Constructional Features of DC Machines 7 Procedure for developing armature winding diagram (i) Collect data about C, S, P and type of winding. (i) Calculate various pitches Y, Y, and Yp (ii) Prepare winding table indicating the back and front end connection between different coil sides. (iv) Represent slot and coil sides in a diagram. (v) Connect the coil sides according to winding table. (vi) Represent commutator segments in the diagram and draw connecting lines between segments and front end connections. (vii) Mark the main pole regions to which the various coil sides belong to, as (Nj, Sj, Nyy Sp, etc) (viii) Mark current direction in the coil sides with reference to pole region, direction of movement and mode of operation. (ix) Prepare equivalent ring winding diagram with reference to winding table. (x) Transfer the current direction marked in the coil sides shown in main winding diagram to equivalent ring winding. (xi) Locate the brush position in the ring winding diagram (xii) Transfer the brush positions to main winding diagram (xiii) Interconnect all positive brushes together and negative brushes together to bring out resultant armature terminals. The exhaustive procedures listed in the above 13 steps are essential only for the beginners to understand the various aspects of armature winding. The following examples illustrates the above procedure for simplex lap winding and simplex wave winding. 1.5.1 Simplex Lap Winding Example 1.1: Develop simplex lap winding for a 12 slot, 4-pole DC armature with 12 commutator segments. Solution: Step (i): Data: Type: Simplex lap. $= 12, P=4, C= 12 («. No. of coils = No. of commutator segments) Step (i); Calculation of pitches: For progressive simplex lap winding, refering to Table 1.1, Y= +2. yj=2C eK =e 7 =64K Y, should be an odd integer nearer to 2C/P. Odd integers S and 7 are equally nearer “to 207P = 6, Selecting ¥, = 5 will give rise to short pitch coil as the value is less than JP 6. Selecting Y, = 7 will give full pitch coll. Unless, otherwise s 70 for a full pitch coil in DC armature winding. Therefore choose ¥,=6+1=7 K8 Electrical Machines | From eqn. (1.6) ¥,=¥,-¥=7-2=5 Step Winding table: 2C =24; ¥,=7; ¥p =5 Table 1.2: 4 pole simplex lep 24 coil sides ‘S.No. | Top coil side | Bottom coil side 1 1—G¢ ¥) 8 2 3-¢ % 4 10 3 5 12 4 7 14 5 9 16 6 ul 18 7 13 20 8 15 2 9 17 24 10 19 (26)2 nl ai (28)4 12 23 30)6 13, 1 - The Table (1.2) is formed in a Zig-Zag manner. Starting from coil side 1 in row 1, back- pitch Y, is added to obtain the bottom layer coil side number 8 to have the back end connection. Now go down cross-wise by subtracting front pitch value from previously obtained bottom layer coil side to obtain the top layer coil side number as 3. Coil sides 8 and 3 are to be connected on the front side. Following the above procedure, obtain the entries in the table so that all the coil side numbers are used only once. Therefore number of effective rows in this winding table is equal to number of coils. At the final verification row, you should end up with the starting coil side, say 1 as DC armature winding is a closed winding. Step (iv): Representation of slot and coil sides. ye gt 5p oF tat 43 15 A7H A971 24) hk eh 23) 3p 1 of egy ho oh hh hh hoof fof oh hk hh fp oh hh ho of of of oh oh fh fob oh hp ho of ohh oh hh oh hh ho of fh oh hh hh hh hoof hf hf fe hoo eh He ot fe 12 ha he he hto Ia Ina Ine Ine heo hk 20 h22 lea Fig. 1.17: Representation of slots and coil sides ‘As shown in Fig. 1.17, initially draw 12 solid lines of equal length and equal spacing. These initial 12 solid lines represents 12 slots in the armature. To represent coil sides within the slot, make use of initial solid line you have drawn as the first top layer coil side in the slot. Now draw dotted lines nearer to the initial solid line representing the first bottom layer coil side in the respective slots.19 Construction! Features of DC Machines top and bottom layer coil sides are to be placed in the same slot, lid line and dotted line for each slot i.e if u = 4 draw two solid drawn alternatively closer to each other. Similar lines for the next ‘om the previous ones. In this example u = 2, Hence present two coil sides per When another set of then draw one more so! ines and 2 dotted lines, slot should have sufficient spacing fr seach slot, one solid line and one dotted line is drawn to re slot. ‘Then assign represented by represented by Step (v): Back and front end connectiot numbers to the coil sides. Odd numbers are assigned to top layer coil sides wolid lines and even numbers are assigned to bottom layer coil sides dotted line as shown in Fig. 1.17. ns: Main winding diagram is shown in Fig. 1.18. Here coil sides shown in Fig, 1.17 are reproduced, then back and front end connections are given with reference to the winding Table (1.2) prepared in step (iii). While showing the back and front end connections, connections from and to the top coil sides till the mid- point is shown by solid lines. Similarly, connection from and to the bottom coil sides are shown by dotted lines. Although the actual connection gives ris ise to continuous close circuit, but when represented in a linear diagram it has to be broken some where. The continuation points at the left and right ends that are marked as 7,, Ty Tsp Tp, and T,3 correspond to the connection towards the respective coil sides. Points F,, Fy, Fig, Fy» and Fzg correspond to the connection from the respective coil sides. Step (vi): Connection to commutator segments: ‘The 12 commutator segments are represented by 12 rectanglular boxes drawn nearer to each other and numbered as shown in Fig. 1.18. The segments representation is drawn slightly below the front end connections. Solid vertical lines are then drawn from the top mid-point of each segment towards the front end connections, thus representing the connections between armature coils and commutator segments. ‘Step (vii): Allocation of coil sides to pole regions: In this example, the DC machine has 4 poles. The total circumferencial length of the armature includes the distance between slots 1 to 24 and a spacing between the 24" slot and the Ist slot. This distance is equally divided into 4 equal parts corresponding to 4 pole. Allocate them as alternate north and south pole regions say N,, S,, Np, and Sy. Step (viii): Marking current direction in the coil sides: If the mode of operation, either generator or motor, and direction of movement of armature are specified, then the current direction in the coil sides can be marked in accordance with them. Flemming’s right-hand tule is followed for finding the current direction when the mode of operation is a generator. When the machine operates as a motor, Flemming’s left-hand rule can be followed to find the current directions. Instead, we can also arbitrarily assume a particular current direction to all the coil sides which are under north pole regions and opposite current directions to the remaining coil sides which are under south pole regions. i In Fig. 1.18, coil sides 1 to 6 and 13 to 18 are under the two north pole regions Ny and N, respectively. On these coil sides arbitrarily a downward current direction is marked.20 : Electrical Machines | Coil sides 7 to 12 and 19 to 24 are under the two south pole regions Si and S; ae The opposite direction namely upward current direction is marked on these coil sides. Step (ix): Preparation of equivalent ring winding diagram: The purpose of drawing the equivalent ring winding diagram is two-fold. (i) To fix the brush positions and (ii) to account the number of parallel paths offered by the winding, __ Inthe main winding diagram, the coil sides are represented as per their actual placement in the armature slots, where as in the equivalent ring winding diagram, cach coil side is Tepresented separately and arranged in the order of connection carried out following the winding Table 1.2. Fig. 1.19 shows the equivalent ring winding diagram of the main winding diagram shown in Fig. 1.18. $1 $1 ——s_ —— ng +» 82 Fis Fat Fig. 1.18: Main winding diagram-4-pole simplex lap winding ‘Step (x): Current direction in ring winding: List out the current directions in different coil sides in the top of the ring winding diagram as shown in Fig, 1.19. These current directions are now transferred to the coil sides represented in the ring winding. Ni — 1106 si — Tie + N2— 181018 82 — 191026 tL) ¥ HY) Cay Jas) 7) 9) a 2a): t al Jrol Jaa Jr fro fral Jeol Joa Jarl J al J a J cy a fe] a Fig. 1.19: Equivalent ring winding dingram—4-pole lap winding, ‘Step (xi): Location of brushes: Starting from the left of the equivalent ring winding | diagram, look for adjacent pair of coil sides having same current directions.Constructional Features of DC Machines 4 Coil sides 12 and 7 are adjacent to each other and carry the same upward current direction. The front end connection between these two coil sides is the location of a particular polarity brush, say a negative (-) brush. Similar location in the front connection can be seen between coil sides 24 and 19. This corresponds to another negative brush location. ‘The pair of adjacent coil sides 18 and 13 carry the current in the same direction. But now as the direction is downwards, the front end connection between these two coil sides gives the location of a positive brush. Similarly, another positive (+) brush location is found in the front end connection between coil sides 6 and 1. Now 4 brush positions are obtained. The number 4 corresponds to the number of poles. ‘Therefore, in a lap winding, the number of brush arms required is equal to the number of poles. Step (eii): Transferring the brush position to main winding diagram: The previous step gives the location of brush position in 4 different end connection points between specified coil sides. Now, refer the main winding diagram and find the corresponding commutator segment on which the brushes are to be situated. Front end connection between coil sides 12 and 7 correspond to segment number 4 where the first negative brush can be situated. While marking brush representation on the commutator segment, the brush width should be shown, at least twice the width of the commutator segment. Similarly, segment no. 10 is the location of second negative brush. Segments 1 and 7 are the two segments where two positive brushes are to be located. Step (xiii): Marking armature terminals: Interconnect all the positive brushes together and bring out a resultant terminal. This corresponds to one of the armature terminal ‘A’. Similarly, interconnect all negative brushes and bring out a resultant terminal and name it as second armature terminal ‘AA’. With these thirteen steps followed one after the other we can complete a DC armature winding diagram. Number of parallel paths ‘The equivalent ring winding diagram shown in Fig, 1.19, apart from helping us to locate the brush positions, also helps us to understand the number of parallel paths offered by a simplex lap winding, Fig. 1.20 is a rearrangement of Fig. 1.19. Fig. 1.20: Parallel paths offered by 4-poles simplex lap winding22 Electrical Machines | It is clear that the entire winding is divided into 4 parallel paths. Again, the number 4 corresponds to the number of poles given in the example 1.1. Therefore, the number Of parallel paths (A) offered by simplex lap winding is equal to the number of poles. ie A= P for simplex lap winding (1.8) The number of coil sides or conductors in each parallel path is therefore, is the total number of coil sides or conductors divided by the number of parallel paths 4 = P Similarly, current through each armature conductor is =“ (1.9) A 7—2a for simple lap winding (1.10) P 1.5.2 Simplex Wave Winding Example 1.2: Develop a simplex wave winding for a 13 slot, 4-pole DC armature with 13 commutator segments. Solution: Step (i) Data: Type - simplex wave S= 13, P=4,C=13,u=2 : 2C42_2C+2 Step (it) 1 ieee _@x13)+2_1, 42 y= = Bax P 4 =6.5+0.5=7 Yy=¥-¥,=14-7=7 Step (iii): Winding Table: H%=7 Y=7 2¢=26 In Table 1.3 starting from coil side 1 in row 1, back pitch Y, is added to obtain the bottom layer coil side number 8 which is to be connected at the back side. To obtain the front end connection, go down cross-wise by adding front pitch Y, Therefore, coil sides 8 and 15 are to be connected at the front side. This procedure is repeated till all coil sides are connected. ‘Steps (i) to (viii): Preparation of main winding diagram: After representing slots and coil sides in Fig. 1.21 back and front end connections _ between coil sides are indicated with reference to winding Table 1.3. ___ Corresponding to 13 coils, 13 commutator segments are represented. The vertical lines m the centre of each segment makes connection between coils and commutator segments. neial length of armature comprising 13 slots are now equally dividedConstructional Features of DC Machines ae 23 | E = | 2 i a 6 x 4q « = t = cI e = ra aq = a » w ‘ ° &) 1 . a 8 Fig, 1.21: Main winding diagram-4 pole simplex: wave winding into 4 sections, corresponding to 4 poles. The first north pole 1, region covers the first 3 slots accomodating coil sides 1 to 6. Coil sides 7 to 12 lies under the first south pole ,. Coil sides 15 to 20 lie under second north pole Nz and coil sides 21 to 26 lie under second south pole S, Slot No. 7 consisting coil sides 13 and 14 lie exactly at the mid: ‘way between S, and N.Constructional Features of DC Machines 25 that the coil sides enclosed between adjacent similar brushes should have the least emf. Therefore, the location of additional positive brush can be selected as the front end connection between coil sides 6 and 13 as coil side 13 does not have any emf. Similarly, additional negative brush is fixed at the front end connection between coil sides 14 and 2. These brushes are shown in Fig. 1.22 in dotted lines. Steps (cit) and (xiii): Now transfer these brush locations to the main winding diagram. The interconnection between the two positive brushes forms one of the armature terminal ‘A and the interconnection between the two negative brushes forms another armature / terminal AA. These thirteen steps complete the development of a simplex wave winding. Number of parallel paths To find the number of parallel paths offered by simplex wave winding, the equivalent ring winding diagram shown in Fig. 1.22 is now rearranged as shown in Fig. 1.23. ta T1823 BS 12 19 26 Fig. 1.23: Parallel paths offered by 4 pole simplex wave winding From Fig. 1.23 only two parallel paths are found. Therefore, a simplex wave winding always offers only 2 parallel paths, irrespective ofthe number of poles the machine has. A = 2 for simplex wave winding (i. I, is the total armature current then current through each armature conductor J, is given by eqn. 1.12 qa : a T=) for simplex wave winding (1.12) 1.5.3 Multiplex Windings From the two examples considered, a simplex lap winding gives rise to P number of parallel paths, whereas, a simplex wave winding gives 2 parallel paths. Suppose, a number of parallel pats requied is other than tat given by simplex lap or wave winding. multiplex lap oF wave windings can be followed. A multiplex winding gives the number of parallel ‘ats_as the integer muliples of that piven by simplex swindinas— focexample for a pole DC machine the simples lap winding will give 6 parallel path, whereas simplex wave winding will give only 2 parallel paths. If 4 parallel_paths are required for 6-pole machine then a duplex wave winding may be followed which will give twice the parallel path that is given by simplex wave w able 1.4 gives the number of parallel paths offered by different types of a DC armature ature windings.) 26 Electrical Machines | Table 1.4: Parallel paths offered by DC armature windings S.No. | Type Multiples | Lap_| Wave 1 | Simples P - 2 | Duplex oP 3 | Triplex 3p | 4 | Quadraplex 4P m_| Multiplex mP sy Equalizer rings In Fig. 1.20 the coil sides are grouped into 4 parallel paths. Further, coil sides belonging to each parallel path lie under adjacent pair of pole regions, N\S,, SyN2, NpS, and S,N). It is impossible to have equal or identical air gap length between different pole faces and armature surface, even if more attention is paid at the time of construction. That is, _ fo say, if the air gap length under the first north pole Nj, is 3 mm, the length under 5, may be 2.95 mm under N, it may be 3.05 mm and at S, it may be 3.02 mm. This difference “in air gap length causes the flux in different pole regions to have slight difference in value. Therefore the net emf av: across each parallel path, induced by coil sides belonging io adjacent pair of poles, differ slightly from one another. The emf induced by coil sides belonging to NS, regions may be, say, 230 V. while it may be 232 V, 228 V, and 231 V in the second, third and fourth parallel paths set up by coil sides belonging to S,N,, N,S, and S,N; respectively as shown in Fig. 1.24. When «the interconnected brushes are placed on the commutator segments, the unequal emfs set up circulating currents in the coil sides through the brushes and commutator segments. In Fig. 1.24, for example a circulating current of 8 A may flow from one positive brush to the other positive brush and a circulating current of 6 A may flow from one negative brush to the other negative brush, Therefore, even when the machine is on no load condition, a DC generator delivering no current to external load, the brushes and the coil sides carries these circulating current. When the machine is on load, a DC generator delivering a load current of say, 30 A, this load current gets superimposed with circulating currents. This results in unequal currents carried by different brushes. For a load current of 30 A, each brush is suppose to carry 15 A only if there is no circulating current. The presence of circulating current causes the brush current to have values marked in Fig. 1.24 as 7, 9, 23, and 21 A. Obviously, the overloaded brushes will give trouble, like temperature rise, when it goes beyond the tolerable limit, they may spark badly also. This problem can be solved by providing equalizer rings along with the armature winding. Any even number of equalizer rings can be provided on the back side of the armature. Each ring will be connected to P/2 coils which are at the same potential on the back side. Provision of equalizer rings by-passes the circulating current not to pass through brushes.Constructional Features of DC Machines = The problem of circulating current and providing equalizer ring does not arise in wave windings. With reference to Fig. 1.23, the armature winding has parallel pa sides belonging to each parallel path lie under all the poles. Therefo across cach parallel path should be equal, irrespective of unequal a different pole: wk 220 ie 4g 20° Ne Fig. 1.24: Circulating current Selective commutation With reference to Figs. 1.22 and 1,23 the simplex wave winding offer only two parallel Paths. Therefore, it is enough to have one pair of brushes, i.e one positive brush and one ~Pemative brush, 10 collect the armature current. However, it is used to provide number of pair of brushes equal to number of pair of poles. The use of more than one pair of brushes does not divide the armature coil sides into more than two parallel paths, but current collected from the armature is divided between the brushes of like polarity. If the brushes are so selected to have equal resistance, then equal current collection can be obtained from 12 re B wwe te A In| af we we ANB Rig. 1.25: Equal current collection In case of slight differences in contact resistance it is easy to see from Fig. 1.26 that the currents collected by the individual brushes may be different and is called “selective commutation’.28 Electrical Machines | _ | rt als 2 et ae a fa aA . cs la = tet a a oF fof (ia, a @) Fig. 1.26: Selective commutation The brushes must therefore be adjusted very carefully to have equal contact resistance when more than two brushes are used in a simplex wave winding. Comparison Table 1.5 below gives comparison between lap and wave winding. Table 1.5: Comparisons of lap and wave winding S.No. | Point of comparison Lap Wave 1 | Winding piteh_Y 42m (2ce2my(P/2) 2 | Front piteh ¥, ¥,-¥ Y~-¥, 3. | No. of parallel paths A mP 2m 4 | Equaliser rings required Not required 5 | Used for Low voltage High | High voltage Low current Machines | current Machines Dummy coils Sometimes, with a certain number of coils, it will not be Possible to satisfy the equation for winding pitch to have an even integer. This may happen when a standard available laminations has to be used. Still the winding can be carried out by choosing effective number of coils for connection slightly less than that given by number of slots. For achieving mechanical balance, all slots are filled up with the same number of coil sides. But while giving winding connection one or two coils can be left out without any connection. These coils are called dummy coils. Example 1.3: Prepare winding table for a 4-pole DC machine armature having 32 coil sides. Number of parallel path required is 4. Data P= 4,2C =32,4=4 ° Aim Since A = 4 = P, the winding table is to be prepared for simplex Lap winding, (+ve sign for getting full pitch coil)constructional Features of DC Machines 29 Yoi2=42 Y¥,=¥-Y=9-2=7 (for progressive winding) ‘Table 1.6: Winding table C = 16; a¥, = 9; ¥p= 7 S.No. | Top coil side | Bottom coil side 1 1@Y) > 10 a 3%) 12 3 5 4 4 7 16 5 9 18 6 WL 20 1 13 2 8 9 17 26 7 ul 21 30 ger® e¥ 12 23 32 ag i775 13 25 4) u 14 27 (36)4 Sen tee is 29 (38)6 16 31 (40)8 a7 1 Example 1.4: A 6-pole DC machine armature has 20 slots. Prepare a winding table to carry out simplex wave winding with 2 coil sides per slot. Data P= 6,5=20,u=2 Aim To prepare winding table for simplex wave winding y Solution: sf No.of coils C= 1 iS =—x2x20=20 Was 2c 2x20 Yy=StK= LK Pe. 6 =6.66+K =7 2C#2_2x204+2_ 4 P/2 6/2 =Y-Y, =14-7=7. Electrical Machines ‘Table 1.7: Winding table C = 20; 2C = 40; ¥, = 7; Y= 7 S.No. Top coil side Bottom coil side 1 | tem 8 2 15 GY) 22 3 29 36 4 (43)3 10 El sg 24 6 31 38 7 (45)5 12 8 19 26 Ld 33 40 10 (47)7 14, lL 21 28 12 35 (42)2, a8 9 16 14 23 30 15 37 (44)4 16 dW 18 17 on 32 18 39 (46)6 19 13 20 20 27 34, Qi (41 EESEEMFUEQUATION Let P-—No. of Poles T — Total no. of turns Z — Total no. of conductors (Z = 27) A — Number of parallel paths ¢ — Flux per pole in Wb N — Speed in rpm. 4 il na \ ’ teh Fig. 1.27: Single conductor moving around one pole-region -Faraday’s second law accounts for the emf induced in a conductor, as es seed pe d aoe dt a single conductor moving round one pole region, a the conductor is