POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

College of Engineering
Electrical Engineering Department






ELECTRICAL MACHINE DESIGN
Design 2: Commutating Poles for DC Generator







Submitted by

PAUIG, MARK ANTHONY C.
BSEE V-3



Submitted to

ENGR. LIBRADO S. GESALTA
Instructor



June ___ , 2014


===== PART 2 : Commutator & Brushes ======== ===================== ====================
40 Diameter of Commutator D
c
26.632 in.
41 Average volts per turn of armature winding 28.24 V
42 Number of turns between bars 1
43 Total number of commutator bars 77
44 Bar pitch 1.087 in.
45 Width of copper bar 1.057 in.
46 Radial depth of bar 2.77 in.
47 Current density at brush contact surface
b
40 amps/in.
2
39.97 amps/in.
2

48 Contact area per brush set 48.76 in.
2
48.8 in.
2

49 Brush arc 1 in.
50 Axial brush length per set 48.8 in.
51 Number of brushes per set 78.08
52 Axial length of commutator L
c
53.3 in
53 Brush-contact drop 2.3 V
54 Brush-contact loss 17,942.56 Watts
55 Brush-friction loss 27,689.79 Watts
56 Total brush loss 45,632.35 Watts
57 Drawing to scale giving leading dimensions of
armature and commutator
9.73 in.































PART 2 :
Item 40: Diameter of Commutator

D
c
= (40.024 2) + 6.62 D
c
= 26.632 in.

This is 66.54% of the core diameter and makes the peripheral velocity

=0.6654 14,145.65

=9412.516 fpm

Items 41 to 43: Number of Commutator Bars
Average volts per turn

E
average
/turn = ___240___ E
average
/turn = 28.24V
136 16
Number of turns between bars
One (1)
Number of Commutator bars
(

) = (4/2 39) 1
*It is desirable to use 77 commutator bars to improve the commutation and to be more suitable and narrower.

Items 44 and 45: Width of Commutator Segments
Bar pitch
Bar pitch =

Bar pitch = 26.632 _ Bar pitch = 1.087 in.
77
Width of copper bar
*using 0.03 in mica insulation
Width
Cu
= Bar pitch - 0.03 = 1.087 0.03 Width
Cu
= 1.057 in.

Item 46: Radial Depth of Segment
Radial depth of bar
h =

+ 15 / 15
h = _26.632 + 15_ h = 2.77 in.
15


Items 47 to 51: Dimensions of Brushes
Current density at brush contact surface
*assume 40 A as preliminary value
b
= 40 amps/ in.
2
Contact area per brush set

_8 975.139 _ 48.76 in.
2

4 40

Brush Arc (Circumferential Width) 1 inch
Axial brush length per set 48.76 in.
Number of brushes per set
Actual area per brush set 48.8 in.
2

*from Art. 34 the usual width of brush is something between the limits of 5/8 in and 1 in, and as a further check on the
desirabledimensions, the width should not exceed one-tenth of the pole pitch referred to the commutator surface.Thus , use a brush of 5/8
in. width
No. of brushes per set = 48.8 / 0.625 = 78.08 Brushes
The Current Density will be slightly decreased to,
40(48.76/48.8)= 39.97 amps/ in.
2



Item 52: Length of Commutator
Axial length of commutator
*In addition to the 48.8 in. which must be provided for the four 5/8 in. Carbon Brushes, the Axial Length for the Commutator face must
allow the following:
a.) Brush Holder and Clearances = 5/2 in.
b.) Staggering of (+) and (-) brushes = 5/8 in.
c.) End clearance for brushes =1 in.
d.) End play =3/8 in.
L
c
= 48.8 + 2.5 +0.625 + 1 + 0.375 L
c
= 53.3 in.

Item 53: Brush-contact Drop
*Brush contact drop for hard carbon at about 40 amps/ in.
2
is 2.085 volts. Allowing the 10% of roughness, chipping and irregularities, this
drop will be about 2.3 volts. *2.3 V

Item 54 to 56: Brush Losses
Brush contact loss
Loss
Brush contact
= Brush contact drop P

= 2.3 8 975.139 Loss

Brush contact
= 17,942.56 Watts
Brush contact friction
*For Peripheral speed greater than 4,000 fpm use c=0.25 for hard carbon; P= 2

W
f
=( c PAN D
c


746)/12 33,000
W
f
= _0.25 2 (48.8 8 ) 26.632 900 746 _ W
f
= 27,689.79 Watts
12 33000
Total brush loss
Loss
TOTAL
= 17,942.56 +27,689.79 Loss
TOTAL
=45,632.35 Watts
Item 57: Drawing to scale giving leading dimensions of armature and commutator
Shaft Diameter = 0.84

= 0.84

= 9.73 in.