New Era

University
College of Engineering and Technology
Department of Electrical Engineering

EE 572
MW 10:00 11:30am

ELECTRICAL MACHINE DESIGN

DESIGN I-A
ITEM 1 - 39

Name: Ortiz, Danica Joy D.

Couse: Electrical Engineering
Year Level: 5th Year

Rating: ___________________________
Date Started: July 13 , 2015
Date Submitted: July 15 ,2015

Engr. Reynaldo M. Dela Cruz

Instructor

I. OBJECTIVE

1. To follow the design procedure items 1- 39.

II.

EQUIPMENTS

III.

Design Manual
Calculator
Computer
Printer
Scanner
Drawing Instruments

PROCEDURE
ITEM 1 39

1.) Number of Poles and Frequency :

Either 6 or 8 poles might be suitable, but since the armature speed is
fairly high, 6 poles will probably be best for a trial design. The f is
F= 6 X1,200 / 120 = 60 f = 60, p = 6

2.) Ratio of Pole Arc to Pole Pitch

Since the machine will provide with commulating poles a suitable Value for
this Ratio is r = 0.64

3.) & 4.) Specific Loading & Air-Gap Density

From p.12 q = 850, from p.11 Bg= 57 500 These are tentative
selections and will be modified to suitable values as the design proceeds.

5.) Line Current

I = 290 000/ 300

I = 966.67 or 967 A

6.) Type of Winding

Since the current per path should not exceed 250 to 300 A it is clear that a
Lap winding must be used in this case. (A wave winding with 2 parallel
paths would make Ic about 966.67/2 = 483.34 A)

7.) Armature Current per Circuit

The current in each armature circuit will be 1/6 of the line current if the
shunt exciting current is neglected. Assuming a Shunt excitation : 0.9%, the
full load I in each armature conductor is (966.67/6)(1+0.009)
Ic = 162.56 A or 163 A

8.) to 10.) Armature Diameter

Refer to Art.2 By Formula 7
IaD2 = (290 000 / 1200)( 6.06x108/ 57 500 x 0.64 x 850)
681.91

laD2 = 4

Using a rectangular pole face, where K in eq (8) = 0.71

Ia =

x 0.64 / 6 x 0.71 x D = 0.472 D

Hence,
D=
4 681
3

0.472

D = 21.49 in.
For the diameter calculated, the peripheral velocity
V=(

x 21.49 x 1200
=
12

V = 6751.28 fpm

11.) to 13.) Number of Inductors,Slots and Conductor

per Slots.
Solution:
Z=

Dq
=( x 21.49 x 850) / 163 = 352
Ic

With 4 conductors per slot, 352/4 = 88, and = 0.767 and note that
this is reasonable. Slots/pole = 88/6 = 14 2/3. The total no. of slots will be
decreased to 87 so that the slots/pole will be an integer +1/2. Thus,
slots/pair of poles = 87/3 = 29 and slots/pole = 14 1/2. Also note that
the no. of slots embraced by each pole arc is an integer in this design; i.e,
14 x 0.64 = 9.28 or 9. With the final value of Z = 361, q is
therefore,361 x (163/21.49 =871.58 .

14.) Axial Length of Armature Core

This may be determined from the final value of the output factor l aD2, since
this is inversely proportional to q, it is equal to:
LaD2 = 4681.91(850/871.58) = 4565.99 or 4566 and
La = 4566/21.492 = 9.89 in.
This length is, however, subject to correction if later flux density
calculations indicate that this is desirable.

15.) Flux per Pole ( Open Circuit )

Using the value of Z:
= (300 x 60 x 6x108) /( 6 x 1200 x 300) = 3 833 000 Maxwells

16.) to 18.) Pole Pitch , Pole Arc and Pole Area.

Pole Pitch ( r ) =

x 21.49 / 6 = 11.25 in.

Pole Arc (rr) = 0.64 x 11.25 = 7.2 in.

Note that la/ rr = 9.89 / 7.2 = 1.37 instead of the value 1.4, originally
assumed. (Pole area) rtla = 7.2 x 9.89 = 71.21 sq. in. The apparent airgap flux density can now be computed and compared with the assumed value
in itme 4. Thus, Bg = 3 833 000/ 71.21 = 53 827 lines per sq. in. Note
that this is less than the ssumed value as used in formula (7) for the
calculation of output factor.

19.) to 22. ) Dimension of Slots and Armature

Conductors

= (700000 / 871.58) + (6751.28 / 4) = 2490.96 amp per sq.in

Whence,
Area of Cross section = Ic / = 163 / 2490.96 = 0.065 sq.in
Trial by the best arrangement of Z = 300 (item 11), s = 75 (item 12)
= x 21.49/87=0.776

Assumed width slot = 0.4 in, which makes the ratio of tooth width to slot
width 1.306. Since a wire having an area of 0.08 in. is rather heavy and
difficult to bend and shape, it will be desirable to use two conductors in
parallel in the winding copper and to arrange them as shown in fig. 17. The
width of each of the four side-by-side. The sot insulation on each side of
the slot is 27+(300/30) = 37 mils, and the cotton covering on each
conductor will add a total of about 16 mils to its thickness. The space left
for each of the four copper conductors, is, therefore, [0.4 (3 x 0.016)
92 x 0.037)]/4 = 0.07 in.
Since the coppr area of 2 conductors is 0.08 sq. in., each conductor will have
a depth of 0.08/2 x 0.07 = 0.572 0r 0.58 in. Allowing about 1/3 of slot
width for the hardwork or fiber wedge, oe 0.135 in., and 37 mils for each of
the insulation spaces above, below and between the coils, d = 0.135 + (3 x
0.037) + (2 x 0.58) = 1.4 in. Thus, s = 0.4 in. and d = 1.4 in.

23.) TOOTH DIMENSIONS

The width at the top of the tooth is t = s = 0.776 0.4 = 0.376
in. The circumference of the circle through the bottom of the slots is
x (21.49 2.8) = 58.72; and since the slots have parallel sides, the width
of the tooth at the root is (58.72/87) 0.4 = 0.275 in. The average
tooth width = 0.388 in.

24.) & 25.) VENTILATING DUCTS

Not more than 3 ducts should be necessary in an armature 9 to 11 in. long,
with each duct 3/8 or 0.375 in. wide.

26.) NET LENTH OF ARMATURE

Ln = 0.92(089 3 x 0.375) = 8.06

27.) NET CROSS SECTION OF TEETH UNDER POLE

The cross section of iron in the teeth under one pole, at the midsection, is
8.06 x 0.388 x (87/6) x 0.64 = 29.02 sq. in.

28.) FLUX DENSITY IN TEETH

The apparent flux density at the center of tooth, under open circuit
conditions 3 833 000/29.02 = 132 081 lines per sq. in. Note that this
value is above the upper limit given in the table for 60 cycles. It will,
therefore, be necessary to corrrect (increase) the lenth of the armature
core to bring the flux density down to a reasonable figure. After some
preliminary calculations an armature length la = 10.5 in. was found to be
satisfactory.
LaD2 = 10.5 x 21.492 = 4 849
Bg = 3 833 000/(7.2 x 10.5) = 50 701 lines per sq. in.
Rrla = 7.2 x 10.5 = 75.6 sq. in.
Ln = (10.5 1.125) 0.92 = 8.63 in.
Bt = (8.06/8.63) x 132 081 = 123 357 lines per sq. in.

29.) LENGTH PER TURN OF ARMATURE COIL

Sin = (1.15 x 0.4)/ 0.776 = 0.6; cos = 0.85
Le = (2 x 11.25)/0.805 + (4 x 1.4) + 3 = 36.55 in. or 37 in.
Therefore, the total lenth per turn = le + 2la = 37 + 21 = 58 in.

30.) to 33.) ARMATURE RESISTANCE

Since the resistance of a conductor of a given material at a given
temperature is directly proportional to its lenth and inversely proportional
to its cross section, a very convenient and easily remmebered rule is that
the resistance of copper is 1/ cir-mil inch at a temperature of 60C.
Therefore, the resistance of 1 turn at 60C will be:
R = 58/[2 x (0.7 x 0.58) x 4/ x 106 = 0.000561
with a total 361/2 = 180.5 or 181 turns divided into 6 parallel paths 9 a
six-pole lap winding), the resistance per ciruit will be 0.000561 x (181/6) =
0.017 , and the total armature resistance will be 1/6 x 0.017 = 0.0028
. The IR drop in the armature winding = 0.017 x 163 = 2.711 or 3

volts, or 1% of the full-load terminal voltage. This compares favorably with

the approximate figures given in art. 16. The watts lost in the armature
winding (item 33) are 3 (163 x 6) = 2 934 W

34.) FULL-LOAD FLUX

It is necessary to develop enough voltage to overcome the internal
resistances. Assuming a brush-contact drop of 2V, and a series-field and
commutating field drop of about that in the armature winding, the total
generated voltage at full load must be 300 + 2 + 3 + 1.5 = 306.5 V. The fullload flux must be 3 833 000 x (306.5/280) = 4 195 766 maxwells

35.) & 36.) FLUX DENSITY IN THE ARMATURE CORE.

INTERNAL DIAMETER.
A density of 73 000 will be suitable. Bearing in mind that the air gap flux
divides into 2 equal parts below the teeth. The armature core flux is of
the total flux. Therefore,
Rd x ln x 73 000 = /2 whence
The radial depth Rd of the armature core below the teeth is Rd = 4 195 766/
(2 x 8.63 x 73 000) = 3.33 in.
The internal diameter of the core stampings is, 21.49 (2 x 3.33) (2 x 1.4)
= 12.03 in.

37.) WEIGHT OF IRON IN CORE

The weight of a cubic iron inch is 0.28 lb, and the total weight of iron in the
core below the teeth will, therefore, be, 0.28 x 8.63 x /4 [(21.49 28)2
(12.03)2] = 388.30 lb

38.) WEIGHT OF IRON IN TEETH

0.28 x 1.4 x (0.388 x 87) x 8.63 = 114.20 lb where the figure 0.388 is
the widt of tooth at the center.

39.) TOTAL WEIGHT OF ARMATURE STANDINGS

388.30 + 114.20 = 502.50 lb

IV.CIRCUIT DIAGRAM

V. DATA AND RESULT

EQUATIONS
EQUATION 14

EQUATION 15

EQUATION 16

EQUATION 17

EQUATION 18

EQUATION 19

EQUATION 20

TABLES

DESIGN SHEET FOR ARMATURE OF

D-C GENERATOR PART 1
ITE
M
NO.

1
2

SPECIFICATIONS:
290 KW; 300 VOLTS;

Armature Core and

Winding
Number of poles
Frequency
Ratio of pole arc to pole
pitch

SYMBO
L

PRELIMINAR
Y OR
ASSUMED
VALUES

FINAL
VALUES

p
f

6
...........

6
60

0.64

0.64

Specific loading

850

871.58

Apparent air gap flux

density (open circuit)

Bg

57 500

50 701

Line current (full load)

...........

967

Type of winding

.....

...........

LAP

Armature current per

circuit

Ia

163

Output factor

.....

4681.91

4849

Armature diameter, in

21.49

21.49

10

Peripheral velocity, fpm

6751.28

6751.28

11

Total number of face

conductors

352

361

12

Number of slots

..........

87

13

Number of conductors per

slot
Axial length of armature
core; gross, in

.....

..........

La

9.89

10.5

14
15

Flux per pole (open

circuit)

3.833 x 106

16

Pole-pitch, in

11.25

17

Pole arc, in

rt

7.2

18

Area covered by pole

face, sq. in
Dimensions of armature
conductors, in. units

.....

71.21

75.6

.....

..........

2(0.0405x
0.58)

19
20

Slot pitch, in

..........

0.776

21

Slot width, in

..........

0.4

22

Slot depth, in

..........

1.4

23

Tooth width, in.

At top
At root
Average

T
.....
.....

..........
..........
..........

0.376
0.275
0.388

..........

24

Number of radial
ventilating ducts

25

Width of radial ducts, in

.....

..........

0.375

26

Net length of armature

core, in
Net tooth section under
pole, at center, sq in

In

8.06

8.63

.....

29.02

30.8

B t

132 081

123 357

.....

..........

58

27
28

29

Apparent density in teeth

under pole, at center, sq
in
Length per turn of
armature coil, in

30

Resistance of one turn,

ohms at 60C

.....

..........

0.000561

31

Resistance of armature,
ohms

.....

..........

0.0028

32

IR drop in armature, volts

.....

..........

33

I R loss in armature
winding, watts

.....

..........

2934

34

..........

4.195766
x 106

35

Estimated full-load flux

per POLE
Flux density in armature
core below teeth

.....

73 000

72 600

36

Internal diameter of core

stampings, in

.....

..........

12.03

37

Weight of iron in core

(without teeth),lb

.....

..........

388.30

38

Weight of iron in teeth, lb

.....

..........

114.20

39

Total weight of armature

stampings, lb

.....

..........

502.50

VI. QUESTION/PROBLEMS

VII. OBSERVATION
I observed in this design that armature
winding in an alternator may be either
closed type or open type. Closed winding
forms star connection in armature
winding of alternator. There are some
common properties of armature winding.
First and most important property of an
armature winding is, two sides of any coil
should be under two adjacent poles. That
means, coil span = pole pitch. Second, the
winding can either be single layer or double
layer. Lastly, winding is so arranged in
different armature slots, that it must
produce sinusoidal emf.

VIII. CONCLUSION
In this design, it is concluded that pole
pitch is defined as peripheral distance
between center of two adjacent poles in dc
machine. This distance is measured in term
of armature slots or armature conductor
come between two adjacent pole centers.
Coil span is defined as peripheral distance
between two sides of a coil, measured in
terms of number of armature slots between
them.