D.C.

Machine Design Problem

(EE401.01 Electrical Machine Design I)

By
Pratik Mochi
CSPIT, CHARUSAT

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Cross Section View of 4 pole DC Machine
 Design Problem
Design a 250kW, 400V, 625A, 600 rpm, lap wound dc compound
generator, provided with suitable commutating winding to
ensure sparkless commutation and permissible limit of
following quantities should not exceed the value given below:
1. Peripheral speed of armature, 25m/sec
2. Voltage between commutator segments, 15V
3. Iron losses, 3kW
4. Total losses at full load, 18kW
5. Temperature rise of any part, 50°C.

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 Solution Steps
DC Machine Design Process (Rotating part)

Design of Design of Design of Performance of

Armature Armature Winding Armature core Armature

No of Conductors Armature losses

Basic Equations
No of slots Φ, β, d, D of core Cu loss
No of poles
Size of Conductor Iron loss
Check for P, D, L
Design of slots &
check

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Solution Steps

DC Machine Design Process (Stationary part)

Design of
Design of field Design of field Design of Overall
Commutator
system Winding Interpole Performance
& Brushes

Main Pole Dimensions Losses

Commutator &
Yoke Shunt Field Brush Airgap Efficiency
AT for iron Dimensions Density
Series Field
part Losses Interpole
Airgap Winding
Temp. rise

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Design of Armature
 Important Equations
 Assumptions made
Bav = 0.63 Tesla , ac = 33000 amp conductors/m
Field Armature Cu loss = 5% of output
Ratio of pole arc to pole pitch = 0.7
Gross length of armature, L = pole arc (square pole face)
Power developed by armature, Pa = 1.05 x 250 = 262.5 kW
Output coefficient C0 = 204.981
D*D*L = 0.129 m2

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Design of Armature
 No of Poles
Assuming frequency of flux reversal to be 30Hz.
P = 120F/N = (120*30)/600 = 6 Poles

Gross length of armature L = pole arc = 0.7(πD/6) = 0.367D

From D*D*L= 0.129 m2 And L = 0.367D

D = 0.72m
L = 0.25m

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Design of Armature
 Check on the selection of P, D and L
1. Peripheral speed = πDn
2. Voltage between commutator segment = 2 Bg*L*v
3. Pole pitch = πD/p
4. Current per Brush arm = load current/pair of poles
5. Armature ampere turns per pole = πD*ac/2p

Net length of armature Li = (0.25-4*0.01)*0.9 = 0.19m

Which means 4 ventilating ducts of 0.01m length are provided
with iron factor = 0.9 .

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Design of Armature Winding
Type of winding assumed- Simple lap, double layer
 No of conductors
Z = E*60*A/φ*p*N
Voltage drop= 3% of terminal voltage (assumed)
E = 400+(400*0.03) = 412 V
For lap winding A = P = 6
Flux per pole φ = Bav*(πDL/p) = 0.0585wb
(equation of specific magnetic loading)

Z = 704

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 Design of Armature Winding
 No of slots
(slot pitch assumed to be 2.6cm)
No of slots = πD/slot pitch = 88
No of conductors per slot = 704/88 = 8 (2x4)
Using single turn coil, no of coils = 704/2 = 352
Current loading in slot = (625/6)*8 = 832A
 Size of conductor
Full load current of generator = 625A
Armature current = 625+5= 630A (Assuming Ish = 5 A)
Current per conductor = 630/6 = 105A
Area of conductor= 105/5= 21mm2 (15mm x 1.4mm without insulation)
(Assuming current density=5A/mm2) (15.4mm x 1.8mm with insulation)

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 Design of Armature Winding
 Dimensions of slots
Thickness of insulation in slot = 0.4mm (Assumed)
Insulation between two layers = 0.5mm (Assumed)
Wedge space = 3mm (Assumed)
Slot Width:
Space occupied by insulated conductor, 4x1.8= 7.2mm
Insulation in slot, 2x0.4 = 0.8mm
Allowance for slackness = 1.0mm
Total slot width = 9.0 mm
Slot Depth:
Space occupied by insulated conductor,2x15.4= 30.8mm
Insulation I slot, 3x0.4 = 1.2mm
Insulation between layers = 0.5mm
Wedge spaces = 3.0mm
Allowance for slackness = 2.5mm
Total slot depth = 38.0 mm
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 Design of Armature Winding
 Check on design of slot
Average flux density in teeth Btav = φ/Ati = 1.41Tesla
Maximum flux density in teeth = 1.41/0.7 = 2.02 Tesla

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 Design of Armature core
 Flux in the core section φc = 0.0585/2 = 0.02925wb
 Flux density in the core Bc = 1.3 Tesla (Assumed)
 Sectional area of the core Ac = 0.02925/1.3 = 0.0225m2
 Depth of core dc = Ac/L = 0.0225/0.19 = 0.12m
 Mean diameter of core Dmc = D-2hs-dc
= 0.72-(2*0.038)-0.12=0.524m
 Internal diameter of armature stamping di = D-2(hs+dc)
= 0.72-2(0.038+0.12)
= 0.4m

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 Performance of Armature
 Armature copper loss
Armature Cu loss = Ia*Ia*Ra
= 630*630*0.0153(calculated) = 6.1kW
Eddy current losses in conductor may be assumed 20% of armature
cu loss. Hence, Total cu loss= 6.1 + 1.22 = 7.32kW
 Iron Losses
Weight of core = 289kg (calculated)
Hysteresis loss per kg at core flux density of 1.3 Tesla and freq 30Hz
can be determined from graph to be = 2.8 W.
Total Hysteresis loss = 2.8*289 = 809 W

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Armature of 500HP DC Machine
 Design of Field System
 Design of Main pole
To avoid magnetic centering of armature, axial length of pole is
kept 1.5cm lesser than length of armature.
Thus axial length of main pole = 25-1.5 = 23.5 cm
1.Width of pole
Leakage factor = 1.2 (Assumed)
Pole flux on full load = 1.2*0.0585 = 0.07wb
Flux density in pole body = 1.6 Tesla (Assumed)
Net area of pole = 0.07/1.6 = 0.0437 m2
Gross area of pole = 0.0437/0.95 = 0.046 m2 (Assume iron factor=0.95)
Width of pole = 0.046/0.235 = 0.196m
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 Design of Field System
2.Height of pole
Height of pole = Height of field winding + Height of pole shoe +
space wasted due to insulation and curvature of yoke (0.1 times pole pitch)

Field AT per pole on full load (Calculated) /AT per meter height of coil
(Calculated)

= 6160/44243 = 0.14m = 14 cm = height of field coil

Height of pole shoe = 4 cm

Total height of pole = 14+4+(0.1*37.7) = 22 cm (Approx)

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 Design of Field System
 Dimension of yoke
Material for yoke = cast steel
Flux density in yoke section = 1.2 Tesla (Assumed)
Flux in the yoke = 0.07/2 = 0.035wb
Area of yoke Ay = 0.035/1.2 = 0.0292wb/m2
Axial length of yoke is assumed to be 1.5times the length of
armature.
Ly = 1.5*0.25 = 0.375m
Depth of yoke Dy = Ay/Ly = 0.0292/0.375 = 0.08m

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 Design of Field System
 Calculation of AT for iron parts
1. AT for pole (flux density = 1.6 Tesla)
AT per meter length = 4800 (From BH curve)
Height of pole = 0.22m
ATp = 4800*0.22 = 1056
2. AT for armature teeth (flux density = 2.02 Tesla)
AT per meter length = 21500 (From BH curve)
Flux path in teeth = 3.8cm
ATt = 21500*0.038 = 817
3. AT for armature core (flux density = 1.3 Tesla)
AT per meter length = 400 (From BH curve)
Flux path in core = 0.137m
ATc = 400*0.137 = 55
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 Design of Field System
 Calculation of AT for iron parts
4. AT for yoke (flux density = 1.2 Tesla)
AT per meter length = 1230 (From BH curve)
Flux path in yoke = 1.24m
ATy = 1230*1.24 = 400

Total field AT for iron parts = ATp + ATt + ATc + Aty

= 1056+817+55+400
= 2328
Total field AT of pole (calculated before) = 6160

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 Design of Field System
 Length of Airgap
Out of total AT, 15% is used to overcome armature reaction.
So, AT needed on load = 0.85*6160 = 5236
Out of 5236, 2328 needed for iron parts.
So ATg = 5236-2328 = 2908
Max. flux density Bg= Bav / Kf = 0.63/0.7 = 0.9 Tesla.
Atg = Bg*Kg*Lg*0.796*10^6
Lg = 0.35cm

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 Design of Field Winding
The field winding will be designed to develop 6160 AT on full load.
Out of 6160, shunt field winding will be designed for 5236 AT
which is sufficient to generate an emf of 400V on no load. The
series field winding is then designed for remained 924 AT.
 Design of shunt field winding
Height of field coil = 14cm
Assuming 80% of above for shunt field winding, the space available
= 0.8*14 = 11.2cm
1. Cross section area of conductor
Assuming 15% of voltage drop in field,Vsh = 0.85*400 = 340V
Voltage across each field coil Vc= 340/6 = 56.7 V.
AT for each field coil = 5236
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 Design of Field Winding
Depth of field winding df = 4.5cm (Assumed)
Thickness of insulation on pole body ti= 1.0cm (Assumed)
Length of mean turn of shunt field winding Lmt = 2(bp+lp)+ π(df +2ti)
= 1.07 m
Cross section area of conductor Ash = Þ*Lmt*AT/Vc = 1.98mm2
2. Permissible loss
Cooling surface of shunt field coil = 2*lmt*height of shunt coil
= 2*1.07*0.112
= 0.24m2
Permissible losses per sq. meter= 725W/m2 (Assumed)
Permissible losses per exciting coil = 725*0.24 = 174W
Total permissible loss of shunt field winding = 174*6 = 1044W

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 Design of Field Winding
3. Exciting current
Ish = 1044/340 = 3.1A
4. Number of turns per exciting coil
= 5236/3.1 = 1690
5. Arrangement of winding
Bare dia of round conductor = 1.6mm (From standard table)
Area of standard conductor = 2.0109mm2
Insulated dia of conductor with insulation = 1.71mm (From standard table)
No of turns in available height of 11.2cm = 11.2/0.171= 65
No of turns per layer = 65
No of layers = 1690/65 = 26
Actual depth of winding = 26*0.171 = 4.45cm
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 Design of Field Winding
6. Resistance of winding
Total turns of shunt field winding = 1690*6 = 10140
Resistance of winding, Rsh = Þ*Lmt*Tsh/Ash =
0.02*1.07*10140/2.0109 = 108Ω
7. Losses in shunt field winding
= (3.1*3.1)*108 = 1038W
 Design of series field winding
AT to be developed by winding = 924, Ise = Ia = 630A.
No of turns per pole = 924/630 = 2 (Approx)
Modified AT for this winding = 2*630 = 1260
Assumed current density = 2.1 A/mm2
Cross section area of conductor = 630/2.1 = 300mm2
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 Design of Field Winding
Size of copper strap = 15mm X 20mm
Rse = 0.00086 Ω (calculated)
Cu loss in series field winding = 630*630*0.00086 = 341W

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 Design of Commutator and Brushes

Cut Section of DC Machine

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 Design of Commutator and Brushes
Voltage drop per brush set = 2V (Assumed)
1. No of commutator segments
= No of armature coils = 352
2. Dia of commutator
= 70% of dia of armature = 0.7*0.72 = 0.5m
3. Dimension of brush
Number of segments covered by brush = 3
Approximate thickness of brush = 3*0.446 = 1.3cm
Standard size of brush selected = 12.5mm thick , 20mm width,
32 mm height
4. No of brushes per spindle
Area of one brush = 12.5*20 = 250mm2 = 2.5cm2
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 Design of Commutator and Brushes
Total current per brush set = 625/3 = 208A
Working current density of brush = 6 A/cm2 (Assumed)
Total area per spindle = 208/6 = 34.7 cm2
No of brushes per spindle = 34.7/2.5 = 14

5.Length of commutator
Thickness of brush box = 0.5cm (Assumed)
Allowance of staggering of brushes = 4cm (Assumed)
Clearance at the end of commutator = 2cm (Assumed)
Allowance of riser = 3cm (Assumed)
Space occupied by one brush box = 2+0.5 = 2.5cm
Total space required by 14 brush boxes = 14*2.5 = 35cm
Length of commutator = 35+4+3+2 = 44cm

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 Design of Commutator and Brushes
6.Commutator losses
Brush Friction loss = µ*Ab’’*p’*Vc
where, coefficient of friction, µ = 0.2 (Assumed)
Brush pressure on commutator, p’ = 12000N/m2 (Assumed)
Total contact area of all brushes = 2.5*14*6 = 210cm2 = 0.021m2
Thus, brush friction loss = 0.2*0.021*12000*15.7 = 791W
And,
Brush contact drop=2*625 = 1250W
Total commutator loss = 791+1250 = 2041W
7. Temperature rise of commutator
Temp rise ϴ = 120*losses in w/m2 / 1+(0.1*Vc)
cooling surface of commutator = πDc*Lc = π*50*43 = 6758cm2
Losses in w/m2 = 2041/6758 = 0.302
Temp rise ϴ = 120*0.305/(1+0.1*15.7) = 14.1ºC
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 Design of Interpole
 Dimensions
1.Axial length of interpole
Lcp = 0.64 times gross armature length
= 0.64*25 = 16cm
2. Width of interpole shoe
Bcp = [(x-1)τc + tb - tm] Da/Dc
x = no of coil sides per layer in armature slot = 4
τc = commutator segment pitch = 0.446cm
Thickness of brush tb = 12.5mm = 1.25cm
Thickness of mica insulation between segments = 0.8mm =0.08cm
Da = Dia of armature , Dc = Dia of core,
Bcp = 3.6cm
3. Airgap under interpole
Lgc= 1.5*Lg = 1.5*0.35 = 0.52cm
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 Design of Interpole
4. Height of interpole
hcp= [(Dyi-D)/2] – Lgc
Internal dia of yoke Dyi = D+2Lg+2hp = 116.7cm
hcp = 21.8cm
 Flux density in the airgap under interpole
Flux density Bcp = (L/Lcp)*(2Ia’Zsλ/βxa)
Ia’ = current in armature conductor = 105A
Zs = no of conductors per slot = 8
βxa = distance moved by armature during commutation of x coil sides in slot = 3.6cm
λ = [0.4π(hc/3bs + ht/bs + bcp/6lgc) + (lfr/L)*{0.23log(lfr/b) + 0.07}]*10^-6
wb/m
where,
hc = copper height in armature slot = 3.08cm
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 Design of Interpole
ht = height above copper in armature slot = 0.55 cm
bs = width of slot = 0.9 cm
b = periphery of four coil sides in layer of slot = 45.2mm
lfr = free length of turn = 57.4 cm

λ = 4.39*10^-6 wb/m

Bcp = 0.32 Tesla

 Interpole Winding
1. No of turns
AT for interpole = ATa + 0.796*Bcp*Kgcp*Lgcp*10^6 = 7580
Current in interpole winding = Ia = 630A
No of turns in each interpole = 7580/630 = 12 (Approx)
Modified AT = 12*630 = 7560
2. Conductor cross section area
Acp = 630/2.3 = 274 mm2 (current density assumed to be 2.3A/mm2)
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 Design of Interpole
3. Arrangement of winding
Height of interpole = 21.8cm
Space for insulation = 3.8 cm , available space for 12 turns =
18cm
Space available for one turn = 18/12 = 1.5cm
Size of conductor selected = 14.5mm x 9.5mm
Size of conductor with insulation = 15mm x 10mm
Depth of winding = 2x10 = 20mm
So, Lmtc = 47.4cm (calculated from above data)
4. Resistance of winding
Rcp = 0.00268 (calculated)
5. Losses in interpole winding
= 630*630*0.00268 = 1064 W

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 Overall Performance
1. Losses
Constant losses = 1.038+2.945+0.791+2.5 = 7.274 kW
Variable losses = 7.32 + 0.341 + 1.064+1.25 = 9.975 kW
Total losses at full load = 7.274+9.975 = 17.25kW

2. Efficiency
At full load η = 250/(250+17.25) = 93.5%
For maximum efficiency,
a*a*9.975=7.274
a = 0.85 time full load
So, load at maximum efficiency = 0.85*250 = 212.5kW
ηmax = 212.5/(212.5+7.274+7.274) = 93.6%

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M&V Patel Department of Electrical Engineering