DIRE DAWA UNIVERSITY

TECHNOLOGY INSTITUTE
Masters of Power Electronics and Electrical Derives
Assignment of Electrical machine about design principles of
Cylindrical rotor Synchronous machine
GROUP 3
Name ID No
1.Abas Hoshi……………………………………………….SCS 0015/12
2.Adem Nasir………………………………………………..
3.Endris Mohammed……………………………………… SCS 0016/12
4.Girma W/Gebriel…………………………………………..

SUBMITED TO DR ING.GETACHEWU BIRU

DIRE DAWA,ETHIOPIA
SUBMITED DATE MARCH 2012 E.C

Contents Page no
CHAPTER ONE...........................................................................................................................................2
 Introduction...........................................................................................................................................2
1.1 Basic principles of synchronous machine......................................................................................3
1.2 Construction of synchronous Machine...........................................................................................4
1.3 Operation of Synchronous Machine................................................................................................6
1.4 Armature Windings of Synchronous machine...............................................................................7
CHAPTER TWO..........................................................................................................................................8
2.1 Principles of non-salient pole synchronous machine design.......................................................8
2.1.1 Design of Stator Parts...............................................................................................................8
2.1.1.1 Output equation.....................................................................................................................8
2.1.1.2 Short Circuit Ratio..............................................................................................................10
2.1.1.3 Length of the air gap............................................................................................................10
2.1.1.4 Selection of number of slots:...............................................................................................11
2.1.1.5 Turns per Phase:..................................................................................................................12
2.1.1.6 Conductor selection:............................................................................................................12
2.1.1.7 Stator slot dimensions.........................................................................................................13
2.1.2 Design of field system.................................................................................................................14
2.1.2.1 Selection of rotor slots:........................................................................................................15
2.1.2.2 Design of rotor winding.......................................................................................................15

CHAPTER ONE
Introduction
The machine which produces 3-phase power from mechanical power is called an
alternator or synchronous machine (Synchronous generator). Alternators are the
primary source of all the electrical energy we consume. These machines are the largest
energy converters found in the world. They convert mechanical energy into AC energy

Design Principle of non-salient pole synchronous machine 1

Synchronous machine constitutes of both synchronous motors as well as synchronous
generators .
asynchronous machine is an AC Machine whose satisfactory operation depends up on the
maintenance of the following relationship.
120 f
Ns=
p
PNS
f=
120
Where Ns=synchronous speed in rpm
F is the supply frequency
P is the number of poles
Synchronous machines are AC Machines having the field circuit excited by external dc
source and the armature circuit with three phase balanced winding excited by an AC
Source. The armature circuit forms the stator of the synchronous machine and the field
circuit constitutes the rotor of the machine. How ever for low power synchronous
machine ,the arrangement similar to DC Machine can also be used with the field on the
stator side and the armature of the rotor side.
Synchronous machine is classified as

If the synchronous machine works as a motor fails to maintain the average speed(Ns) the
machines will not develop sufficient torque to maintain its rotation and will stop. Then the
motor is said to be pulled out of step.

When the synchronous machine is operating as generator ,it has to run at fixed speed
called synchronous speed to generate the power at a particular frequency.

Design Principle of non-salient pole synchronous machine 2

 1.1 Basic principles of synchronous machine
Asynchronous machine is just an electrical machine an electromechanical transducer
which converts mechanical energy in to electrical energy or vise verse. The fundamental
phenomena or low which makes this conversion possible are known as the law of
electromagnetic induction and law of interaction.

I. Law of electro-magnetic induction

This law is also called faraday’s first law of electromechanical induction. This law relates to
the production of emf (emf is induced in a conductor whenever it cuts across the magnetic
field.

II. law of interaction

This law related to the production of force or torque I.e. whenever a current carrying
conductor is placed in the magnetic field ,by the interaction of the magnetic field produced
by the current carrying conductor and the main field, force is exerted on the conductor
producing torque.

Design Principle of non-salient pole synchronous machine 3

 1.2 Construction of synchronous Machine
Asynchronous machine has 3,-phase winding on the stator and a d.c. field winding on the
rotor

Stator is the stationary part of the machine and is built up of sheet-steel laminations
having slots on its inner periphery. A 3-phase winding is placed in these slots and serves as
the armature winding of the Synchronous machine . The armature winding is always
connected in star and the neutral is connected to ground Stator .

The rotor carries a field winding which is supplied with direct current through two slip
rings by a separate d.c. source. This d.c. source (called exciter) is generally a small d.c.
shunt or compound generator mounted on the shaft of the alternator. Rotor construction is
of two types, namely

1. Salient pole rotor

2. non-Salient pole rotors

In salient pole type of synchronous machine rotor consist of large number of projected
poles (salient poles) mounted on a magnetic wheel. The projected poles are made up from
laminations of steel. The rotor winding is provided on these poles and it is supported by
pole shoes.

 Salient pole rotors have large diameter and shorter axial length.

Design Principle of non-salient pole synchronous machine 4

  They are generally used in lower speed electrical machines, say 100 RPM to 1500
RPM.
 As the rotor speed is lower, a greater number of poles are required to attain the
required frequency. (Ns = 120f / P   therefore, f = Ns*p/120   i.e. frequency is
proportional to number of poles). Typically, number of salient poles is between 4 to
60.
 Flux distribution is relatively poor than non-salient pole rotor, hence the generated
emf waveform is not as good as cylindrical rotor.
 Salient pole rotors generally need damper windings to prevent rotor oscillations
during operation.

Salient pole synchronous generators are mostly used in hydro power plants.

II.Non salient pole(cylindrical rotor) synchronous machines

 Non-salient pole rotors are cylindrical in shape having parallel slots on it to
place rotor windings. It is made up of solid steel. Sometimes, they are also called as
drum rotor.

Design Principle of non-salient pole synchronous machine 5

  They are smaller in diameter but having longer axial length.
 Cylindrical rotors are used in high speed electrical machines, usually 1500 RPM to
3000 RPM.
 Winding loss as well as noise is less as compared to salient pole rotors.
 Their construction is robust as compared to salient pole rotors.
 Number of poles is usually 2 or 4.
 Damper windings are not needed in non-salient pole rotors.
 Flux distribution is sinusoidal and hence gives better emf waveform.
 Non-salient pole rotors are used in  nuclear, gas and thermal power plants.

1.3 Operation of Synchronous Machine

The rotor winding is energized from the d.c. exciter and alternate N and S poles are
developed on the rotor. When the rotor is rotated in anti-clockwise direction by a prime
mover, the stator or armature conductors are cut by the magnetic flux of rotor poles.
Consequently, e.m.f. is induced in the armature conductors due to electromagnetic
induction. The induced e.m.f. is alternating since N and S poles of rotor alternately pass the
armature conductors. The direction of induced e.m.f. can be found by Fleming’s right hand
rule and frequency is given by

f =P∗Ns/120

Design Principle of non-salient pole synchronous machine 6

where N = speed of rotor in r.p.m. P = number of rotor poles

The magnitude of the voltage induced in each phase depends upon the rotor flux, the
number and position of the conductors in the phase and the speed of the rotor

1.4 Armature Windings of Synchronous machine

A.C. armature windings are always of the non salient-pole type and are usually
symmetrically distributed in slots around the complete circumference of the armature.
Synchronous machine armature windings are generally open-circuit type i.e., both ends are
brought out. An open-circuit winding is one that does not close on itself . i.e. a closed circuit
will not be formed until some external connection is made to a source or load. The
following are the general features of Synchronous machine armature windings:

 synchronous machine armature windings are generally distributed windings i.e.;

they are symmetrically distributed in slots around the complete circumference of
the armature. A distributed winding has two principal advantages.
1. a distributed winding generates a voltage wave that is nearly a sine curve.
2. copper is evenly distributed on the armature surface. Therefore, heating is more
uniform and this type of winding is more easily cooled.
 Synchronous machine armature windings may use full-pitch coils or fractional-
pitch coils. A coil with a span of 180° electrical is called a full-pitch coil. In this case,
the two sides of the coil occupy identical positions under adjacent opposite poles
and the e.m.f. generated in the coil is maximum. A coil with a span of less than 180°
electrical is called a fractional-pitch coil. For example, a coil with a span of 150°
electrical would be called a 5/6 pitch coil. Although e.m.f. induced in a fractional-
pitch coil is less than that of a full-pitch coil, fractional-pitch coils are frequently
used in synchronous machine . machines for two main reasons. First, less copper is
required per coil and secondly the waveform of the generated voltage is improved.
 Synchronous machines use double layer armature windings. In a double layer
winding, one coil side lies in the upper half of one slot while the other coil side lies
in the lower half of another slot spaced about one-pole pitch from the first one. This
arrangement permits simpler end connections and it is economical to manufacture.

Design Principle of non-salient pole synchronous machine 7

  Since most of synchronous machines are of 3-phase type, the three windings of the
three phases are identical but spaced 120 electrical degrees apart.
 A group of adjacent slots belonging to one phase under one pole pair is known as
phase belt. The angle subtended by a phase belt is known as phase spread. The 3-
phase windings are always designed for 60° phaser.

CHAPTER TWO
2.1 Principles of non-salient pole synchronous machine design
2.1.1 Design of Stator Parts
The basic design of non-salient pole(cylindrical rotor) synchronous machine involves the
dimensioning of the magnetic circuit, electrical circuit, insulation system ,thermal circuits and is
carried out by applying analytical equations. An electrical designer will be familiar with

 National or international standards

 Specifications (that deals with machine ratings, performance requirements etc., of
the consumer)
 Cost of material and labor
 Manufacturing constraints

Factors for consideration in electrical machine design

The basic components of all electromagnetic apparatus are the field and armature windings
supported by dielectric or insulation, cooling system and mechanical parts. Therefore, the factors
for consideration in the design are,
1. Magnetic circuit or the flux path: Should establish required amount of flux using minimum
mmf. The core losses should be less.
2. Electric circuit or windings: Should ensure required emf is induced with no complexity in
winding arrangement. The copper losses should be less.

3. Insulation: Should ensure trouble free separation of machine parts operating at different
potential and confine the current in the prescribed paths.
4. Cooling system or ventilation: Should ensure that the machine operates at the specified
temperature.
5. Machine parts: Should be robust.

2.1.1.1 Output equation

PФ = BavπDL, and 3Iph Zph/ π D = ac
Q = 3* 2.22*Pns/2* ФZph Kw Iph * 10-3 kVA
Output to motor = 1.11 * Bav π D L* π D ac * ns Kw 10-3 kVA

Design Principle of non-salient pole synchronous machine 8

Q = (1.11 π2 Bav ac Kw 10-3) D2Lns kVA
Q = (11 Bav ac Kw 10-3) D2Lns kVA
Therefore, Output Q = Co D2Lns kVA
where Co = (11 Bav ac Kw 10-3) = Output coefficient
Choice of Specific loadings: From the output equation it is seen that choice of higher value
of specific magnetic and electric loading leads to reduced cost and size of the machine.

I. Specific magnetic loading: Following are the factors which influences the
performance of the machine.
Iron loss: A high value of flux density in the air gap leads to higher value of flux in the iron
parts of the machine which results in increased iron losses and reduced efficiency.
Voltage: When the machine is designed for higher voltage space occupied by the insulation
becomes more thus making the teeth smaller and hence lower value of gap density should
be used.
Transient short circuit current: A high value of gap density results in decrease in leakage
reactance and hence increased value of armature current under short circuit conditions.

Stability: The maximum power output of a machine under steady state condition is
inversely proportional to synchronous reactance. If higher value of flux density is used it
leads to smaller number of turns per phase in armature winding. This results in reduced
value of leakage reactance and hence increased value of power and hence increased steady
state stability.

Parallel operation: The satisfactory parallel operation of synchronous machines

depends on the synchronizing power. Higher the synchronizing power higher will be the
ability of the machine to operate in synchronism. The synchronizing power is inversely
proportional to the synchronous reactance and hence the machines designed with higher
value air gap flux density will have better ability to operate in parallel with other machines.
The usual Bav assumed value for Cylindrical rotor synchronous machine :0.55 to 0.65
wb/m2

II. Specific Electric Loading: Following are the some of the factors which influence
the choice of specific electric loadings.

 Copper loss: Higher the value of ‘ac’, larger will be the number of armature
conductors which results in higher copper loss. This will result in higher
temperature rise and reduction in efficiency.
 Voltage: A higher value of ‘ac’ can be used for low voltage machines since the space
required for the insulation will be smaller.

Design Principle of non-salient pole synchronous machine 9

  Synchronous reactance: High value of ‘ac’ leads to higher value of leakage
reactance and armature reaction and hence higher value of synchronous reactance.
Such machines will have poor voltage regulation, lower value of current under short
circuit condition and low value of steady state stability limit and small value of
synchronizing power.
 Stray load losses: With increased value of ‘ac’ stray load losses will increase. The
usual values of ‘ac’ for non-salient pole synchronous machines is 50000 to 100000
amp-Cond/m .
In Non-salient pole synchronies machine the diameter of the machine will be smaller
than the axial length. As such the diameter of the rotor is limited from the consideration
of permissible peripheral speed limit. Hence the internal diameter of the stator is
normally calculated based on peripheral speed. Peripheral speed for these machines
must be below 175 m/s.

2.1.1.2 Short Circuit Ratio

it is defined as the ratio of field current required to produce rated voltage of open
circuit to the field current required to circulated rated current on short circuit. The
major effects of SCR on machine performance are
 Voltage regulation
 Stability
 Parallel operation
 Short circuit current

Voltage regulation:- A high value of SCR means that the synchronous reactance has a low
value resulting in to good voltage regulation.

Stability:- A machine with high value of SCR. i.e. lower value of X d, will lead to higher
synchronizing power and thus giving a higher stability limit.

Parallel operation:- A machine with low value of SCR means a large value of X d giving a
small value of synchronizing power. Such a machine has problem during parallel operation.
Short circuit current:- A small value of SCR means a large value of X d which will limit the
short circuit current during fault conditions.
For non-salient pole synchronous machine SCR value varies from 0.7 to 1.1

2.1.1.3 Length of the air gap

Length of the air gap is a very important parameter as it greatly affects the performance of
the machine. Air gap in non-salient pole synchronous machine affects the value of SCR and
hence it influences many other parameters. Hence, choice of air gap length is very critical in
case of non-salient pole synchronous machines. Following are the advantages and
disadvantages of larger air gap.

Design Principle of non-salient pole synchronous machine 10

Advantage
 Stability: Higher value of stability limit
 Regulation: Smaller value of inherent regulation
 Synchronizing power: Higher value of synchronizing power
 Cooling: Better cooling
 Noise: Reduction in noise
 Magnetic pull: Smaller value of unbalanced magnetic pull

Disadvantages:
 Field mmf: Larger value of field mmf is required
 Size: Larger diameter and hence larger size
 Magnetic leakage: Increased magnetic leakage
 Weight of copper: Higher weight of copper in the field winding
 Cost: Increase overall cost.
The approximate value of air gap length can be expressed in terms of pole pitch.
For non-salient pole synchronous machine, the value of lg = (0.02 to 0.026) x pole pitch.
Synchronous machines are generally designed with larger air gap length compared to that
of Induction motors.

Estimation of length of air gap: Length of the air gap is usually estimated based on the
ampere turns required for the air gap.
Armature ampere turns per pole required is calculated as ATa = 1.35 Iph Tph Kw /p
Where Tph = Turns per phase, Iph = Phase current,
Kw = winding factor, p = pairs of poles
No load field ampere turns per pole (ATfo) = SCR *Armature ampere turns per pole ATfo =
SCR *ATa Ampere turns required for the air gap will be approximately equal to 80% of the
no load field ampere turns per pole. mmf for air gap is also equal to 800000B g Kg lg 0.8 ATfo
= 800000 Bg Kg lg lg = 0.8 ATfo/800000 Bg Kg

2.1.1.4 Selection of number of slots:

Following factors are considered for selection of number of slots. Balanced winding:- The
number of slots are so selected that a balanced 3-phase winding is obtained. Unbalance
winding will leads to generation of space harmonics and overheating. Tooth flux density:-
selection of large number of slots will lead to narrower teeth resulting in to increased tooth
flux density beyond permissible limits.

Leakage reactance:- With less number of slots, the conductors are nearer leading to
increased leakage flux and thereby increased leakage reactance.

Design Principle of non-salient pole synchronous machine 11

Tooth ripples:- With large number of slots tooth ripples and therefore pulsation loss
decreases.

Temperature rise and cost:- Selection of too small a number of slots will lead to crowding
of conductors, disturbance in air circulation and hence developing high internal
temperature. also, smaller number of slots result in saving in labour because of less
number of coils to wind, insulate, place in to slots and connect. Considering all the above
points number of slots per pole phase for non-salient pole synchronous machine may be
selected as 7 to 9 slots per pole per phase. Slot pitch must be within the following
limitations .

 Low voltage machines 2.5 cm

 Medium voltage machines up to 6kV 4.0 cm
 High voltage machines up to 15 kV 6.0 cm
2.1.1.5 Turns per Phase:
Turns per phase can be calculated from the emf equation of synchronous machine.
Induced emf Eph=4.44*f*ϕ*Tph*kw
Hence turns/phase can be calculated as
Tph=Eph/4.44*f*kw*ϕ
Where Eph= induced emf per phase
Kw=winding factor
F=frequency
ϕ =flux per pole
Tph= turns per phase

2.1.1.6 Conductor selection:

Current per phase = (kVAx 1000)/ 3* Eph
The conductor current Iz = Iph, when all the turns per phase are connected in series. But I z =
Iph/A , if there are ‘A’ number of parallel paths per phase.
Sectional area of the stator conductor a s= Is /δs where δs is the current density in stator
windings and Is is stator current per phase. A suitable value of current density has to be
assumed by considering the advantages and disadvantages.

Advantages of higher value of current density:

 reduction in cross section

Design Principle of non-salient pole synchronous machine 12

  reduction in weight
 reduction in cost

Disadvantages of higher value of current density

 increase in resistance
 increase in cu loss
 increase in temperature rise
 reduction in efficiency
Hence higher value is assumed for low voltage machines and small machines. Usual value
of current density for stator windings is 3 to 5 amps/mm2.

2.1.1.7 Stator slot dimensions

Because parallel sided slots are used the teeth are tapered having minimum width at the
gap surface. The flux density in teeth at the air gap surface at no load does not exceed about
1.7 to 1.8 wb/m2 .
ϕ
Wt ( min )=
1.8∗Ss
∗Li∗ᴪ
p
Where ᴪ =ratio of pole arc to pole pitch
Ss=stator number of stator slots
Li=net iron length
P=number of poles
The depth of the slot d s is now determined by the space requirement for copper and
insulation. The depth of slot is normally about 3 times the width.
The length of mean turn: Lmt = 2L+ 2.5 τp + 0.06 kV + 0.2 m
Number of Pole(P)=120∗f / N Where f=frequency, N=Speed in RPM
Slot per Pole per phase (SPP)=S /(m∗p) where S= Total number of slots
m=number of phase and p= number of poles
Full pitch of armature winding =S / P Where S=slot ,P=number of poles
slot angle (α )= p∗180/ S Where P= number of poles= number of slots
Dr=Vr /( π∗n) where Dr=rotor speed
Vr=rotor velocity and n=speed in rps
Armature Reaction( ATa)=1.35∗Tph∗Iph∗kw/(P /2) where Tph=turns per phase

Design Principle of non-salient pole synchronous machine 13

Ampere turns on no load=Scr∗ATa
Where Scr= short circuit ratio and Ata=Armature Reaction
Stator core Inner Diameter (Di) = Dr + (2 x Lg)
π∗Di
Pole Pitch ( PP ) = Where Di=Stator Core Inner Diameter
p
P= Number of Pole
Bav∗π∗Di∗L
Flux Per Pole(ϕ)=
P
π∗Di
Slot Pitch ( SP )=
S
Slot Width ( SW )=Slot Pitch ( SP )−Total widthat the air gap
0.021∗Lmt∗Tph
Stator Winding resistance per phase ( Rph )= where Lmt=mean length of ture
As
As=cross sectional area of the conductor ,Tph= turns per phase

DC Copper Loss ( Pcu )=3∗Ip h 2∗Rph∗10−3

Eddy current loss ( Peddy )=( Average loss factor−1 )∗Pcu
Total copper loss∈the stator winding =Pcu+ Peddy

ϕ
Depth of Stator Core ( Dcs ) =
2 Bc∗Li

Outer Diameter of Core ( Do )=Di+2∗(Hs+ Dc)

2.1.2 Design of field system

In non-salient pole synchronous machine , the rotor windings or the field windings are
distributed in the rotor slots.

Design Principle of non-salient pole synchronous machine 14

Normally 70% of the rotor is slotted and remaining portion is unslotted in order to form
the pole. The design of the field can be explained as follows.

2.1.2.1 Selection of rotor slots:

Total number of rotor slots may be assumed as 50 – 70 % of stator slots pitch. However, the
rotor slots must satisfy the following conditions in order to avoid the undesirable effects of
harmonics in the flux density wave forms.
 There should be no common factor between the number of rotor slot pitches and
number of stator slot pitches.
 Number of rotor slots should be divisible by 4 for a 2-pole synchronous machine.
That means the number of rotor slots must be multiple of 4.
 Width of the rotor slot is limited by the stresses developed at the rotor teeth and
end rings.

2.1.2.2 Design of rotor winding

(a) Full load field mmf can be taken as twice the armature mmf(ATfl) = 2 xATa = 2 x
1.35 x Iph x Tph x kw /p
(b) Standard exciter voltage of 110 - 220 volts may be taken. With 15-20 % of this may
be reserved for field control. Hence voltage across each field coil V f = (0.8 to 0.85) V/p
(c) Length of the mean turn lmt = 2L+ 1.8 τp + 0.25 m
(d) Sectional area of each conductor af = ρ x lmt x (If x Tf) / vf
(e) Assume suitable value of current density in the rotor winding. 2.5 – 3.0 amp/mm2
for conventionally cooled machines and 8 – 12 amp/mm2 for large and special cooled
machines.
(f) area of all the rotor conductors per pole = 2 x (I f x Tf)/δf
(g) the number of rotor conductors per pole = 2 x (If x Tf) / (δf x af)
(h) Number of field conductors per slot = 2 x (If x Tf) / ( δf x af x sr), where sr is the
number of rotor slots.

Design Principle of non-salient pole synchronous machine 15

 (i) Resistance of each field coil Rf = ρ x lmt x Tf / af
(j) current in the field coil If = vf/ Rf

Design Principle of non-salient pole synchronous machine 16

Design Principle of non-salient pole synchronous machine 17