POLYTECHNIC UNIVERSITY OF THE PHILIPPINES College of Engineering Electrical Engineering Department

ELECTRICAL MACHINE DESIGN

Design 1: DC Generator Armature Design

Submitted by DACAYAN, MARVIN C. BSEE V-2

Submitted to ENGR. LIBRADO S. GESALTA Instructor

July 4, 2012

Design Sheet for a DC Generator Armature

ITEM NO.
===== 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

SPECIFICATION : 650KW, 230/250V, 900rpm, DC Generator

PART 1 : ARMATURE CORE & WINDING Number of poles / frequency Ratio of pole arc to pole pitch Specific loading Apparent air-gap density Line current Type of winding Armature current per circuit Output factor Armature diameter Peripheral velocity Total number of face conductors Number of slots Number of conductors per slot Axial length of armature core Flux per pole Pole pitch Pole arc Area covered by pole face Dimensions of armature conductors Slot pitch Slot width Slot depth Tooth width : at top at root average Number of radial ventilating ducts Width of radial ducts Net length of armature core Net tooth section under pole, at the center Apparent density at teeth under pole at center Length per turn of armature coil Resistance of one turn, ohms at 60C Resistance of armature IR drops in the armature 2 I R loss in armature winding Estimated full-load flux per pole Flux density in armature core below teeth Internal diameter of core stampings Weight of iron in core(without teeth) Weight of iron in teeth Total weight of armature stampings PART 2 : Commutator & Brushes Diameter of Commutator Average volts per turn of armature winding Number of turns between bars Total number of commutator bars Bar pitch

SYMBOL
======== P /f r q Bg I Ic 2 laD D v Z S la la S d

PRELIMINARY OR ASSUMED VALUES

===================== 0.64 930 2 60000 lines/in.

FINAL VALUES
==================== 8 poles / 60 Hz 0.64 924.16 2 60055 lines/in. 2600 A Lap Winding 15246 33 in. 7678.84 fpm 220 55 4 14 in.

435.5 A 12255.5 32.59 in. 7678.84 fpm 218

11.33 in. 6 6.97 10 maxwells 12.96 in. 8.29 in. 2 93.93 in.

116.06 in. 2(0.095 0.84) 1.88 in. 0.5 in. 1.95 in. 1.38 in. 1.16 in. 1.27 in. 3 0.375 in. 11.845 in. 60055 lines/in. 66.03 in. 0.000325 0.000559 1.96 V 6828.64 watts 6 7.73 10 maxwells 2 73000 lines/in 20.16 in. 1147.14 lbs. 451.75 lbs. 1598.89 lbs. ==================== 20.5 in. 18.18 V 1 110 0.5855 in.
2

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 ===== 40 41 42 43 44

n ln Bt 9.39 in. 2 52.47 in. 2 132830 lines/in.

73000 lines/in.

======== Dc

=====================

45 46 47 48 49 50 51 52 53 54 55 56 57

Width of copper bar Radial depth of bar Current density at brush contact surface Contact area per brush set Brush arc Axial brush length per set Number of brushes per set Axial length of commutator Brush-contact drop Brush-contact loss Brush-friction loss Total brush loss Drawing to scale giving leading dimensions of armature and commutator

40 amps/in. 2 29.03 in.

Lc

0.5555 in. 2.66 in. 2 38.71 amps/in. 2 30 in. 1 in. 30 in. 24 39.5 in 2.3 V 8013.2 Watts 3275.75 Watts 11288.95 Watts

Solutions:
PART 1: Item 1: Number of Poles and Frequency f = 60Hz P = _60 Hz 120_ 900rpm Item 2: Ratio of Pole Arc to Pole Pitch r = 0.64 Items 3 and 4: Specific Loading and Air-gap Density q = 930 Bg = 60000 Item 5: Line Current I = _650000 W 250V Item 6: Type of Winding Item 7: Armature Current per Circuit Ic = _2600_ 1.005 6 Items 8, 9, 10: Armature Diameter Output Factor IaD2 = _650000_ ____6.06 108_____ 900 60000 0.64 930 Armature Diameter _____________________ D = 3 _650000_ ____6.06 108_____ ___900______60000 0.64 930_ 0.354

P = 8 poles @ 60 Hz frequency

r = 0.64

q = 930 Bg = 60000

I = 2600 A

*Lap winding

Ic = 435.5 A

IaD2 = 12255.5

D = 32.59 in.

Peripheral Velocity v = _32.59 900 12

v = 7678.84 fpm

Items 11, 12, 13: Number of Inductors, Slots, and Conductors per Slot Number of Conductors Z = _32.59 930 _ 435.5 Number of Slots Number of Conductors per Slot Specific loading q = _220 435.5_ 33 Item 14: Axial Length of Armature Core Gross Armature Length IaD2 = 12255.5 930 924.16 Ia = 12332.95 332 Item 15: Flux per Pole (Open Circuit) Flux per Pole = _230 60 8 108_ 900 8 220 Items 16, 17, 18: Pole Pitch, Pole Arc, and Pole Area Pole Pitch = _33 _ 8 Pole Arc = 12.96 0.64 Pole Area Ia = 8.29 11.33

Z = 218 ; use 220 S = 75 *4 q = 924.16

IaD2 = 12332.95 Ia = 11.33 in.

= 6.97 106 maxwells

= 12.96 in.

= 8.29 in.

Ia = 93.93 in.2

Air-gap density (final) Bg = _6.97 106_ 14 8.29 Items 19 to 22: Dimensions of Slots and Armature Conductors Amperes per square inch = 700000 + 7678.84 930 4 Area of cross section _Ic_ = 435.5 2672.4 Slot Pitch = _33 _ 55 Slot width s = 0.5 (assumed) Space for conductors 0.5 (3 0.016) (2 0.035) 4 Slot depth d = 0.167 + (3 0.035) + (2 0.84) Item 23: Tooth Dimensions Tooth width at the top Ttop = 1.88 0.5 Tooth width at the root Troot = (91.42 55) 0.5 Tooth width average Taverage = _1.38 + 1.16_ 2

Bg = 60055 lines/in.2

= 2672.4 A/in.2

_Ic_ = 0.16 in. 2 = 1.88 in.

s = 0.5 in. = 0.095 in.

d = 1.95 in.

Ttop = 1.38 in. Troot = 1.16 in. Taverage = 1.27 in.

Items 24 and 25: Ventilating Ducts Ventilating ducts *Use 3 ducts with 0.375 in. width

*3 ducts 0.375 in. wide

Item 26: Net Length of Armature Net length of the armature core In = 0.92 [11.33 - (3 0.375)]

In = 9.39 in.

Item 27: Net Cross Section of Teeth under Pole Net tooth cross section under pole Tooth Section = 9.39 1.27 _55_ 0.64 8 Item 28: Flux Density in Teeth Apparent Flux Density at teeth Bt = _6.97 106_ 52.47 Item 29: Length per Turn of Armature Coil Length per turn of armature coil lc = 38.03 in. ; L/T = 38.03 + (2 14)

Tooth Section = 52.47 in.2

Bt = 132.83 103 lines/in.2

la = 14 in. L/T = 66.03 in.

Items 30 to 33: Armature Resistance Resistance at 60C R@60C = ______ _66.03_ _ 2(0.095 0.84) (4 ) 106 Resistance of the armature Ra = 0.000325 _(2202)_ 82 IR drop in the armature IR = 435.5 0.0045 I2R loss in the armature I2R = (435.5 8) 1.96 Item 34: Full-load Flux Full-load flux per pole FL = _6.97 106 254.94_ 230

R@60C = 0.000325

Ra = 0.000559

IR = 1.96 V I2R = 6828.64 Watts

FL = 7.73 106 maxwells

Items 35 and 36: Flux Density in Armature Core Internal diameter of core stampings Dinternal = 33 (2 4.47) (2 1.95) Item 37: Weight of Iron Core Weight of iron in core (without teeth) Wcore = _0.28 11.845 _ [(33 3.9)2 (20.16)2] 4 Item 38: Weight of Iron in Teeth Weight of iron in teeth Wteeth = 0.28 1.95 (1.27 55) 11.845 Item 39: Total Weight of Armature Stampings Total weight of core stampings Wtotal = 1147.14 + 451.75

Dinternal = 20.16 in.

Wcore = 1147.14 lbs.

Wteeth = 451.75 lbs.

Wtotal = 1598.89 lbs.

PART 2 : Item 40: Diameter of Commutator Diameter of Commutator Dc = (33 2) + 4

Dc = 20.5 in.

Items 41 to 43: Number of Commutator Bars Average volts per turn Eaverage/turn = ___250___ Eaverage/turn = 18.18 V 220 16 Number of Commutator bars *It is desirable to use 110 commutator segments to improve the commutation and to be more suitable and narrower.

Items 44 and 45: Width of Commutator Segments Bar pitch Bar pitch = _20.5 _ 110 Width of copper bar WidthCu = 0.5855 - 0.03 Item 46: Radial Depth of Segment Radial depth of bar h = _20.5 + 15_ _4768.562_ 15 45002 Items 47 to 51: Dimensions of Brushes Current density at brush contact surface b = 40 (29.03 30) Contact area per brush set _8 435.5_ 3 40 Axial brush length per set Item 52: Length of Commutator Axial length of commutator Lc = 30 + 7.5 +0.625 + 1 + 0.375 Item 53: Brush-contact Drop Item 54 to 56: Brush Losses Brush contact loss LossBrush contact = 2.3 8 435.5 Brush contact friction Wf = _0.25 2 6 10 20.5 900 746 _ 12 33000 Total brush loss LossTOTAL = 8013.2 + 3275.75

Bar pitch = 0.5855 in.

WidthCu = 0.5555 in.

h = 2.66 in.

b = 40.04 amps/ in.2 = 29.03 in.2 *30 in.

Lc = 39.5 in. *2.3 V

LossBrush contact = 8013.2 Watts Wf = 3275.75 Watts

LossTOTAL = 11288.95 Watts