NATIONAL UNIVERSITY
College of Engineering
ELECTRICAL ENGINEERING DEPARTMENT
DESIGN OF ARMATURE ( STATOR) OF AC
GENERATOR
( Design 1)
A Design Report Submitted
In Partial Fulfillment of the Requirements
in
AC MACHINERY
Submitted by
Paulo P. Bautista
BSEE
SN: 2018-100872
Submitted to
DR. ROGELIO B. ANIEZ, JR., PEE
PROFESSOR
PROGRAM CHAIR , EE DEPARTMENT
Date Submitted: FEBRUARY 7, 2021
INTRODUCTION
AC Generator is an electrical device that is used to convert mechanical
energy into electrical energy. This electrical energy that this device generates
is in a form of sinusoidal wave, on which the mechanical energy this device
uses usually came from steam turbines and waterwheel. The way this works
is by the principle of Faraday’s Electromagnetic Induction, on which this
phenomenon happens when a magnet passes through a coil, which causes
the generation of electricity with the help of magnetic field. The current
produces from this phenomenon would be greater, if the magnet or the coil is
moving at a higher rate of speed, or if there are more coil turns, or if the
magnet has a strong magnetic field. The coils mentioned here is placed in a
part of the generator called the ―stator‖, on which the conductors are placed
here, and the magnet is fixed in a certain place inside the generator, and the
electricity is generated when the stator with sufficient winding will turn at a
rated speed.
The following data and computation are the things that would represent
and show the rough estimates of a stator which is specifically designed for the
following specifications:, 2,500 KVA output , 4,800 volts terminal voltage, 60
Hz frequency, and 3,600 rpm.
DESIGN PROBLEM
DESIGN OF ARMATURE (STATOR) OF AC GENERATOR
Output, KVA ___________________ 2,500 kVA
Number of Phases ______________ 3
Terminal Voltage _______________ 4800 volts
Power factor of the load _________ 0.8
Frequency ____________________ 60 Hz
Type of Drive __________________ Steam Turbine
Speed, rpm ___________________ 3600 rpm
Inherent regulation______________ within 25 per cent rise when full load
. is thrown off.
Exciting Voltage _______________ 130 volts
Permissible temperature rise after 6 hr., full load _____ 45 °C
Ventilating Fan ________________ independently driven (not part of the
. generator)
DESIGN SHEET
DESIGN SHEET FOR ARMATURE OF A-C GENERATOR
(Dimensions in inches unless otherwise stated)
Assumed or
Symbols approximate Final Values
values
1 Number of poles………………. …………… 2
2 Peripheral Speed (fpm)………. 15,000
3 Diameter of Rotor……………... …. 15.91
4 Line Current……………………. …………….. 300
5 Phase Connection (Star or Delta) …. Y Y
………………………………
6 Volts per phase………………… …. ……………. 2771
7 Specific Loading q 775 765
8 Current in armature …………… 300
conductors…………………………
9 Armature ampere-turns per 10956.62
pole…………………………………
10 Length of air gap at center…… 7/10 7/10
11 Internal diameter of stator 18 18
(armature)…………………………..
12 Pole pitch ………………………. ……………. 28.27
13 Pole arc…………………………. …. Distributed Winding
14 Percentage of armature …. Distributed Winding
covered by poles…………………...
15 Number of inductors per phase. 48.69 48
16 Total Number of Inductors…….. …………… 48 × 3 = 144
17 Number of armature slots per 4 4
pole per phase……………………...
18 Total number of slots in …. …………… 24
armature ……………………………
19 Slot pitch ……………………….. 2.355 2.355
20 Number of inductors per slot…. 6 6
21 Flux per pole (no load)………… 45.67×106 45.67×106
22 Average flux density over pole 31,000 30,800
pitch (open circuit)…………………
23 Axial length of the armature 52 52
core (gross)………………………...
24 Axial length of armature 47.8 47.8
core(net)…………………………….
25 Type of winding ………………... …. Double Layer
26 Current density in armature 2091 2091
conductors…………………………..
27 Size of conductor………………. …. ……………..
28 Slot width……………………….. …………….. 1
29 Slot depth………………………. …………… 3.95
30 Apparent tooth density (no load) ……………. 67,000
at center of tooth…………………..
31 Flux density in armature core, …. ……………... 52,000
lines per sq. in. …………………….
32 Radial depth of armature core... ……………… 11
33 Weight of iron in core, lb……… …. ……………. 7,500
34 Weight of iron in teeth, …. ……………… 370
lb……………………………………..
35 total core loss, including …. ……………… 16.47
teeth(kw)—open circuit……………
36 Length mean turn of armature …. ……………… 200
winding……………………………...
37 Resistance per phase, ohms…. …. ……………… 0.02637
38 IR drop per phase (full-load …. ……………… 8.3
current) volts………………………..
39 Total armature copper loss (full- …. ……………… 10.725
load current), kw……………………
40 Amount of copper loss to be
radiated from core………………….
41 Approximate temperature rise
of armature………………………….
42 IX drop (ends), volts per phase 137
winding……………………………….
43 Full-load developed, volts per 2862.66
phase winding………………………
DESIGN COMPUTATION
CALCULATIONS
Items 1 to 12: With A frequency of 60 cycles per second and a speed
of 3600 rpm, the number of poles is
Poles
At a peripheral velocity of 15,000 fpm, the diameter of the rotor would be
in
Since the air gap is not likely to be much less than 1 in, let us decide
upon an internal diameter of the armature D= 15.91+2=17.91 or 18 in. and
determine the exact dimensions of the rotor after the air gap has been
decided upon.
The line current is:
Amps
√ √
And if we select the star connection of phases, this is also the current
per phase winding. (Item 8)
The volts per phase are ⁄ ⁄
√ √
volts/phase
Referring to Art.71 for values of the specific loading, we find that the
average value there suggested is q= 775
The pole pitch (item 12) is
in.
and since
*( )( ) +
the approximate armature ampere-turns per pole will be
Referring to Art.72, we can get a preliminary idea of the required length
of the air gap. We shall, in this design, deliberately select a high value for the
air gap flux density and, if necessary, saturate the teeth of the rotor while
keeping the density in the armature teeth within reasonable limits to prevent
excessive hysteresis and eddy-current loss. Let us try
., which is higher than the upper limit of the
range suggested in Art.72
The principal advantage if using high flux densities is that the axial
length of the rotor can thus be reduced; but; f it is found later that the selected
value of leads to unduly high flux density in the teeth, it will have to be
modified. By formula (70) on page 180, we have
In the case of medium-speed salient-pole designs, the peripheral
velocity would not be decided upon by merely selecting the upper limit of
8,000 fpm as given in Art. 6. This has to be considered in connection with the
pole pitch (see Art.71), a preliminary diameter of rotor being selected in
keeping with what seems to be a reasonable pole pitch. A few rough
calculations will very soon show whether or not the tentative value of will
lead to a suitable axial length of armature core.
Items 15 to 20. On the basis of 775 the number of conductors per
phase would be
( ) ( )
With four slots per pole per phase, and
conductors in each slot, we have , which is
close enough to the desired value. Furthermore, the fact that each slot will
contain 6 conductors, an odd number means that only a single-layer winding
is possible; a double layer winding always involves an even number of
conductors per slot. Each of the 4 slots/pole/phase x 2 poles x 2 coils
sides/slot x 1 coil/2coil sides = 8 coils per phase will, therefore, have 6 turns
in series [48/ (2 X 4)] = 6. To construct such a single layer in a 24-slot core
requires a coil span of 24 slots x 2 coil sides/slot x 1 coil/ 2 coil sides = 12-1 =
11 slots; i.e., the coil pitch must be from slot 1 to slot 12 , from an odd-
numbered to an even-numbered slot. Such a pitch, one slot beyond full-pitch,
is electrically equivalent to a fractional pitch winding each of whose coils is
one slot short of full pitch or 180 electrical degrees. Therefore,
( ) . Also, with four slots per pole per phase,
( )
. Hence
( )
A complete diagram showing the coil arrangement and winding
connections is given in Fig.93.
For item 19 we have, , giving a corrected value for
peripheral loading of
Items 21 to 24. For the purpose of calculating the flux required an open
circuit, we may use formula (64a) of Art. 69, where . The
√
required flux per pole is, therefore,
Փ
√
With the assumed value of 31,000 lines per sq in. for
, the axial length of armature core will be
la
This is a short armature for a machine with a rotor 15.91 in. in diameter; but it
is what we are aiming at, and, if the field winding can be accommodated in the
space available, the design should be satisfactory.
We shall attempt to ventilate this generator by means of axial air ducts
only, which is admittedly not in accordance with modern practice for the larger
steam-turbine-driven generators but should be satisfactory in connection with
this machine of comparatively small size. If, then, there are no radial air
spaces, the net length of iron in the armature core will be approximately ln =
0.92la = 0.92 x 52 = 47.84 in. (Art. 16); but these dimensions cannot be finally
decided upon until the slot proportions and the tooth densities have been
settled.
Items 25 to 30. As previously pointed out, a single-layer winding must
be used (see Art. 73). The current density in the armature windings cannot be
determined by the empirical formula of Art. 74, because this is not applicable
to speeds higher than 8000 fpm, and, in any case, the conditions of cooling in
an enclosed machine with forced ventilation are not the same as for a self-
ventilating generator. In a turbo-alternator there is usually plenty of room for
the armature conductors, the chief trouble being with the rotor winding which
may have to be worked at a high current density. There is no definite rule for
the most suitable current density in the armature conductors, the permissible
copper cross section being dependent on the length of the armature core, the
position and area of the vent ducts, and the supply of air that can
economically be passed through the machine. The specific loading will
obviously have some effect on the allowable current density in the copper;
and, as a guide in making a preliminary estimate, we may use the formula
=
which gives us for item 26 a current density of 2091 amp per sq in. of
armature copper.
It is well to laminate the conductors in a direction parallel to the slot-
leakage flux, and we my build up each conductor of four flat strips each L =
0.143/(21/32) = 0.0545 by ., giving a total cross section
of 0.143 sq in. per conductor.
There will be 24 copper strips in each slot, the total thickness, including
the cotton insulation, being about in. To determine the slot insulation,
formula (16) in Art. 13 cannot be used since it applies to machine voltages
below 2,000; for voltages between 6,000 and 14,000 a formula which agrees
with modern practice is
Thickness of slot insulation (one side) in mils =
The slot insulation will, therefore, be 50 + (4800/55) = 137 mils, and the
total slot space for winding and insulation will be 1 in. wide by in. deep.
The thickness of wedge might be in., and we shall, in this design,
allow an extra slot depth of in. above the wedge, with a view to increasing
the slot inductance, and so limiting the instantaneous rush of current in the
event of a short circuit. This increased armature inductance might have been
obtained by using a smaller width and greater depth of copper conductor; but,
in as much as the width of tooth will probably be sufficient, the proposed
design of slot (as shown in Fig. 94) has the advantage that the eddy-current
loss in the armature inductors will be very small.
The width of copper strip has been selected to fit into the 1-in. slot,
because this seems to provide a suitable cross section for the stator tooth.
Thus, a section halfway down the tooth, or (say) 2 in. from the top, will have a
diameter of 22 in., and the average width of tooth will be [(π x 22) / 24] – 1 =
1.88 in. On the basis of = 31,000 lines per sq in., and a sinusoidal flux
distribution over the pole pitch, the ―apparent‖ tooth density (item 30) would be
= = 67,000 lines per sq in.
which is not too high (see Art. 72).
Items 31 to 35. Assuming a flux density of 52,000 lines per sq in. in the
armature core (see Art. 79), the net radial length depth of stampings below
the slots will be
= 9.17 in.
The actual radial depth should be greater than this to allow for the
reduction of section due to the presence of axial vent ducts. In this particular
machine it is proposed to ventilate, if possible, with axial ducts only, and a
fairly large cross section of air passages must, therefore, be allowed. An
adequate supply of air will probably be obtained if the total cross section of air
duct through the body of the stampings in square inches is not less than 0.005
x cubic inches of iron in stator below slots. In this case the volume of iron in
the stator ring will be approximately π ((18+2(3.95)) + 9.17) x 9.17x 47.84 =
48,500 cu in.; and the total cross section of air ducts in the stampings should
be 0.005 x 48,500 = 242.5 sq in.
The actual radial depth of stamping below the teeth can be calculated
by assuming that the air ducts reduce the gross depth by an amount equal to
, or (say) = in. Let us make the depth Rd (item 32)
= 11 in. and provide vent ducts arranged generally as shown in Fig. 95, where
there are 10 holes per slot, each 1.25 in. in diameter, making a total air duct
cross section in the armature stampings of ( ) x (1.25)2 x 10 x 24 = 295 sq in.
The weight of iron in core (item 33), is
0.28 x 47.84 x {π [(17.91)2 – (6.91)2] – 295} = 7500 lb. (approx.)
The weight of iron in the teeth (item 34) is
0.28 x 47.84 x {π [(6.91)2 – (2.96)2] – (2 x 1 x 3.95)} = 370 lb.
Taking the approximate flux densities as previously calculated (items 30 and
31), and referring to the iron-loss curve (Fig. 67), the iron loss per pound for
carefully assembled high-grade armature stampings is found to be 3.648 and
2.016 watts in teeth and core respectively*. (The figures as read off the curve
have been reduced 20%).
The loss in the teeth* (It is here assumed that the apparent flux density
at the center of tooth is about the same as the actual flux density at a point
one-third of the slot depth measured from the narrow end of the tooth, which
is the section recommended for tooth-loss calculations in Art. 52) is, therefore,
3.648 x 370 = 1350 watts, and in the core below the slots, 2.016 x 7500 =
15120 watts, making a total iron loss of (say) 16.47 kw, or 0.66% of the rated
kilovolt-ampere output.
Items 36 to 39. In a machine of so large an output as the one under
consideration, the weight and cost of copper should be determined by making
a drawing of the armature coils and carefully measuring the length required.
Since this design is being worked out for the purpose of illustration only, we
shall use the formula (71) of page 188 and assume the length per turn of
armature winding (item 36) to be
(2 x 52) + (2.5 x 28.27) + (2 x 4.8) + 6 = 190.275 in.
It will be safer to use the figure 200 in. for this mean length, because all
the coils will probably be bent back and secured in position by insulated
clamps in order to resist the mechanical forces which tend to displace or bend
the coils when a short circuit occurs.
The cross section of the conductor (four strips in parallel) is 0.143 sq
in., or 182,000 cir. mils. The number of turns per phase is 24, and, since the
resistance per circular-mil-inch at 60oC is 1 ohm, the resistance per phase at
60oC is (200 x 24) / 182,000 = 0.02637 ohm. The IR drop per phase (item 38)
is 300 x 0.02637 = 7.91, or (say) 8.3 volts, in order to include the eddy
currents in the conductors. The I2R loss in armature winding (item 39) is 3 x
0.02637 x (300)2 = 7150 watts, which should be increased about 50 per cent
(see Art. 79) to cover sundry indeterminate load losses. The total full-load
armature copper loss may, therefore, be estimated at 7150 x 1.5 = 10.725 kw,
or 10725/2,500,000 = 0.429 percent of the rated full-load kilovolt-ampere
output.
Items 40 to 41. These are included because they would be required in
connection with the design of a self-ventilated, slow-speed, open-type
generator for which the calculations are made generally as for a dc-generator
(refer to Art. 60) in the case of a turbo-alternator cooled by forced ventilation,
the necessary supply of air to be passed through the machine would be
calculated after all the losses, including those in the rotor field windings, have
been determined.
Items (42 to 43). The reactive voltage drops per phase due to the cutting of
the end flux cannot be predetermined accurately; but we may use the
empirical formula (75) of Art 78, where in the symbols gave the following
numerical values:
n = 3, k = 3.5, d = 0.949, f = 60, ns = 4, Cs = 6,
p=2
The equivalent average projection of the winding beyond the ends of
the slots may be computed by noting that, with a mean length per turn of 200
in., the average projection beyond ends of slots will be
l' = x 2.54 = 50.12 cm
Since we have a single-layer winding, the factor (π / 2) must be
introduced into the formula (75), whence-with the current Ic = 300- the reactive
voltage due to cutting of end flux, with full-load current per phase, is
300 x ( 3√ ) x (3.5)( 0.949)2) x 60 (4 x 6)2) x 2 x 50.12 x 10-8
= (say) 138 volts
We are now in a position to draw a vector diagram similar to Fig. 90
and calculate the length of the vector OEd which represents the full load
developed voltage and is, therefore, a measure of the flux actually cut by the
conductors at full load. (the flux entering the teeth through the air gap is
somewhat greater since it must include the slot-leakage flux which is not cut
by the conductors and, therefore, does not produce an emf in the armature
windings.) the numerical values of the component vectors are:
OEt = 2771.28, Et P = 8.3, PEd = 138
The angle is 36° 0’ 52‖ since the power factor cos(Փ) is specified as 80
percent. Thus, the full load developed voltage (item 43) is :
OE = √
√ = 2862.66 volts
This is the last item called for in the design sheet, and all the quantities
required in connection with this problem have been calculated.
The design of the filed magnet (rotor) for this machine will be taken up
at the close of the next chapter.
DRAWING
Fig. 93 Winding Diagram.
Fig. 94. Details of armature (stator) slot.
Fig. 95. Armature stamping of a 2,500-kva turbo alternator.
Vector Diagram for the 2,500-kva, 4800 volts turbo alternator.
