Computer Aided Design of Electrical Machines

DC Machine

Lecture #4

Instructor: Mr. Jaafar Alnoor

jaawish@gmail.com

Electrical & Electronics Engineering Department

Faculty of Engineering & Architecture
National University
 Lecture Outlines:
• Selection of Number of Poles
• Frequency
• Weight of the iron used for the yoke
• Weight of iron used for the armature core (from the core loss point
of view)
• Weight of overhang copper
• Armature reaction
• Overall diameter
• Length of the commutator
• Flash over
• Labour charges

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Selection of Number of Poles
As the armature current increases, cross sectional area of the conductor and
hence the eddy current loss in the conductor increases.
In order to reduce the eddy current loss in the conductor, cross-sectional area
of the conductor must be made less or the current / path must be restricted.
For a normal design, current / parallel path should not be more than about
200A. However, often, under enhanced cooling conditions, a current / path of
more than 200A is also being used.
By selecting a suitable number of paths for the machine, current / path can be
restricted and the number of poles for the machine can be decided.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Selection of Number of Poles (cont…)
While selecting the number of poles, the following conditions must also be
considered as far as possible.
In order to decide what number of poles (more or less) is to be used, let the
different factors affecting the choice of number of poles be discussed based on
the use of more number of poles.
• Frequency
• Weight of the iron used for the yoke
• Weight of iron used for the armature core (from the core loss point of view)
• Weight of overhang copper
• Armature reaction
• Overall diameter
• Length of the commutator
• Flash over
• Labour charges
Lecture #4 Mr. Jaafar Alnoor, FEA, NU
 Frequency
As the number of poles increases, frequency of the induced EMF f = PN/120
increases core loss in the armature increases and therefore efficiency of the
machine decreases.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Weight of the iron used for the yoke
Since the flux carried by the yoke is approximately φ/2
and the total flux φT = pφ is a constant for a given machine, flux density in
the yoke

It is clear that Ay is α 1/p

as By is also almost constant for a given iron. Thus, as the number of poles
increases, Ay and hence the weight of iron used for the yoke reduces.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Weight of iron used for the armature core (from the core loss point of view)
Since the flux carried by the armature core is φ /2, eddy current loss in the
armature core

Thus the weight of iron used for the armature core reduces as the number of
poles increases.
Lecture #4 Mr. Jaafar Alnoor, FEA, NU
 Weight of overhang copper
For a given active length of the coil, overhang ∝ pole pitch goes on reducing
as the number of poles increases. As the overhang length reduces, the
weight of the inactive copper used at the overhang also reduces.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Armature reaction

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Overall diameter
When the number of poles is less, 𝐴𝑇𝑎 / pole and hence the flux, produced by
the armature is more. This reduces the useful flux in the air gap.
In order to maintain a constant value of air gap flux, flux produced by the field
or the field ampere-turns must be increased. This calls for more field coil turns
and size of the coil defined by the depth of the coil df and height of the coil hf
increases. In order that the temperature rise of the coil is not more, depth of the
field coil is generally restricted. Therefore height of the field coil increases as
the size of the field coil or the number of turns of the coil increases.
As the pole height, is proportional to the field coil height, height of the pole
and hence the overall diameter of the machine increases with the increase in
height of the field coil.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Overall diameter (cont…)
Obviously as the number of poles increases, height of the pole and hence the
overall diameter of the machine decreases.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Length of the commutator
Since each brush arm collects the current from every two parallel paths,
current / brush arm = 2𝐼𝑎 / A
and the cross sectional area of the brush / arm
𝐴𝑏 = 2𝐼𝑎 / A𝛿𝑏 = 2𝐼𝑎 / P𝛿𝑏
∝ 1 / P reduces as the number of poles increases.

wb – width of the brush,

tb – thickness of the brush,
nb – number of brushes per spindle

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Length of the commutator(cont…)
As 𝐴𝑏 = tb wb nb and tb is generally held constant from the commutation
point of view, wb nb reduces as 𝐴𝑏 reduces. Hence the length of the
commutator
Lc = (wb nb + clearances) reduces as 𝐴𝑏 reduces or the number of poles
increases.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Flash over
As the number of poles increases, voltage between the segments

increases. Because of the increased value of 𝐸𝑏 and carbon dust collected in

the space where the mica is undercut, chances of arcing between commutator
segments increases.
The arc between the segments in turn may bridge the positive and negative
brushes leading to a dead short circuit of the armature or flash over.

Lecture #4 Mr. Jaafar Alnoor, FEA, NU

 Labour charges
As the number of poles increases cost of labour increases as more number of
poles are to be assembled, more field coils are to be wound, placed on to the
pole, insulate, interconnect etc.
It is clear that, when the number of poles is more, weight of iron used for yoke
and armature core, weight of inactive copper, overall diameter, length of
commutator and effect of armature reaction reduces. On the other hand
efficiency reduces chances of flash over increases and cost of machine
increases.
Since the advantages outnumber the disadvantages, more number of poles is
preferable. Thus, though more number of poles is preferable, it is not advisable
from the cost point of view. In general the number of poles should be so
selected that good operating characteristics are obtained with minimum weight
of active material and minimum cost of construction.
Lecture #4 Mr. Jaafar Alnoor, FEA, NU