Electrical and Electronics Engineering Department (EEE)

ELECTRICAL MACHINE DESIGN

Design 1: DC Generator Armature Design

Submitted by:
Bacomo, Lester Allen G.
Samson, John Arnold

Submitted to:
Engr. Melodia Pahati

June 18, 2018

1
DESIGN SHEET FOR ARMATURE OF D-C GENERATOR (PART – 1)

SPECIFICATION: Preliminary or
ITEM Final
SYMBOL Assumed
NO. 1550 kW ; 660/750 Volts ; 500 rpm Values
Values

ARMATURE CORE AND WINDING

1 Number of Poles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P 12 12
Frequency, Hz - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ƒ - -------- 50
2 Ratio of pole arc to pole pitch - - - - - - - - - - - - - - - - - - - - - - - - - - - - r 0.64 0.64
3 Specific Loading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - q 1,055 1,055
4 Apparent Air-gap flux density (open circuit) - - - - - - - - - - - - - - - - Bg
'' 62,550 70,706.506
5 Line Current (full load) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - -------- 2,348.485
6 Type of Winding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- lap
7 Armature current per circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ic 392.59
8 Output factor (laD2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- 44,481.004 50,682.602
9 Armature diameter, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D 57.34 57.34
10 Peripheral velocity, fpm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ν 7,509.72 7,509.72
11 Total number of face conductors - - - - - - - - - - - - - - - - - - - - - - - - - Z 484 484
12 Number of slots - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S - -------- 20
13 Number of conductors per slot - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 24
14 Axial length of armature core; gross, in - - - - - - - - - - - - - - - - - - - - la 13.53 15.415
15 Flux per pole (open circuit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ϕ 16.363 x106
16 Pole pitch, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - τ 15.012
17 Pole arc, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - rτ 9.61
18 Area covered by pole face (rτla), sq in - - - - - - - - - - - - - - - - - - - - - - ----- 130.023 148.138
19 Dimensions of armature conductors, in. units - - - - - - - - - - - - - - - - ----- - -------- (0.185x0.345)
20 Slot pitch, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - λ - -------- 9.007
21 Slot width, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - s - -------- 0.8
22 Slot depth, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - d - -------- 1.104
23 Tooth width, in. At top - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - t - -------- 8.207
At root - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 7.86
Average - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 8.034
24 Number of radial ventilating ducts - - - - - -- - - - - - - - - - - - - - - - - - n - -------- 1
25 Width of radial ducts, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 0.375
26 Net length of armature core, in - - - - - - - - - - - - - - - - - - - - - - - - - - - ln 12.103 13.837
27 Net tooth section under pole, at center, sq in - - - - - - - - - - - - - - - - - ----- 103.718 118.577
28 Apparent density in teeth under pole, at center, sq in - - - - - - - - - - Bt
'' 157,770.458 91,999.51
29 Length per turn of armature coil, in - - - - - - - - -- - - - - - - - - - - - - - - - ----- - -------- 68.602
30 Resistance of one turn, ohms at 60°C - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 0.000422
31 Resistance of armature, ohms - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 0.0085
32 IR drop in armature, volts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 6.674
33 I2R loss in armature winding, watts - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 31,441.889
34 Estimated full-load flux per pole - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 16.661x106
35 Flux density in armature core below teeth - - - - - - - - - - - - - - - - - - - ----- 76,000 76,002.571
36 Internal diameter of core stampings, in - - - - - - - - - - - - - - - - - - - - - ----- - -------- 39.572
37 Weight of iron in core (without teeth), lb - - - - - - - - - - - - - - - - - - - - ----- - -------- 4,484.022
38 Weight of iron core in teeth, lb - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 665.487
39 Total weight of armature stampings, lb - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 5,149.509

2
 DESIGN OF ARMATURE CORE AND WINDING

Item1: Number of poles (P) and frequency (ƒ)

Referring to Art. 3, for an output of 1550 kW, a speed of up to 500 rpm and 12 poles would be
suitable for this trial design, therefore,
P N 12(500)
ƒ = = = 50 Hz
120 120

Item 2: Ratio of Pole Arc to Pole Pitch

Refer to Art. 2. Since the machine will be provided with commutating poles, a suitable value for this
ratio is;
r = 0.64

Item 3: Specific Loading (q)

2,000−1,500 1,550−1,500
=
1,100−1,050 q – 1,050

q = 1,055
amp .−conductor
¿

Item 4: Apparent Air-gap Flux Density, open circuit (Bg’’)

63,000−62,500 1,550−1,500
=
2,000−1,500 B g ’ ’ – 62,500
lines
Bg’’ = 62,550
¿2

Item 5: Line Current , Full Load ( IL )

fullload output 1,550,000
IL = = = 2,348.485 Amp
full load voltage 660

Item 6: Type of Winding

Simplex Lap Winding
Refer to Art. 6. Since the current per path should not exceed 250 to 300 amp, lap winding with two
parallel paths could be used for this trial design.

Item 7: Armature Current per Circuit ( Ic )

IL
Ic = (1+ excitation)
P1
From Art. 47, % of excitation for 1000 and larger is 0.3 to 0.4, thus, 0.3 may be used.

3
 Then,
2,348.485
Ic = (1+0.003) = 392.59 Amp
6

Item 8: Output factor ( IaD2 )

} q r}
B¿g
8
6.06 x 108 1,550,000 6.06 x 10
IaD2 = = [ ] = 44,481.003 in3
¿ 500 ( 62,550 )( 1,055 ) (0.64)
W
¿
N

Item 9: Armature Diameter (D)

Using a rectangular pole face, where k = 0.71
πr π (0.64)
la = ( D) = (D) = 0.236 D
Pk 12(0.71)
Hence,
D = √3 44,481.003/0.236 = 57.34 in.

Item 10: Peripheral Velocity (fpm)

πDN π ( 57.34 ) (500)
ν= = = 7,509.72 fpm
12 12

Item 11: Total number of Face Conductors (Z)

πDq π ( 57.34 ) (1,055)
Z= = = 484 conductors
Ic 392.59

Item 12: Number of Slots (S)

Assuming that there are 24 conductors per slot
Z 484
S= = = 20 slots
conductors per slot 24

S
And the Slot per Pole ( ) would be,
P
S 20
= =1.67 slots per pole
P 12
S 20
= =3.33 slots per pair pole
P 6
2
4
Item 13: Number of Conductors per Slot ( CS )
Z 484
C s= = =24 conductors per slot
S 20

Item 14: Axial length of Armature Core ( la )

Solving for la ,
l a D2 44,481.003
l a= 2 = =13.53∈¿
D (57.34 )2

Item 15: Flux per Pole, Open Circuit ( ϕ )

From Voltage Equation for dynamo;
ϕPNZ
E=
P1 60 x 108
Solving for ϕ ,
E P 1 60 x 108 660(12)(60 x 108 )
ϕ= = =16,363,636.36 maxwells
PNZ 12(500)(484)

Item 16: Pole Pitch ( τ )

π D π (57.34 )
τ= = =15.012∈¿
P 12

Item 17: Pole Arc ( r τ )

rτ=0.64 x 15.012=9.61∈¿

Item 18: Area covered by Pole Face ( rτ l a )

rτ l a=9.61 ( 13.53 )=130.023 ¿2

Item 19: Dimensions of the Armature Conductors

Assuming k = 700,000
k ν 700,000 7,509.72 amp .
∆ = + = + = 2,540.94
q 4 1,055 4 ¿2
Then,
Ic 392.59
Area of Cross Section = = = 0.155 ¿2
∆ 2,540.94

5
 Referring to Appendix I (Wire Table, bare and DCC Copper Ribbon), an insulated copper conductor
having a cross sectional area of 0.184 ¿2 has a thickness of (t=0.185) and width of (w=0.345)
respectively.

Item 20: Slot Pitch ( λ )

π D π (57.34 )
λ= = =9.007∈¿
S 20

Item 21: Slot Width ( s )

E 660
Insulation thickness = 27 + = 27 + = 49 mils or 0.049 in
30 30
s=3 t +5(insulation thickness)
s=3 ( 0.185 )+5 ( 0.049 )=0.8∈¿

Item 22: Slot Depth ( d )

1
d=2 w+ 3 (insulation thickness ) + s
3
1
d=2( 0.345)+3 ( 0.049 )+ (0.8)
3
d=1.104 ∈¿

Item 23: Tooth Width ( t )

At Top,
t Top =λ−s=9.007−0.8=8.207∈¿
At Root,
π ( D−2 d ) π [ 57.34−2(1.104) ]
t Root = −s= −0.8=7.86∈¿
S 20

Therefore the Average Tooth Width is,

t Top +t Root 8.207+7.86

t Ave = = =8.034∈¿
2 2

Item 24: Number of Radial Ventilating Ducts

6
 Refer to Art. 16. Not more than three ducts should be necessary in an armature 9 to 11 in long, with
3
each duct in. wide.
8
Therefore,
Use one (1) radial ventilating duct.

Item 25: Width of Radial Duct ( l v )

3
lv = in or 0.375 in
8

Item 26: Net length of Armature Core ( ln )

Refer to Art. 16.
l n=0.92 ( l a−l v ) =0.92 [ 13.53−1(0.375) ] =12.103∈¿

Item 27: Net Cross Section of Teeth Under Pole

l n ( t ave ) ( SP ) ( r )=12.103 ( 8.034 ) ( 2012 ) ( 0.64 ) =103.718¿ 2

''
Item 28: Apparent Density in Teeth Under Pole (Bt )
ϕ 16,363,636.36 lines
B ''t = ( Net Cross Section oTeeth )
=
103.718
=157,770.458
¿ 2

l ines
But referring to the table on number 17, a 50 cycles have a B ''t of 126,000 2
and
¿
lines
applying the 10 % tolerance, a 50 cycles should be below 138,600 .
¿2

Since the preliminary value of B 't' is above the upper limit, therefore, it will be necessary to
correct (increase) the length of the armature core to bring the Flux Density down to a reasonable
figure.

'' lines
Assuming Bt = 138,000
¿2
16,363,636.36
Net Cross Section of Teeth = = 118.577 ¿2
138,000

Net Length Armature is.

7
 Net Cross Section of Teeth 118.577
l n= = =13.837∈¿
S 20
t ave x x r
P
8.034
12 ( )
(0.64)

To solve for the new and final value of la ,

ln 13.837
l a= +l v = +0.375=15.415∈¿
0.92 0.92

Then,

l a D2 =( 15.415 ) (57.34)2=50,682.602 ¿3
2
rτl a=( 9.61 )( 15.415)=148.138¿

16,363,636.36 lines
B ''g = =110,462.112 2
148.138 ¿

B 't' =105,180.305 ( 12.103

13.837 )=91,999.51
lines
¿2

'' ''
Now both B g ∧Bt have an acceptable values wherein both values are within ± 10 %
tolerance.

Item 29: Number of Radial Ventilating Ducts

By referring to Art. 16,

1.15 s 1.15(0.8)
sin α = = =0.102
λ 9.007
Then,
−1
α =sin 0.102=5.854 ° ; cos α =cos 38.16=0.995

2τ 2(15.012)
I c= +4 d+ 3= +4 ( 1.104 ) +3=37.772∈¿
cos α 0.995

Therefore,

Total Length per Turn = Ic + 2 Ia = 37.772+ 2 ( 15.415 )=68.602∈¿

8
Item 30: Resistance of one turn, Ohms at 60 ℃

Total Length per Turn 68.602

R= = =0.000422Ω
4 6 4 6
2 ( t x w ) x x 10 2 [ ( 0.185 ) (0.345) ] x x 10
π π

R
Item 31: Resistance of Armature, (¿¿ c )
¿

Total Number of Turns 484

Rc =R ( P1 ) =0.000422 ( )
12
=0.017 Ω

Finally, the Total Resistance in the Armature

1
Total Armature Resistanc e= ( 0.017 )=0.0085Ω
2

Item 32: IR Drop in Armature

Rc x I c =0.017 x 392.59=6.674 Volts

Item 33: I2R Loss in Armature Winding

I 2 R Loss=I c 2 x Rc P=392.592 ( 0.017 ) (12 ) =31,441.889 watts

Item 34: Full load Flux

Assuming a brush contact drop of 2 volts, and a series field and commutating-field drop of about
one-half that in the armature winding, the total generated voltage at full load must be,

IR drop
Total Generated Voltage at Full Load=V FL + Brush drop+ IR drop+
2
6.674
¿ 660+2+6.674+
2
= 672.011Volts

9
 Therefore, the Full Load Flux must be,

Full Load Flux =ϕ ( Total GeneratedVVoltage at Fullload )

FL

¿ 16,363,636.36 ( 672.011
660 )
¿ 16,661,429.75 maxwells

Item 35: Flux density in Armature Core below Teeth

From Art. 17, the suitable density for a frequency of 50 Hz is 76,000. Bearing in mind that the air-
gap is into two equal parts below the teeth, the armature flux is one-half of the total flux. Therefore,
lines
density in core is 76,000 2
.
¿

ϕ 16,363,636.36
Rd = = =7.78∈¿
2 x l n x Density ∈Core 2 ( 13.837 ) (76,000)

And the final value of Flux Density in Armature Core below Teeth is,

ϕ 16,363,636.36 lines
Flux Density ∈Armature Core= = =76,002.571 2
2 x l n x Rd 2 ( 13.837 ) (7.78) ¿

Item 36: Internal Diameter of Core Stampings

Di=D−2 R d−2d =57.34−2 ( 7.78 ) −2 (1.104 )=39.572∈¿

Item 37: Weight of iron Core

The weight of a cubic inch of Iron is 0.28 lb, and the total weight of iron Core below the Teeth will
be,

10
 D−2 d
¿
¿
¿
π
Weight of Iron Core=0.28 x l n x ¿
4

¿ 0.28(13.837) ( π4 ) {[ 57.34−2(1.104)] −(39.572) }

2 2

¿ 4,484.022 lb

Item 38: Weight of iron Teeth

Weight of Iron Teeth=0.28 x d x ( t ave x S ) x l n

¿ 0.28(1.069)(8.034 x 20)(13.837)
¿ 665.487 lb

Item 39: Total Weight of Armature Stampings

Total Weight=Weight of IronCore +Weight of Iron Teeth

¿ 4,484.022+665.487
¿ 5,149.509lb

11
DESIGN SHEET FOR ARMATURE OF D-C GENERATOR (PART – 2)

SPECIFICATION: Preliminary or
ITEM Final
SYMBOL Assumed
NO. 1550 kW ; 660/750 Volts ; 500 rpm Values
Values

COMMUTATOR AND BRUSHES

40 Diameter of Commutator, in Dc --------- 36.45

41 Average volts per turn of armature winding ------- --------- 37.19
42 Number of turn between bars ------- --------- 1
43 Total number of Commutator bars ------- --------- 239
44 Bar pitch, in ------- --------- 0.479
45 Width of copper bar (on surface), in ------- --------- 0.449
46 Radial depth of bar, in ------- --------- 3.43
47 Current density at brush-contact surface, amp per sq in ∆b 40 40.061
48 Contact area per brush set, sq in ------- 19.63 19.6
49 Brush arc (circumferential width), in ------- --------- 1.0
50 Axial brush length (total) per set, in ------- -------- 19.6
51 Number of brushes per set ------- --------- 31.36
52 Axial length of Commutator, in Lc --------- 22.85
53 Brush-contact drop, volts ------- --------- 2.3
54 Brush-contact loss, watts ------- --------- 9,096.684
55 Brush-friction loss, watts ------- --------- 12,684.355
56 Total brush loss, watts ------- --------- 21,781.039
57 Drawing to scale giving leading dimensional of ------- Fig. II
Armature and Commutator

DESIGN OF COMMUTATOR AND BRUSHES

12
Item 40: Diameter of Commutator (Dc)
From Art. 14, a diameter of Commutator not exceeding 80 % of the Armature Core Diameter is
D
generally found practical, although a reasonably good rule to follow is to make Dc= + R d ∈¿ .
2
Thus,
57.34
Dc= + 7.78=36.45∈¿
2

This is 63.57 % of the core diameter and makes the peripheral velocity,
ν c = 0.6357 x 7,509.72 = 4,773.929 fpm

Item 41: Average Volts per Turn of Armature Winding

E 750
= =37.19 Volts
Z 484
2 P 1 2(12)

Item 42: Number of Turns between Bars

One (1)

Item 43: Total Number of Commutator Bars

C= ( Cs2 x S)−1=( 242 x 20)−1=239 Commutator Bars

Item 44: Bar Pitch
π Dc π (36.45)
= =0.479∈¿
C 239

Item 45: Width of Copper Bar (On Surface)

Using 0.03 in mica for insulation, the width of copper bar = Bar Pitch ― 0.03, therefore, 0.479―
0.03 = 0.449in at the Commutator surface.

Item 46: Radial Depth of Bar

Since the Peripheral Velocity is less than 4,500 fpm, the Radial Depth of the Commutator Segment
should be about,
Dc +15 36.45+15
h= = =3.43∈¿
15 15

13
Item 47: Current Density at Brush-Contact Surface ( ∆ b )
amp .
The Current Density over the Brush Contact Surface is about 30 to 50 , taking 40
¿2
amp.
as preliminary value.
¿2

Item 48: Contact Area per Brush Set

PIc 12(392.59)
= =19.63¿ 2
6(40)
( P2 )(∆ ) b

Item 49: Brush Arc (Circumferential Width)

1.0 inch

Item 50: Axial Brush Length per Set

Contact Area 19.63
= =19.63∈¿
Bruh Arc 1.0

Item 51: Number of Brushes per Set

The actual area per Brush Set is,
2
Axial Brush Length x Brush Arc=19.63 x 1.0=19.6 ¿

5 1
From Art. 34, the usual width of Brush is something between the limits in and 1 in.,
8 4
and as a further check on the desirable dimensions, the width should not exceed one-tenth of the
5
pole pitch referred to the Commutator surface. Thus, use a Brush of in. width.
8
Then,
19.6 19.6
No. of Brushes per Set= = =31.36 Brushes
5 0.625
8
The Current Density will be increased slightly to;

40 ( 19.63
19.6 )=40.061
amp .
¿ 2

Item 52: Axial Length of Commutator (Lc)

14
 5
In addition to the 19.6 in which must be provided for the four in Carbon Brushes, the Axial
8
Length of the Commutator Face must allow for the following:
5 5
a. Brush holder and clearances = 4 = ∈¿
16 4

5
b. Staggering of (+) and (-) Brushes = ∈¿
8

c. End clearance for Brushes = 1 in

3
d. End Play = ∈¿
8

Total Length will be,

5 5 3
Lc =19.6+ + +1+ =22.85∈¿
4 8 8

Item 53: Brush Contact Drop

amp.
Referring to Fig. 38, the Brush Contact Drop for Hard Carbon at about 40. is 2.085 volts.
¿2
Allowing the 10 % of roughness, chipping and irregularities, thi drop will be about
2.3 volts.

Item 54: Brush Contact Loss

Brush Contact Drop x P x Ic = 2.3 (12 x 329.59) = 9,096.684 watts

Item 55: Brush Friction Loss

lb
For a peripheral speed greater than 4,000 fpm, use c = 0.25 for hard carbon; P = 2 2
¿

cPAN D c π x 746 0.25 (2 )( 19.6 x 12)(500)(36.45) π x 746

Wf = = =12,684.355 watts
12 x 33,000 12 x 33,000

Item 56: Total Brush Loss

Total Brush Loss=Brush Contact Loss +Brush Friction Loss

¿ 9,096.684 + 12,684.355
¿ 21,781.039 watts

15
Item 57: drawing to Scale giving leading Dimensions of Armature and Commutator

Shaft Diameter=0.84
√
3 Output ∈watts
N

¿ 0.84
√
3 1,550.000
500
¿ 12.25∈¿

16