Course Name / Code : Design of Electrical Machines/ EE8002

Degree/Branch : B.E/ EEE

Semester / Section : VI

UNIT – III – DESIGN OF DC MACHINES

Construction - Output Equations – Main Dimensions – Choice of specific loadings – Selection of

number of poles – Design of Armature – Design of commutator and brushes – design of field
Computer program: Design of Armature main dimensions

PART – A

1. What is real and apparent flux density? [M/J 2016]

The real flux density is due to the actual flux through a tooth. The apparent flux density is d\ue to
total flux that has to be passing through the tooth. Since some of the fluxes pass through slot so that
the real flux density is always less than the apparent flux density.
Total flux in a slot pitch
Apparent flux density Bapp  Tooth area
Actual flux in a tooth
Real flux density Breal  Tooth area
2. Define field form factor. [M/J 2016]
It is defined as the ratio of average gap density over the pole pitch to the maximum flux density in
Bav Bav Pole arc L
the gap. K f   . Also K f    Pole Pitch  
Bg Bm

3. Write the expression for output coefficient of DC machine. [N/D 2016]

Output coefficient Co=Π2Bav ac Х 10-3.
Where, Bav Specific Magnetic Loading ac Specific Magnetic Loading
4. Mention guiding factors for the selection of number of poles. [N/D 2016]
i) The frequency should lie between 25 to 50 Hz.
ii) The value of current per parallel path is limited to 200A, thus the current per brush armature
should not be more than 400A.
iii) The armature mmf should not be too large. The mmf per pole should be in the range 5000
to 12500 AT.
iv)Choose the largest value of poles which satisfies the above three conditions.

5. Distinguish between real and apparent flux densities in the tooth section of slot. [M/J 2017]
Apparent Flux Density Real Flux Density
Total flux in a slot pitch Actual flux in a tooth
It is defined as, Bapp  Tooth area
It is defined as, Breal  Tooth area
Bapp=Breal+4Π Х 10-7(Ks-1) Since some of the flux passes at real (K s-1)
Where Ks=(L ys)/(LiW t) through slot, the real flux density is always less
than the apparent flux density.
6. Write down the expression for brush friction losses. [M/J 2017]
Brush friction loss Pbf = µ Pb P Ab Vc .
Where, µ Coefficient of friction
Pb Brush contact pressure on commutator. P Number of poles
AbEffective area af all brushes Vc Peripheral speed of commutator.
7. Define specific electric and magnetic loading. [N/D 2017], [N/D 2018]
Specific Electric Loading:
The number of armature or stator ampere conductors per metre of armature periphery at the air
gap is known as specific electric loading.
I Z
ac  Z , amp.cond / m
D
Where, Iz current through conductor in each parallel path,
Z total number of armature conductors.
D Diameter of armature or stator bore.
Specific Magnetic Loading:
The average flux density over the air gap of a machine is known as specific magnetic loading.
Total flux around the airgap P
Bav   , Wb / m 2 or tesla
Area of flux path of the airgap DL
8. State the advantages of having larger number of poles in a DC machine. [N/D 2017]
When increasing the number of poles in machine which reduces the weight of iron parts, weight
of copper, Length of commutator and distortion of field form.
9. Mention the two types of armature winding used in dc machine and compare. [M/J 2018]
i) Lap winding ii) Wave winding

10. What factor decides the minimum number of armature coils? [M/J 2018]
The maximum voltage between adjacent commutator segments decides the minimum number of
coils. Minimum Number of coils C= (EP)/15.

11. What are the constituents of magnetic circuits in a DC machine? [N/D 2018]
The various elements in the flux path of salient pole machines are poles, poles shoes, air gap,
armature teeth, armature core and yoke. The various elements in the flux path of non-salient pole
machines are stator core, stator teeth, air gap, rotor teeth and rotor core.
12. What are the factors to be considered in the design of commutator of a DC machine? [A/M
2019]
 Peripheral speed
 Voltage between adjacent segments
 Number of coils in the armature
 Number of brushes
 Commutator losses
PART – B & C
Output Equations
1. Derive the output equation of a dc machine and point out the salient features. (8) [M/J 2016],
[A/M 2019]

Main Dimensions - Choice of Specific Electric and Magnetic Loading

2. Determine the main dimensions of a 80 KW, 4 pole, 600 rpm dc shunt generator, the full load
terminal voltage being 220 V. The maximum gap density is 0.75 Wb/m 2 and ampere conductors per
metre are 27000. Assume a square pole face. (8) [M/J 2017]
3. Find the main dimensions and the number of poles of a 37KW, 230V, 1400 rpm shunt motor, so
that a square pole face is obtained. The average gap density is 0.5 wb/m 2 and the ampere conductors
per meter are 22000. The ratio of pole arc to pole pitch is 0.7 and the full load efficiency is 90%.
[M/J 2016], [M/J 2018] (16)

4. State and explain the factors which govern the choice of specific magnetic loading in a DC
machine. [M/J 2016] (8)

5. A design is required for a 50KW, 4 pole, 600 rpm, dc shunt generator, the full load terminal
voltage is 220V. If the maximum gap density is 0.83wb/m 2 and the armature ampere conductors per
metre are 30000. Calculate suitable dimensions of armature core to give a square pole face. Assume
that the full load armature voltage drop is 3 percent of the rated terminal voltage and the field current
is 1 percent of rated full load current. Ratio of pole arc to pole pitch is 0.67.

6. A 5KW, 250V, 4 pole, 1500 rpm DC shunt generator is designed to have a square pole face. The
specific Magnetic loading and specific electric loading are 0.42wb/m 2 and 15000 ac/m respectively.
Find the main dimensions of the machines. Assume full load efficiency is 87% and pole arc to pole
pitch ratio is 0.66. (8) [A/M 2019]

Selection of number of poles

7. What are the advantages and disadvantages of large number of poles in a dc machine? (5)
[M/J2018]
8. Explain the procedure for the selection of number of poles in dc machine. (16) [N/D 2016]

9. Find the main dimensions, number of poles and length of air gap of a 600KW, 500V, 900 rpm
generator. Assume average gap density is 0.6wb/m 2 and ampere conductors per metre 35000.
The ratio of pole arc to pole pitch is 0.75 and the efficiency is 85%. The following are the
design constraints: Peripheral speed should not be greater than 40 m/s, frequency of flux
reversal should not be greater than 50Hz, current per brush arm should not be greater than
400A, armature mmf per pole should not be greater than 7800AT. The mmf required for air gap
is 60percent of armature mmf and gap contraction factor.

Design of Armature

10. For a preliminary design of a 50HP, 230 V, 1400 rpm, dc shunt motor. Calculate the armature
diameter and core length, the number of poles and peripheral speed. Take B av=0.5 wb/m2,
ac/m=25000, efficiency=0.9.(13) [N/D 2016]

11. Determine the diameter and length of armature core for a 55KW, 110 V, 1000 rpm, 4 pole shunt
generator assuming specific electric and magnetic loading of 26000 ampere conductor per metre and
0.5Wb/m2 respectively. The pole arc should be about 70% of pole pitch and length of core about 1.1
times the pole arc. Allow 10 ampere for the field current and assume a voltage drop of 4 V for the
armature circuit. Specify the winding used and also determine the values of the number of armature
conductors and number of armature slots. (16) [N/D 2017], [N/D 2018]

12. Explain the various steps involved in the design of armature winding of DC machine. (15) [A/M
2019]

Design of commutator and brushes

13. Design a suitable commutator for a 350 KW, 600 rpm, 440 V, 6 pole dc generator having an
armature diameter of 0.75 m. The number of coils is 288. Assume suitable values whenever
necessary. (8) [M/J 2018]

14. The armature of a 10 pole 1000KW, 500 V, 300 rpm DC generator has a diameter of 1.6m.
There are 450 coils. Determine suitable length and diameter of the commutator, giving details of
brushes having regard to commutation conditions and temperature rise. The design limitations are;
peripheral speed of commutator ≤ 20 m/s, pitch of segments ≥ 4, current per brush ≤ 70 A,
Temperature rise ≤ 400C. The other data given are: The brushes span three segments approximately,
brush contact drop 1.5 V, coefficient of friction 1.5, brush pressure 20 KN/m 2. Cooling
coefficient=0.012/(1+0.1Vc). Make suitable assumptions for clearance between brushes, staggering
of brushes and end play. (15) [N/D 2018]