ELECTRICAL MACHINE

DESIGN

EE409
3-0-0
Credits-3

Binesh Mohan, AP in EEE, CETkr 1

 Course Objectives
• To impart knowledge on principles of design of static
and rotating electrical machines.
• To give a basic idea about Computer Aided Design
(CAD) and Finite Element Method(FEM)

Expected outcome
• Able to design transformers, DC machines,
synchronous machines and induction motors

Binesh Mohan, AP in EEE, CETkr 2

 Text Books
1. A K Sawhney, “ A Course in Electrical Machine Design”,
Dhanpatrai and sons, Delhi.”

2. M. V. Deshpande, “ Design and Testing of Electrical

Machines”, Wheeler Publishing.

3. R. K. Agarwal, “ Principles of Electrical Machine Design”,

Essakay Publications, Delhi.

4. Ramamoorthy M, “Computer Aided Design of Electrical

Equipment”, East-West Press.

5. M. N. O. Sadiku, “ Numerical techniques in

Electromagnetics”, CRC Press Edition-2001
Binesh Mohan, AP in EEE, CETkr 3
 Module-1
Principles of electrical machine design - General design
considerations - specifications of machines
Types of enclosures - types of ventilation - heating - short time
rating - overload capacity- temperature rise time curve - hot
spot rating.

Magnetic circuit calculation - calculation of field ampere turns -

air gap M.M.F - effect of slot and ventilating duct - active iron
length – M.M.F for teeth - real and apparent flux densities –

M.M.F per pole Magnetic Leakage Calculation- Effects of

Leakage. Armature Leakage – Components. Unbalanced
Magnetic Pull-Practical aspects of unbalanced magnetic pull

Binesh Mohan, AP in EEE, CETkr 4

FUNDAMENTAL CONCEPTS

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 Introduction
• The magnetic flux in all electrical machines (generators,
motors and transformers) plays an important role in
converting or transferring the energy.
• Field or magnetizing winding of rotating machines
produces the flux while armature winding supplies either
electrical power or mechanical power.
• In case of transformers primary wing supplies the power
demand of the secondary.
• The basic design of an electrical machine involves the
dimensioning of the magnetic circuit, electrical circuit,
insulation system etc., and is carried out by applying
analytical equations.
Binesh Mohan, AP in EEE, CETkr 6
 Introduction
A electrical designer must be familiar with
a) National and international standards Indian Standard(IS),
 Bureau of Indian Standard (BIS),
 India British Standard (BS),
 England International Electro technical Commission (IEC)
 NEMA (The National Electrical Manufacturers
Association).
b) Specifications (that deals with machine ratings,
performance requirements etc., of the consumer
c) Cost of material and labor
d) Manufacturing constraints

Binesh Mohan, AP in EEE, CETkr 7

What is meant by Electrical Machine Design?

• Design may be defined as a creative physical

realization of theoretical concepts.

• Engineering design is application of science,

technology and invention to produce machines to
perform specified tasks with optimum economy and
efficiency.

Binesh Mohan, AP in EEE, CETkr 8

 Basic considerations to develop a design
1. Design base
• Matching the existing experience with R and D.
• Bringing in the latest material and technology.
• Limitations in design.
• Convenience in production line and transportation.
• Working safety and reliability.
• Maintenance and repair.
• Environmental conditions.
2. Specification
• Meeting with the customer’s requirements.
• Guarantees
• Satisfy the national and international standards.
Binesh Mohan, AP in EEE, CETkr 9
Basic considerations to develop a design cont…
3. Design transfer
• Transfer of design to factory foreman.
(Drawings, processes instructions, job flow, meeting the
delivery schedule)
4. Information updating
• Technical journals.
• R and D papers and reports.
• Interaction in meetings.
• Seminars and Conferences

Binesh Mohan, AP in EEE, CETkr 10

Major considerations to develop a design
• The design should be carried out based on the given
specification using available materials economically
and to achieve the following
1. Lower cost
2. Durability
3. Conformity with performance criteria as laid down in
specifications

Binesh Mohan, AP in EEE, CETkr 11

 Limitations in Design
1. Saturation of magnetic parts:
Increased core losses and excitation at higher flux density
resulting in higher cost for the field system.
2. Temperature rise:
Increased temperature rise under higher output weakens the
insulation and affects the life of machine.
3. Insulation:
It should be able to withstand the electrical, mechanical and
thermal stresses which are produced in the machine.
4. Mechanical strength:
Specially in turbo machine due to large size and high speed.
5. Commutation :
In DC machine output is limited because of commutation
problem Binesh Mohan, AP in EEE, CETkr 12
 Limitations in Design
6. Efficiency:
If high efficiency is the aim, the machine becomes costly.
For lower efficiency higher running cost and temperature rise
with associated problems.
7. Customer’s specifications:
Imposes limitations to identify criterion for best design

8. Power factor:
Power factor imposes a limitation specially in case of 3 phase
induction motor.
9.Standard specification:
Specification is biggest strain on the design because of the both
the manufacturer as well as the consumer cannot get away
from them without satisfying them.

Binesh Mohan, AP in EEE, CETkr 13

 Basic structure of electrical machine

1. Magnetic circuit : core, yoke, air gap etc.

2. Electric circuit : stator, rotor winding and transformer

winding

3. Dielectric circuit : insulation

4. Thermal circuit : heating and cooling medium

5. Mechanical parts : frame, bearings and shaft

Binesh Mohan, AP in EEE, CETkr 14

 Materials for Electrical Machines
1. Conducting materials.
Commonly used conducting materials are copper and
aluminum. Some of the desirable properties a good
conductor should possess are listed below.

 Low value of resistivity or high conductivity

 Low value of temperature coefficient of resistance
 High tensile strength
 High melting point
 High resistance to corrosion
 Allow brazing, soldering or welding so that the joints are
reliable
 Highly malleable and ductile 8. Durable and cheap by cost

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 Materials for Electrical Machines cont…
2. Magnetic materials:
The magnetic properties of a magnetic material depend on the orientation of
the crystals of the material and decide the size of the machine or
equipment for a given rating, excitation required, efficiency of operation
etc.
• Low reluctance or should be highly permeable or should have a high value
of relative permeability
• High saturation induction (to minimize weight and volume of iron parts)
• High electrical resistivity so that the eddy emf and the hence eddy current
loss is less
• Narrow hysteresis loop or low Coercivity so that hysteresis loss is less and
efficiency of operation is high
• A high curie point. (Above Curie point or temperature the material loses
the magnetic property or becomes paramagnetic, that is effectively non-
magnetic)
• Should have a high value of energy product (expressed in joules / m3 ).
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 Materials for Electrical Machines cont…
3. Insulating materials : To avoid any electrical activity between parts at
different potentials, insulation is used. An ideal insulating material should
possess the following properties.
• Should have high dielectric strength.
• Should with stand high temperature.
• Should have good thermal conductivity
• Should not undergo thermal oxidation
• Should not deteriorate due to higher temperature and repeated heat cycle
• Should have high value of resistivity ( like 1018 cm)
• Should not consume any power or should have a low dielectric loss angle
• Should withstand stresses due to centrifugal forces ( as in rotating machines),
electro dynamic or mechanical forces ( as in transformers)
• Should withstand vibration, abrasion, bending
• Should not absorb moisture
• Should be flexible and cheap
• Liquid insulators should not evaporate or volatilize
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 Materials for Electrical Machines cont…
4. Special purpose Alloys:
 High nickel permalloy (iron+molybdenum+copper or chromium),
used in current transformers, magnetic amplifiers etc.,
 Low nickel Permalloy (iron+silicon+chromium or manganese),
used in transformers, induction coils, chokes etc.
 Perminvor (iron +nickel +cobalt)
 Pemendur (iron+cobalt+vanadium), used for microphones,
oscilloscopes, etc.
 Mumetal (Copper + iron)
5. Amorphous alloys (often called metallic glasses):
Amorphous alloys are produced by rapid solidification of the alloy
at cooling rates of about a million degrees centigrade per
second. The alloys solidify with a glass-like atomic structure
which is non-crystalline frozen liquid. This can produce sheets as
thin as 10µm and a meter or more wide.
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 Enclosure

The enclosure of
the motor must
protect the windings,
bearings, and other
mechanical parts
from moisture, chemi
cals, mechanical
damage and abrasion
from grit.

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 Types of Enclosures

1. Open Drip Proof (ODP):

Allows air to circulate

through the windings for
cooling, but prevent drops
of liquid from falling into
motor within a 15 degree
angle from vertical.
Typically used for indoor
applications in relatively
clean, dry locations.
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 Types of Enclosures cont…
2. Totally Enclosed Fan Cooled
(TEFC):
Prevents the free exchange of air
between the inside and
outside of the frame, but
does not make the frame
completely air tight.
A fan is attached to the shaft
and pushes air over the
frame during its operation to
help in the cooling process.
The TEFC style enclosure is the
most versatile of all. It is
used on pumps, fans,
compressors, general
industrial belt drive and
direct connected equipment.
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 Types of Enclosures cont…
3. Totally Enclosed Non-
Ventilated (TENV):
Similar to a TEFC, but has no
cooling fan and relies on
convention for cooling. No
vent openings, tightly enclosed
to prevent the free exchange of
air, but not airtight.
These are suitable for uses which
are exposed to dirt
or dampness, but not very
moist or hazardous (explosive)
locations.

Binesh Mohan, AP in EEE, CETkr 22

 Types of Enclosures cont…

4. Totally Enclosed Air

Over (TEAO):

Dust-tight fan and blower duty

motors designed for shaft
mounted fans or belt
driven fans.
The motor must be mounted
within the airflow of
the fan.

Binesh Mohan, AP in EEE, CETkr 23

 Types of Enclosures cont…
5. Totally Enclosed Wash
down (TEWD):
Designed to withstand high
pressure wash-downs or
other high humidity or wet
environments.
Available on TEAO,TEFC and
TENV enclosures totally
enclosed, hostile and
severe environment motors
Designed for use in
extremely moist or
chemical environments, but
not for hazardous locations.

Binesh Mohan, AP in EEE, CETkr 24

 Types of Enclosures cont…
6. Explosion-proof enclosures
(EXPL):
The explosion proof motor is a totally
enclosed machine and is
designed to withstand an
explosion of specified gas or vapor
inside the motor casing and
prevent the ignition outside the
motor by sparks, flashing or
explosion.
These motors are designed for specific
hazardous purposes, such as
atmospheres containing gases or
hazardous dusts. For safe
operation, the maximum motor
operating temperature must be
below the ignition temperature of
surrounding gases or vapors.
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 Types of Enclosures cont…
7. Hazardous Location
(HAZ):
Hazardous
location motor applications
are classified by the type of
hazardous environment
present, the characteristics of
the specific material creating
the hazard, the probability of
exposure to the environment,
and the maximum
temperature level that is
considered safe for the
substance creating the hazard.
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 Types of Enclosures cont…
8. Water Tight machine(WT):
It will withstand, without damage or sign of leakage, complete
immersion in water to a depth of not less than 1m or subjection
to an external water pressure of 0.1kg/cm2 for a period of one
hour.
9. Submersible Machine: A machine capable of working for an
indefinitely long period when submerged under specified head of
water.
10. Whether Proof machines(WP): It can work without further
protection from whether conditions specified by the purchaser.
11. Open Machines: There is no restriction to ventilation other
than that necessitated by good mechanical construction.

Binesh Mohan, AP in EEE, CETkr 27

 Cooling and Ventilation
• All rotating electrical machines generate heat as a
result of the electrical and mechanical losses inside the
machine.

• Losses usually increase with increased loading. Cooling

is necessary to continuously transfer the heat to a
cooling medium, such as the air.

• The cooling of electrical machines by means of an air

stream is called the ventilation of the machines. The
cooling systems can be grouped into three types viz
natural cooling, self cooling and separate cooling.
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 Types of Ventilation
The ventilation of the machine can be classified into three
categories, according to the scheme of ventilation
incorporated in the machine.
1. Open circuit ventilation
2. Closed circuit ventilation
3. Surface ventilation.
Open circuit ventilation can be divided into two types.
i. Induced ventilation
ii. Forced ventilation.

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Types of Ventilation cont…

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 Types of Ventilation cont…

The ventilating system can be further classified into four

types in accordance with the provision of cooling ducts
and how the air passes over the heated parts of the
machines.

(1) Radial Ventilating System.

(2) Axial Ventilating System.
(3) Combined Radial and Axial Ventilating System.
(4) Multiple-Inlet Ventilating System.

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 Magnetic circuit
• The magnet possesses a magneto motive force.
• The m.m.f generates a magnetic flux.
• The flux exists within the magnet and the air gap between the
poles. The enclosed flux path is called a magnetic circuit.
• A stronger m.m.f. will produce more flux.
• The lower the reluctance of the magnetic circuit, the more
flux will be produced.

Binesh Mohan, AP in EEE, CETkr 39

 Magnetic circuit cont…
• The Series Magnetic Circuit is defined as the magnetic circuit
having a number of parts of different dimensions and materials
carrying the same magnetic field.

• A magnetic circuit having two or more than two paths for the
magnetic flux is called a parallel magnetic circuit.

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 Estimation of total MMF
• knowledge of dimension and configuration of the
magnetic circuit.
• May be connected in series or parallel.

• The parts of magnetic circuits are:

i. Air gap
ii. Core: Stator core and rotor core
iii. Teeth: Stator teeth and rotor teeth
iv. Pole : In case of dc machine & salient pole
synchronous m/c
v. Yoke: In case of dc machine

Binesh Mohan, AP in EEE, CETkr 41

 M.M.F. for Air Gap
 The iron surfaces around the air gap are not smooth.
 Flux concentrated in the teeth.
 Radial ventilating duct for cooling
 Air gap is not uniform in salient pole machines

Let
L= Length of core
Lg= gap length
ys= slot pitch
Ws= width of slot
Wt= width of tooth
Wo= slot opening
nd= number of radial duct
Wd= width of each duct
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 Case-1, Iron surfaces on the two sides of the air gap to
be smooth and the gap length to be uniform.
• The flux is uniformly spread over the entire slot pitch
• Flux goes straight across the air gap
• The reluctance of air gap,

Where,
lg=length of magnetic path in meter
A= Area of magnetic path, square meter
μ0= Permeability of free space

Binesh Mohan, AP in EEE, CETkr 43

 Case-2, Iron surfaces on one side of the air gap to be
smooth and slotted on the other side (effect of slot)
• The effective area of flux path is decreased.
• Increasing in reluctance of air gap
• Flux confines to the tooth width.

The effective or contracted slot pitch,

Reluctance of air gap,

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 Case-2, Iron surfaces on one side of the air gap to be
smooth and slotted on the other side cont…

• flux can not confine to a width alone but to fringing it will spread
over to a greater width.
• The value of reluctance now decrease but more than in case-1.
• A slot pitch the flux is spread over to a width,
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 Case-2, Iron surfaces on one side of the air gap to be
smooth and slotted on the other side cont…

Where, Kcs=Carters gap co-efficient

Its value depends up on ratio slot width, ’Ws’/gap length, ’lg’

OR
Where,

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 Case-2, Iron surfaces on one side of the air gap to be
smooth and slotted on the other side cont…

Reluctance of air gap with slotted armature,

Let, Ratio of reluctance of air gap of slotted armature to

reluctance of air gap of smooth armature be ‘Kgs’

Where, ‘Kgs’ is called gap contraction factor for slots.

Binesh Mohan, AP in EEE, CETkr 47

Case-3, Consider the iron surface of the air gap having
radial ventilating ducts ( effect of ventilating duct )

• Contraction of flux in the axial direction.

• Effective axial length of the machine reduces.
• Increase in the reluctance of air gap.

Binesh Mohan, AP in EEE, CETkr 48

Case-3, Consider the iron surface of the air gap having
radial ventilating ducts cont…
Contracted of effective axial length

• Where ‘Kcd’ is the Carter’s co-efficient for ducts

(Its value depends up on duct width, ‘Wd’/Gap length, ‘lg’ )
• Ratio of reluctance of air gap with ducts to reluctance of air gap
without ducts, Kgd

• ‘Kgd’ is called gap contraction factor for duct.

Binesh Mohan, AP in EEE, CETkr 49
 Case-3, Consider the iron surface of the air gap
having radial ventilating ducts cont…
• Slotting and the ventilating effect in a single expression

• Reluctance of air gap of a smooth armature without

ducts =

• Reluctance of air gap of a slotted armature with ducts =

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 Case-3, Consider the iron surface of the air gap
having radial ventilating ducts cont…

• Ratio= Reluctance of slotted armature with ducts/

reluctance of smooth armature without ducts

• (Kg=Total gap contraction factor)

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Case-3, Consider the iron surface of the air gap
having radial ventilating ducts cont…

• For induction Motor slots on both sides of air gap

• Stator slots and rotor slots

• Gap contraction factor for stator slots=Kgss

• Gap contraction factor for rotor slots=Kgsr
• Total gap contraction factor for slots=Kgs
Kgs= Kgss * Kgsr

Binesh Mohan, AP in EEE, CETkr 52

Carters co-efficient for Semi-closed slots:
Contracted or effective slot pitch,

Gap contraction factor,

Note: M.M.F Required for the gap with slotted armature

is ‘kg” times the M.M.F required for gap with smooth
armature.

Binesh Mohan, AP in EEE, CETkr 53

 M.M.F. calculation
For air or other non-magnetic material, m.m.f per meter,

 So m.m.f per meter for air gap = 8,00,000 B

 m.m.f required for air gap having a length ‘lg’ meter
with smooth armature,
ATg = mmf/m * length = 800000*B*lg
 m.m.f required for air gap having a length ‘lg’ meter
with slotted armature,
ATg = 800000*Kg*B*lg

Binesh Mohan, AP in EEE, CETkr 54

 M.M.F. calculation cont…
.

Where,

This means that there is a contraction in the air gap area and the
gap area has contracted to a value,

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 M.M.F. calculation cont…
Air gap m.m.f. for smooth armature
• ATg = mmf/m * length = 800000*B*lg
Air gap m.m.f. for slotted armature
• ATg = 800000*B*(Kg*lg)

Note: The length of air gap is increased ‘Kg’ times due

to the provision of slots and ducts. Thus effective gap
length.

Binesh Mohan, AP in EEE, CETkr 56

 Effect of saliency
• In salient poles the air gap is minimum at the centre along
the direct axis and increases as the pole tip is approached.

• Distribution of the magnetic field in the air gap is required

to calculate the reluctance of air gap

• MMF required for the air gap is find out from the reluctance
of one flux tube and the flux flowing through it.

• mmf, ATg= flux in a flux tube × Reluctance of flux tube.

Binesh Mohan, AP in EEE, CETkr 57

Effect of saliency cont…

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 Effect of saliency cont…
• Let us consider a flux tube at the centre of the pole.
Flux in the flux tube at the centre
=Flux density × Area of flux tube
= Bg × area of flux tube
Reluctance of flux tube at centre=

Binesh Mohan, AP in EEE, CETkr 59

 Effect of saliency cont…
Therefore,

Where, Kg= gap contraction factor for a gap length at the centre of the pole.

field form factor (Kf):

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 Effect of saliency cont…
.

Flux density at the centre of pole,

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 Net length of Iron
• Core of magnetic circuit- laminated steel plates.
• Laminations insulated from each other by paper.
• Vent spacers for cooling-ventilating ducts.
• Iron space factor called stacking factor.
• Ratio of actual length of iron in a stack to total axial length of
stack.
• Gross iron length, Ls = length of slot portion conductor.
= Core length – length of ventilating duct

Net iron length,

• Ki= Stacking factor, average value 0.9

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 M.M.F for teeth
The calculation of teeth m.m.f is difficulty due to
1.The teeth are wedge shaped or tapered:
Different values of flux density over the teeth length
2.Slot shunting the tooth: The reluctance of one part
effect the other.

Calculation of m.m.f required for tapered teeth

(a) Graphical Method
(b) Three ordinate method(Simpson’s Rule)
(c) Method

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 1. Graphical method
•M.m.f per meter not uniform for the
whole length.

•Graph showing variation of ‘a-t” over

tooth length

•The total m.m.f for the teeth = ∫H.dl

•Total m.m.f required for the tooth,

ATt= mean ordinate × height of tooth

The height of tooth, ls = depth of slot, ds

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 2. Three ordinate or Simpson rule method
Applied to teeth of very simple form
and small taper

Assumption- curve relating ‘at’ vs ‘B’ is

parabola

‘at’ is obtained from ends of the tooth

and its centre

Mean value of ‘at’

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 3. Method
• Applied for teeth of smaller taper.
• Most simple method
• ‘at’ at one-third length is calculates and multiplied by
teeth length or slot depth.
=Flux density at 1/3rd height from narrow end

Total m.m.f for teeth,

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 Real and Apparent Flux densities
•Flux follows the path through iron
•Slots provide alternate path for flux
•So the flux pass through the slots
can not be avoided
•Real flux passing through the teeth
is always less than the total flux
•Real flux density in the teeth is
always less than the apparent flux
density .

Bapp:
Total flux in a slot pitch/tooth area
Breal:
Actual flux in a tooth/tooth area

Binesh Mohan, AP in EEE, CETkr 67

 Real and Apparent Flux densities cont…
• The flux over one slot pitch, two parallel paths
1. Iron Path:
Area of Iron path, Ai= Tooth width × net Iron length =Wt ×
Li
2.Air Path:
Area of air path, Aa =Total area-Iron area
=(Slot pitch × core length)-(tooth width × Net iron length)
=
If Φs= Φi+ Φa
Φi= Flux passing through iron over a slot pitch
Φa= Flux passing through air over a slot pitch
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