POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

College of Engineering
Electrical Engineering Department






ELECTRICAL MACHINE DESIGN
Design 1: DC Generator Armature Design








Submitted by

PAUIG, MARK ANTHONY C.
BSEE V-3



Submitted to

ENGR. LIBRADO S. GESALTA
Instructor





June ___ , 2014

Design Sheet for a DC Generator Armature

ITEM
NO.
SPECIFICATION :
1400KW, 220/240V, 900rpm, DC Generator
SYMBOL PRELIMINARY OR
ASSUMED VALUES
FINAL VALUES
===== PART 1 : ARMATURE CORE & WINDING ======== ===================== ====================
1 Number of poles / frequency P /f 8 poles / 60 Hz
2 Ratio of pole arc to pole pitch r 0.64 0.64
3 Specific loading q 1040 1054.72
4 Apparent air-gap density B
g
62,400 lines/in.
2
85,691.81 lines/in.
2

5 Line current I 5833.333 A
6 Type of winding Lap Winding
7 Armature current per circuit I
c
975.139 A
8 Output factor l
a
D
2
22,696.571

20,040.03

9 Armature diameter D 40.024 in. 40.024 in.
10 Peripheral velocity v 14,145.65 fpm 14,145.65 fpm
11 Total number of face conductors Z 134 136
12 Number of slots S 39
13 Number of conductors per slot 4
14 Axial length of armature core l
a
13.97 in. 12.51 in.
15 Flux per pole 10,784,313.73 maxwells
16 Pole pitch 15.72 in.
17 Pole arc 10.06 in.
18 Area covered by pole face l
a
140.54 in.
2
125.85 in.
2

19 Dimensions of armature conductors (0.185 0.345)
20 Slot pitch 3.22 in.
21 Slot width S 0.73 in.
22 Slot depth d 2.69 in.
23 Tooth width :
at top
at root
average

2.49 in.
2.06 in.
2.28 in.
24 Number of radial ventilating ducts n 3
25 Width of radial ducts 0.375 in.
26 Net length of armature core l
n
11.59 in. 11.16 in.
27 Net tooth section under pole, at the center 82.44 in.
2

28 Apparent density at teeth under pole at center B
t
130,814.09 lines/in.
2
88,993.56 lines/in.
2

29 Length per turn of armature coil 70.21 in.
30 Resistance of one turn, ohms at 60C 0.000432
31 Resistance of armature 0.0037
32 IR drops in the armature 7.16 V
33 I
2
R loss in armature winding 55,836.62 watts
34 Estimated full-load flux per pole 11,408,823.53 maxwells
35 Flux density in armature core below teeth 73000 lines/in.
2
72,986.13 lines/in
2
36 Internal diameter of core stampings 21.404 in.
37 Weight of iron in core(without teeth) 1821.21 lbs.
38 Weight of iron in teeth 747.44 lbs.
39 Total weight of armature stampings 2568.65 lbs.




Solutions:
PART 1:

Item 1: Number of Poles and Frequency
f = 60Hz
P = _60 Hz 120_ P = 8 poles @ 60 Hz frequency
900rpm
NUMBER OF POLES AND USUAL SPEED LIMITS OF DYNAMOS
OUTPUT, KILOWATT NO. OF POLES SPEED, RPM
2 or less 2 Over 1,250
2 to 75 4 900 to 1,750
75 to 200 6 Up to 1,200
200 to 500 6 or 8 Up to 1,200
500 to 1,500 8 to 12 Up to 900
1,500 to 2,500 12 to 14 Up to 500
2.500 to 5,000 14 to 24 Up to 375

Item 2: Ratio of Pole Arc to Pole Pitch
r = 0.64 r = 0.64

Items 3 and 4: Specific Loading and Air-gap Density

APPROXIMATE VALUES OF APPARENT AIR-GAP DENSITY
OUTPUT, KW Bg q OUTPUT, KW, q Bg
5 37,000 400 750 950 61,000
10 42.000 450 1,000 1k 62,000
20 45,000 500 1,500 1.050k 62,500
30 47,000 550 2,000 1.1k 63,000
40 48,500 600 2,500 1.150k 63,500
50 50,000 625 3,000 1.2k 64,000
100 53,000 700 4,000 1.225k 65,000
200 56,500 800 5,000 1.250k 65,500
300 57,500 850 7,500 1.275k 66,500
400 58,500 875 10,000 1.3k 67,000
500 59,000 900 LARGER 1.3k 67,500

q = 1.040K q = 1.040K
B
g
= 62,400 B
g
= 62,400

Item 5: Line Current
I = _1400000 W I = 5833.333 A
240V

Item 6: Type of Winding *Lap winding



Item 7: Armature Current per Circuit
I
c
= _5833.333_ 1.003 I
c
= 975.139 A
6
Items 8, 9, 10:
Output Factor
I
a
D
2
= _1400000_ ____6.06 10
8
_____ I
a
D
2
= 22696.571 cu. in.
900 62400 0.64 1040
Armature Diameter
Using rectangular pole face, where k = 0.71
I
a =

(D) =

(D)
= .354 D I
a
= .354 D
_____________________
D =
3
_1400000_ ____6.06 10
8
_____ D = 40.024 in.
___900______62400 0.64 1040_
0.354

Peripheral Velocity
v = r D =_40.024 900 v = 14,145.65 fpm
P 8











Items 11, 12, 13: Number of Inductors, Slots, and Conductors per Slot
Number of Conductors
Z =

= _40.024 1040 _ Z = 134; use 136

975.139
Number of Slots S = 39
Number of Conductors per Slot *4
Specific loading
q =

= 136 975.139_ q = 1054.72
40.024
Item 14: Axial Length of Armature Core
Gross Armature Length
I
a
D
2
= 22696.571 1040 I
a
D
2
= 22,379.81
1054.72
I
a
= 22379.81 I
a
= 13.97 in.
40.024
2

Item 15: Flux per Pole (Open Circuit)
Flux per Pole
= _220 60 8 10
8
_ = 10,784,313.73 maxwells
900 8136

Items 16, 17, 18: Pole Pitch, Pole Arc, and Pole Area
Pole Pitch
=D = _40.024 _ = 15.717 in.
P 8
Pole Arc
= 15.717 0.64 = 10.06 in.

Pole Area
I
a
= 10.06 13.97 I
a
= 140.54 in.
2


Items 19 to 22: Dimensions of Slots and Armature Conductors
Amperes per square inch Assuming k=700,000
=

= 700,000 + 14,145.65 = 4,200 A/in.
2

1054.72 4
Area of cross section
_I
c
_ = 975.139 _I
c
_ = 0.23 in.
2

4,200
Slot Pitch
= _40.024 _ = 3.22 in.
39
Slot width
Insulation thickness = 27 + E/30 =27 +220/30 = 34.333 mils or .034 in
s =3t + 5(insulation thickness) = 3 (0.185) + 5 (0.034) s = 0.73 in.

Slot depth
d = (1/3)(.73) + (3 0.034) + (2 0.345) d = 2.69 in.























Item 23: Tooth Dimensions
Tooth width at the top
T
top
= s = 3.22 - 0.73 T
top
= 2.49 in.
Tooth width at the root
T
root
= (D -2d ) s = (40.024 2(2.69)) 0.73 T
root
= 2.06 in.
S 39
Tooth width average
T
average
= _2.49 + 2.06_ T
average
= 2.28 in.
2











Items 24 and 25: Ventilating Ducts
Ventilating ducts
*Use 3 ducts with 0.375 in. width *3 ducts 0.375 in. wide

Item 26: Net Length of Armature
Net length of the armature core

I
n
= 0.92[13.97 - (1 0.375)] I
n
= 11.59 in.

Item 27: Net Cross Section of Teeth under Pole
Net tooth cross section under pole

Net cross section of teeth = 11.59 2.28 _39_ 0.64 Tooth Section = 82.44 in.
2

8
Item 28: Flux Density in Teeth under pole (B
t
)
Apparent Flux Density at teeth
B
t
= = 10,784,313.73 B
t
= 130,814.09 lines/in.
2
Tooth section 82.44
But for 60 Hz, flux density in Teeth should be 123,500 lines per sq. inch, applying 10% tolerance
Assuming B
t
=135,850 lines per sq. inch
UPPER LIMITS OF FLUX DENSITY IN DYNAMO ARMATURES
(Maxwells per Sq in.)








Frequency, f Density in teeth (at center) Density in core
10 150,000 95,000
20 142,000 90,000
30 135,000 85,000
40 130,000 80,000
50 126,000 76,000
60 123,500 73,000

Net cross section of teeth = / B
t
=10,784,313.73 /135,850 =79.384 in.
2

11.16 in.
New and final value of
,

= (12.51)

=20,040.03

I
a
=(10.06)(12.51) = 125.85 in.
2

B
g
= 10,784,313.73/125.85 = 85,691.81 lines/in.
2
B
t
=85,691.81 (11.59/11.16) =88,993.56 lines/in.
2




Item 29: Length per Turn of Armature Coil
sin a =1.15 s/ =1.15 (0.73)/3.22 = 0.261
a =

= 15.13; cos a = cos 15.13 =.965

l
c
=

+ 4d +3 =

+ 4(2.69) +3= 45.19 in.
l
c
= 45.19 in. ; l
a
= 12.51 in.
L/T = 45.19 + (2 12.51) L/T = 70.21 in.


Items 30 to 33: Armature Resistance
Resistance at 60C
R
@60C
=

R
@60C
= 0.000432


Resistance of the armature
R
a
= R (total number of turns)
P
R
a
= 0.000432 _(136) = 0.00734/2 R
a
= 0.0037
8
IR drop in the armature
IR = 975.139 0.00734 IR = 7.16 V
I
2
R loss in the armature
I
2
RP = (

0.00734 8) I
2
R = 55,836.62 Watts



Item 34: Full-load Flux
Total generated voltage at full-load

= 232.74 volts


Full-load flux per pole

FL
= (Total generated voltage at full-load )
FL
= 11,408,823.53 maxwells

= 10,784,313.73 (232.74)
220



Items 35 and 36: Flux Density in Armature Core below Teeth
For 60 Hz use 73,000 lines per sq. inch for density in core.
UPPER LIMITS OF FLUX DENSITY IN DYNAMO ARMATURES
(Maxwells per Sq in.)

=_______________________ =__10,784,313.73__

=6.62 in
2 x

x density in the core 2 x 11.16 x 73,000

Final value of Flux density in Armature Core
=_______________________ = __10,784,313.73__ = 72,986.13 lines/in.
2

2 x

2 x 11.16 x 6.62

Internal diameter of core stampings
D
internal
= D-2

-2d
D
internal
= 40.024 (2 6.62) (2 2.69) D
internal
= 21.404 in.

Item 37: Weight of Iron Core
Weight of iron in core (without teeth)
W
core
= 0.28

( /4) [(D 2d)

2
(Di)
2
]
W
core
= 0.28 11.16 ( /4) *(40.024 (2 x 2.69))
2
(21.404)
2
] W
core
= 1821.21 lbs.


Item 38: Weight of Iron in Teeth
Weight of iron in teeth
W
teeth
=0.28 x d x (T
average
S ) x

W
teeth
= 0.28 2.69 (2.28 39) 11.16 W
teeth
= 747.44 lbs.

Item 39: Total Weight of Armature Stampings
Total weight of core stampings
W
total
= W
core
+ W
teeth

W
total
= 1821.21 + 747.44 W
total
= 2,568.65 lbs.









Frequency, f Density in teeth (at center) Density in core
10 150,000 95,000
20 142,000 90,000
30 135,000 85,000
40 130,000 80,000
50 126,000 76,000
60 123,500 73,000
===== PART 2 : Commutator & Brushes ======== ===================== ====================
40 Diameter of Commutator D
c
26.632 in.
41 Average volts per turn of armature winding 28.24 V
42 Number of turns between bars 1
43 Total number of commutator bars 77
44 Bar pitch 1.087 in.
45 Width of copper bar 1.057 in.
46 Radial depth of bar 2.77 in.
47 Current density at brush contact surface
b
40 amps/in.
2
39.97 amps/in.
2

48 Contact area per brush set 48.76 in.
2
48.8 in.
2

49 Brush arc 1 in.
50 Axial brush length per set 48.8 in.
51 Number of brushes per set 78.08
52 Axial length of commutator L
c
53.3 in
53 Brush-contact drop 2.3 V
54 Brush-contact loss 17,942.56 Watts
55 Brush-friction loss 27,689.79 Watts
56 Total brush loss 45,632.35 Watts
57 Drawing to scale giving leading dimensions of
armature and commutator
9.73 in.


PART 2 :
Item 40: Diameter of Commutator

D
c
= (40.024 2) + 6.62 D
c
= 26.632 in.
This is 66.54% of the core diameter and makes the peripheral velocity

=0.6654 14,145.65

=9412.516 fpm

Items 41 to 43: Number of Commutator Bars
Average volts per turn

E
average
/turn = ___240___ E
average
/turn = 28.24V
136 16
Number of turns between bars
One (1)
Number of Commutator bars
(

) = (4/2 39) 1
*It is desirable to use 77 commutator bars to improve the commutation and to be more suitable and narrower.

Items 44 and 45: Width of Commutator Segments
Bar pitch
Bar pitch =

Bar pitch = 26.632 _ Bar pitch = 1.087 in.
77
Width of copper bar
*using 0.03 in mica insulation
Width
Cu
= Bar pitch - 0.03 = 1.087 0.03 Width
Cu
= 1.057 in.

Item 46: Radial Depth of Segment
Radial depth of bar
h =

+ 15 / 15
h = _26.632 + 15_ h = 2.77 in.
15


Items 47 to 51: Dimensions of Brushes
Current density at brush contact surface
*assume 40 A as preliminary value
b
= 40 amps/ in.
2
Contact area per brush set

_8 975.139 _ 48.76 in.
2

4 40
Brush Arc (Circumferential Width) 1 inch
Axial brush length per set 48.76 in.
Number of brushes per set
Actual area per brush set 48.8 in.
2

*from Art. 34 the usual width of brush is something between the limits of 5/8 in and 1 in, and as a further check on the
desirabledimensions, 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
No. of brushes per set = 48.8 / 0.625 = 78.08 Brushes
The Current Density will be slightly decreased to,
40(48.76/48.8)= 39.97 amps/ in.
2



Item 52: Length of Commutator
Axial length of commutator
*In addition to the 48.8 in. which must be provided for the four 5/8 in. Carbon Brushes, the Axial Length for the Commutator face
must allow the following:
a.) Brush Holder and Clearances = 5/2 in.
b.) Staggering of (+) and (-) brushes = 5/8 in.
c.) End clearance for brushes =1 in.
d.) End play =3/8 in.
L
c
= 48.8 + 2.5 +0.625 + 1 + 0.375 L
c
= 53.3 in.

Item 53: Brush-contact Drop
*Brush contact drop for hard carbon at about 40 amps/ in.
2
is 2.085 volts. Allowing the 10% of roughness, chipping and
irregularities, this drop will be about 2.3 volts. *2.3 V

Item 54 to 56: Brush Losses
Brush contact loss
Loss
Brush contact
= Brush contact drop P

= 2.3 8 975.139 Loss

Brush contact
= 17,942.56 Watts
Brush contact friction
*For Peripheral speed greater than 4,000 fpm use c=0.25 for hard carbon; P= 2

W
f
=( c PAN D
c


746)/12 33,000
W
f
= _0.25 2 (48.8 8 ) 26.632 900 746 _ W
f
= 27,689.79 Watts
12 33000
Total brush loss
Loss
TOTAL
= 17,942.56 +27,689.79 Loss
TOTAL
=45,632.35 Watts
Item 57: Drawing to scale giving leading dimensions of armature and commutator
Shaft Diameter = 0.84

= 0.84

= 9.73 in.