New Era University

College of Engineering and Technology

Department of Electrical Engineering

EE572
MW 10:00-11:30AM
Electrical Machine Design

Design 1-B
Design of Commutator and Brushes
Item 1 - 39
440kW, 450V

Name: Torrente, Arvin Joseph K.

Course: BS Electrical Engineer
Year: 5th year

Rating: __________
Date Started: July 30, 2015
Date Submitted: August 2015

Engr. Reynaldo M. Dela Cruz

Specifications: 440kW, 450V

I. Objective:
- To follow the design procedure from item 1 - 39
II. Materials/Instruments:
- Drawing Materials
- Laptop
- Calculator
- Printer
- Book
III. Procedure:
Item 40 : Diameter of Commutator. Refer to article 14.
A diameter of commutator not exceeding 80 percent of the armature core
diameter is generally found practically although a reasonably good rule to follow
is to make Dc = D /2 + 4. Thus,
Dc = 19/2 +4 = 13.5 inches
This is 70.9 percent of the core diameter and makes the peripheral
velocity of 0.709 x 5970 = 4235
fpm near the upper limit. This
dimension is subjected to correction if the thickness of the individual bars does
not work out satisfactory.
Item 41 to 43 : Numbers of commutator bars.
The potential difference between adjacent commutator segments in a 250
volt machine might be anything between 4 to 12 volts. The average per turn of
armature winding is
=
2

300
=
450
2(6)

If the commutator is constructed with the same number of segment as

slots there will be two turn between adjacent segments, because for a lap
winding and four effective commutator segment will, moreover, be desirable to
use 150 commutator segment, with a resulting improvement in commutator and
a more suitable, narrower segment.
Item 44 and 45 : Width Commutator segment.
The bar pitch is 3.14 x 13.5 /222 = 0.40 inch and with mica 0.03 inch the
bar width 0.325 0.03 = 0.295 inch at the commutator surface.
Item 46 : Radial Depth of segment.
The proper depth of copper in the cross section of commutator bar is
usually determined by mechanical considerations (chapter 13). It must be
sufficient to prevent appreciable deflection under the action of centrifugal force.
For peripheral velocities up to about 4500 fpm the radial depth of the
commutator segment should be about h=(Dc+15)/15; for higher speeds the
depth should be increased in portion to the square of velocity. Thus,
=

19. +15
15

4235
4500
10

Item 47 to 51: Dimension of Brushes.

Unless a very soft quality of carbon is used the current density over the
brush-contact surface is about 30 to 50 A/sq. Taking 40 as a preliminary value to
be modified later, if necessary to accommodate a standard size of brush, the
contact surface of one set of brushes will be (6 x 117.7) / (3x40) = 5.885 sq. in.
A 1 inch width of brush, Art 34. Will cover a little over three bars which is
reasonable for an armature with 150 segment. The total length for brushes per
set, measured in a direction parallel to the axis of the machine will be 5.885 or
say 6 which can be made up of eight brushes 8 x 1. The current density will
thus be increased slightly to 40 x(5.885/6) = 39.23 amp per sq. in.
Item 52 : Length of Armature.
In addition to the 8 inches which must be provided for 6 1 x 1 inches
carbon brushes axial length of the commutator face must allow the following:
a. Brush holders and clearance 8 x 5/16 = 2 1/2
b. Staggering of (+) (-) = 5/8
c. End clearance for brushes = 1 inch
d. End play = 3/8
The total length will, therefor be Lc = 7 + 2 1/2 + 5/8 + 1 + 3/8 = 11.5 inches
Item 53 : Brush Contact Drop.
Referring to Figure 38 the brush contact drop for hard carbon at about 40
amps per sq Inch is 2.08. Allowing 10 percent for roughness, chipping and
irregularities this drop will be about 2.3V.
Item 54 to 56: Brush Losses.
The brush contact loss will be 2.3 x (6x117.7) = 1625 watts. The
brush-friction loss may be calculated by using the formula (48), page 143, where
Wf = c PANDc x 3.14 x 746 / 12 x 33 000
Using c = 0.25 for hard carbon, P = 1.5 lb for a peripheral speed greater 4000fpm
0.25 1.5 6 5 1200 13.5 3.14 746
=
=
.
12 33000
Total Brush Loss = 1078.60 + 1625 = 2703.60 watts
Item 57 : The illustration or Figure 18 gives the leading dimensions of armature
and commutator as worked out in this design. The diameter of the shaft
supporting the armature may be calculated by formula 160 in chapter 13
treating of mechanical features of the design of electrical machinery.
This is 0.084 = 4.7 or 5 inches

11

IV. Circuit Diagram

Section of core and commutator for illustrative example of Art. 18.

Assembly of armature
core and commutator for
small dynamo or motor

Armature and commutator for d-c machine of large outpu

12

Small
commutator

High-speed commutator of
large size

Illustrating calculations for

strength and stiffness of
long commutator bars.

13

V. DATA AND RESULT

DESIGN SHEET FOR ARMATURE OF D-C GENERATOR
Item
No.
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

Specifications: 440KW; 450V;

1200rpm
Commutator and Brushes
Diameter of commutator, in......
Average volts per turn of armature
winding
Number of turns between bars
Total number of commutator bars
Bar pitch, in.............................
Width of copper bar (on surface), in
Radial depth of bar, in..............
Current density at brush-contact
surface, amp per sq in...............
Contact area per brush set, sq in.......
Brush arc (circumferential width), in
Axial brush length (total) per set,
in...
Number of brushes per set.........
Axial length of commutator, in...
Brush-contact drop, volts........
Brush-contact loss, watts.........
Brush-friction loss, watts..........
Total brush loss, watts
Drawing to scale giving leading
dimensions of armature and
commutator........................................

Symbol

Preliminary or
assumed
values

Final values

Dc

.....

40

.....

......

.....
.....
.....
.....
.....

.....
.....
.....
.....
......

1
150
0.40
0.295
2

40

39.23

.....
.....

5.885
.....

6
1.0

.....

.....

.....
Lc
.....
.....
.....
.....

.....
.....
.....
.....
.....
.....

6
11.5
2.3
1625
1078.60
2703.60

.....

Fig. 18

VI. Question/Problems:
1. Given a dc-dynamo: developed volts=100; total number of slots = 53; number of
inductors per slot = 6; number of poles = 4; speed = 1000rpm; winding, series (or
wave). Calculate the flux per pole.
2. A certain four-pole simplex-lap-wound dc generator has 768 armature inductors and
revolves at 20 rps. If the flux per pole = 715,000 Maxwell, calculate the generated
voltage.
3. The lap-wound armature of a six-pole generator has 600 active conductors, the speed
is 1000rpm. The area of each pole face is 100 sq. in., and the average air-gap flux
density under the pole face is 8000gauss. Calculate the emf between positive and
negative brushes.
VII. Remarks:

14

V. Data and Results:

DESIGN SHEET FOR ARMATURE OF D-C GENERATOR- PART 1
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
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

Specifications: 440kW, 450V

Symbol

Armature Core and Winding number of Poles

Frequency
Ratio of Pole Arc to Pole Pitch
Specific Loading
Apparent air-gap flux density (open-circuit)
Line Current (full load)
Type of Winding
Armature Current per Circuit
Output factor (laD2)
Armature Diameter
Peripheral Velocity, fpm
Total number of face conductors
Number of slots
Number of conductors per slot
Axial length of armature; gross, in.
Flux per pole (open circuit)
Pole pitch, in.
Pole arc, in.
Area covered by pole face
(r la), sq. in.
Dimensions of armature conductors, in.
Slot pitch, in.
Slow width, in.
Slot depth
Foot width, in.
Top
Roof
Average
Number of radial ventilating ducts
Width of radial ducts, in.
Net length of armature core, in.
Net tooth section under pole at center, sq. in.
Apparent density in teeth under pole at center, sq. in.
Length per turn of armature coil, in.
Resistance of one turn, @ 60C
Resistance of armature, ohms
IR drop in armature, volts
I2R loss in armature, volts
Estimated full-load flux per pole
Flux density in armature core below teeth
Internal diameter of core stampings, in.
Weight of iron core without teeth, lb
Weight of iron teeth, lb
Total weight of armature stampings, lb.

p
f
r
q
Bg
I
IC
D
v
z
S
la

Preliminary or
Assumed Values
6
0.64
900
59000
lap
201
6537.73
24
7550
337
11.50
5.11 10
12.56
8.04

79

92.13

s
d

10.06
39.17
130457
73000
-

2 (0.032 1.23)
0.967
0.4
2.46
0.567
0.368
0.468
4
0.375
11.03
42.95
118985
67
0.00067
0.0037
4.42
5331
5.21 10
71274.15
12.58
500
277.33
777.33

n
ln
Bt
-

Final Value
6
60
0.64
1040
55468
978
lap
7200
24
7550
390
78
5
12.50
-

VI. Question/Problems:
4. Given a dc-dynamo: developed volts=100; total number of slots = 53; number of
inductors per slot = 6; number of poles = 4; speed = 1000rpm; winding, series (or
wave). Calculate the flux per pole.
5. A certain four-pole simplex-lap-wound dc generator has 768 armature inductors and
revolves at 20 rps. If the flux per pole = 715,000 Maxwell, calculate the generated
voltage.
6. The lap-wound armature of a six-pole generator has 600 active conductors, the speed
is 1000rpm. The area of each pole face is 100 sq. in., and the average air-gap flux
density under the pole face is 8000gauss. Calculate the emf between positive and
negative brushes.
VII. Remarks:

15