Design of Commutator and Brushes

 Commutator and brush arrangement are used to convert the bidirectional current to
unidirectional current

 Brushes are located at the magnetic neutral axis ( mid way between two adjacent
poles)

 The phenomenon of commutation is affected by resistance of the brush, reactance

emf induced by leakage flux, emf induced by armature flux.

 Classification of commutation process

 Resistance commutation

 Retarded commutation
 Accelerated commutation

 Sinusoidal commutation

 Commutator is of cylindrical in shape and placed at one end of the armature

 Consists of number of copper bars or segments separated from one another by a

suitable insulating material of thickness of 0.5 to 1mm

 Number of commutator segments = no. of coils in the armature

 Materials used :
 Commutator segments: Hard Drawn Copper or Aluminum Copper

 Insulation :Mica, Resin Bonded Asbestos

 Brushes :Natural Graphite, Hard Carbon , Electro Graphite, Metal Graphite

Design formulae
1. No. of commutator segments, C = ½ u.S a

where, u – coils sides/slot

Sa – no. of armature slots

2. Minimum no. of segments = Ep/15

3. Commutator segment pitch = βc = πDc/C

where,
Commutator Diameter Dc – 60% to 80% of diameter of armature

βc ≥ 4mm
4. Current carried by each brush Ib= 2Ia/P for lap winding
Ib= Ia  for wave winding

5. Total brush contact area/spindle Ab= Ib/δb

6. Number of brush locations are decided by the type of winding

 Lap winding: No of brush location = no. of poles
Wave winding : No of brush location =2

7. Area of each individual brush should be chosen such that , it does not carry more
than 70A

Let ,

ab – Contact area of each brush

nb – Number of brushes / spindle

 Contact area of brushes in a spindle, Ab = nb. ab

also ab = wb.tb

Ab = nb. wb.tb

Usually, tb = (1 to 3) βc

wb = Ab/ nb. Tb = ab/tb

8. Lc – depends on space required for mounting the brushes and to dissipate the heat
generated by commutator losses

Lc = nb(wb + Cb) + C1 + C2

where, Cb - Clearnace between brushes (5mm)

C1 - Clearance allowed for staggering of brushes (10mm, 30mm)

C2 – Clearance for allowing end play (10 to 25 mm)

9. Losses :

 Brush contact losses: depends on material, condition, quality of

commutation

 Brush friction losses

Brush friction loss Pbf = μ pb AB.Vc

μ – Coefficient of friction

pb-Brush contact pressure on commutator (N/m 2)

AB - Total contact area of all brushes (m2)

AB =P Ab (for lap winding)

= 2 Ab (for wave winding)

Vc – Peripheral speed of commutator (m/s)

 Design of Interpoles

 Interpoles: Small poles placed between main poles

 Materials Used: Cast steel (or) Punched from sheet steel without pole shoes

 Purposes:

 To neutralize cross magnetizing armature MMF

 To produce flux density required to generate rotational voltage in the coil

undergoing commutation to cancel the reactance voltage.

 Since both effects related to armature current, interpole winding should be

connected in series with armature winding

 Average reactance voltage of coil by Pitchelmayer’s Equation is, Erav = 2Tc ac Va.L .λ

Inductance of a coil in armature =2Tc2 .L .λ

 Normally, Length of interpole = length of main pole

Flux density under interpole, Bgi = ac. λ .(L/Lip)

where, Lip- length of interpole

In general,

Bgi = 2 Iz. Zs. (L/Lip). (1/Va.Tc).λ

mmf required to  mmf required to over come 

ATi    
establish Bgi  armature reaction 

MMF required to establish Bgi = 800000Bgi.Kgi.lgi

MMF required to 
 Iz .Z
overcome   ( without compensating winding)
2P
armature reaction
I .Z
 (1 -  )  z  ( with compensating winding)
AT 2P
No.of turns  i
Ia
Current density in 
, δi  2.5 to 4 A/mm
2

interpole winding 
Area of X - section of  Ia
A ip 
interpole conductor,  δi
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