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f
- Current density in the field winding(A/mm
2
)
Design of field system
Tentative design of field winding
Cooling surface of the field winding, S=2L
mt
h
f
-- (1)
Permissible copper loss in each field coil, S
qf
=2L
mt
h
f
q
f
-- (2)
Area of X-section of field coil=h
f
d
f
-- (3)
Area of copper in each section=S
f
h
f
d
f
-- (4)
i.e, T
f
a
f
=S
f
h
f
d
f
-- (5)
Copper loss in each field coil, Q
f
=I
f
2
R
f
=I
f
2
(T
f
L
mt
)/a
f
i.e., Copper loss o o
f
2
(Square of the current density)
Design of field system
( )
( )
Copper of Volume
6
2
2
2
2
o =
o =
|
|
.
|
\
|
o =
|
|
.
|
\
|
=
f f
mt f f f f
f
mt f
f f
f
mt f
f f
Q
) ( L a T Q
a
L T
a
a
L T
I Q
To have temperature rise within the limit, the copper loss should be equal to the
permissible loss.
Using Eqns. (2) & (6),
2L
mt
h
f
q
f
=o
f
2
L
mt
(S
f
h
f
d
f
) =>
MMF per metre height of field winding
Design of field system
) (
d S
q
f f
f
f
7
2
= o
(8) - - 10 height meter per MMF
10 2
2
2
4
8
f f f
f f f
f f
f f
f
f f f
f
f f f f
f
f f f
f
f f
f
fl
d S q
] m . [
d S q
d S
d S
q
d S
h
h d S
h
T a
h
T I
h
AT
=
O =
= o =
o
=
o
=
= =
Normal values:
Permissible loss, q
f
-700W/m
2
Copper Space factor, S
f
:
Small wires: 0.4
Large round wires: 0.65
Large rectangular conductors: 0.75
Depth of the field winding, d
f
:
Design of field system
Armature Dia (m) Winding Depth (mm)
0.2 30
0.35 35
0.5 40
0.65 45
1.00 50
1.00 and above 55
Height of field,
Total height of the pole,
h
pl
=h
f
+h
s
+ height for insulation and curvature of yoke
where,
h
s
- Height of the pole shoe (0.1 to 0.2 of the pole height)
Design of field system
f f f
fl
f
fl
f
d S q
AT
h
AT
h
4
10
(8), Eqn Using
height meter per Turns Ampere
=
=
Design of shunt field winding
Involves the determination of the following information
regarding the pole and shunt field winding
Dimensions of the main field pole ,
Dimensions of the field coil ,
Current in shunt field winding,
Resistance of coil,
Dimensions of field conductor,
Number of turns in the field coil ,
Losses in field coil.
Dimensions of the main field pole
For rectangular field poles
o Cross sectional area, length, width , height of the body
For cylindrical pole
o Cross sectional area, diameter, height of the body
Area of the pole body can be estimated from the knowledge
of flux per pole , leakage coefficient and flux density in the
pole
Leakage coefficient (C
l
) depends on power output of the
DC machine
Bp in the pole 1.2 to 1.7 wb/m
2
p
= C
l
.
A
p
=
p
/B
p
When circular poles are employed, C.S.A will be a circle
Ap = d
p
2
/4
t = / Ap 4 d
p
Design of shunt field winding
When rectangular poles employed, length of pole is chosen
as 10 to15 mm less than the length of armature
L
p
=L (0.001 to 0.015)
Net iron length L
pi
= 0.9 L
p
Width of pole, b
p
= Ap/L
pi
Height of pole body h
p
= h
f
+ thickness of insulation and
clearance
Total height of the pole h
pl
= h
p
+ h
s
Design of shunt field winding
Field coils are former wound and placed on the poles
They may be of rectangular or circular cross section
depends on the type of poles
Dimensions L
mt
, depth, height, diameter
Depth(d
f
) depends on armature
Height (h
f
) - depends on surface required for cooling the
coil and no. of turns(T
f
)
h
f
, T
f
cannot be independently designed
Design of shunt field winding
L
mt
- Calculated using the dimensions of pole and depth of
the coil
For rectangular coils
L
mt
=2(L
p
+ b
p
+ 2d
f
) or (L
o
+L
i
)/2
Where L
o
length of outer most turn & L
i
length of inner most turn
For cylindrical coils
L
mt
= (d
p
+d
f
)
No of turns in field coil: When the ampere turns to be
developed by the field coil is known, the turns can be
estimated
Field ampere turns on load, AT
fl
= I
f
. T
f
Turns in field coil, T
f
= AT
fl
/I
f
Design of shunt field winding
Power Loss in the field coil:
Power loss in the field coil is copper loss, depends on
Resistance and current
Heat is developed in the field coil due to this loss and it is
dissipated through the surface of the coil
In field coil design , loss dissipated per unit surface area is
specified and from which the required surface area can be
estimated.
Surface area of field coil depends on L
mt
, depth and height of
the coil
Design of shunt field winding
L
mt
estimated from dimensions of pole
Depth assumed (depends on diameter of armature)
Height estimated in order to provide required surface area
Heat can be dissipated from all the four sides of a coil. i.e,
inner , outer, top and bottom surface of the coil
Inner surface area= L
mt
(h
f
d
f
)
Outer surface area = L
mt
(h
f
+ d
f
)
Top and bottom surface area = L
mt
d
f
Total surface area of field coil, S= L
mt
(h
f
d
f
)+ = L
mt
(h
f
+ d
f
)+
L
mt
d
f
+ L
mt
d
f
S= 2L
mt
h
f
+L
mt
d
f
= 2L
mt
(h
f
+d
f
)
Permissible copper loss, Q
f
=S.q
f
[q
f
-Loss dissipated/ unit area]
Design of shunt field winding
Substitute S in Q
f
,
Q
f
= 2L
mt
(h
f
+d
f
).q
f
Actual Cu loss in field coil=I
f
2
R
f
=E
f
2
/R
f
Substituting R
f
=(L
mt
T
f
)/ a
f
,
Actual Cu loss in field coil=E
f
2
.a
f
/(L
mt
T
f
)
Design of shunt field winding
f mt
f
2
f
f f f mt
T L
a E
) d (h q 2L = +
f f f
f f
d h S
coil field
of section - X of Area
X factor space Copper
coil Field
in area Conductor
a T
conductor field
of section - X of Area
X turns No.of
coil field
in area Conductor
=
|
|
.
|
\
|
=
)
`
=
|
|
.
|
\
|
=
)
`
+
)
`
=
reaction armature
come over to required mmf
B establish
to required mmf
ATi
gi
winding) ng compensati with (
2P
.Z I
) - (1
winding) ng compensati without (
2P
.Z I
reaction armature
overcome
to required MMF
z
z
=
=
Losses and efficiency :
1. Iron Loss - i)Eddy current loss ii) Hysteresis loss
2. Rotational losses - Windage and friction losses
3. Variable or copper loss
Condition for maximum efficiency :
Constant Loss= Variable Loss
I
A
conductor, interpole
of section - X of Area
A/mm 4 to 2.5 ,
winding interpole
in density Current
I
AT
turns No.of
i
a
ip
2
i
a
i
=
)
`
=
)
`
=
Design of Interpoles