Course Contents

GENERAL ASPECTS
Introduction, Insulating Materials & Classifications, heating of electrical
machines , Cooling of Transformer and rotating machines, Electrical and
Magnetic Loading, output coefficient and factor affecting size of machines.

DESIGN OF TRANSFORMER
Types of transformers, position of HV and LV windings, core and yoke cross-
sectional area, Different types of transformers windings. Different methods for
cooling of transformer, Different positions of tapings. Output equation for
single phase and three phase transformers (Core & Shell type), window space
factor, factors affecting window space factor. Relation between emf per turn
and transformer rating, factors affecting constant K, stacking factor, examples.
Course Contents

Selection of flux density and current density, Window dimensions, Yoke

dimensions and overall core dimension calculations examples. Design of HV
and LV windings (No. of turns and area of cross section). Estimation of
operating characteristics. Primary and secondary winding resistance. Leakage
reactance calculation of cylindrical coil with equal height, Leakage reactance
of unequal windings and heights. No load current calculations for 3 phase
transformers. Temperature rise of transformer, design of tank with tubes,
calculation of dimensions of tank, examples. Optimum design for minimum
cost and loss. Variation of output and losses in transformer with linear
dimensions.
Recommended Books

TEXT BOOK
1. Sawhney, A.K., “A Course in Electrical Machine Design”, 6thEdition,
Dhanpat Rai and Sons, 2006

REFERENCES
1. Agarwal, R.K., “Principles of Electrical Machine Design”, S.K.Kataria and
Sons, 2002
2. Mittle,V.N. and Mittle, A., “Design of Electrical Machines”, Standard
Publications and Distributors, 2002.
Fundamental Concepts

What is meant by an electrical machine design?

 Design may be defined as a creative physical realization of theoretical
concepts
 Engineering design is application of science, technology and invention to
produce machines to perform specified tasks with optimum economy and
efficiency
 The problem of design and manufacturing of electrical machinery is to
build as economically as possible, a machine which fulfils a certain set of
specifications and guarantees.

The major considerations to evolve good design are

a) Cost
b) Durability
c) Compliance with performance criteria as laid down in specifications
Basic Considerations to Develop a Design are:

1. Design base

 Matching the existing experience with R and D

 Bringing in the latest material technology
 Limitations in design
 Convenience in production line and Transportation
 Working safety and reliability
 Maintenance and repair
 Environmental conditions
Basic Considerations to Develop a Design are:

2. Specifications
 Meeting with the customer’s requirements
 Guarantees
 Satisfy the national and international standards

3. Design transfer
 Transfer of design to factory foreman i.e. drawings, processes
instructions, job flow, meeting the delivery schedule.

4. Information updating
 Technical journals, R and D papers and reports, interaction in meetings,
seminars and conferences.
Major Considerations to Develop a Design are

The design should be carried out based on the given specification using
available materials economically and to achieve the following

 Lower cost
 Durability
 Conformity with performance criteria as laid down in specifications
Limitations in Design

1. Saturation of magnetic parts

Increased core losses and excitation at higher flux density resulting in higher
cost for the field system.

2. Temperature rise
Increased temperature rise under higher output weakens the insulation and
affects the life of machine.

3. Insulation
It should be able to withstand the electrical, mechanical and thermal stresses
which are produced in the machine.
Limitations in Design

4. Mechanical strength
Specially in turbo machine due to large size and high speed.

5. Efficiency
If high efficiency is the aim, the machine becomes costly, for lower efficiency
higher running cost and temperature rise with associated problems.

6. Customer’s specifications
Imposes limitations to identify criterion for best design.

7. Commutation
In DC machine output is limited because of commutation problem.
Limitations in Design

8. Power factor
Power factor imposes a limitation specially in case of 3 phase induction motor.

9. Standard specification
Specification is biggest strain on the design because both the manufacturer as
well as the consumer cannot get away from them without satisfying them.
Basic Structure of Electrical Machines

Magnetic circuit: Core ,yoke, air gap etc.

Electric circuit: Stator, rotor winding and transformer winding

Dielectric circuit: Insulation

Thermal circuit: Heating and cooling medium

Mechanical parts: Frame, bearings and shaft

Classification of Design Problems

1. Electromagnetic Design

2. Mechanical Design

3. Thermal Design

4. Dielectric Design
Design and Constructional Elements of Transformer

A. Design

1. Specification: Rating according to standard, loading type,

frame size, temperature rise and efficiency.

2. Performance: Transient behaviour, system considerations, no

load characteristics, short circuit characteristics, mechanical
forces and optimization.

3. Manufacture: Material procurement, handling and processes,

skill and talent, transportation to site.
Design and Constructional Elements of Transformer

B. Constructional Elements

1 Cores: Material, core and yoke, laminations, insulation, clamping, flux

density, window, space optimization, core loss, weight.

2. Windings: Type, current density, conductors, turns, layers, strands,

tappings, insulation, transposition, resistance, I2R loss, leakage reactance,
mechanical forces, thrust block, shielding, insulation gradient, weight.

3. Frame: Size, stiffness, fixing, tank, heat exchanger, conservator,

bushings, relays, weight.
Design and Constructional Elements of Transformer

Transformer’s Main Parts

1. Three-limb core
2. LV Winding
3. HV Winding
4. Tapped Winding
5. Tap Leads
6. LV Bushings
7. HV Bushings
8. Clamping Frame
9. ON-Load Tap Changer
10. Tank
11. Conservator
12. Radiators
Design and Constructional Elements of Transformer
Design and Constructional Elements of a Rotating
Machine

A. Design

1. Specification: Rating according to standard, loading type, frame size,

starting method, temperature rise and efficiency.

2. Performance: Starting torque, Transient behaviour, system

considerations, no load characteristics, short circuit characteristics, force under
short circuit, losses and optimization.

3. Manufacture: Material procurement, handling and processes, skill and

talent, transportation to site.
Design and Constructional Elements of Transformer

B. Constructional Elements

1. Cores: Material, Stator and rotor stampings, insulation, clamping, flux

density, space optimization, core loss, weight.

2. Slots and teeth: Suitable combination, size, space factor, flux density,
insulation, core loss, mechanical forces.

3. Windings: Type, current density, conductors, turns, layers, strands,

tappings, insulation, transposition, resistance, I2R loss, leakage reactance,
connections, temperature rise, cooling, slip-rings, commutator, weight.

4. Frame: Size, rigidy, fixing, enclosure-type, vibration, weight

Design and Constructional Elements of Transformer

5. Shaft: Size, stiffness, deflection, speed

6. Bearings: Type, loss, cooling, lubrication

Electrical Motors Basic Components

Constructional elements of rotating machines

1. Stator
2. Rotor
3. Others

A.(a) DC Machine
Stator: Yoke, Field Pole, Pole Shoe, Field Winding, Interpol
Rotor: Armature Core, Armature Winding , Commutator
Others: Brush and Brush holder
A.(b) Squirrel cage induction motor
Stator: Frame, stator core and stator winding
Rotor: Rotor core, rotor bars and End rings
Standard Specifications

The standard specifications of electrical machines are

1. Standard ratings of machines

2. Types of enclosure
3. Standard dimensions of conductors to be used
4. Method of marking ratings and name plate details
5. Performance specifications to be met
6. Types of insulation and permissible temperature loss
7. Permissible loss and range of efficiency
8. Procedure for testing of machine parts and machines
9. Auxiliary equipment's
Name Plate Details

 KW or KVA rating of machine

 Rated working voltage

 Operating speed

 Full load current

 Class of insulation

 Frame size

 Manufacturers name

 Serial number of the machine

Name Plate Details
Name Plate Details
Name Plate Details
ISO numbers with year

 IS 325-1966 : Specifications for 3ph induction motor

 IS 4029-1967 : Guide for testing 3ph induction motor
 IS12615-1986 : Specifications for energy efficient induction
motor
 IS13555-1993 : Guide for selection & application of 3ph
induction motor for different types of driven equipment
 IS8789-1996 : Values of performance characteristics for 3ph
induction motor
 IS 12066-1986 : 3ph induction motors for machine tools