$36 BLECTRICAL MACHINE D&&GN Slot Depth Inrulated conductor 2418-78374 mem Main insulation tel =30mm Separator =10 mm Wedge and Lip 35mm Slack “hom ‘Total slot depth ‘Thus the slot size is 46% 10°5 mm. Refer to Fig. 9°39 for insulation de Beample 918. A 500 EF, 460 V, 8 pole, 875 r.p.m. compound tor bs armature diameter of 1'1m anta core length of 0-35 m. Design a symmetrical armature winding, giving the detaile of rqualizers. ‘he ampere conductors per metre are 34000. The internal soltage drop ia 4 per cent of terminal voltage and the field current is 1 per cent of output ourrent. The ratio of pole arc to pole pitch ia 0°7. ‘The voltage batween adjacent segments at ood shud Wik espeed 13 andthe aol loading should nol exceed 15004. he te meter of commataton i 0°65 of armature diameter and the minimum allowable pitch of segments ie & mm. Make other anitable azewmptions. Solution. Type of winding, Generated emf FmV+Iemml"04x 460478 V. = SO 1087 A. Load current Field current 0°01 x1087aaI1 A. Armature current Lom 1087-+11 =01098 A. With wave winding : Gurrent per parallel path Zy= 2098 msg A ‘This exceeds the limit of 200 A per parallel path. Therefore a simplex wave winding ‘cannot be used for this machine. With lop winding ; Current per parallel path fn mi6 A. ‘This is within limits and therefore a simplex lap winding is used for this machine, Nember of condacters Armature ampere conductors per metre oe c Number of armature conductors Zine , PS? apy 2X 11% 94000D.C. MACHINGS a7 Number of Slots 1. The slot pitch varies from 25mm to 35mm, Therefore le suber of tuts from £%!'1 9g to FXO 9 vary 0035 o025 2 2. The number of slots per pole vary from 9 to 16. The minimum number of slots ix 8X9=i2 and the maximum number iv dX" =128," ‘Thus the slots should be taken from the range 98 to 126. 3. Inordertohave a symmetrical lap winding, the numbirof 2) multiple of pair of poles, i.e. 4 in this case. Thus we can select the slots from the following 100, 104, 108, 112, 116, 120, 124, 128. 4, In order to reduce flux jons the slots per pole should be an integer 4-$. Thus the slots should be selected from 100, 108, 116, 124. Further reducing the flux pulsations, we should make the slots per pole arc as an intever-+¢. '8==108 gives slots per pole arc approximately equal to an integer+4. Winding, In order that the voltage between adjacent segments be limited to 15 V at no load, minimum number of coils Cm-42 a <69%8 nogs, sPoube be a With 85108 ; Conductors per lore 4 792, But the number of conductors per slot has to be an even integer. Taking conductors slot Zy=8, there will be a difference of nearly | per cent in the calculated ye value used for conductors. pe teed! value and c. Number of conductors ured=8 x 108=864, Now we have to find out the number of coil sides per slot. With «=2, C= 108 ; w=, Cm216 ; u=6, Cm 324 ; 8, Om432, Thus we cannot use w=2 or wand as they give the number of coils lower than the required minimum, ‘We cannot use w==6 as in that cate the number of conductors is is 1 ee eae luctors per slot is not divisible Taking w=8 we have, m482. <. Turns per coil 7, Before we finally decide the winding details we must apply the following checks + 1, Slot Loading : . Current in each conductor Iy=136 A.538 coils. ‘ELBOTRICAL MACHINE DESIG) Slot loading= J, . Z=196X8=1088 ampere conductors, This is within the limit of 1500 amg ste conductors. 2. Cone: utator segment pitch Diameter of commutator Dyea0'6! X1'1=0°715 m. h of commutator sep.ve.a° 3s = 7715 5-2 mum, \ciigher thau the minimum allowable value of 4 mm} Thus we have, Sm1vh number of coils Cm 33, Oma32, os, wustub:: 1; comductors per let Zim, nunier of tarna per oil Tal, Wading layout, Bk pitch woe ke 2X82 4 e105, crake yo=l05 as wit the M1:, sn integer and therefore we do not get split ‘Taking a progressive winding : front pitch yymyo—2—105—2—108, Commutator pit. yem=+1 and total pitch Yum+2. Equalizer Connections, The uate * cf ut aid be xtween 19 to20, In order to obtain symmetry the number of coil: st..ued us stnvaaible by number of rings. Taking n wnber ofrings = w= 12, Number 0 cappugs amb mioxd mts, . Equipo + ntial po'ch Tan e 2X 492 108 coils. Phase pitchD.C. MACHINES 539 DESIGN OF FIELD SYSTEM 931, Pole Design. The design of poles involves, the determination of area of eros section of the poles, their height and the design of field windings. 931-1, Area of poles, Flux in pole body ©, =leakage co-efficient X useful flux per pole=Cix ®. ‘Thus the determination of flux in the field poles involves the knowledge of leaka co-efficient. The leakage flux can be determined by the application of Eqn. 4'111 (page 176). This relationship involves the knowledge of total flux and the useful flux which can be determined if the dimensions of the main poles are known (See Eqns. 4'107 and 4°108). But these dimeusions are not known at this stage. Thus, in order to proceed, we have tc assume a suitable value of leakage co-efficient. Table 9"7 gives the approximate values of leakage coefficient. Table 9-7, Leakage co-efficient. Ones Maakens efile 50 11210 125 100 41 to 122 200 410 to 1:20 00 - 109 te 118 1000 Tb. ote ‘The flux density in the vole shonk (po bdyt sas. 1-7 Why? for laminates pric oak Aye 22@ Acwa of p les ok Ayipt ope (9°29) iength of pole is taken less than that of armature in order to permit end play and avoid magnetic centring. The difference in length is about 10 to 15 mm. Length of pole J»=L—(0'001 to 0°015) (9°30) 2 Width of pole shank (body), by 22m 52 (9°31) where Zpeenet iron length of pole cores=0'9 Ly. However, for machines using laminated core for poles, the axial length of poles is equal to that of armature core and therefore Ipt= Zs. 9312, Height of pole, The height of pole is decided by the mmf to be provided on the pole at full load. So the first thing would be to find out the field mmf required at full load. In order to doso we must know the open circuit characteristics (magnetization curve) of the machine and in order todraw the magnetization curve for the machine, we must know the mmf required forthe pole and the yoke, which can only bbe known if the height of the pole is known. Thus the field mmf required at full load and the height of pole are in ted and can be known only when one of them is known, But ‘at present neither of the two is known. In order to proceed with the design we assume the value of field mmf at full load. Full lead field maf, In order to the effects of armature reaction becoming tno aot, thn ld yn vo Sap Sat th by the field coils is soffciendy powerful in comparison with the mmf developed by the armature at full iced.510 ELECTRICAL MACHINE DESIGN In the case of all logically designed machines, there is thus a certain minimum value for the eatio of Geld munf at fll load, AT, to armature mimf at full load ATs, that is regarded ‘as a safe limit. Dependirg upon the duty which the machine has to perform, we should decide upon the value of thi. ratio. The normal designs aie baee upon a ratio, - am field mmf at fill loa 7 carga! to 1°25. (9°82) 9:32 creative design of field winding. Taking the case of a cylindrical coil, the end surfaces may be neglected while ccnsidering cooling. The inner and outer surfaces taay be considered effective for rooling. Let, ATp=mnf developed by field winding at full load Aysheight of winding, m; dysdepth of winding, m ; A=cooling surface of field toll, m*; Zeitength of mean turn of field winding, m Ry=resistance of each field coil, Q ; Tyenumber of turns in each field coil ; ‘asmarea of each conductor of field winding, m* : Ty=current in the field winding, A; 3yecurrent density in the field winding, A/mm* ; Qr=copper loss in each field coil, W ; gr=permissible loss per unit winding surface for normal temperature rise, W/m* ; ‘Br=copper space factor; p=resistivity, Om. Cooling surface of field winding, neglecting top and bottom surfaces Se=2Lmi Me Permissible copper loss in each field coilm gsm 2Zms hy of ‘Area of crosmsection of field coil=hy dy Area of copper in each field coil=5y hy dy =(9'35) But area of copper in each field coil is alao equal to 1 ay : or Ty ogmiy by dy 49°36) Copper loss in each feld coil Qral® Remi Tee te {he Typ Las mip late (937) But Let Ts 7=volume of copper in each field coil Copper loss Q7=8;! p x volume of copper. incidental hat volume . ‘This in ly proves that for @ partinler of copper, the copper lose ia From Eqns. 9°36 and 9°37, Qr=8i" p Let By hy dy +(9'38) Tn order that the temperature rise in the field coil does not exceed the specified limits, the copper loss should be equal to the permissible loss as given by Eqn. 9'33. Equating Eqns. 9°33 and 9°38, we have : 2 Laws Ar gem" p Lams By hy or im (3e on(9'99) Manf per metre height of feld windings 2 Ae wet ea (Substituting the value of 1; ay from Eqn. 9°36)‘D.C. MACHINES 541 tems 3S. Ardy (rom Eqn. 99) =f eee 2s 4 (940) a0 aaF oral] with p= 2X 10-* Q-m and gy expressed in W/m! and dy exprewed in m. Therefore, for a particular temperature rise, the mmf per metre of height of field ‘winding is proportional to under root of product of three factors : (i) qr—permissible loss per m* of ~noling surface excluding the top and the bottom surfaccs. Its value may be taken as 700 W/m!. (i) Sp—copper space factor. Its value may be as low as 0°4 for small wires increas- {ng to 0°65 for large round wires and to 0°78 for large rectangular con- luctors. dy—depth of winding. It should not exceed 40 to 50 mm otherwise the tempera- ture difference between the hot spot and outside would be very large. (i Table 9°8 gives the usual values of winding depth. Table 98, Depth of shunt field winding. The height of field winding hy can be calculated after assuming Syand gp. on AT Ax) Height of Geld re s7 oa ==(9"42) Total height of pole hat=hy-+ he-+height taken by insulation and height wasted due to curvature of yoke. ‘The height of pole shoe, he, is assumed to be 0"1 to 0°2 of height of pole, ‘The height of insulation and the space wasted because of curvature may be taken ai shou sw 0b Spring on the size of the machine. atic for Yoke ira He tan nt hepa Pre Frou or Fes ira tale ny woe eo ing omens Fut in the yobs @yeloahage co-elelast x} msful ux pr polomh 01 4. oom be Say eect lye i eal en 12 Waa? while in laminated342 ELECTRICAL MACHINE DESIGN ° Area of yoke Ay=@,/By and depth of yoke dy=Oy/Bylyt 1s (9;43) where By=flux density in yoke and Iyt=net axial length of yoke In the case of cast atee! yokes, the net axial length of yoke is equal to the actual axial Aength of yok For machines with laminated yokes the net axizl length of yoke is equal to net iron length of armature. 933, Magnetic circuit. The fundamental relationships for magnetic circuit calculations have aleady been discussed in Chapter 4. The magnetic ‘circuit for a 6 pol dic. machine is illustrated in Fig. 9°40, which shows that the magnetic circuit .per pair of poles comprises the yoke, the pole the air gap, the armature teeth and the armature core below the teeth, Mrf r-quired for air gap A7=800,000 By Ke le. (See Eqn. 4°37 page 128) The method of calculating mmf required for tapered teeth is explained in Art. 4 page 131. Mr for teeth ATi=ateX de where als=mmf per metre corresponding to flux density at $ height from narrow end and dy=depth of slot. Mrnf required for armatute core ATs=alsXle where alsmmf per metre correspond- ing to flux density in core, and Bde —de) (9°44) Jemlength of flux path in core=™ Pig. 940, Magnetic trout of d.c, macbine, ‘Mnf required for body AT'p=aty X het wrhare eneal r mace comeacdlog tus deni i pole body,D.C. MACHINES 54s ‘Monf required for yoke AT y=atyX ly here oly=mumf per metre corresponding to fux density in yoke, and Igeslength of fiux path in yokem-T(2+2 a datas) on(9'48) ‘The values of ats, sty, aty and oly are taken from B-H curves of the materials used. Total mmf per pole at no load and normal voltage AT pm AT + AM +ATe+ATy+ATy. Example 916. 4 multi-pole d.o. machine has the following dimensions Cross-section of pole body=0°08 m! 5 he 0°25 m 5 section = 106 wh men far pub in goed 9 m pale tip as aon aac tO 8 Length of fluc path in core=0'45 m (pole to pole) ; area of pole facem0'12 mt ; Length of air gopm5 mm, There are 18 slots and the width of each tooth ie 15 mm (40 ). The Length of machine Ss O88 m and Ke ratio o pole one poa ich w O07 mn tne) The Find the to gi 0.1 Wo. The relative permeabiti i and for reat ef map “seit Pot aah 6 slacking factor of 09. hata eater a4 011 xo-005 ex 10X01 9920 A. Solution, Muf required for air gap ATs=, ao ce . = has O1x025 - Mf required for pole AT y= 8 mine IG TRO TE 200 A- Flux in yoke ©=0'1/2—0°05 Wb. Length of flux path in yoke fy==0'9/2—0'45 m . - Oras _ Mf required for yoke AT =0°0SX sap sq TOT KODE TH A+ Flux in core ©=0'1/2—0°05 Wb. Length cf flux path in core l=0°45/2—0°225 m. ., 7 0225 = ‘Manf required for core AT,=0°05 T200x4nx 107 KOS 180 A. Teeth per: pole arent S 0°67 128, Flux in each tooth= T1m00125 Wh. , 40x10-* - Baa required for teeth AT sm 0°0125 % pepe ROSEN TE 200 A *. Total mmf required per pole==$320+200-+290-+-180+-1200—5190 A. os. ‘Magnetization carve (0.C.C.). ‘The emf is directly proportional to flux if nee ig kept content Tired to ctabibh Siferent Salucs of wah fax. Tt a Salues necessary to calculate the mmf per pole ° ee of whl out for differ tt th oon of ee pr gle Below ? i i i i i 1344 ‘HLECFRICAL MACHINE Datsic 935, Design of shunt Held winding. Shunt Geld windings for small machi employ coils of a few hundred turns of small section varnish covered wire. The insulate conductors are encapsuled in an epoxy resin moulding and fixed to the pole in a sing! uperation. In large machines, the field current is large and therefore rectangular conductor may be wed. With fan ventilated machines, and high speed machines, sectionalized coils may t used. With these coils, instead of having conductors in one solid mass, they are woun in setions ‘Those retions ate separated by dlatanc pieces 40 that ventilation spaces formed between them. The sectionalized coils, therefore, result in improved ventilatio conditions. ewig thtat machines, the entire winding pace spree along the height of pole is takes up b the winding while in compound machines, 80% of the wit is taken u shur field and the rest 20% by series field. ing "pace P Design Procedure, 1, Assume a suitable depth dy, for the winding from ‘fable 9'8. 2. Calculate the length of mean turn. ‘The length of mean turn it Lost 2(Ip-+b7) +26) (QA 3. In order to allow for voltage regulation, in generators asume that 15 to 20 pe cent of rated voltage is absorbed by the field rheostat, In the case field controlled moton this allowance depends upon range of speed control. ", Voltage across the shunt field winding==(0'8 to 0°85) V and voltage across eac shunt field coil a 8 ‘a 0°85) V (9°40 are as many, hunt field coils asthe number of poles and they are all connected it ss the 4, Resistance of each field coil Rye” or area of shunt field conductor aya 7 pit ATi elm (9°48 ‘Thus the area of shunt field conductor is known from Eqn. 9°48. 5. Choose a suitable cross-section for the conductor. For amall cron-section standart round wire sizes should be used as given in Chapter 17. For larger cross-sections square 01 rectangular conductors should be used. 6. Calculate the winding height. ‘The space for winding along the radial height is, Aymhet—height of shoe—insulation and clearance ‘= h—(0'1 10 0°2) Ar—(0'l to 0°15) 9 nsf 9°48, 7. ‘Nember of tums provided rat oo eof 980 ‘The space facto for wand tanat insulated oondacton OS Ulan whore d cot ft 'tre hottie of bare wed Tonaassd"conducsae respectively, (Bee pages 200 & 201). 1p He Er aD.C. MACHINES « Tn order to account for the additional space required for winding inaulation, the factor for the entire winding is assumed as Sy=0°75 (d/d,)*. The increase in Giameter liameter on account of varnish coating ou the conductors is assumed as 0 | mm. 8. Find the resistance of each coil with 7's turns and area of cross-section of conduc tors provided. Resistance of each field coil By=: 9, Find the value of the shunt field current with the above value of resistance. Field current Lys]. 10, heck for current density in the shunt field winding. Current density 8m 1j/%. ‘The value of current density in shunt field should be between 1:2 to 2° A/mm*. In case of windings with air ducts it may go upto 3°5 A/enm*, 11, Find the mmf provided ATy=1/7. Check whether the mmf provided on the shunt field is nearly equal to the vaiue required. Fits les than the required value, the depth of winding. sbould be, increned but iffit is in excess the depth should be ¢ calculations should be repeated till the value of maf provided is nearly equal tothe value required, 12, Calculate the 32 loss in each field coil. PR loss in each field coil QrmI Ry. 18. Calculate the cooling surface of the coil. ‘Cooling surface of each coil S=2Lms (ar+d)). See Fig. 3°59 page 112. 14, Assume a suitable value of cooling covefiicient from Table 3.6. (Page [11) " 0°14 to 016 ‘Cooling co-efficient c= THOT.” 15. Calculate the temperature rise of the coil. Temperature rise tam %*, (See Bgn. 352 page 16) ‘he vale of tecpeatre rin ould be wih ha ek specified. If the yémmpera- “ize rie exceeds the specified limit, sume a greater dapth, (or winding. and’ repuk the caleuaton. 9°36, Design of sertes field. The series Geld winding is wound with rectangular conductors. The conductors may be flat wound or wound on edge. The insulation between the turns of series field depends mainly upon whether the coil is fat-wound or wound on edge. In flat wound copper coils, the inter turn insulation consists of a ope Tightly’ ‘wider than the copper strip. The tape is compcaed of dry. asbestos. pay thickness of asbestos varying between 0°2 to 0'4 mm in thickness. In flat-wound Eoin which uml conde of two ornare secon, the flan error econ a wher of about 0'1 to 0'5 mm thickness, coosisting of micanite or of s gomposite material made up from asbestos paper and woven glass cloth polyester” varnish bonded and prened to tise, Innere povie the maa ination, the wie tel. conduct long with thom of shunt field are epoxide moulded or cast resin .nqulated (encapsulated! be alba peed yin fat fll ied ely fe fron 15. 28 cent of armature mmfand for normal machines it may be taben as 20 per cent. pe Manf of series field per pole £7+=(0'15—0'25) ATs. Number of series field curna Tye AP/Iy- ‘Aron of series Setd conductors as==lafte, . Tye Les ay6 ‘BLECTRICAL MACHINE DESIGN ‘The current density used for the series field bas a somewhat higher value thar that for ‘the shunt field owing to better cooling conditions. SOLVED EXAMPLES Design of field coils ‘The method for solving problems on elect iven in Art. 5°4 page 198, A few examples have alio "been given. The ‘mudont is advised to fae go cheogh the let “given there before solving problems on feld coils of dic. machines, The equations derived earlier for coils of electromagnets are valid for d.c. machine field coils In fact there is no fundamental difference between theni, Refer to Fig. 8.59 (page 112) for reactangular coils and to Fig. 5 6 (page 198) for circular coils. In the following examples, area ay bas been expresacd in mm* and the rest of the dimensions are in as. The value of .p wed is in Q/m and mm‘, While using different units proper conversions should be made, Example 917. The following particulare refer to the shunt field coil for a 440 V, 6 pole, d.c. generator : ‘Muf pet polem7000 A; depth of windingm50 mm; length of inner turnm I'L Jangth of outer turn=e1-4 m ; lois radiated from outer awrface excluding enda=.400 W/m apace factor 0°02 ; resistivity 0°02 O/m and ment, aleulate (a) the diameter of wire (b) length of coi (0) number of turne and (d) exciting ‘Ascume « vollage drap of 20 per cent of terminal voltage across the fleld regulator. Selution, Voltage across the shunt field winding=0°8 x 440—=352 V. Voltage across each field coil Zym$52/6—58°7 V. Lotly Vat TE Te Length of mean turn mae =125 w. Area of field conductor agen Tp Tat 20 KORN 08 mm, Diameter of bare-conductord=1°95 mm. ‘Number of turns Tym SRLS 5 100m PSE OOS eset 04x10" by on (8) ‘Area of outer surface excluding ends=eLs hy=1"4 Iy. Ss Permuisible loss Qym 1400 % 1°4 ym 1960 dy. Field current In Yew resv4 iy. Now — APymly’ Lye038'4 by 7y=7000 (given) or Tr=2l0fhy Ail) Equating (i) and (ii) we have MP4 1 Ayr Ew 104 18, _ fo, Number of tums in each field coil Tym1475. k toch Sl at Rwy BZ = WISXO HIS Flekd cyrrent Lym Bj/itp=58'7/\P4—473 A. Ba gett ol raha te 1240D.C. MACHINGS a the coil ia 40 ¥,, and the resistivity of rownd wire used (2 0'021 Ci/m and mm. twinding ie 35 mm approzimataly ani the lengih of mean turn is I'm. Design a coil a0 thatthe psa dasipate fe 700 Wn ofthe tla oil erfac ic. ole, ier, tp ond boli). Take the diameter of the insulated wire 0'2 mm greater than that of bare wire. Solution, Area of conductor ayn AEE Lent _ 900001021 X14 6g mm, Diameter ‘of bare conductors d= 29 mm. Diameter of insulated conductor d,==29-+0'2=3'1 mm. Space factor Sya0°75(d/,)%=—0°75(2'9/8'1)*=0'66, Total winding area Au=dyxhy=0°035 hy. 2. Total area of conductors=0°66%0°035 Ay=0'0231 hy. Winding area is also equal to Ty a/X 10+ (as ay is expressed in mm), 0281 10* Example 9°18, A shunt feld coil has to develop on mmf of 9000 4, ae Tu sae op Tyasx 0-0-0231 hy or Tym Iy=m3'5X 108 hy. eli) Total dissipating area of a coil considering all surfaces, 2 Le (hyde) m2 1°4 (By+0°035)—2°8 hy +0-098 + Permissible loss Qy=700(2'8 hy-+0'098)=1960 fy +68°6. Permissible loss Qrmel;? Rem. ae te (40x66 _ 0'36x 10# am ~Txowixrs ~— Fr (lity Equating (i) and ($i), we have, Gu 238X108 0'36x 10 1960 by+-68'6=—= a or T= F560 OOS onto) Equatnig (3) and (3) S3X10 hm pergeg oF A015 m. 2s Number of turns Tym 7g @SSAIE 38, osexton Permaimible loa Ore: =386 W. “ce Fidd current im Gntones A Example 9:19, A Sele OY de, chant genres with ol th field cotle connected ‘neta Toast oe, ata eas vation te 120K 98 met, Determine: (0) the crose-sestion ares of wire, (b) the number of turns, Otc W/m" based upon the area of the ouleide eurface and the tao ondae BLECTRICAL MACHINE DESHOW A conductor of rownd cross-section ia uatd. The resitivity ia 0°02 O/m ond mot ond the inscationomthcoanen tnereavea, the diameter by O°2 mm. Allow a volag drop gavin he field regulator. Solution, Voltage across the shunt field winding=500—50—480 V. Voltage across each field coil Hy=450/8—5625 V. Length of mean turn Zm=2(Ly-+b)+dafe2(200+120)-+4%25—=740 mm=0'74 m, (@) Area of shunt field conductor ayn Alig mt Lt _ 5000 26 02 X074 0a32 mt (0) Diameter of bare conductor d=13 mm. Diameter of insulated conductor d,=#1°30+0'l=1°4 mm. Space factor Sy=0°75 (dfd;)¥—=0°75(1°3/1 4)"= 065 Space for conductors 0'65X 120%25—1950 mu‘. 2. Number of turns Ty= 1950/1 ‘321480 Resnik lcm MODAEORAE =166 0. Shunt field current Ime Zom3'99 A, ss Mumf provided ATy=3 99x 1480=5017 A. (0) BPR loss in each Geld coil Qrm Is Ry=(3'39)*x 166—190°8 W. Length of outer turn Lys Ler+2dym69044x 25790 mm=0 79 m. Cooling area of outer cylindrical surface, and the top and the bottom surfaces B= Ly +2 Lua dy (Sce Fig. 8 59 page 112) =0°79.x0 12+2%0 74X0 025—0'182 m*, Dissipation gyeQy/S=190'8/0"1S2—1445 W/m?, noite 910, A 0p. dre A807, 600 rpm shunt mor wave wound ith 770 conduotore, The leakage fartor for the poles is 12. ‘The oles fork of drelar in erovosecions ‘he tld col art 70-0 Ih and produce on im of 10,000 4 role. The flus dansity in the poles ia 1'6 Wo/m* Caloulate the (a) diameter of pole, (b) diameter of fleld wire, (c) length of fald oil, (a) turna per pole and, (0) fald current, . Keep 20% of voltage applied to shunt fald coil in reserve for sneed control, Ascume that the thickness of insulation over wires is C155 mm, permlesible lose is 1600 W/m* of ezternal cylindrical surface. Resistivity of copper ie 0 02 O/m ond mm’. olution, (0) Speed n= 10 rp ‘ Exo _ 40x: “+ Unefal fax per pole == anh nea “82107 Flux in pole body @,=ileakage factor x useful fux per pole’ + mo 12 812% 10-0 37°¢x 107? Wh, ss Area of each pole Ay=@p/By=37°4X 107/1°5en25 x 10% mt, or diameter of each pole Dyn Sx25x107)" 014m,‘D.C. MACHINES: we (y Length of mean turn Lmi=m(Dp-+4/)=n(0'18-+0°07)=0°785 m. Voltage across each shunt field coil Ey=0'8 x 480/4=96 V. = Area of conductor em Tt 0000x002 x0'785 =1°64 mm, Diometer of bare conductor on 45, mm aed diameter of insulated conductor 4, 1°45+0:25—01°70 mm. (0) and (d) Outer diamter of the feld coil 18+2X0'07=20'92 m, Length of outer turn Lye 0°32 “0 m Outer cylindrical surface=hy Lq=hyX 1=hy. , Permissible loss Qy-= 1600 dy. Field current p= (y/ Hy= 1600 hy/96=1 6 7 hy. Now, field mmf=l/2/=16 66 hyT/=10(00 (given) 2, hyPy='P00-m 00, Space factor Sy==0 75 (d,d,)*=0°75(1°45/1°7)*=0) 546 Spr dy 108 yx 0107 108 aot 164 From (é) and (ii), we have + Ty#=600 x 23'3 x 10* or 7773740 From (i), height of field winding 4y=600/3740=0'16 ta. (0) Resistance of field coil ym 3740 x 22 XO a 359 g, =23°3 x 18 hy Field current [y= £//Ry=96/35'8=2°68 A. Example 921, Coloulaie the size of conductor and number of turns for the flelé colt ofa bol 4 460, dc. ahunt motor. The coil is to aupply an mmf of 4000 A at working tem the length of inside turn is 0°74m, the length available for uinding is O'lam, the for the winding is 0.52, and the permissible diesipation from caternal owrface mfoa foiw, olution should ot be altempled by ‘aseuming a numerical alee for winding depth, Rata of conductors ie 0 02 Q/m and mmt. Keep 15% of applied voltage as reserve for speed control. Golution. "Voltage across shunt fi.ld winding =0'85 x 469=390 V. Voltage across each field coil Zy=390/6—65 V. Let the depth of wining be dy <. Length of mean turn LmimZi+4 dym0'74+4 dy, and length of outer turn Ly =Lei-+2 dym0-74-+8 dy. External dissipating surface of each coil excluding top and bottom surface Bem Ly hymn (07448 dy) X 0°13 8'0961 +1'04 dy + Los dimipated Qy=1200(0°0950-+ 1°04 &) 115 +1248 dy ‘Also rm Bere tp TLE Hat IUD tt ’ -k x 4000 x 002007444 ann (59 24320 dy) wits) where ay is exptemwed in mm’. ‘Total aren of conductors= Sf hy dy=0'52X0'15 dpme00676 dy salle) ‘Bu, tal conductor area=Ty 07x 10MLECTRICAL MACHINE DESIGN 0°0676"dyx 10° sao) Area of each conductor 7 Substituting this, we have value in (sé) low dissipated Qy=(592+320 dq EE ae = REO ex 4000 aee(vi) Equating (ii) and (oi), 115+1248 dyn ESA Depth of winding dy 00273 m=27'S mm. From (ii) loss dissipated Qr=115+1248 x 0°0278— 149 W. Length of mean turn Lmi=0°74+2 dpmO'74-42X0'0279—20°795 mm. Area of field winding conductor ay=IyTy Beet HOOK OKO TS oy 078 mm* From (oi), number of Seld turns 7yem-2 0876-41 10" 10° 1887. Example 9°22, A rectangular fleld cvil is to produce an mmf of 7500 A when dissipating 220 W at atemperature of 60°C. The inner dimensions of coil are : length=0'24 m, width 0:10 mand height=0'15 m. The heat dissipation ie 30 W/m*—" the outer aurfuce, neglecting top and bottom ourfaces of coil. Temperature of ambient air ie 20°0. olcatate the thickness of the coil, the apace factor and the current density. Resistivity ie 0°02 Q/m and Length of inner turn Ly 2\0°24+0'10)=0°68 m. Length of mean turn=0 68+4 dy. Length of outer turn Ly=0'68+8 cy ‘Temperature rise @=60—20= 40°C. Loss dissipated per unit surface grm30 x 40=1200 W/m* Pat based upon outer surface excluding ends. Permissible loss (y=220 W. . Outer surface area required=220/1200=—0 1885 m4 oi) Outer surface area excluding endse= Lyhy=(0'68-+8 dy) x0°15 alld) “From (é) and we have : (0°68-+8 dy) X0'15=0'1835 or depth of winding d= 0°0682 m et 68 mm Length of mean turn Imi=0'6B+4 dyem0'68+-4x0'068—0'982 m, “Perminible ous QrmtsRemt? TA Le wcryny, 2.» ta Substituting the values for 1/1, Ime and p in the above exprenion r= ro000 x} xouaxogszeniss suit) But Jy/ay is the current density in A/mm* : J 220 , ‘. Current density whats =1°65-A/oam?. ‘Total area of conductors==TipayX 10-* . atl ATs, 7000 4 5 10% me ASE 10 oe DE x 1000404 mtD.C. MACHINES Sst Total area for winding de=shyX dymm0"15 X 0°068=0'0102 m* total area of conductors_ 0.00424 _ 941g total area of winding ~ O'vl0z . Example 923. 4 6 pole, 220 V, 200 kW dynamo isto be leort compounded. The mmf required per pole ia 7500 A at no load and 9000 A at full load. Caloulate the number of aeréce turns per pole, and show a suitable arrangement for these turns, The hight of winding 0°16 m, the field coile are 50 mm thick and fit around a! square pole of 0°23 m aide Calculate the diameter of shunt field conductor. If snaulation increasca the diameter by 0'1 mm, calow- late aleo the shunt feid current, Resistivity ie 0°02 Q/m and mm, Keep 10% of the voltage across the ahunt field in reserve. Solution. The mmf required at no load is developed by the shunt field while the extra mmf required at full load is developed by the series field. <. Manf of shunt field winding=7500 A and mmf of series field winding ATs=9000—7500=1500 A. 200% 1000 oo 4, Assuming the generator to be short shunt, Current thiough series field = 11-909 A, Series field turns per pole T+=1500/909=."65, This is a mixed number. ‘Tne umber of turns should be an integer. Divide the series field in three parallel paths. Current per parallel path=909/3=303 A, 1. Series field turns per polo=1500/303a05, ‘Thus there are 5 turns connected in 3 parallel paths. Two parallel paths have two turns cach while the third parallel path has one turn. The path with one turn has a resistor connected in series with the tura, the resistor has resistance equal to the resistance of each turn. Shunt Field Length mean tura Lmi=2(0'23-+0'23)+4x0'05=1°12 m. Voliage across shunt field winding=0'S x220=198 V. Voltage across each field coil By=198/6—38 V, Area of shunt field conductor aymATeg mt 7800x002 112 =5-09 mm, Diameter of bare conductor 6=2'54 mm jiameter of insulated conductor d,=2'54+-0'1—=2'64 mm. ‘Assume that the winding height taken by shunt field is 80 per cent of the total winds ing height available, the rest 20 per cent is taken by series field. Height of shunt field winding Ay=0°8x0'15=0°12 m, 254)" Space factor 5)=0.75 & =07694 0604x0'15 0°05 Space factor Sym Line current at full load i=' + Number of turns T= 1022 Now, Bm XSAN 5.0 and Yai arss A. ‘Munf provided by shunt fieki=7°33 x 1022007496 A,Sez . ‘BLACTRICAL MACHINE DESIGN COMMUTATION ¥ 37, Commutation phenomenen, When the commutator segments to which the armature coils are connected pass under the brushes, the armature coils are succesively transferred from. one parallel path, in which the current has one direction to an in Parallel path, in which the current has the opposite direction. During this period, the Polls are short-circuited ‘by the brush and the current. must be ‘reduced from. its original value to zero and then built up to an equal value in the opposite direction. ‘This process ieknown a1 commulation and ‘the time “during which it takes place i called the tim of commutation, ‘One of the most important limiting factors on satisfactory operation of a d.c. machine is proper commutation. Good commutation conditions require the transfer of necessary armature current through the brush contact at the ccmimutator Without sparking and without excessive local losses and heating of brushes and the commutator. Sparking at the brushes results in destructive blackening, pitting and wear of brushes as well as the commutator. A worsening of these conditions may ‘lead to burning of copper and carbon. The reatons for bad commutation may be both electrical and mechanical in nature. The former enditions are seriouly influenced by the armature reaction and the armature leakage ux. Consider the case of an idealized winding with single-turn full pitch coils and brush with equal to the width of a commutator segment. Fig. 941 shows the conditions in a particular coil (i.e. coil 1 shown with heavy line) as the commutator segments to which its two Coll sty “lz Coil ty — 2lz o . ® @ ae Fig. 9°41. Coll undergoing commutation. ends are connected pass under a brush through which a constant current Is flows. ‘Initially é.2. just before the commutation of the coil | is in, the coll current is +lem Dol as dows ba Fig. 941 (a). (The coll current eerla), * Finally i.e. just after the commutation of coil 1 is to:end, the current is —Jomlo/2 as shown in Fig 9'41 (o). Fig. 9°41 (6) depicts conditions dering the process of commutation.D.C. MACHINGS 588 Therefore, during the time of commutation the curfent change from + to —Is and the total change in current is 2 Jp-e2 Ie/a. Thestime of commutation tin this caso, is the interval between the time when the leading edge of the brush just touches segment 2 and the time when the trailing edge of Iprush just leaves aegraent If we neglect the thickness of the mica strip, the cime of commutation of one coil is given by : tombi/Vo. If the thickness of mica strip is considered to=e(4s—H)/Po where Vemperipheral speed of commutator, m/s ; tomthickness of the brush, m; ‘-=thickness of mica strip, m, If we assume that the thickness f of the brush is equal to pitch of a comunutator seg- ment, then the brush can short cieuit one coil ata time, Just at the beginning of short circust, the brush covers one complete segment. [he average current density in the brush is therefore given by: Bnan==2 Le] Av=2 Lolads where Ao is the area of the brush. 938, Form of current in coil uadergoing commutation. During the commu- sation the current in the coil is aot constant but is changing. Let us denote it by 4, being ponitive in the direction shown in Fig. 9°42, The form of the current during commutation will depend upon the resistance of and the emfs induced in the commutation circuit, The resistance in the circuit consists of : i) the resistances r, and r, of the two contact areas between the brush and the two commutator segments, Gi) the resistance Ry of each riser, (ii) the resistance Re of the coil. ‘The ems induced in the coil undergoing commutation are the : ii) emf of self induction or latically induced emf. The current in the coil changes from -++Js to ~/eand the coil has a selt-inductace owing to slot leakage and overhang leakage flux. Therefore, a voltage is induced in the coil due to change of lux linkeges. T'su ta also known as the reactance voltage. In d.c. machines, there may be several coil sides per slot. The statically induced emfs may be due to self-inductance.of a coil side and mutual inductance between coil sides in the same slot. (8) dynamically induced emf or rotational emf. ‘The source of production of rotational emfs are explained below # +) If the brushes are left in the geometric neutral position, the armature reaction pro duces.a field there, when the machine isloaded. The armature cols eu thrvagh this field and a rotational emf is produced in them. (®) If the brushes sre given a shift, the armature coils actively cut through the field of the pole towards which the ‘brushes are shifted and thus there is a rotational emf produced in them, 0 view of the resistances and the onal listed, the commutation process becomes highly ths onload ent ed the ronsanes sate col uolergung soasasts in conf and the reagcawoe d couimuta- tion are Pape ‘Under this condition, a rm do be, bee govenct resistance main. factor gurrent seven comm: ease * “fa known an PeatstamesBLECTRICAL MACHINE DESIGN Referring to Fig. 9°42 which represents the position of the brush at a time ¢ after the commutation begins, we obtain the following relations. heli and i= let. ‘The thicknesses of the portio: leading edge : t=t . t/te, and trailing edge : toy =te (1 ~ t/te). Let Rp be the total contact resistance of brush and As, and Ayy be the areas of contact of the brush at the entering an | leaving edges respectively. Resistances of two contact areas are : to Be, fn te trailing edge : ra=Bs. = . t-4r contact with the two brushes are + ' Ay leading edge: rym. mR. On the assumption that no emfs are present in the short circuit paths, the sum of all voltage drops, according to Kirchoff’s law, must be equal to zero. Thus, iReti( Retr) —i (Retr) =0 where Re and Ry are resistances of coil and risers respectively. Substituting the values of iy, r and rg in the above relationship. nt( et \ Bet ie) (te \( Betts mo Solving the above equation we have : = Feb t a 7 where © Kym (Re-+2R+)/2Ro. However, the values of resistance: of coil (He) and risers (Re) are quite small compared with the brush contact resistance Ry and therefore, K,=0. Hence, whire resistances of coil and sisers are negligible and the rotational emf and the reactance voltage neglected, the current in the coil und:rguing commutation is given by ints(1-% mle (1%) (9 52) ‘Therefore, the curve for é over the time period to is linear as shown in Fig, 9°43, Hence we codclude that if the brush contact resistance is made very large, the current inthe coll undergoing commutation follows a linearlaw or a “‘siraight line commutation” results. ‘Therefore, if brushes of high contact ressitance are used and the emf in the coil under evltig commutation is zero, a straight line commutation is obtained: ‘Let us examine the value of current density in the brush at any time ¢, ‘Current at the leading edge ° (1 2tadmels « Dt. Area of brush carrying this current, Ajj= Ay t/to== As . t/t>. ‘se Opsrent density in the leading edge of the brush a rer ay Current at the trailing edge dgmelet ime Let dh --28fts) —2Is (tft). 51)0.¢. MACHINES 855 rata tol | -~ t/t) ‘Area of brush carrying this current i= Ay “ly Current | density | Fylav) ot Fig 943. Straight line commutation, The cucrent densities at any instant in both leading and traili equal to the average current density leading and trailing edges of the brush are Resistance commutation is used in small machines designed without interpoles. Some modern small machines employ face plate commutators as thown in Fig. 9°44, These commutators use sector shay ed commmutators which can These i 2S volt, and. therefore, Fig. 9:44. Feoe piate commutator, Produce elcanve dntceaton ocliions fi wal tachi) yo586 ELECTRICAL MACHINE DESION The rate of change of areas of leading and trai tienzed in order to give a uniform current density over the brush. ing edges are optimized in 9382, Retarded commutation. The reactance voltage produced in the coil due to the reversal of the current must always be present because of the inductance of coil. The reactance voltage is of such a nature that it opposes the change which produces it. The change which produces the reactance voltage is the reversal of current and therefore, it must oppose the reversal of current. Thus the nature of the reactance voltage is to retard or delay conimutation. ‘As discussed in Art. 9°18 page 513 the armature reaction field for a generator has polarity main of pole which the coil has just left behind. Due to rotation of the coil in this field an ‘emf in generated which tries to maintain the current of the type flowing under the pole which ithas left. For example, suppote a cuil crosse the geometric neutral leaving behind a N pole and comes under a 8 pole. The armature reaction produces in it an emf corresponding to N pole even beyond the geometrical neutral axis Thus the coil trics to maintain current corresponding to a N pole even when it has crossed the geometrical neutral axis. However, the coil should carry current corresponding to § pole after crossing the geometrical neutral axis. Therefore, the tendency of the armature reaction is to delay commutation. +h] i 5 3 Tz Traitin edge? Pig 9°45. Retarded commutation. Fig. 9°46. Variation of coil current and curreat ‘denisty 20 brush with retarded commutation. ‘Thus, both the reactance voltage and the rutational emf due to the armature reaction field delay the commutation and lead to a current variation of the type shown in Fig. 9°45, The current ratio i/Ze is plotted against relative time t/t. Gurrent density at the leading édge of the brush y=" 2— m- Aa By 4° 1 i, or Bley) "he We “Glas “Tee + tan ay, s+, Current density at the leading edge of brash 8,=8)(o») x ¢ tan 8, +(9 53) + Similarly, current density at trailing edge of brush Syms (00) Xdtan ag (9°54). Examining thé curve for retanled commutation, we find that ag is greater than «,. ‘This means that the current density in the trailing edge of brush is haa that fa ch(D.C. MACHINES: 37 leading cdge (Fig. 9°46). This current ts ‘may assume a very bigh valuc resulting in glowing of the brush, which would lead to high commutator temperaturcs, rapid deteriora. tion of the brushes and excessive brush contact loss. ‘The commutation may be delayed tothe extent as shown in Fig. 9°47, In such a completed before the current can reach its final value and therefore the current has to jump through air in the form of a spark. Sparking damages the commutator leading to still greater brush wear. 9383, Accelearted commutation, If the brushes of a generator are shifted beyond the magnetic neutral position, the coil undergoing commutation actively cuts through the fringe of the pole towards which it is moving, the dynamic emf produced is of such a nature at to help in the reversa! of current or ocslerate commutation. brush shift is given to the brush erated commutation would rer, ig. 940 anaes the curve for accelerated commutation. Leading edge: railing Trailin, edge ‘edge . 9°47. Retarded z Fig. ot. Variation of coil Fig. 9 commutation and sparking. io ation current and current Hts cae that oy is greter than ty, Therefor, the curent danstyin the lending edge of the brush is greater than that in the trailing edge (see Eqns 9°58 and Acute case the, current, density in leading edge may becoune very excenive giving rie to slowing of truth, which would lead to high commutator temperatures, rapid sega tien he common high wal accelerated the coil current has a value diferent from I, even before the commutation starts. ‘Thus both delayed and accelerated commutation conditions are bad because both of ‘ham rerlt in non-uniform eurent density over the brash with conmquent deletarieut “$304, Slawseldal commtation, From the shove, dicosion, we quer th with deleyed' or retarded commutation, the current density is exe. ceive of the while it ts email ot the leading “with sessleraich somenahchion, crvowt denolg: te eotootee Sots lending alps ond calls the hing ees oe$88 . ELECTRICAL MACHINE DEON ‘Thus a consideration of the two forms would indicate that it is desirable to retard the commutation during the first moments and to accelerate it at the later stage commutation. ‘This is known as sinusoidal commutation, Commutation is thus retarded in the first half of time f ; it becomes normal at t=elo/2 and is then accelerated during second half of ty. DESIGN OF INTERPOLES 9-39, Interpoles. It is clear from above that if the resultant emf in the coil undergoing commutation is zero, and if the resistance of brush contacts is appreciably higher than that of coil and risers, a straight line commutation results which is ideal in d.c. machines. However, in actual practice, emfs are produced in the short-circuited coil. These ‘emfs may delay or accelerate the commutation. For example, the reactance voltage and the rotational voliage produced on account of cross magnetizing armature tend to retard the commutation. In order to aid the commutation process, another rotational voltage is produced in the short-circuited coil which opposes tne reactance voltage. The general Principle of producing in the coil undergoing commutation a rotational voltage which is tual to and oppotits in sign to reactance voltags, a principle called voltage commutation is uted in all modern dc. machines. The appropriate field required at the geometric neutral axis to generate the neutralizing rotational voltage is produced by interpolee or commutating The interpoles are the smaller poles placed in between the main poles as shown in Fig 948. The polarity of the interpole must be that of the main pole just ahead for a generator and just behind it for a motor. The winding of the interpole must produce an mmf which is sufficient to neutralize the cross magnetizing armature mmf at the interpolar axis and enough more to produce the flux density required to generate rotational voltage in the coil undergoing commutation to cancel the reactance voltage. ‘The mmf required for interpoles should be correctly estimated. If it is too weak, it leads to retarded commutation ; and if it is too strong, it leads to accelerated commutation. Since both the armature reaction and reactance voltage are proportional to armature current, the interpole winding should be connected in series with the armature for production of neutralizing effect at all conditions of load. In order to preserve linearity, the interpoles should be so designed that they work at low saturation levels. We have seen above, that with the use of interpoles, the resultant emf in the coil undergoing commutation is reduced to z2ro and hence if brushes with high contact. resistance are used a straight line commutation is achieved, Therefore, by the use of interpoles or commutating poles, a sparkles commutation is secured over a wide range. 94. Time of commutation, The time of commutation for a tingle coil in an idealised case where the width of brush is equal to pitch of commutator segments is t=hy/V. oF tv=(ts—4Vu if the thickness of insulation, t¢ between the sectors is'considered. However, ia actual tice, the commutation is a much more complicated process and therefore the Getermsation of effecties time of comarutation ra, during which Induced emf are produced in a coil as a result of current changes in associated coils is far more involved than that which appears at the first sight on account of the following reasons : : (0) ‘The width of brushes ie not equal to the width of coteraee segments, brushes normally span 2 to 4 commutator segments (not necesparily a whole muaber) fhe verah that commtation takes place in more than obe coll davleaneousy. (Wi) ‘There are many coll sides to a slot belonging to different col and thaeafore, tn fo tof wl Lad Aa he eal sidr Haced fs fee mame a ee taker m taran cot. on Socount of change in ctbut collie in the eame dot and this i?