TECHNOLOGICAL INSTITUTE OF THE PHILIPPINES

938 Aurora Blvd. Cubao, Quezon City

EE023 - Electrical Machines 1

DESIGN FOR A DC GENERATOR

SPECIFICATIONS :

GIVEN RATING = 30 kW

POLES = 4

VOLTAGE = 230/250V

SPEED = 1200 rpm

FREQUENCY = 40Hz

Designed By:

Jazmin, Rina Jane S.

DESIGN
1. No. of Poles and Frequency
4×1200
𝑓 = 120
= 40 𝐻𝑧
2. Ratio of Pole arc to Pole Pitch
𝑟 = 0. 64
3. Specific Loading (q)
𝑞 = 550
4. ABC Gap Density (Bg’’)
𝐵𝑔'' = 47, 000
5. Line Current (I)
𝑘𝑊 30000
𝐼𝑐 = 250
= 250
= 120 𝑎𝑚𝑝
6. Type of Winding

Wave Winding
120
𝐼𝑐 = 2
= 60 𝑎𝑚𝑝
7. Armature Current per circuit (Ic) Assume shunt excitation 2.5%
120
𝐼𝑐 = 2
(1 + 2. 5%) = 60. 54 𝑎𝑚𝑝
8-10. Armature Diameter

( ) = 9157. 40
8
2 30000 6.06×10
𝑙𝑎𝐷 = 120 47000×0.64×550
π(0.64)
𝑙𝑎 = 4(0.71)
× 𝐷 = 0. 71𝐷
3 9157.40
𝐷= 0.71
= 23. 45 𝑖𝑛.
Solving for the peripheral velocity
𝐹𝑝𝑚 3000 ≤ 𝑣 ≤ 10000

π𝐷𝑁 π(23.45)(1200)
𝑉= 12
= 12
= 7367. 03 𝑓𝑝𝑚
For the condition Armature Ampere Conductor should not exceed 25,000
𝑍𝐼𝑐 𝑞π𝐷 (550)(π)(23.45)
𝑃
= 𝑝
= 4
= 10129. 67
11-13 Number of inductors, slots, and conductors per slot.

A. Total no. of phase conductor

(π)(23.45)(550)
𝑍= 60
= 675. 31 𝑎𝑚𝑝
B. No. of slots
Assuming 50 conductors per slot:
675.31
𝑆𝑙𝑜𝑡𝑠 = 50
= 13. 51
C. No. of slots per pole
𝑆𝑙𝑜𝑡𝑠 14
𝑝𝑜𝑙𝑒
= 4
= 3. 5
𝑆𝑙𝑜𝑡𝑠 14
𝑃 = 2 = 7 𝑠𝑙𝑜𝑡𝑠 𝑝𝑒𝑟 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑝𝑜𝑙𝑒
2

Assume slot = 55
27. 5 × 0. 64 = 17. 6
𝑍 = 838. 95 + 17. 6 = 856. 55
675.31 60
𝑞𝑛𝑒𝑤 = π
× 23.45
= 550

14. Axial Length of Armature

2
𝑙𝑎𝐷 𝑛𝑒𝑤 = 9157. 40 ( ) = 9157. 40
550
550
9157.40
𝑙𝑎 = 2 = 16. 65 𝑖𝑛.
23.45
15. Flux per pole
8
(230)(60×10 )(4)
ϕ = 1200(4)(550)
= 2, 090, 909. 091 𝑀𝑎𝑥𝑤𝑒𝑙𝑙𝑠
16-18. Pole Pitch
π×𝐷 π×23.45
𝑃𝑜𝑙𝑒 𝑃𝑖𝑡𝑐ℎ = 4
= 4
= 18. 42
𝑃𝑜𝑙𝑒 𝐴𝑟𝑐 = 𝑟τ = (0. 64)(18) = 11. 52 𝑖𝑛.
𝑃𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 𝑟τ𝑙𝑎 = (11. 52)(17) = 195. 84 𝑖𝑛.
Where:
ϕ 1,352,941.18 𝑙𝑖𝑛𝑒𝑠
Bg’’ =
𝑟τ
= 129.06
= 10, 483. 04 2
𝑖𝑛
19-22 Dimension of Armature Conductors
700,000 5975.31 𝐴
∆ = 850
+ 4
= 2317. 36 2
𝑖𝑛
𝑘 = 700, 000
 Area of Cross Section
𝐼𝑐 60.54
∆
= 5975.31
= 0. 010 𝑠𝑞. 𝑖𝑛

Slot Pitch
π×𝐷 π×23.45
λ= 𝑆𝑙𝑜𝑡
= 55
= 1. 34 𝑖𝑛.
Width of Slot
𝑠 = 0. 40 𝑖𝑛
Ratio of Width to Slot
𝑡
𝑠
= 1. 718
Slot Insulation
𝑆𝑙𝑜𝑡 𝐼𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 27 + ( ) = 35 𝑚𝑖𝑙𝑠
230
30
Cotton Converging on Each Conductor
𝐶𝑜𝑡𝑡𝑜𝑛 𝐶𝑜𝑛𝑣𝑒𝑟𝑔𝑖𝑛𝑔 𝑜𝑛 𝑒𝑎𝑐ℎ 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 = 16 𝑚𝑖𝑙𝑠
0.4−(3×0.016)−(2×0.035)
𝑆𝑝𝑎𝑐𝑒 𝑙𝑒𝑓𝑡 𝑓𝑜𝑟 𝑒𝑎𝑐ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑜𝑢𝑟 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 = 4
= 0. 07 𝑖𝑛
0.08
𝑑𝑐 = 2(0.07)
= 0. 572 𝑖𝑛. 𝑜𝑟 0. 58 𝑖𝑛.
Allow ⅓ of the slot width for the hardwood or fiber wedge or 0.135 in., and 35 mils
for each of the insulation spaces above, below ,and between the coils.
1 1
𝑑 = 3
𝑠 + (3 × 0. 035) + 2(𝑑𝑐) = 3
0. 40 + (3 × 0. 035) + 2(0. 036)
=0.31
23. Tooth Dimensions
𝑊𝑖𝑑𝑡ℎ 𝑎𝑡 𝑡ℎ𝑒 𝑡𝑜𝑝 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑜𝑜𝑡ℎ 𝑖𝑠 𝑡 = λ − 𝑠 = 1 − 0. 4 = 0. 6 𝑖𝑛.
𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝐶𝑖𝑟𝑐𝑙𝑒 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑡ℎ𝑒 𝑏𝑜𝑡𝑡𝑜𝑚 𝑠𝑙𝑜𝑡 = π × (23. 45 − 2. 8) = 64. 87
64.87
𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑜𝑜𝑡ℎ 𝑎𝑡 𝑡ℎ𝑒 𝑟𝑜𝑜𝑡 𝑖𝑠 55
− 0. 4 = 0. 78 𝑖𝑛
0.6+0.78
Average width= 2
= 0.69
24-25 No. of Radial Ventilating Ducts
A. For armature lengths more than 11 inches, use four 3/8-inch-wide ventilation ducts.
B. In 9-11 in. armatures, a maximum of three ducts are allowed. with each duct
measuring 3/8 inches in width.
26. Net Length of Armature
𝑙𝑛 = 0. 92(16. 65 − (4 × 0. 375)) = 13. 94
27. Net Cross Section of Teeth Under Pole
2
13. 94 × 3. 5 × 0. 64 = 31. 23 𝑖𝑛

28. Flux Density in Teeth

2,090,909.091
𝐵𝑡'' = 31.23
= 66951. 94 𝑙𝑖𝑛𝑒𝑠/𝑠𝑞. 𝑖𝑛
29. Length per turn of armature coil
1.15𝑠 1.15×0.4
𝑆𝑖𝑛 α = λ
= 1.34
= 0. 34
−1
𝐶𝑜𝑠α = 𝑠𝑖𝑛 (0. 34) = 19. 88= cos(19.88)= 0.94
𝑇𝑜𝑡𝑎𝑙 𝐿𝑒𝑛𝑔𝑡ℎ 𝑃𝑒𝑟 𝑇𝑢𝑟𝑛 = 2𝑙𝑎 + 𝑙𝑐 = 2(16.65)+ 60.54 = 93.84
30-33. Armature Resistance of one turn, Ohms at 60 °C
93.84
𝑅60°𝐶 = 4 6 = 0. 00170Ω
2×0.07×0.31× π ×10
Armature Resistance Per Circuit
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑟𝑛𝑠 337.66
𝑅𝐶 = 𝑅 ( 𝑃1
) = 0. 00170( 2
) = 0. 287Ω
60°𝐶
Total Armature Resistance
1
𝑅𝐴 = 6
(0. 287) = 0. 04783Ω
IR Drop in Armature
𝑅𝐶 × 𝑙𝑐 = 0. 287 × 60. 54 = 17. 37 𝑉
2
𝐼 𝑅 𝐿𝑜𝑠𝑠 𝑖𝑛 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑊𝑖𝑛𝑑𝑖𝑛𝑔 𝑃𝑙𝑜𝑠𝑠
𝑃𝑙𝑜𝑠𝑠 = 17. 37 × 6(60. 54) = 6309. 4788𝑊
34. Full-load flux
𝐸𝑔 = 230 + 2 + 17. 37 + 8. 69 = 349. 06𝑉
Therefore, Full load Flux must be
349.06
𝐹𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑓𝑙𝑢𝑥 = 2, 090, 909. 091( 230
) = 3173272. 727 𝑀𝑎𝑥𝑤𝑒𝑙𝑙𝑠
35-36 Flux Density in Armature Core Below Teeth
Reasonable Density for 40Hz is 76,000.
2,090,909.091
𝑅𝑑 = 2(13.94)×76000
= 0. 99 𝑖𝑛.
2,090,909.091
𝐹𝑙𝑢𝑥 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑐𝑜𝑟𝑒 = 2(13.94)×0.99
= 75754. 28 𝑖𝑛.
Internal Diameter of the Core Stampings
𝐷𝑖 = 23. 45 − 2(0. 99) − 2(0. 31) = 20. 85
37. Weight of Iron in Core
𝑊𝑓𝑒 = 0. 28 × 13. 94 ×
π
4 (
⎡⎢ 23. 45 − (2 × 0. 31)
⎣ ) − (20. 85)2⎤⎥⎦ = 1262. 68𝑙𝑏
38. Weight of Iron Teeth
𝑊𝑡 = 0. 28 × 0. 31 × (0. 78 × 22) × 13. 94 = 20. 76 lb
39. Total Weight of Iron in Teeth
𝑊𝑓𝑒 + 𝑊𝑡 = 1262. 68 + 20. 76 = 1283. 44
40. Diameter of Commutator
23.45
𝐷𝐶 = 2
+ 0. 22 = 11. 95 𝑖𝑛
This is 70% of the core diameter and makes the peripheral velocity,
𝑣𝐶 = 0. 70 × 9856 = 6899. 2
41-43 Number of Commutator Bars
𝐸 250
𝑍/2𝑃1
= 168.83
= 1. 481𝑉

𝐵 = 168. 83
44-45 Width of Commutator Segments
π𝐷𝐶 π(11.95)
𝐵𝑎𝑟 𝑃𝑖𝑡𝑐ℎ = 𝐵
= 168.83
= 0. 222 𝑖𝑛
Width of Copper Bar using 0.03 in mica for insulation, the width of copper bar is
𝑊𝐶𝐵 = 0. 222 − 0. 03 = 0. 192
46. Radial Depth of Segment
11.95+15
ℎ= 15
= 1. 7967
47-51. Dimensions of Brushes
𝐴
Current Density assumed to be 40 2
𝑖𝑛
Contact Area per Brush Set
4(60.54) 2
𝐴𝑏 = 2(40)
= 3. 027 𝑖𝑛
Axial Brush Length per Brush Set
3.027
𝐼𝑏 = 1
= 3. 027 𝑖𝑛.
3.027
𝑁𝑜. 𝑜𝑓 𝐵𝑟𝑢𝑠ℎ𝑒𝑠 𝑝𝑒𝑟 𝑠𝑒𝑡 = 5/8
= 4. 84 ≈ 5
𝐴𝑏𝑛𝑒𝑤 = 40 × ( 3.027
3.027×1 ) = 40 𝐴
2
𝑖𝑛
52. Length of Commutator
a. Brush holders and clearances
5 5
𝑁𝑜. 𝑜𝑓 𝑏𝑟𝑢𝑠ℎ𝑒𝑠 × 16
= 5× 16
= 1. 5625 𝑖𝑛
b. Staggering of (+) and (-) Brushes
5
8
𝑖𝑛.
 c. End Clearances of Brushes
1 𝑖𝑛.
d. End Play
3
8
𝑖𝑛.
Therefore, Total length of Commutator
5 3
𝐿𝐶 = 3. 027 + 1. 5625 + 8
+ 8
= 5. 5895 in
53. Brush Contact Drop
𝐴
The brush contact drop for hard carbon about 40 2 is at 2.08 Allowing 10% for toughness,
𝑖𝑛
chipping and irregularities, the brush contact drop will be at about 2.3V.
54-56. Brush Losses
𝐵𝑙 = 2. 3 × 60. 54 × 4 = 556. 968 𝑤
Brush Friction Loss
0.25×2×(3.025×1200)×13π×746
𝑊𝑓 = 12×33000
= 139. 64
Total Brush Loss
𝑇𝐵𝐿 = 556. 968 + 139. 64 = 696. 608𝑊
57. Dimension of Armature
The illustration gives the leading dimensions of armature and commutator as worked out in this
design is the diameter of the shaft supporting the armature may be calculated by
3 𝑃𝑜
𝑆ℎ𝑎𝑓𝑡 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0. 84 𝑁
3 30000
𝑆ℎ𝑎𝑓𝑡 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0. 84 1200
=2.46 in.

ITEM SPECIFICATION: SYMBOL Preliminary or Final Values

NO. Assumed Values

ARMATURE CORE AND WINDING

1 No. of Poles 4 4

Frequency, Hz 50

2 Ratio of pole arc to pole pitch 0. 64 0. 64

3 Specific Loading 550 550

4 Apparent Air-gap flux density 47, 000 47, 000
(open circuit)

5 Line Current (full load) 120 𝑎𝑚𝑝 120 𝑎𝑚𝑝

6 Type of Winding Wave Winding

7 Armature current per circuit 20. 6 𝑎𝑚𝑝 20. 6 𝑎𝑚𝑝

8 2
Output factor (la𝐷 ) 12524. 80 12525

9 Armature diameter, in. 0. 71𝐷 0. 71𝐷

10 Peripheral velocity, fpm 7367. 03 7367. 03

11 Total number of face 675. 31 675. 31

conductors

12 Number of slots 13. 51 13. 51

13 Number of conductors per slot 7 7

14 Axial length of armature core; 16. 65 𝑖𝑛

gross, in

15 Flux per pole (open circuit) 2, 090, 909. 091

16 Pole pitch, in. 18. 42

17 Pole arc, in. 11. 52

18 Area covered by pole face 195. 84

(rτla), sq. in.

19 Dimensions of armature 0. 010 𝑠𝑞. 𝑖𝑛

conductors, in. units

20 Slot pitch, in. 1. 34

21 Slot width, in. 0. 40

22 Slot depth, in 1. 718

23 Tooth width, in. 0. 6

At top

0. 78 𝑖𝑛
At root

0.69
Average

24 Number of radial ventilating 1

ducts

25 Width of radial ducts, in 0.375

26 Net length of armature core, in 13. 94

27 Net tooth section under pole, 31. 23

at center, sq in

28 Apparent density in teeth 66951. 94

under pole, at center, sq in

29 Length per turn of armature 0. 34

coil, in

30 0 Resistance of one turn, ohms 0. 00170

at 60°C

31 Resistance of armature, ohms 0. 287 0. 04783

32 IR drop in armature, volts 17. 37

33 I2R loss in armature winding, 6309. 4788

watts

34 Estimated full-load flux per 349. 06𝑉

pole

35 Flux density in armature core 75754. 28

below teeth

36 Internal diameter of core 20. 85

stampings, in

37 Weight of iron in core (without 1262. 68

teeth), lb
38 Weight of iron core in teeth, lb 20. 76

39 Total weight of armature 1283. 44

stampings, lb

40 Diameter of Commutator, in 11. 95

41 Average volts per turn of 1. 481

armature winding

42 Number of turn between bars 1

43 Total number of Commutator 168. 83

bars

44 Bar pitch, in 0. 222

45 Width of copper bar (on 0. 192

surface), in

46 Radial depth of bar, in 1. 7967

47 Current density at 3. 027 𝑖𝑛

2
brush-contact surface, amp per
sq in

48 Contact area per brush set, sq 40

in

49 Brush arc (circumferential 5

width), in

50 Axial brush length (total) per 3. 027

set, in

51 Number of brushes per set 5

52 Axial length of Commutator, in 1. 5625

53 Brush-contact drop, volts 2.3

54 Brush-contact loss, watt 556. 968

55 Brush-friction loss, watts 139. 64

56 Total brush loss, watts 696. 608

57 Drawing to scale giving leading 2.46

dimensional of Armature and
Commutator