inches Air gap and teeth = 2,032.35 A-t inches Total = 2,490.37 A-t inches

For 240 V Flux entering armature per pole = 2,983,219 Flux density At armature =
lines/in2 /2 x At = 2,983,219/2 x 29.4 = 50,735

At pole core = [1.125] / 51.7 = 64,920 lines/in2 At yoke ring = 1.15(2,983,219)/2 x 28 = 61,300 lines/in2 At air gap = 2,983,219/81.8 = 36,500/6.44 = 5663 gauss

Ampere turn per inch Armature: Annealed = 13 Pole core: Annealed = 25 Yoke ring: Magnet = 35

At armature = 13 A-t x 3.32 in = 43.12 A-t inches At pole core = 25 A-t x 7 in = 175 A-t inches At yoke ring = 35 A-t x 10 in = 350 A-t inches Air gap and teeth = 2663 A-t inches

Total = 3231.12 A-t inches For 260 V Flux entering armature per pole = 4,330,000 Flux density At armature = /2 x At = 4,330,000/ 2 x 29.4= 73,700 lines/in2 At pole core = [1.125] / 51.7 = 94,200 lines/in2 At yoke ring = 1.15(4,330,000)/2 x 28.06 = 89,000 lines/in2 At air gap = 4,330,000/81.8 = 53000 lines/ in2

Ampere turn per inch Armature: Annealed = 16 Pole core: Annealed = 38 Yoke ring: Magnet = 52

At armature = 16 A-t x 3.6 in = 61 A-t inches At pole core = 38 A-t x 6.5 in = 266 A-t inches At yoke ring = 52 A-t x 8.9 in = 520 A-t inches Air gap and teeth = 4,250 A-t inches Total = 5,097 A-t inches

ITEM 18-22. Shunt field winding Assuming about inch for insulation at the top and bottom and for space between shunt and series coils, the total length of the winding space will be: 6 - = 5 = 5.75 inches

Dividing this in the proportion to the shunt and series ampere turns equals: (3231.12 x 5.75) / 4378.5 = 4.24 inches Series coil winding apace: 5.75 4.24 = 1.51 inch Width of shunt field coil = 4.24 + = 4.49 inches Length of the shunt field coil = 8.28 + 0.25 = 8.53 inches Assuming a total thickness of the winding(w) = 1 inches, the mean length per turn(m) will therefore be: m = 2(lsf + wsf) + (w x ) where: lsf = length of the shunt field coil wsf = width of the shunt field coil w = total thickness of the winding m = 2 x ( 8.53 + 4.59 ) + (1 x ) m = 30.17 inches It will be therefore supposed that the shunt field rheostat adsorbs 15% of the voltage on the open circuit. By formula, (m) = ( m x TInl x P ) / ( E x 0.85 ) where: m = mean length per turn TInl = ampere turns per pole at no load P = number of poles E = voltage at no load ( m ) = ( 30.07 x 2,490.37 x 6 ) / ( 220 x 0.85 ) ( m ) = 2410.73 circular mils

Refer to wire table II at the appendix of the reference book

Gage # 75oC # 14

CM Nearest

turns/in2

R in ohms per 1000ft @

4545.0

182

2.78

Having a resistance of 2.78 ohms per 1000ft., the resistance at 60oC will be: (R60 / R75) = (T + 60) / (T + 75) Where T = 234.5 oC for a annealed copper conductor is R60 = (2.78)( 234.5 + 60) / (234.5 + 75) R60 = 2.65 ohms per 1000ft. Since there is 182 wires per sq. inch, it means about 13 wires per inch will be used. Wires per layer = 13 x width of the shunt field coil = 13 x 4.49 Wires per layer = 61 wires per layer Number of layers per coil = 1 x 13 = 16.88 say 17 layers per coil Making allowance for manufacturing and paper insulation layers, it will be assumed there will be 61 x 17 = 1037 turns per coil Resistance per coil = (m x TC x R60 ) / 12, 000 Where: m = mean length per turn TC = turns per coil R60 = resistance at 60 oC Resistance per coil = ( 30 x 1037 x 2.65 ) / 12000 Resistance per coil = 68.7 or 69 ohms and the current will be: At no load: (220 X 0.85) / ( 6 x 68.7 ) = 0.454 amperes At full load: ( 240 / 220 )( 0.454) = 0.545 amperes

Checking on the ampere turns: At no load: 1037 turns per coil x 0.454 amperes = 470.8 ampere-turns / coil At full load: 1120 turns per coil x 0.545amperes = 565.17 ampereturns / coil The current at full load is: = 0.545 / ( 4545 / (4/ x 106 )) = 152.68 or 163 amperes / sq. inch Item 23 to 26: Series Field Coils Available winding space = 0.5 inch Number of turns = ( NI per pole / Ia ) = 1147.38 / ( 666.67 + 0.545) Number of turns = 1.72 or 2 turns Assume a current density = 1600 ampere/ sq. inch Cross section of copper = (Ia / ) = ( 666.67 + 0.545) / 1600 Cross section of copper = 0.417 sq. inch Thickness of copper = cross section of copper / available winding space Thickness of copper = 0.417 sq. inch / 0.5 inch Thickness of copper = 0.834 inches Assuming length connections equal to 50 inches, therefore, Total length of copper = ( 6 x 2 x 30) + 50 Total length of copper = 410 inches Total resistance of series field = total length of copper / ( As x (4/ x 106))

Total resistance of series field = 410 / ( 0.417 x (4/ x 106)) Total resistance of series field = 7.72 x 10-4 ohms Total copper loss in the series field will be: I2R = ( 666.67 + 0.545)2 x (7.72 x 10-4) I2R = 343.68 watts

Item 27: Temperature Rise of Field Coils Total Cooling Surface = 2( total winding space + w )(m) Where: w = total thickness of winding m = mean length per turn Total cooling surface = 2( 4.49 + 1 1/4 ) ( 30) Total cooling surface = 344.44 sq. inches Watts lost in Series and shunt field winding per pole: = (Total loss in the series field / P) + ( If2 ) x Resistance per coil of shunt field = ( 344.44 / 6 ) + ( 0.545)2( 69) = 77.9 or 78 watts For V = 5970 fpm (from Design 1) The coefficient of cooling, c = 0.0087 W/in2/C Temperature rise, t = /c x s = 78 watts/(0.0087 x 344.44 in 2 ) = 26.03C Tables: Approximate Values of Apparent Air gap Density Output, KW 5 10 20 30 Bg 37000 42000 45000 47000 Output, KW 750 1000 1500 2000 Bg 61000 62000 62500 63000

40 50 Output, KW 100 5 200 10 300 20 400 30 500 40 50 100 200 300 400 500

48000 50000 q 53000 400 56500 450 57500 500 58500 550 59000 600 625 700 800 850 875 900

2500 3000 Output, KW 4000 750 5000 1000 7500 1500 10000 2000 Larger 2500 3000 4000 5000 7500 10000 Larger

63500 64000 q 65000 950 65500 1000 66500 1050 67000 1100 67500 1150 1200 1225 1250 1275 1300 1300

Output, KW 2 or less 2 to 75 75 to 200 200 to 500 500 to 1500 1500 to 2500 2500 to 5000

Number of poles 2 4 6 6 or 8 8 to 12 12 or 14 14 to 24

Speed, rpm Over 1250 900 to 1750 up to 1200 up to 1200 up to 900 up to 500 up to 375

Approximate values of q for interpole dynamos

Number of poles and usual speed limits of dynamos

Upper limits of Flux density in Dynamos Armature

Frequency 10 20 30 40 50 60

Densit y in teeth 150,00 0 142,00 0 135,00 0 130,00 0 126,00 0 123,50 0

Density in core 95,000 90,000 85,000 80,000 76,000 73,000

DESIGN SHEET FOR ARMATURE OF D-C GENERATOR

ITE M NO.

SPECIFICATIONS: 160KW; 220/240 VOLTS; 1160RPM

ARMATURE CORE AND WINDING

SYMBOL

PRELIMINAR Y OR ASSUMED VALUES

FINAL VALUES

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

NUMBER OF POLES FREQUENCY RATIO OF POLE ARC TO POLE PITCH SPECIFIC LOADING APPARENT AIR-GAP FLUX DENSITY (OPEN CIRCUIT) LINE CURRENT, Ampere TYPE OF WINDING ARMATURE CURRENT PER CIRCUIT OUTPUT FACTOR ARMATURE DIAMETER, INCHES PERIPHERAL VELOCITY, rpm TOTAL NUMBER OF FACES CONDUCTORS NUMBER OF SLOTS NUMBER OF CONDUCTORS PER SLOTS AXIAL LENGTH OF ARMATURE CORE; GROSS, INCHES FLUX PER POLE, MAXWELL POLE PITCH, INCHES POLE ARC, INCHES AREA COVERED BY POLE FACE, INCHES DIMENSION OF ARMATURE CONDUCTORS SLOT PITCH, INCHES SLOT WIDTH, INCHES SLOT DEPTH, INCHES TOOTH WITDH AT TOP, INCHES AT ROOT, INCHES AVERAGE, INCHES NUMBER OF RADIAL VENTILATING DUCTS WIDTH OF RADIAL DUCTS NET LENGTH OF ARMATURE CORE NET TOOTH SECTION UNDER POLE, AT CENTER, SQ. IN. APPARENT DENSITY IN TEETH UNDER POLE, AT CENTER, LINES PER SQUARE INCHES LENGTH PER TURN OF THE ARMATURE COIL, in.

p
f

6 .. 0.64 760 55,100 .. .. 112.31 3,014.85 5970 404 101 8.144 2,651,000 9.95 6.37 51.88 .. .. . . . . . .. .. 6.46 10.23 259,000 ..

6 60 0.64 780 48,620 666.67 Lap 112.31 3,090 19 5970 415 105 4 8.56

r Q B g I .. Ic .. D v Z S .. la r rr .. .. S D t .. . n .. ln .. BT ..

2(0.0705x1/3)

0.5685 0.4 0.905 0.1685 0.1143 0.1414 3 0.375 6.84 10.833 245,000 57.6

24 25 26 27 28 29

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

RESISTANCE OF ONE TURN, OHMS AT 60C RESISTANCE OF THE ARMATURE, OHMS IR DROP IN THE ARMATURE, VOLTS IR LOSS IN ARMATURE WINDIN, WATTS ESTIMATED FULL-LOA FLUX PER POLE, MAXWELL FLUX DENSITY IN THE ARMATURE CORE BELOW TEETH INTERNAL DIAMETER OF THE CORE STAMPINGS, INCHES WEIGHT OF IRON IN CORE (WITHOUT TEETH), lb WEIGHT OF THE IRON IN TEETH, lb TOTAL WEIGHT OF ARMATURE STAMPINGS, lb DIAMETER OF COMMUTATOR, INCHES AVERAGE VOLTS PER TURN OF ARMATURE WINDING, VOLTS NUMBER OF TURNS BETWEEN BARS TOTAL NUMBER OF COMMUTATOR BARS BAR PITCH, INCHES WIDTH OF COPPER BAR (ON SURFACE), INCHES RADIAL DEPTH OF BAR, INCHES CURRENT DENSITY AT BRUSH CONTACT SURFACE, AMPERE PER SQUARE INCHES CONTACT AREA FOR BRUSH SET, SQUARE INCHES BRUSH ARC (CIRCUMFERENCE WIDTH), INCHES AXIAL BRUSH LENGTH (TOTAL) PER SET, INCHES NUMBER OF BRUSHES PER SET AXIAL LENGTH OF COMMUTATOR, INCHES BRUSH-CONTACT DROP, VOLTS BRUSH-CONTACT LOSS, WATTS BRUSH-FRICTION LOSS, WATTS TOTAL BRUSH LOSS, WATTS DRAWING TO SCALE GIVING LEADING DIMENSION OF ARMATUREAND COMMUTATOR

.. .. .. . .. .. .. .. .. .. Dc .. .. .. .. .. .. b .. .. .. .. Lc .. .. .. .. ..

. .. .. . .. 73,000 .. .. .. .. .. .. .. .. .. .. .. 40 5.62 .. .. .. .. .. .. .. .. ..

0.000963 0.00555 3.71 2,500 2,983,219

11.19 260 26 286 13.5 6.94 1 208 0.204 0.174 2.073 43 6 1.0 6 8 10.5 2.29 1,543.14 1,487.15 3,030.29 ..

DESIGN SHEET FOR POLE CORES, FRAME, AND YIELD WINDINGS OF DC GENERATOR

ITE M

SPECIFICATION: 160KW; 220/240 VOLTS; 1160 RPM; ALLOWABLE TEMPERATURE RISE OF FIELD COILS = 26C

SYMBO L

PRELIMIN ARY ASSUME D VALUES .. .. .. .. .. ..

FINAL VALUES

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

GIVEN OR ASSUMED DATA NUMBER OF MAIN POLES NUMBER OF COMMUTATING POLES DIAMETER OF ARMATURE CORE AXIAL LENGTH OF ARMATURE CORE; GROSS RATIO OF POLE ARC TO POLE PITCH AIRGAP UNDER CENTER OF POLE LEAKAGE FACTOR CALCULATIONS MAXIMUM FLUX DENSITY IN POLE CORE ( FULL LOAD ) CROSS SECTION OF POLE CORE LENGTH (RADIAL) OF WINDING SPACE ON POLE FLUX DENSITY IN FRAME CROSS SECTION OF YOKE RING OUTISIDE DIAMETER OF FRAME TI PER POLE FOR TOTAL MAGNETIC CIRCUIT ( NO LOAD ) TI PER POLE ON SHUNT FIELD ( FULL LOAD ) TI PER POLE TOTAL AT FULL LOAD, VOLTS TI PER POLE IN SERIES WINDING, VOLTS LENGTH OF WINDING SPACE FOR SHUNT COILS WIDTH OF WINDING SPACE FOR SHUNT COILS SIZE OF SHUNT-FIELD WIRE ( B&S GAGE) NUMBER OF TURNS IN WIRE PER SHUNT-FIELD COIL SHUNT FIELD CURRENT (FULL LOAD ) Amperes

p .. D la r

6 6 20.6 9.89 0.65 0.19 1.18 95,000 37.05 8.28 .. 2.08 2,490.37 3,231.12 4,378.5 1,147.38 4.49 1.51 14 1120 0.545

lf .. Ac .. .. .. .. .. .. .. .. . w .. .. ..

1.18 95,000 .. 8.28 90,000 20 .. .. .. .. .. .. .. .. .. ..

23 24 25 26 27

NUMBER OF TURNS IN SERIES WINDING PER POLE CROSS SECTION OF SERIES WINDING RESISTANCE (HOT) OF SERIES WINDING ( OHMS ) IR LOSS IN SERIES FIELD COILS ( WATTS) watts SUREFACE TEMPERATURE RISE ON FIELD COILS (DEGRES C)

.. .. .. .. ..

.. .. .. .. ..

2 0.417 7.72x10-4 343.68 26.03

TECHNOLOGICAL INSTITUTE OF THE PHILIPPINES

DEPARTMENT OF ELECTRICAL ENGINEERING

EE583D1 FIRST SEMESTER

EE52FC1 SY 2011 2012

DESIGN NO. 1

DIRECT CURRENT GENERATOR

SPECIFICATIONS: 1. POWER OUTPUT 2. SPEED 3. TERMINAL VOLTAGE A. OPEN CIRCUIT B. FULL LOAD

240kw 1600 rpm 440V 480 V

SUBMITTED BY: SIBAG, JOHN GLEN MARI S.

BSEE 2011

APPROVED BY: ENGR EDGARDO O. DOMINGO, PEE

INSTRUCTOR