Net Length of Iron (Unit-2 DC machines)

The cores of magnetic circuits are built up with laminated sheets and these are insulated from each other by varnish
(i.e., Kaolin clay or enamel).

In order to improve the effective cooling of the machine, the length of the core is divided into pockets of about 40 to
80mm width separated by vent spacers.

These vent spacers form ventilating ducts through which air is circulated. The ducts are radial as shown in fig.(a) and
their width normally varies from 8 to 10mm.

From above, it is clear that whole of the machine is not occupied by the iron. Some part of the length is taken by
insulation between steel laminations and air spacers created by irregularities in thickness of lamination.
𝑨𝒄𝒕𝒖𝒂𝒍 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝑰𝒓𝒐𝒏 𝒊𝒏 𝒂 𝒔𝒕𝒂𝒄𝒌
It is used to define Iron space factor called stacking factor, 𝑲𝒊 = 𝑻𝒐𝒕𝒂𝒍 𝒂𝒙𝒊𝒂𝒍 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒅 𝒔𝒕𝒂𝒄𝒌

Gross iron length 𝐿𝑔 = 𝐿𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑠𝑙𝑜𝑡 𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟

= 𝐶𝑜𝑟𝑒 𝐿𝑒𝑛𝑔𝑡𝑕 − 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑣𝑒𝑛𝑡𝑖𝑙𝑎𝑡𝑖𝑛𝑔 𝑑𝑢𝑐𝑡𝑠 = 𝐿 − 𝒏𝒅 𝑾𝒅

Net iron length 𝑳𝒊 = 𝑲𝒊 ( 𝑳 − 𝒏𝒅 𝑾𝒅 )

Stacking factor, 𝐾𝑖 depends thickness of plate and the type of insulating material employed. The manufacturers specify
the 𝐾𝑖 for a single lamination. A 0.9 may be assumed for all practical purposes.

Real and apparent flux densities

Slot flux due to saturation in teeth

The flux entering an armature from the air gap flows in teeth. The air gap flux while entering the tooth section divides
along two parallel paths. One part is passing through the tooth. Other part is passing through the slot.

As per concept, flux is only confined to iron only. But at higher flux density, a flux passing through slot becomes large
and it cannot be neglected. Any calculation based on upon no slot flux leads to wrong result. As a result the real flux
density in the tooth is always less than the apparent flux density. (𝐵𝑟𝑒𝑎𝑙 < 𝐵𝑎𝑝𝑝 )

Let, 𝐵𝑎𝑝𝑝 = 𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 flux density; 𝐵𝑟𝑒𝑎𝑙 = 𝑟𝑒𝑎𝑙 𝑓𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦

𝑻𝒐𝒕𝒂𝒍 𝒇𝒍𝒖𝒙 𝒊𝒏 𝒂 𝒔𝒍𝒐𝒕 𝒑𝒊𝒕𝒄𝒉 𝝓𝑺

𝐵𝑎𝑝𝑝 = =
𝑻𝒐𝒐𝒕𝒉 𝒂𝒓𝒆𝒂 𝑨𝒊

𝑨𝒄𝒕𝒖𝒂𝒍 𝒇𝒍𝒖𝒙 𝒊𝒏 𝒂 𝑻𝒐𝒐𝒕𝒉 𝝓𝒊

𝐵𝑟𝑒𝑎𝑙 = =
𝑻𝒐𝒐𝒕𝒉 𝒂𝒓𝒆𝒂 𝑨𝒊

In actual machines, taking flux over one slot pitch (there are two parallel paths)
1. Iron path
Area of iron path , 𝑨𝒊 = 𝑻𝒐𝒐𝒕𝒉 𝒘𝒊𝒅𝒕𝒉 𝑿 𝑵𝒆𝒕 𝒊𝒓𝒐𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 = 𝑾𝒕 𝑿 𝑳𝒊
2. Air Path
Area of air path, 𝑨𝒂 = 𝑻𝒐𝒐𝒕𝒉 𝒂𝒓𝒆𝒂 − 𝑰𝒓𝒐𝒏 𝒂𝒓𝒆𝒂 𝒘𝒊𝒅𝒕𝒉 𝑿 𝑵𝒆𝒕 𝒊𝒓𝒐𝒏 𝒍𝒆𝒏𝒈𝒕𝒉(𝑾𝒕 𝑿 𝑳𝒊 )
= 𝑺𝒍𝒐𝒕 𝒑𝒊𝒕𝒄𝒉 𝑿 𝒄𝒐𝒓𝒆 𝒍𝒆𝒏𝒈𝒕𝒉 − ( 𝑾𝒕 𝑿 𝑳𝒊 )
If flux over one slot pitch
𝜑𝑆 = 𝜑𝑖 + 𝜑𝑎
𝜑𝑖 = 𝑓𝑙𝑢𝑥 𝑝𝑎𝑠𝑠𝑖𝑛𝑔 𝑡𝑕𝑟𝑜𝑢𝑔𝑕 𝐼𝑟𝑜𝑛 𝑜𝑣𝑒𝑟 𝑎 𝑠𝑙𝑜𝑡 𝑝𝑖𝑡𝑐𝑕
𝜑𝑎 = 𝑓𝑙𝑢𝑥 𝑝𝑎𝑠𝑠𝑖𝑛𝑔 𝑡𝑕𝑟𝑜𝑢𝑔𝑕 𝑎𝑖𝑟 𝑜𝑣𝑒𝑟 𝑎 𝑠𝑙𝑜𝑡 𝑝𝑖𝑡𝑐𝑕
𝜑𝑆 𝜑𝑖 𝜑𝑎
𝐵𝑎𝑝𝑝 = 𝐴𝑖
= 𝐴𝑖
+ 𝐴𝑖
𝜑𝑎 𝐴𝑎
= 𝐵𝑟𝑒𝑎𝑙 + 𝐴𝑎
∗ 𝐴𝑖
---------(1)

𝐵𝑎𝑝𝑝 = 𝐵𝑟𝑒𝑎𝑙 + 𝐵𝑎 𝐾 − − − − − − − (2)

𝐵𝑎 = 𝑓𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑎𝑖𝑟 = 𝜇0 𝐻 = 4𝜋 𝑋 10−7 ′𝑎𝑡 ′ 𝑟𝑒𝑎𝑙
where ′𝑎𝑡 ′ 𝑟𝑒𝑎𝑙 = mmf/meter across the tooth for tooth density , 𝐵𝑟𝑒𝑎𝑙
𝐴𝑎 𝑎𝑖𝑟 𝑎𝑟𝑒𝑎 𝐿𝑦 𝑠 − 𝐿𝑖 𝑊𝑡
In equation (1) K= = =
𝐴𝑖 𝑖𝑟𝑜𝑛 𝑎𝑟𝑒𝑎 𝐿𝑖 𝑊𝑡

From (2) , 𝐵𝑟𝑒𝑎𝑙 = 𝐵𝑎𝑝𝑝 − 4𝜋 𝑋 10−7 ′𝑎𝑡 ′ 𝑟𝑒𝑎𝑙 ∗ 𝐾

𝐿𝑦 𝑠 𝐿𝑖 𝑊𝑡
𝐵𝑟𝑒𝑎𝑙 = 𝐵𝑎𝑝𝑝 − 4𝜋 𝑋 10−7 ′𝑎𝑡 ′ 𝑟𝑒𝑎𝑙 −
𝐿𝑖 𝑊𝑡 𝐿𝑖 𝑊𝑡

𝐵𝑟𝑒𝑎𝑙 = 𝐵𝑎𝑝𝑝 − 4𝜋 𝑋 10−7 ′𝑎𝑡 ′ 𝑟𝑒𝑎𝑙 𝐾𝑆 − 1

𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑣𝑒𝑟 𝑎 𝑠𝑙𝑜𝑡 𝑝𝑖𝑡𝑐 𝑕 𝐿𝑦 𝑠
Where ,𝐾𝑆 = 1 + 𝐾 = =
𝐼𝑟𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑣𝑒𝑟 𝑎 𝑠𝑙𝑜𝑡 𝑝𝑖𝑡𝑐 𝑕 𝐿𝑖 𝑊𝑡

Problems based on real and apparent flux density

1. Calculate the apparent flux density at a particular section of a tooth from the following data: Tooth width =12mm; slot
width =10mm; gross core length =0.32mm; number of ventilating ducts =4 each 10mm wide; real flux density = 2.2
wb/m2. Permeability of teeth corresponding to a real flux density = 31.4 X 10-6 H/m: stacking factor =0.9.

2. Determine the apparent flux density in the teeth of a DC machine when the real flux density is 2.15 wb/m: slot pitch is
28mm, Slot width is 10mm and gross core length 0.35m. The number of ventilating ducts is 4, each 10mm wide. The
magnetizing force for a flux density of 2.15 Wb/m2 is 55000 AT/m. The iron stacking factor is 0.9.

3. Find the apparent tooth density at a section of the tooth in the following case when the real tooth density at that
section is 2.15 Wb/m2. Gross armature length is 32cm; number of ventilating ducts = 4, each 1 cm wide. Tooth width at
the section =1.2 cm, slot width = 1 cm. Permeability of the teeth corresponding to real tooth density = 35.8 X 10-6.

4. Calculate the apparent flux density at the armature tooth section of DC machine from the following data at that
section, slot pitch 2.5cm; slot width 1.2cm, length of armature core including 5 ducts each 1cm wide, is 45cm; core
stacking factor is 0.92. Real flux density in the tooth at the section is 2.2 Tesla, for which ampere turns required per
meter is 70,000.
5. Determine the air gap length of dc machine from following particulars: L = 0.12 m, number of ventilating ducts =1,
width of duct = 10mm, slot pitch = 25mm, slot width = 10mm, carter’s co efficient = 0.32, gap density at pole centre =
0.7 wb/m2, field mmf per pole = 3900 A, mmf required for iron part of magnets =800A.

6. A 16 kw, 230 V, 4 pole DC machine has following data D = 0.25m, L= 0.125m, l g at pole centre = 2.5mm, flux per pole=
11.7 X 10-3 wb, ratio of pole arc to pole pitch =0.66. calculate air gap mmf (ATg), Condition (i) smooth armature surface
(ii) slotted armature surface and Kg