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Electrical Machine Design Design 1: DC Generator Armature Design
Electrical Machine Design Design 1: DC Generator Armature Design
Submitted by:
Bacomo, Lester Allen G.
Samson, John Arnold
Submitted to:
Engr. Melodia Pahati
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
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
From Art. 47, % of excitation for 1000 and larger is 0.3 to 0.4, thus, 0.3 may be used.
Then,
2,348.485
Ic = 6
(1 + 0.003) = 392.59 Amp
3
Item 8: Output factor ( IaD2 )
𝑊 6.06 𝑥 108 1,550,000 6.06 𝑥 108
IaD2 = 𝑁
( "
𝐵𝑔 𝑞 𝑟
) =
500
[ (62,550)(1,055)(0.64) ] = 44,481.003 in3
Hence,
3
D = √44,481.003 ⁄0.236 = 57.34 in.
𝑆
And the Slot per Pole ( 𝑃
) would be,
𝑆 20
= = 1.67 𝑠𝑙𝑜𝑡𝑠 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒
𝑃 12
𝑆 20
= = 3.33 𝑠𝑙𝑜𝑡𝑠 𝑝𝑒𝑟 𝑝𝑎𝑖𝑟 𝑝𝑜𝑙𝑒
𝑃⁄ 6
2
4
Item 15: Flux per Pole, Open Circuit ( 𝜙 )
From Voltage Equation for dynamo;
𝜙𝑃𝑁𝑍
𝐸 =
𝑃1 60 𝑥 108
Solving for 𝜙,
𝐸𝑃1 60𝑥108 660 (12)(60𝑥108 )
𝜙= = = 16,363,636.36 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠
𝑃𝑁𝑍 12 (500)(484)
Then,
𝐼𝑐 392.59
Area of Cross Section = ∆
= 2,540.94 = 0.155 𝑖𝑛2
Referring to Appendix I (Wire Table, bare and DCC Copper Ribbon), an insulated copper conductor
having a cross sectional area of 0.184 𝑖𝑛2 has a thickness of (t=0.185) and width of (w=0.345)
respectively.
5
Item 22: Slot Depth ( 𝑑 )
1
𝑑 = 2𝑤 + 3 (𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠) + 𝑠
3
1
𝑑 = 2(0.345) + 3 (0.049) + (0.8)
3
𝑑 = 1.104 𝑖𝑛
6
𝑆 20
𝑙𝑛 (𝑡𝑎𝑣𝑒 ) ( ) (𝑟) = 12.103 (8.034) ( ) (0.64) = 103.718 𝑖𝑛2
𝑃 12
Since the preliminary value of 𝐵𝑡′′ 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 𝑖𝑛2
16,363,636.36
Net Cross Section of Teeth = 138,000
= 118.577 𝑖𝑛2
𝑙𝑛 13.837
𝑙𝑎 = + 𝑙𝑣 = + 0.375 = 15.415 𝑖𝑛
0.92 0.92
Then,
16,363,636.36 𝑙𝑖𝑛𝑒𝑠
𝐵𝑔′′ = = 110,462.112
148.138 𝑖𝑛2
12.103 𝑙𝑖𝑛𝑒𝑠
𝐵𝑡′′ = 105,180.305 ( ) = 91,999.51
13.837 𝑖𝑛2
Now both 𝐵𝑔′′ 𝑎𝑛𝑑 𝐵𝑡′′ have an acceptable values wherein both values are within ± 10 % tolerance.
7
Item 29: Number of Radial Ventilating Ducts
By referring to Art. 16,
2𝜏 2 (15.012 )
𝐼𝑐 = cos 𝛼
+ 4d + 3 = 0.995
+ 4 (1.104) + 3 = 37.772 𝑖𝑛
Therefore,
1
𝑇𝑜𝑡𝑎𝑙 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = (0.017) = 0.0085 Ω
2
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 = 𝑉𝐹𝐿 + 𝐵𝑟𝑢𝑠ℎ 𝑑𝑟𝑜𝑝 + 𝐼𝑅 𝑑𝑟𝑜𝑝 +
2
6.674
= 660 + 2 + 6.674 + 2
= 672.011Volts
= 16,661,429.75 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠
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,
density in core is 76,000 𝑙𝑖𝑛𝑒𝑠⁄𝑖𝑛2 .
𝜙 16,363,636.36
𝑅𝑑 = = = 7.78 𝑖𝑛
2 𝑥 𝑙𝑛 𝑥 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 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 𝑖𝑛 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝐶𝑜𝑟𝑒 = = = 76,002.571
2 𝑥 𝑙𝑛 𝑥 𝑅𝑑 2(13.837)(7.78) 𝑖𝑛2
9
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,
𝜋
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐼𝑟𝑜𝑛 𝐶𝑜𝑟𝑒 = 0.28 𝑥 𝑙𝑛 𝑥 [(𝐷 − 2𝑑)2 − (𝐷𝑖)2 ]
4
𝜋
= 0.28(13.837) ( 4 ) {[57.34 − 2(1.104)]2 − (39.572)2 }
= 4,484.022 𝑙𝑏
10
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
11
DESIGN OF COMMUTATOR AND BRUSHES
This is 63.57 % of the core diameter and makes the peripheral velocity,
𝜈𝑐 = 0.6357 x 7,509.72 = 4,773.929 fpm
12
Item 47: Current Density at Brush-Contact Surface (∆𝑏 )
𝑎𝑚𝑝. 𝑎𝑚𝑝.
The Current Density over the Brush Contact Surface is about 30 to 50 𝑖𝑛2
, taking 40 𝑖𝑛2
as
preliminary value.
From Art. 34, the usual width of Brush is something between the limits 5⁄8 in and 1 1⁄4 in., and as
a further check on the desirable dimensions, the width should not exceed one-tenth of the pole
pitch referred to the Commutator surface. Thus, use a Brush of 5⁄8 in. width.
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;
19.63 𝑎𝑚𝑝.
40 ( ) = 40.061
19.6 𝑖𝑛2
13
Total Length will be,
5 5 3
𝐿𝑐 = 19.6 + + + 1 + = 22.85 𝑖𝑛
4 8 8
Item 57: drawing to Scale giving leading Dimensions of Armature and Commutator
3 𝑂𝑢𝑡𝑝𝑢𝑡 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑆ℎ𝑎𝑓𝑡 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0.84 √
𝑁
3 1,550.000
= 0.84 √ 500
= 12.25 𝑖𝑛
14