Technological institute of the Philippines

938 Aurora Boulevard Cubao Quezon city

EE 023 - Electrical Machines 1

Design of Direct Current Generator

Specifications:

Rating = 300 kW

Pole = 6 Poles

Voltage = 230/250 V

Speed = 1200 rpm

Frequency = 60 Hz

ENGR. ALVIN DELA CRUZ

 Electrical machine design

Design specifications:
Given:

300-kW, 6-Poles, 1,200 rpm, 230/250 V

Computation:

Item no.1: No. of Poles and Frequency

f = 6 x 1200= 60 hz
120

Item no. 2: Ratio of pole arc to pole pitch

r = 0.64

Item no. 3: Specific loading (q)

q = 850

Item no. 4: ABC gap density (Bg")

Bg" = 57,000
Item no. 5: Line current (I)

Ic = kW = 300,000 = 1200 amp

250 250

Item no. 6: Types of winding

Lap winding

Ic = 1200 = 600 amp for wave winding

2

Item no. 7: Armature current per circuit (Ic) assume shunt excitation 0.9%

Ic = (1,200/6)(1 + 0.009) = 201.8 amp

Item no. 8, 9 & 10: Armature diameter refer to art. 2.

A = 300,000 6.06x108 = 4,850

1,200 (57,500)(0.64)(850)

B = π (0.64) x D = 0.472D
6(0.71)

D =3 √ 4,850 = 22 inch.
0.472

Solving for the pheriperal velocity

Fpm 3000 < ν ≤ 10000
V = πDN = π (22)(1,200)
12 12

= 6,900 fpm

Another condition is that the armature ampere conductor should not exceed 25000

ZIc = qπD
P p

= 850(π)(22) = 9,800
6

Item no. 11, 12 & 13: Number of inductors, Slots, Conductors per Slot.

A. total no. of phase conductor

z = π (22)(850) = 292
201.8

B. No. of slots

Slots = 292 = 73
4

Slot/pole = 73/6 = 12 1/6

A slot must have an odd and even integer plus ½ the slot increases to 75. 75/3 = 25
and slot per pole equals 12 ½

(12 ½)(0.64) = 8; Z = 300

qnew = 300 201.8 = 875

π 22

Item no. 14 Axial length of armature.

laD2 new = 4,850 850

875

= 4.710
 la = 4,710/222 = 9.75 in.

Item no. 15: Flux per pole

Flux = (230)(60x 108)(6) = 3,833,000 Maxwells

(1,200)(6)(300)

Item no. 16, 17 & 18: Pole Pitch, Pole Arc, and Pole Area.

A. Pole pitch = π x D = π (22) = 11.5 in.

6 6

B. Pole arc = 𝒓𝝉 = (0.64) (11.5) = 7.37 in

C. Pole area =𝒓𝝉 la = (7.37)(9.75) = 71.8 in2

Where:
𝝓 𝟑,𝟖𝟑𝟑,𝟎𝟎𝟎 𝒍𝒊𝒏𝒆𝒔
Bg" = 𝒓𝝉
= 𝟕𝟏.𝟖
= 53,400 𝒊𝒏𝟐

Item no. 19-22: Dimensions of Slots and Armature Conductors.

𝑨
D = 700,000 + 6,900 = 2,525 𝒊𝒏𝟐
875 4
Where:
k = 700,000

Area of cross section = Ic = 201.8 = 0.080 sq.in

∆ 2,525

Slot pitch = 𝝀 = π x D = π (22) = 0.922 in

Slot 75

Width of slot, s

s = 0.40 in
𝒕
ratio of tooth width to slot width = 𝒔 = 1.305
𝟐𝟑𝟎
slot insulation = 27 + ( 𝟑𝟎 ) = 35 mils and cotton cotton covering on each conductor = 16
mils.

The space left for each of the four conductors is

0.4 - (3 x 0.016) - (2 x 0.035) = 0.07 in
 4

Wc = 0.08 = 0.572 in or 0.58 in

2(0.07)

Allow 1/3 of the slot width for the hardwood or fiber wedge or 0.135 in., and 35 mils for
each of the insulation space above, below, and between the coils,

d= 0.135 + (3 x 0.035) + 2(0.58) = 1.4 in

Item no. 23: Tooth Dimensions.

The width at the top of the tooth is 𝒕 = 𝝀 − 𝒔 = 𝟎. 𝟗𝟐𝟐 − 𝟎. 𝟒 = 𝟎. 𝟓𝟐𝟐 𝒊𝒏

The circumference of the circle through the bottom of the slot is = 𝝅 × (𝟐𝟐 − 𝟐. 𝟖) = 𝟔𝟎. 𝟑
𝟔𝟎.𝟑
and since the slots have parallel sides, the width of the tooth at the root is 7 𝟕𝟓 8 − 𝟎. 𝟒 =
𝟎. 𝟒𝟎𝟓 𝒊𝒏 the average width is 0.463 in.

Item no. 24 & 25: Ventilating Ducts. Refer to Art. 16.

No. of radial ventilating ducts

Refer to art. 16. Not more than three ducts should be necessary in an armature 9 to 11 in.
long with each duct ¾ in. wide.

Item no. 26: Net Length of Armature.

ln = 0.92 (9.75 - 3 x 0.375) = 7.94 in

Item no. 27: Net Cross Section of Teeth under Pole.

𝟕𝟓
𝟕. 𝟗𝟒 × 𝟎. 𝟒𝟔𝟑 × 𝟔
× 𝟎. 𝟔𝟒 = 𝟐𝟗. 𝟒 in2

Item no.28: Flux density in Teeth.

Bt” = 3,833,000 = 130,300 lines/sq .in

29.4

Note that this value is above the upper limit given in the table on page 40 for 60 cycle. It
will, therefore, be necessary to correct (increase) the length of the armature core to bring
the flux density down to a reasonable figure. After some preliminary calculations an
armature length ln = 10.25 in. was found to be satisfactory.
laD2 = 10.25 x 222 = 4,970

𝟑,𝟖𝟑𝟑,𝟎𝟎𝟎 𝒍𝒊𝒏𝒆𝒔
𝑩𝒈 " = 𝟕.𝟑𝟕×𝟏𝟎.𝟐𝟓
= 𝟓𝟎, 𝟕𝟎𝟎 𝒊𝒏𝟐

𝒓𝝉 𝒍𝒂 = 𝟕. 𝟑𝟕 × 𝟏𝟎. 𝟐𝟓 = 𝟕𝟓. 𝟓 𝒊𝒏𝟐

𝒍𝒏 = (𝟏𝟎. 𝟐𝟓 − 𝟏. 𝟏𝟐𝟓)𝟎. 𝟗𝟐 = 𝟖. 𝟒 𝒊𝒏

𝟕. 𝟗𝟒 𝒍𝒊𝒏𝒆𝒔
𝑩𝒕 " = × 𝟏𝟑𝟎, 𝟎𝟎𝟎 = 𝟏𝟐𝟑, 𝟏𝟎𝟎
𝟖. 𝟒 𝒊𝒏𝟐

Item no. 29: Length per Turn of Armature Coil

𝟏.𝟏𝟓𝒔 𝟏.𝟏𝟓 ×𝟎.𝟒

sin α = 𝝀
= 𝟎.𝟗𝟐𝟐
= 𝟎. 𝟓; 𝒄𝒐𝒔𝜶 = 𝟎. 𝟖𝟔𝟔

lc = 2(11.5) + 4 (1.4) + 3 = 35.2 in., or say 35.5 in.

0.866

The total length per turn = lc + 2la = 35.5 + 20.5 = 56 in.

Item no. 30 - 33: Armature Resistance of one turn, ohms @ 60°C will be

𝟓𝟔
R60°C = 𝟒 = 𝟎. 𝟎𝟎𝟎𝟓𝟒𝟐 𝛀
𝟐(𝟎.𝟎𝟕 ×𝟎.𝟓𝟖)× ×𝟏𝟎𝟔
𝝅

Resistance per circuit R60°C = 0.000542 x (150/6) = 0.0136 ohm and the total resistance will be
1/6 of this = 0.0023 ohm.

The IR drop is = 0.0136 x 201.8 = 2.74 V

Ploss = 2.74 (201.8 x 6) = 3,320 W.

Item no. 34: Full-load flux. Assume 2-V for voltage drop across carbon brush.

Eg = 250 + 2 + 2.74 + 1.37 = 256.1 V

Full load flux = 3,833,000 256.1 = 4,270,000 maxwells

230

Item no. 35 - 36: Flux density in Armature Core. Internal diameter. Refer to Art. 17. A
density of 73,000 will be available.

𝝓
𝑹𝒅 × 𝒍𝒏 × 𝟕𝟑, 𝟎𝟎𝟎 =
𝟐
𝟒, 𝟐𝟕𝟎, 𝟎𝟎𝟎
𝑹𝒅 = = 𝟑. 𝟒𝟖 𝒊𝒏 𝒐𝒓 𝒔𝒂𝒚 𝟑. 𝟓 𝒊𝒏
𝟐 × 𝟖. 𝟒 × 𝟕𝟑, 𝟎𝟎𝟎

Di = 22 - 2 (3.5) – 2 (1.4) = 12.2 in

Item no. 37: Weight of Iron in Core. The weight of a cubic in. of iron is 0.28 lb and the total
weight of iron in the core below the teeth will be
𝝅
Wfe = 𝟎. 𝟐𝟖 × 𝟖. 𝟒 × 𝟒 [(𝟐𝟐 − 𝟐. 𝟖)𝟐 − 𝟏𝟐. 𝟐𝟐 ] = 𝟒𝟎𝟕 𝒍𝒃

Item no. 38: Weight of iron in teeth.

Wt = (0.28) (1.4) (0.463) (75) (8.4)

= 115 lb

Item no. 39: Total weight of Armature Stampings.

407 + 115 = 522 lb

Item no. 40: Diameter of Commutator. Refer to Art. 14.

𝑫
𝑫𝒄 = + 𝟒 𝒊𝒏.
𝟐
𝟐𝟐
𝑫𝒄 = + 𝟒 𝒊𝒏 = 𝟏𝟓 𝒊𝒏.
𝟐

Item no. 41 – 43: Number of Commutator Bars.

B = 150
𝑬
Volt/turn = 𝒁 = 𝟏𝟎 𝑽
𝟐𝒑
Item no. 44 - 45: Width of Commutator Segments.

Bar pitch = πDC

B
π (15) = 0.134 in with an insulation of (i.e. mica) of 0.03 in. 0.134 –0.03 = 0.284 in
150

Item no.46: Radial Depth of Segment.

2
h = 15 +15 4,700 = 2.19 in or say 2.25 in
15 4,500

Item no. 47 - 51: Dimension of Brushes.

𝑨
Current density assume to be 40 𝒊𝒏𝟐 .

Ab = 6(201.8) = 10.09 in2

(3) (40)

𝒍𝒃 = 10.09 = 10.09 or say 10 in

1

No. of brushes = 8; 1 ¼ x 1 in.

𝑨
Ab new = 40(10.09/10) = 40.4 𝒊𝒏𝟐

Item no. 52: Length of Commutator.

Length of brush = eight 1 ¼ in
Brush holder and clearances = 𝟖 × 𝟏𝟔 = 𝟐 𝟏O𝟐 𝒊𝒏
𝟓

Staggering of (+) (-) brushes = 5/8 in

End clearances per brush = 1 in
End play = 3/8
The total length will be, LC = 10 + 2 ½ + 5/8 + 1 + 3/8 = 14.5 in

Item no. 53: Brush-contact Drop.

The brush-contact drop for hard carbon at about 40 amp. per sq.in is
2.08. Allowing 10% for toughness, chipping and irregularities.

Brush contact drop = 2.3 V

Item no. 54-56: Brush Losses.

Brush loss = Brush contact drop x no. poles x Ic

= 2.3(201.8)(6) = 280.42 watts

Brush friction loss

The brush friction loss may be calculated by using the formula,

Wf = cPANDcπ x 746
12 x 33,000

= (0.25)( 2 x 10)( 6 )(15)p(1,200)( 746)

12 x 33,000

= 3,190 watts

Total loss Brush

= Brush loss + Wf = 2,780 + 3,190 = 5,970 W

Item no. 57: Dimension of Armature.

The illustration gives the leading dimensions of armature and commutator as

worked out in this design the diameter of the shaft. Supporting the armature will be.

𝟑 𝟑𝟎𝟎, 𝟎𝟎𝟎
𝟎. 𝟖𝟒 P = 𝟓 𝟏O𝟒 𝒊𝒏.
𝟏, 𝟐𝟎𝟎
 Preliminary or assumed
Item no. Specification: 30 kw, 4 poles, 1800 rpm, 230/250 volts Symbol values Final values

1 Number of poles p 6 6
frequency f 60 60
2 Ratio of pole arc to pole pitch r 0.64 0.64
3 Specific loading q 850 875
4 Apparent air-gap flux density (open circuit) Bg" 57,500 50,700
5 Line current (full load) I ……………. 1200
6 Type of winding Lap winding lap
7 Armature current per circuit Ic 201.8
8 Output factor (Iad^2) 4,850 4,970
9 Armature diameter, in D 22 22
10 Peripheral velocity, fpm v 6,900 6,900
11 Total number of faceconductors Z 292 300
12 Number of slots S 75
13 Number of conductors per slot 4
14 Axial length of armature core; gross, in la 9.75 10.25
15 Flux per pole (open circuit) Flux 3,833,000
16 Pole pitch, in τ 11.5
17 Pole arc, in rτ 7.37
18 Area covered by pole face (rrls), sq in 71.8 75.5
19 Dimension of Armature conductors, in. units 2(0.07 x 0.58)
20 Slot pitch, in 0.922
21 Slot width, in s 0.4
22 Slot depth, in d 1.4
23 Tooth width, in .348
At top t 0.522
At root 0.463
Average 3
24 Number of radial ventilating ducts n 0.375
25 Width of radial ducts, in 𝑙5 7.94 8.40
26 Net length of armature core, in 4.945 5
27 Net tooth section under pole, at center 29.4 31.2
28 Apparent density in teeth under pole,at center sq in Bt" 130,300 123,100
29 Length per turn of armature coil, in 56
30 Resistance of one turn, ohms at 60 deg 0.000542
31 Resistance of armature, ohms 0.0023
32 IR drop in armature, volts 2.74
33 I^2R loss in armature winding,watts 3,320
34 Estimated full-load flux per pole 4.27 x 106
35 Flux density in armature core below teeth 73,000 72,600
36 Internal diameter of core stampings, in 12.2
37 Weight of iron in core (without teeth), lb 407
38 Weight of iron teeth, lb 115
39 Total weight of armature stampings, lbs 522
40 Diameter of commutator, in Dc 15
41 Average volts per turn of armature winding 10
42 Number of turns between bars 1
43 Total number of commutator bars 150
44 Bar pitch, in 0.314
45 Width of copper bar, in 0.284
46 Radial depth of bar, in 2.25
47 Current density at brush-contact surface,amp per sq. in 40 40.4
48 Contact area per brush set, sq. in 10.09 10
49 Brush arc (circumferntial width), in 1.0
50 Axial brush length 10
51 Number of brushes per set 8
52 Axial length of commutator, in Lc 14.5
53 Brush-contact drop,volts 2.3
54 Brush-contact loss,watts 2,780
55 Brush-friction loss, watts 3,190
56 Total brush loss,watts 5,790
57 Drawing to scale Figure 18