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Presentation No.

Armature Design

College of Engineering
Armature Design includes

Choice of armature winding


Number of armature conductors
Number of armature coils
Number of armature slots
Cross section of armature conductors
Insulation of armature winding
Slot dimensions
Armature voltage drop
Depth of Armature core
Armature Winding
Simplex (no.of parallel path=no.of poles) lap or wave
windings are preferred

No.of conductors required in lap winding is p/2 times that in


wave winding but the cross-sectional area of each conductor
in a lap winding is 2/p times that of wave winding and
therefore the total volume of copper used in both the
windings is the same.

Current per parallel path is limited to 200A. So wave


winding cannot be used in machines with rating more than
400A

Small and medium rating machines wave winding is


preferred due to smaller no. of conductors

CEP
Armature Conductors

Number of armature conductors is


given by the expression Z=E.a/np

CEP
No. of Armature coils

Normally single turn coils are used for lap


winding and multi turn coils are preferred
for wave winding
The no.of turns per coil and no.of coils are
chosen in such a way that the voltage
between adjacent commutator
segments(Ecm) limited below flash over
voltage
Normally Ecm<30V

CEP
Maximum voltage between
adjacent commutator segment
(Ecm)
Average voltage between adjacent segments at no
load
Ec=no.of conductors between adjacent segments x
voltage per conductor at no load
=2x turn between adjacent segments x average
voltage per conductor at no load
=2 x turns per coil x no.of coils between adjacent
segments x average voltage per conductor at no load
= 2.Tc.Nc.ez
Nc= p/2 for wave winding and 1 for lap winding
Average voltage per conductor at no load, ez = Bave. L. Va

CEP
Average voltage between adjacent
segments under no load
Ec=2Tc.Nc.Bav.LVa
Maximum voltage between adjacent
segments under no
load=2Tc.Nc.Bg.L.Va
Let Bgm be the maximum value of flux
density at load
Maximum voltage between adjacent
segments under load
(Ecm)=2Tc.Nc.Bgm.L.Va
=2Tc.Bgm.L.Va for lap
And Bgm=1.3Bg
Maximum voltage between adjacent
segments under load (Ecm)=2Tc.
1.3Bg.L.Va
weEknow that Bg=Bave/Kf, abd
cm 4TC N C Bave LVa 4TC N C e z
Kf=0.66
Ecm
ez
4TC N C

30 7.5
We have already
ez saidthat Ecm<30V
4TC N C TC N C
No.of turns per coil Tc=Z/2C
Ecm=4. Z/2C. Nc,ez
=2Z.Nc/C. ez
So the minimum no. of cols required in order that the
maximum voltage between adjacent segment
should not exceed 30V.
C=2ZNc. Ez/Ecm=2ZNc. ez/30=ZNc. ez/15
ez=Bav.LVa and Va=Dn
C=ZNc/15 . Bav.L. Dn and Bav=p/ DL
C=(Znp).Nc/15=EaNc/15
For wave winding a=2 and Nc=p/2
Minimum no.of coils required C=Ep/15
For lap winding a=p Nc=1
Minimum no.of coils required C=Ep/15
Selection of no.of coils considering
mechanical design of commutator
segments
The minimum thickness of commutator segments at the
outer circumference is in between 3mm-4mm.

The thickness of mica insulation between adjacent


commutator segment is about 0.8mm

There fore the minimum pitch of commutator segment is


about 3+0.8=3.8mm4mm

The no.of commutator segment is equal to no.of coils is


selected in such a way that commutator pitch
c=Dc/C>=4mm
Where Dc is the commutator diameter.
Dc=0.62D for 350/700V machine
Dc=0.68D for 200/250V machines
Dc=0.72D for 100/125V machines
Selection of no.of armature slots

Mechanical difficulties (Slot pitch)


Cooling of armature conductors (Slot
loading)
Flux pulsations
Commutation
Cost
Suitability for winding
Mechanical difficulties (Slot pitch)

Larger no. of slots decreases the slot pitch


and hence the decreases the width of
tooth.

The value of slot pitch lies between 20-


40mm as extreme limit

The usual limit is in between 25-35mm


Cooling of armature conductors (Slot
loading)
No. of slots are more then less no.of
conductors per slot and therefore
only few conductors are bunched
together then conductors get proper
cooling.

The no.of ampere conductors per slot


Iz.Zs<1500A for getting proper
cooling
Flux pulsations
Flux pulsations are occurred due to
change in air gap reluctance due to
slotting.
When the armature rotates change in
local air gap reluctance occurs.
This can be monimised with large
length of air gap, small slot opening
and slot per pole shoe as an integer
+1/2
Commutation

Pulsations and oscillations of the flux


under inter poles must be avoided as
they cause sparking during
commutation.
A large air gap and larger no.of slots
in the inter poles reduces the effect
of slotting.
The no.of poles in the interpole
should be at least 3
(1-).slots/pole >=3 taking =0.67
Slots/pole>=3/ (1-)>=9
Suitability for winding
Selection of armature slots needs to
suits the armature winding as
regards the no.of coils and no.of coil
sides per slot.
The no. of armature slots/pole for
machine rating upto 5kW greater
than 8
The no. of armature slots/pole for
machine rating upto 5-50kW greater
than 10
The no. of armature slots/pole for
DC windings are two layer type. So the no. of slots
are selected in such a way that no. of conductors per
slot is an even number.

The no. of conductors/slot are selected in such a way


that they are divisible by no. of coil side per slot. If
this is not done turns per coil become fractional
number.

In the case of lap windings equalizer connections are


used, therefore the windings must be symmetrically
arranged with respect to poles, that is no. of slots
must be multiple of pair of poles.

Commutator pitch yc=1 for lap winding


1
.u.S 1
For a wave winding C 1 2
yc
p/2
should be an integer p/2

where S no.
of slots
u no.of coil sides
per slot
Therefore S and u/2 should not be a
multiple of pair of poles.
If yc is fractional then winding
become unsymmetrical that is
winding requires dummy coil.
Cross section of Armature conductors

Armature current Ia=PaX103 /E


Ia=IL+If for a generator
Ia=IL-If for a motor
Area of each armature conductor a z= Iz/a
Where a current density in armature conductors
Current density should be as high as possible to decrease the area
of conductor and therefore savings in the cost of copper.
Also slot area requirement is small and that is beneficial for the
commutation condition.
Large machine with normal ventilation a=4.5A/sq.mm
Small machine with very good normal ventilation a=5 A/sq.mm
High speed fan ventilated machines a=6 7 A/sq.mm
For conductors having small area of cross
section round wires are used

For cross sectional area above 10 sq.mm


square or rectangular conductors are used.

The maximum depth of the machines that can


be used in DC armatures is about 19mm at
25Hz
.
For high frequency the conductor depth should
not exceed 15mm.
Insulation of armature winding
High class insulations such as F, B and E etc are
used to meet the demand of high output from a
given frame size.
Conductors are coated with polyvinyl acetal
( pva) enamel.
The conductors of large sized machines are
rectangular in shape.
Built up mica wrap backed by fine glass cloth is
used as slot insulation
The armature coils are retained in the slots by
wedges made of an insulating material having a
high mechanical strength
Slot dimensions
Excessive flux density:- The dimensions of the armature
slots should be so chosen that they will accommodate the
armature conductors with the necessary insulation with
out producing excessive flux density in the armature
tooth.
Flux pulsations:- In order to reduce flux pulsations narrow
opening slots are used.
Eddy current loss in conductors:- With slots having large
depths eddy current loss in conductors increases. Depth
of slot is fixed based on frequency of flux reversal.
Reactance voltage:- With deep slot the specific
permeance of the slot increases consequently reactance
voltage is high. This reactance voltage retards
commutation
Mechanical difficulties:- With deep slots the thickness of
teeth at the root may become too small.
Armature Voltage Drop
The length of mean turn of armature
.3 5d s
Lmt 2 L 2as
winding can be estimated
1 Lmt

Resistance of each conductor
2 az
Z Lmt
Resistance of each parallelpath
a 2a z
1 Z Lmt Z Lmt
ra
Resistance of armature a a 2a z 2 a 2az

Armature Voltage drop =Ia.ra


Depth of Armature Core

c 1
Area of armature core
Ac Li d c
Bc 2 Bc

Where dc is the depth of core

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