PRELIMINARY CALCULATIONS:
DESIGN OF THE ARMATURE OF D.C. GENERATOR

Specification: 500 kilowatts, 240V, 900 RPM

I. ARMATURE CORE AND WINDING

ITEM 1: Either 6 poles or 8 poles are suitable. We picked p = 6 poles. Based on Table 1.1.

Output, kW 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 or 14 Up to 500
2,500 to 5,000 14 to 24 Up to 375
Table 1.1 NUMBER OF POLES AND USUAL SPEED LIMITS OF DYNAMOS

ITEM 2: Since the machine will be provided with commutating poles values should be between 0.6
~ 0.64. Therefore r = 0.64.

ITEM 3: Base on the table on Table 1.2. Since the specification is 500 kilowatts. I choose q = 900.

Output, kW Q Output, kW q
5 400 750 950
10 450 1,000 1,000
20 500 1,500 1,050
30 550 2,000 1,100
40 600 2,500 1,150
50 625 3,000 1,200
100 700 4,000 1,225
200 800 5,000 1,250
300 850 7,500 1,275
400 875 10,000 1,300
500 900 Larger 1,300
Table 1.2 APPROXIMATE VALUES OF q FOR INTERPOLE DYNAMOS
(Ampere Conductors per Inch of Armature Periphery)

ITEM 4: Base on the table on Table 1.3. Since the specification is 500 kilowatts. I choose Bg” =
59,000.
  

Output, kW B” Output, kW B”
5 37,000 750 61,000
10 42,000 1,000 62,000
20 45,000 1,500 62,500
30 47,000 2,000 63,000
40 48,500 2,500 63,500
50 50,000 3,000 64,000
100 53,000 4,000 65,000
200 56,500 5,000 65,500
300 57,500 7,500 66,500
400 58,500 10,000 67,000
500 59,000 Larger 67,500
Table 1.3 APPROXIMATE VALUES OF APPARENT AIR-GAP DENSITY

ITEM 7: Since the based kilowatt on specification is 500 kilowatts, therefore 0.5 percent is used.
Note that the line current is 2173.913 amps and the pole is 8.

Ic = (2173.913/8)(1+0.005) = 273.08 amperes

Exciting current
Output of machine, kW percentage of
rated current
10 3.0
25 2.5
50 1.6
100 1.2
200 0.9
300 0.7
500 0.5
1,000 and larger 0.3 to 0.4
Table 1.4 USUAL VALUES OF SHUNT-FIELD CURRENT

ITEM 8: Calculating the Output Factor (laD2). Note that Output power = 500 kilowatts, N = 900 RPM,
Bg” = 59,000, r = 0.64, q = 900.

, .
l aD 2 =
, .

laD 2 = 9906.62
  

ITEM 9: Calculating the armature diameter, use 0.71 as the value of k.

.
la = xD
.

la = 0.354D

.
D= = 30.361 inches.
.

ITEM 10: Calculating the Peripheral Velocity,

.
v= = 7153.62 fpm.

ITEM 11: Calculating the Total Number of Face Conductor.

.
Z= . = 220 face conductors

ITEM 14: Calculating the axial length of armature core.

laD 2 = 9906.62 = 6960

.

la = = 10.427 inches
.

ITEM 15: Calculating the Flux per pole if the D.C. Generator is in Open Circuit.

ᶲ = = 4,732,510.29 maxwells

ITEM 16: Calculating the Pole Pitch.

.
Pole Pitch (τ) = = 11.92 inches

ITEM 17: Calculating the Pole Arc.

Pole Arc (rτ) = 11.92 0.64 .

ITEM 18: Calculating the Area Covered by pole face.

rτla = 7.63 10.427 79.56 sq. in.

  

ITEM 26: Calculating the Net length of Armature core.

ln = 0.92 ( 10.427 – 3 x 0.375 ) = 8.56 inches

ITEM 27: Calculating the Net tooth section under pole. The cross section of iron in the teeth under
one pole. Note that ln = 8.09 inches (Based on Item 26), the Average tooth width is 0.4 inches (This
is calculated in final calculation), Number of Slots is 111 slots (This will be shown in Final
Calculations), Poles is 6 poles (Based on Item 1), and r = 0.6 (Based on Item 2).

81
8.56 0.71 0.64 . . .
8

ITEM 28: Calculating the Flux Density in Teeth. The apparent flux density at the center of the tooth,
under open-circuit conditions.

, , .
Bt” = = 120, 562.89 lines per sq. in.
.

ITEM 35: Usual flux densities for different frequencies are given in Table 1.7. Suitable flux density for
60 Hz is 73,000. Bearing in mind that the air-gap flux divides into two equal parts below the teeth,
the armature-core flux is one-half of the total flux. Choose 73,000.

Density in teeth
Frequency, f Density in core
(at center)
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
Table 1.7 UPPER LIMITS OF FLUX DENSITY IN DYNAMO ARMATURES
(maxwells per in2)
  

II. COMMUTATOR AND BRUSHES

ITEM 1: Number of Main poles p = 8 poles

ITEM 2: Number of Commutating Poles = 8 commutating poles.

ITEM 3: Diameter of Armature Core; D = 30.36 inches

ITEM 4: Axial length of Armature core la = 10.21 inches

ITEM 5: Ratio of Pole Arc to Pole Pitch; r = 0.64

ITEM 7: For the Leakage Factor, from the Table 1.7, since the specification is 500 kilowatts we used
Leakage Factor from 1.18 to 1.09. I used lf = 1.15.

Output of machine, kW Leakage Coefficient

50 1.25 to 1.12
100 1.22 to 1.11
200 1.20 to 1.10
500 1.18 to 1.09
1,000 1.16 to 1.08
1,500 1.14 to 1.07
2,000 1.12 to 1.06
Table 1.7 Leakage Coefficient

ITEM 8: For the Maximum flux density in pole core (Full Load). The flux estimated in item 34 of this
design is 6,258,228 maxwells. From the B-H curve it appears that 95,000 lines per sq. in. will not
require as excessive number of ampere-turns.

ITEM 9: Calculating the Cross section of the pole core. The full-load flux per pole based on Item 34
of the Armature Design is 6,258,228 maxwells.

Ac= (Фe x lf) / Фm

where: Фe = estimated flux

lf = leakage factor
Фm = maximum flux

Cross section of the pole core = (6,258,228 x 1.17) / 95000

Cross section of the pole core = Ac = 77.1 sq. inch

  

ITEM 10: Calculating the radial length of winding space on pole. This dimension will tentatively be
made 6 inches. And is subject to change if later temperature-rise calculations indicate that
it should be modified. It should be noted that the radial dimension of the pole must correspond
approximately with that of the commutating pole, which was not designed for this machine.
However, the dimensions for the main and commutating poles are not particularly critical at this
stage and may be altered one way or another when the final design is completed and accurate
drawings must be prepared for the manufacture of the machine.

ITEM 11: Since the Flux density in Frame should be the same, or somewhat less than, the maximum
density in the core. I used 90,000 lines per sq. in.

ITEM 12: Calculating the Cross section of yoke ring. Remember that the total useful and leakage
flux divides as its enters the yoke. Note that the estimated Full-load flux per pole is 6,258,228
maxwells (Based on Item 34 of Armature Design Sheet), lf = 1.17 (Based on Item 7) and the Flux
Density in yoke ring is 90,000 lines per sq. in. (Based on Item 11).

ITEM 14: Calculating the axial length of armature core. Note: laD 2 = 7,548 (Based on Item 8), q1 =
900 (Based on Item 3), q2 = 934 (This is based on the final value on Item 3 that will be explained in
Final Calculation of the design sheet), and D = 25 inches (Based on Item 9).

laD 2 = 7,548 = 7,276

la = = 10.21 inches

Note: The Final value of axial length of Armature Core will be known as the calculation proceeds
further.

ITEM 15: Calculating the Flux per pole if the D.C. Generator is in Open Circuit. Note: 230 volts is the
voltage in an Open Circuit or if No Load, f = 60 hz. and p = 6 poles (Based on Item 1), N = 1200
RPM and Z2 = 204 (This is based on the final value on Item 11 that will be explained in Final
Calculation of the design sheet).

ᶲ = = 4,732,510.29 maxwells
,

ITEM 16: Calculating the Pole Pitch, Note that D = 25 inches (Based on Item 9) and the number of
poles are 6.

Pole Pitch (τ) = = 11.92 inches

ITEM 17: Calculating the Pole Arc. Given are τ = 13.26 inches (Based on Item 16) and r = 0.63 (Based
on Item 2).

Pole Arc (rτ) = 13.26 0.63 .

  

ITEM 18: Calculating the Area Covered by pole face. Note that rτ = 8.35 (Based on Item 17) and
la = 11.34 inches (Based on Item 14).

rτla = 8.35 11.34 77.87 sq. in.

ITEM 47: Calculating the Current Density at brush-contact surface. Unless a very soft quality of
carbon is used, the current density over the brush-contact surface is about 30 to 50 amp per in2,
(see Figure 1.18). Taking 40 as a preliminary value. Therefore Δb = 40 ampere per sq. in.

ITEM 48: Calculating the Contact area per brush set.

(8 X 273.10) / (3 X 40) = 18.207 sq. in.

III. GIVEN OR ASSUMED DATA

ITEM 7: For the leakage factor, from the Table 1.6, with specification given as 500KW we used
Leakage Factor from 1.18-1.09. Used If=1.15

Output of machine, kW Leakage Coefficient

50 1.25 to 1.12
100 1.22 to 1.11
200 1.20 to 1.10
500 1.18 to 1.09
1000 1.16 to 1.08
1500 1.14 to 1.07
2000 1.12 to 1.06

Table 1.6 Leakage Coefficient

ITEM 8: Calculating the radial length of winding space on pole. This dimension will tentatively be
made 6.5in and is subject to change if later temperature-rise calculations indicate that it should
be modified. It should be noted that the radial dimension of the pole must correspond
approximately with that of the commutating pole, which was not designed for this machine.

ITEM 11: Since the Flux density in Frame should be the same, or somewhat less than, the maximum
density in the core. I used 90,000 lines per sq. in.

ITEM 11: Calculating the Cross section of yoke ring. Remember that the total useful and leakage
flux divides as its enters the yoke.

, , .
= = 32.74 sq. in.

 

DESIGN 1
(Final Calculations)

ELECTIVES 3:
MACHINE DESIGN

DEOCUARIZA, RAFAEL Q.
BSEE 5-2