Electrical Machine

Design & Maintenance

Dr Suhail Khokhar
Associate Professor
Electrical Engineering Department
QUEST Nawabshah
1
 Lecture 1 (21.10.2019)
Introduction to Syllabus

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 Syllabus
PART 1 Machine Design
1. Design Problem
Basic consideration, Specific loads and output equations, Limitations, Design and constructional features of rotating
machine, Basic principles of electrical machines and Basic machine forms
2. Materials & Electrical Machines
Electrical conducting materials, Magnetic materials, Insulting materials, Classes and Testing of insulating materials
3. Heating, Cooling and Ventilation of Electrical Machines
Modes of heat transfer, The heat flow problems, Temperature rise-time relation, Duty cycles, Enclosures, Cooling and
ventilation of rotating electrical machine, Limits of temperature rise and Measurement of temperature rise
4. Transformer
Transformer types, Standard conductors, Cooling, Output equation, Design of core section, Design of insulation and
Design of tanks with tubes
5. Three-phase and Single-phase Induction Motor
Design, Output equation, Calculation of man dimensions, Specifications, Output equation, Stator design and Rotor
design
6. Synchronous Machines
Design, Main dimensions and Design of salient pole rotor
7. Mechanical Design
Design of shaft, Bearings, mechanical strength of rotors and Design of fan
PART 2 Installation, Maintenance and Troubleshooting of Electrical Machines
Safety and security consideration, Troubleshooting and emergency repairs, installation, commissioning, testing,
maintenance and trouble shooting of (i) Transformers and (ii) Induction motors and (iii) AC generators.

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 RECOMMENDED BOOKS

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 Important Note

The case studies on “Electrical machines design and

Maintenance” will be submitted by a group of 5 students for
sessional evaluation.

(Two weeks before the end of the semester)

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 List of Projects
1. Design of Power Transformer
2. Design of Distribution Transformer
3. Design of separately excited DC machine
4. Design of self excited DC machine
5. Design of single-phase split-phase induction motor
6. Design of single-phase capacitor start induction motor
7. Design of single-phase shaded-pole induction motor
8. Design of three-phase slip ring induction motor
9. Design of three-phase Squirrel cage induction motor
10. Design of non-salient pole generator
11. Design of Salient pole generator

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 List of Projects
12. Preventive maintenance of Distribution Transformer
13. Preventive maintenance of power transformer
14. Troubleshooting of transformers
15. Troubleshooting of Generators
16. Cooling of transformers
17. Cooling of rotary machines
18. Installation and commissioning of Transformers
19. Installation and Commissioning of Alternators
20. Testing of Transformers
21. Testing of three-phase induction Motors
22. Testing of Synchronous Machines

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 Course Learning Outcomes
1. Explain the related circuits and design parameters of electrical
machines.

2. Analyze the equations related to electrical machines design.

3. Apply techniques to meet requirement of maintenance and

troubleshooting of machines.

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 Program Learning Outcomes
1. Engineering Knowledge 7. Environment and Sustainability
2. Problem Analysis 8. Ethics
3. Design/Development of Solutions 9. Individual and Team Work
4. Investigation 10.Communication
5. Modern Tool Usage 11.Project Management
6. The Engineer and Society 12.Lifelong Learning

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 Lecture 2 (23.10.2019)
Basic consideration
 Electrical Machines and Applications

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 Chapter 1
Design Problem
 Basic consideration
 Specific loads and output equations
 Limitations
 Design and constructional features of rotating machine
 Basic principles of electrical machines
 Basic machine forms

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 Electrical Machines and Applications
 Electrical machines, as the main drive sources, have been widely employed in
industry, agriculture, defense, community facilities, domestic appliance and
electronic products, etc.
 Electrical machines consume about 46% of total electricity generated worldwide
which is the largest portion of electricity use up to now.
 Therefore, motor energy efficiency is crucial for the energy conservation,
environment protection, and global sustainable development.
 Consequentially, high-efficiency motors will dominate the market development of
electrical machines worldwide.
 Besides the energy efficiency, there are many other specifications and/or
requirements for the design and optimization of electrical machines, such as
torque, power density, volume and weight.
 Thus, all performance specifications and requirements including energy efficiency
are vital for the application of electrical machines.

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 Lecture 3 (24.10.2019)
Basic consideration
 What is Design?

 Aim of Design

 Design and constructional features of a rotating machine

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 What is Design?
 The creative translation of a concept into a reality.
 The application of science, technology and invention to the realization of a machine to
perform specified functions with optimum economy and efficiency.
 The design activities in a large-scale manufacturing process include the balanced
consideration of the following.
1. Basics: Previous experience and new ideas; research into extension of technology of
materials, stresses and limits; manufacturing and transport facilities; ergonomics,
environmental effects, aesthetics, safety, reliability, maintenance; economics and cost
analysis.
2. Communication: Transfer of design to factory floor (drawings, instructions, processes,
numerical and automatic methods); job-flow, critical path, timing, delivery date.
3. Specification: Customer's requirements; standards, codes; interpretation of specification,
subdivision into specialist design areas, co-ordination.

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 What is Design?
4. Information: Data sources (previous contracts, technical journals, research
reports); ad-hoc research and development.
5. Design Team: Allocation of tasks; technical design analyses; group design,
computation; synthesis of group designs, matching and compatibility, prediction of
performance, achievement of specification and guarantees.
6. Optimization: An optimum solution can be so only in relation to specific
objectives, but the choice of these depends on what is meant by optimization. It
may not be merely 'cost reduction', but may involve a quantitative appreciation of
all the criteria that identify the best design for a given duty. A single criterion, such
as minimum mass or minimum manufacturing cost, might be readily definable;
more often the weighted combination of several conflicting requirements is the
determining factor. Such formulations are inherently less amenable to
quantization than are analyses of technical performance.

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 Aim of Design
 Aim of design is to determine the dimensions of each part of the machine, the
material specification, prepare the drawings and furnish to manufacturing units.

 Design has to be carried out keeping in view the optimizing of the cost, volume and
weight and at the same time achieving the desired performance as per
specification.

 Knowledge of latest technological trends to supply a competitive product is must.

 Design should conform to stipulations specified by International/National

standards.

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 Aim of Design
 Design is the most important activity. The designer should be familiar with the
following aspects:
a) Thorough knowledge of international/national standards.
b) Properties of good electrical materials (like copper), magnetic materials (like
silicon steels), insulating materials (like Epoxy, mica), mechanical and
metallurgical properties of all types of steel.
c) Governing laws of electrical circuits.
d) Laws of heat transfer.
e) Prices of materials used, foreign exchange rates, types of duties levied on
products.
f) Labour rates of both skilled and unskilled labour
g) Knowledge of competitor's products.

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 Design and constructional features of a rotating machine
 Specification: rating, standards, guarantees, loadings, frame size, starting,
efficiency, temperature-rise.
 Performance: starting torque, transient behaviour, system considerations,
short-circuit forces, load loss, optimization.
 Manufacture: materials handling, works practice, works processes,
available skills, transportation to site.

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 Design and constructional features of a rotating machine
1) Windings: type, connection, conductors, turns, transposition, bracing, current
density, resistance, eddy-currents, loss, cooling, leakage inductance,
insulation, connections, commutator / slip-rings, mass.
2) Slots and Teeth: dimensions, insulation, flux density, core loss, mechanical forces,
wedges.
3) Cores: material, stamping, clamping, insulation, mounting, dimensions, flux
density, core loss, mass.
4) Frame: size, stiffness, vibration, fixing, enclosure, distortion, expansion, brush
gear, mass.
5) Air gap: length, gap factor, flux distribution, space harmonics, clearance, magnetic
pull, noise.
6) Bearings: type, loading, loss, cooling, lubrication.
7) Shaft: size, stiffness, deflection, critical speed.
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