PRIN. OF ELEC.

MACHINE DESIGN (BATU ELECT, m a x i m u m Ope th

The can reach during
operatio
temperature the insulation

ambient
Gaseous: The examples are emperatur
s t a n d a r d i z e d

and sum
of
the
Alr used in switches, air condensers,
transmission
and is
centigrade,
nissible temp erature ris
permissible

40 degree
hot spot in
for hot spot
distribution lines etc., cables etc. ie. allowance
tolerance
winding.
pressure re of class
capacitors, HV gas and temperature af
rogen use in maximum
dielectric, generally the
not used as a example, 40
Hydrogen though
is (ambient
temperature
allow
spot tolerance
insulation
used as a coolant vapos rise 80
+ hot
and sodium
nen gases neon, arqon, mercury temperature
weakest against heat
lement against
element
heat andis
the
used for neon
generally sign lamps. m Insulation
is
the life
life of el
of
used under high
pressure
factor in deciding
electric
ca
alogens like fluorine, critical

cables satisfies all the equipment.

The
m a x i m u m
operating

of insulation are
temperat
practice different class for
material in
which for
No insulating material prescribed

hours. The heigha

Therefore a
be
healthy lifetime of 20,000
properties must
is uc
desirable
desirable properties for the machine parts
satisfies most of the permitted
temperature
Thermal about 2000C at the maximum. Exceeding th
selected Based on

of Insulating
Materials
temperature will affect the life
Cassification maximum
operating
for thumb, the lifetime of th-
Consideration insulation class) As a rule ot
called the insulation.
The insulation system (also
motors
transformers and
insulation will
be reduced by half for even
generators, winding t
Wires used in
is divided
into The present day trend is
temperature.
electrical
components
10°C rise in
other
wire-wound
temperature
that they machine using class
F insulation for clas
difterent classes
according the design the
t e m p e r a t u r e rise.
can sately w i t h s t a n d

Standard (Thermal evaluation and EXERCISE

As perIndian
IS. No. 1271, 1985,
of Electrical Insulation, of
classification international standard
1. Namne the basic structural parts
revision) and other
first H electromagnetic rotating machine.
classified by letter grades A, E, B, F,
insulation is
the factors those
limit the design of
(previous Y, A. E, B, F, H, C). 2 What are

Table 1.3 machine?

the view point
electrical machines from
Typical Materials cm
Maximum
Sr. tnsulation
3 Classify
No. Class Operating manufacturing process.
Temperature inductiom
inC 4. How the Faraday's law of electromagnetic
electrical
in design of an
90 Cotton, silk, paper, wood, cellulose,
fiber
principle is applied
etc, withoutimpregnation orimmersed machine?
with law as applicableim
105 The material of class Y impregnated Biot-Savart's
natural resins, cellulose esters, insulating
5. Briefly explain
oils etc, and also laminated wood,
electric machine design.
the main dimensions in machine design
6. What are
vamished paper etc.
E 120 Synthetic resin enamels of vinyl acetate or 7. What do you mean by specific loading?
laminates of
nylon tapes, cotton and paper 8 Develop the output equation
withformaidehyde bonding etc () d.c. machine
Mica, glass fiber, asbeslos etc., with
130
suitable bonding substances, built up mica (i) a.c. machine

glassfiber and asbestos laminates 9. What is output coefficient of machine?

size of rotating
155 The matenals of Class B with more thermal
10. What are the factors those affect the
resistance bonding materials machines?
180 Glass fiber and asbestos matenals and built
requirements
of hig
upmica with appropriate silicone resins
11 What are fundamental

conductivity material?
C 180 Mica, ceramics, glass quartz and asbestos
with binders or resins of super thermal 12 Write short note on magnetic material
stability
 Should not consurrie atiy ponst or shy) yaye p

dielectric loss anyle d

Should withstarid stresses due to rentrifugal forres (n
Ir rotatirig machiries), electro dynaric or tmehain a
forces ( as in transformers)
-H/ H Should withstand vibration, abrasiorn, beridirig
+H
Should not absorb Ioisture
Should be flevible and cheap
Factors Affecting the Electrical Properties
B Dirmensions of test piece
.m.s. value, wave form and frequency of inpressed
(c)
Fig. 1.6: Hysteresis loops
voltage
Temperature and moisture conternt of tsst piere
Hard or permanent magnetic materials have large size
Mechanical pressure on test piece
loss is more) and
hysteresis loop (obviously hysteresis Applications of Insulating Materlals Employed for the
gradually rising magnetization curve. insulationof
Ex.: carbon steel, tungsten steal, cobalt steel, alnico, Wires for magnet coils and windings of machine
hard ferrite etc. Larminationsfor Machines and transformers
Properties of Good Magnetic Material Insulating Materlal Classificatlon
The some of the properties that a good magnetic Insulating materials can be classified as
material should possess are listed below. Solid

Low reluctance or should be highly permeable or Liquid

Gas
should have a high value of relative permeability
Vacuum.
The term insulting material is sometimes used in a
High saturation induction (to minimize weight and broader sense to designate also insulating liquids, gas
volume of iron parts) and vacuum.
High electrical resistivity so that the eddy emf and Solid: Used with field, armature, transformer windings etc.
the hence eddy current loss is less The examples are:
Narrow hysteresis loop or low coercivity so that Fibrous or inorganic animal or plant origin, natural or
hysteresis loss is less and efficiency of operation is wood, card board, jute, silk
synthetic paper, cotton,
high etc., rayon, nylon, terelane, asbestos, fiber glass etc,
A high curie point. (Above Curie point or Plastic or resins. Natural resins-lac, amber, shellac etc.,
temperature the material loses the magnetic Synthetic resins-phenol formaldehyde melamine,.
property or becomes paramagnetic, that is polyesters, epoxy, silicon resins, bakelite, Teflon, PVC
effectively non-magnetic) etc

Should have a high value of energy product
(expressed in joules / m).
L.18 INSULATING MATERIALS
o avoid any electrical activity between parts at different
otentials, insulation is used. An ideal insulating material
nould possess the following properties.
Should have high dielectric strength.
Should with stand high temperature.
Should have good thermal conductivity
Rubber natural rubber, synthetic rubber-butadiene,
silicone rubber, hypalon, etc.,
Mineral: mica, marble, slate, talc chloride etc.
Ceramic: porcelain, steatite, alumina etc.,
Glass soda lime glass, silica glass, lead glass,
borosilicate glass
Non-resinous mineral waxes, asphalt, bitumen,
chlorinated naphthalene, enamel etc.,
Liquid: Used in transformers, circuit breakers, reactors
rheostats, cables, capacitors etc., & for impregnation. The

Should not undergo thermal oxidation examples are

Should not deteriorate due to higher temperature and Mineral oil (petroleum by product)
repeated heat cycle
Synthetic oil askarels, pyranols etc
Should have high value of resistivity (like 1018 Wem) Varnish, French polish, lacquer epoxy resin etc,
 MACHINE DESIGN (BATU ELECT.) hysteresis loops
are more or lese
PRIN. OF ELEC. whose narro
Trans.temp.- 1.18
K Uranium- 1.6 (a) and (b)]. silicon steel, nickel kel- iron
Example: Alluminium Figs.
For note that copper,
silver, gold etc, all
0.80 K It is interesting to etc.)
but do not soft magnetic
are very good
conductors at room temp., These materials are called
terials. S
( vice versa for other magnetic materials are used in the
exhibit superconducting

metals and
properties.
alloys) Application
be
of superconductor It
can electrical machines, transformers and nanufacture
nany

transformers rotating electrical

and
machines, electrical apparatus, instruments and devices. kinds
used for the reduction of
depending upon the comparative gain in the Classifications:

full load copper losses against the cost for provision of Solid core materials
cryogenic conditions
Laminated core material for pulsating fluxee
1.17.2 Magnetic Materials
to Electrical sheet and strip
All magnetic materials possess magnetic properties
a greater or a lesser degree. The magnetic properties Special purpose alloys
their relative Solid Core Materials: For steady flux
of materials are characterized by
In accordance with the
value of relative Thees
materials are normally used for parts of magnar
permeability.
permeability, materials may be divided
into three
circuits carrying steady flux as cores of
magnet
Electromagnets, relays and field frame (i.e.
dc
broad classes.
1. Ferromagnetic Materials The relative
d.c. machines. Examples: cast iron, cast steel and Fes
yoke) o
much greater
permeabilities of these materials are cobalt
than unity and these permeability
values are
Laminated Core Material for Pulsating Fluxee
dependent upon the magnetizing force
These materials are normally used for parts-
Relative permeability -ur >> 1 (Nickel, cobalt, iron,
magnetic circuits carrying pulsating flux as cores of d-
steel, silicon steel etc.,)
2. Paramagnetic Materials These materials have armature, stator and rotor of ac machines
their relative permeabilities only slightly greater Electrical Steel Sheets Dynamo Grade Steels: Lo
than unity. The value of susceptibility, is thus silicon content are used in rotating electrical machines
positive for these materials. Transformer Grade Steels : High silicon content ar
Relative permeability -Hr> 1 (Air, Alluminium, used in transformers. Cold rolled grain oriented stee-
palladium etc.,)
3. Diamagnetic Materials: These materials have
(CRGO) is suitable for use in large transformers anca
-

turbo alternators
their relative permeabilities slightly less than
unity.
In both Paramagnetic and
Diamagneticmaterials Special Purpose Alloys : Are used in instrumen-
the value of permeability is independent of the transformers, induction coils and choke. Example
magnetizing force. permalloys, superpermalloy, perminvar etc.,
Relative permeability Hard
ur < 1 (Bismuth, silver, lead, Magnetic Materials
copper, water etc.)
Materials with broad hysteresis
Ferromagnetic materials are very useful for electrical
loops [Fig 1.6 (C)] ars
called hard magnetic materials. These materials ars
engineering applications. Why? used in certain
When types of electrical machines. rating, an
ferromagnetic material is placed in a magnetic
a
in all kinds of
instruments and devices requinns
field, there is considerable
distortion and, therefore, the permanent magnets which set up magnetic fields o
force exerted is
very large. This property makes their own.
magnetic materials very useful for ferro-
electrical engineering B
applications.
Example: ron, nickel, cobalt, and many of their
ferromagnetic. alloys are

Types of Magnetic Materials B

B_
1Soft Magnetic Material
2. Hard H
1.
Magnetic Materials H +H e H
Soft Magnetic
Material
The hysteresis loss
hysteresis loop. For this depends upon the area of
reason, magnetic cores
alternating magnetic fields are made used in
-B
from materials
 2. Material of Low Conductivity conductors
(High
FRI
Aluminum Iron steel Alloys of copper
COpper as resistors
resistance
Material:
u s a y called high
Copper Rela
elative mmunity from ondation and corrosio resistance cos resistance
elements or heatng
Can be tasi trasd as
high m a l e a b i e
&ductle meta' eements- are used to dissipate electrcal energy
lie:1 wn mechi ined easily soldered Anmealed agh heate starting and regulating devices or motors
and har dra tooper warat8e 15ed Uced for heating devvces thermo coupes es stance
tvtyopper
h
ietrical machines

he e5ig coDDe a deposits are Categories According to their Purposes

used for Precision work for makng
I Group: Matenal's
Aluminium

Btig and the pie of copper lu TuBtes dely

standard resstances and resistance boxes
many ppig a t o n
Properties
degrebse
ahumi
1ein smal trarsiorme Stablity of reustance over the pencd
ina'atively lescer than coppe) and wegh doring Aur tuations of termoerature
ryerallx
than toppe) Aumintum teoerature co-efficient
(arsprarenately3 fimet tighr
largi trarztormer incrRRteR Cverall cost ts Mnium thermo electne efect
when e d
in

FeSSfit h tme higher than roppe nd i7e ts mate does ntroduce

han (oDDer easureents
volume apyrosimatel
14 imet greste
Material: Manganin (Cu 86% Mn 12%and Ni 2
due arrount should be taken of ther
whie detigning
differe es in esitivity cost weigh conductivity temp n Group: Materials used for making heostats
Properties
et Should have large thermo- emf
Steel Steel alioyed with chromium and
Iron and Large resstance temmperature co-eficiert
Aluminium irobustness with good heat dissipation) for Special Requirement
making starte rheostats Cast iron resistance grids to be igh permissible working temperature ard
in staters of large motors
Used

Alloys of Copper Bronze (copper base alloys contain1ng

Material Constantan (Cu 65% and 40 to 35% N
Sometumes small amounts of manganese and ron ' s
tin cadmium & bernyllhum) po5sesses higher resistvity and
ncluded
mechana strength Berylium copper current carry1ng
m Group : Materals sed for makng heating deces
siidng contacts and iknife switch
springs brush holders eectnc furmaces and loading hecstats
blades admium copper contact wires and commutator
Special Requirements
segments 8rass (66% Cu and 34% Zinc) has greater Hgh permussatble workung temperature ow

mechanica strength wear resistance and ower and shoulid have non-corrosive
conductivit widely used in current carry1ng materials Material Nchrome (Nickel chromum nd
0.06% to 0.19%) has (optimum workung termperature- 900 to :000
Coppe silver alloy (99.10% and
resistance to thermal shortening and creep (turbo 3. Electrical Carbon Materiais ectrca
matenais are made trom grapnite and other torms
alternators
carbon coal
Best conducing material is silver. Next best is copper and
Properties
then aluminum Properties of these are compared in the
Negative temp Co eficent contact Gitage r o t
foliowing tabie decreases with increasing temp
Table 1.2
LOw wear and tear (due to seif luoncant property
Material:Carbon, carcon graphite graphite aecs
S .No
Propenty Unit Silver Copper Aluminium graphite metal graprte usec for maxing brusnes tor
eectncal mad
Conauctivity 10 0975 0.585
4 Super Conducting Materiais : Matenais =«nDin
1 TT7 280 zero value or resistvity are known as uper conductors
fesistivity A-Cm
A large mDer or metais Decome super-ionduct
emcoe per C 337 393 04
Deio a partcuas teipesase alaLTEf
Cos Pronitativer y LO partica meta Tn tamper at
vans.t.on peratre
fugr
 IN OF ELE
SOLVED EXAMPLES
V
ZnZn 660 500
dc
S00 V
450 rpm, 6-pole

Eample
1.1
A 35D ii
omoture
diometer of 087
m and
= 0.101 wb A50/60
b i t with
gn
ormature hos 66o
wound
etor
m The lap Specific magnetic loading
length of 032 specific
electric and magnetic
Coiculote the po
otAtors
B D 6x0101
x 087x032
Solution: Given 06929 Wb/m
350 w 1.17 ELECTRICAL ENGINEERING MAY
- 450/60 rps
Materials used in Electrical machines AATERLA
D

Z 660
087m three types
1 Conducting
cassfed
V = 500 V 2 Magnetic
6 3 Insulating
L 0.32m Design of electrical machines depends mainy a
Lap wound materials used. low quality
materials ara
machine will be less efficient, more
Specific electric loading bulky, hinh
and higher cost. Operational running cost
higher. A designer should have perfect kn
properties and cost of these materials nowete
Specifc magnetic loading
so that t
can be both efficient and
cost-effective
1.17.1 Conducting Materials
Conducting Materials are of Following Categorin
The power output of the generator
P VMx 10 in kWN
1 High conductivity materials
2. High resistivity materiais
full load current,
3 Electrical carbon materials
P 350
V10
x 500x 10 /00 amps 4 Super conducting materials
Neglecting field current 1. High Conductivity Materials (Low Resistace
for windings of electrical machines and upn
Material with lowest resistance shouid be seikae
curent through
armature current that it contributes lowest ohmic loses to
each armature No. of paraliel paths a efficiency and to reduce temp-rise.
conductor
Requirements of high conductive materials
116.67 amps Highest Possible conductivity least Resste
of res
(a = p in lap wound) Least possible temperature coefficient
specific electric loading Adequate resistance to corrosion
Adequate mechanical strength and ng
acac 1667 x660
TD Tx 0.87
strength
= 28173 amp.cond/m
Suitable for jointing by brazing/solaerny
ac 28173 amp.cond./m so that the joints are highly relilaoie
Induced emi in de
generator lowest resistance.
draw abuin s

Suitable for roll ability

E =Zn =
oZn for lap
winding Conductors of required shape (wire
P a) manufactured
 (BAT

MACHINE
DESIGN Maximum allowable specitic
ELEC. .. (1.6)
N. OF

=
Width of the slot
w,
Let. unit area
of the slot dissipated per
d, = Depth be inferred that
the heat
factor It can
electric loading.
Slot space
proportional to
specific
S =

of armature is
allowable specific
Slot pitch that
=
it is clear
ys From equation (1.6) rise
temperature
8 Current density by
allowable
electric loading is fixed be
related to the value of ac can
can be coefficient. A high
electric loading and the cooling
specific rise is
The temperature
by the
equation, machine when a high
terms used in a
above
.. (1.4) temperature
rise it a
maximum allowable
ac d, (w/y,) 8S allowed. The
insulating
the specific loading determined by the type of
(1.4) it is clear that machine is
insulating
equation In higgh quality
S. in it. When better
From factor
proportional
to slot space materials used
rises
is directly thickness is high temperature
can withstand
insulation
machines, greater materials which
voltage factor for these increased values of specific
used in the machines,
therefore the space
and are
in
required
an increase
in voltage will, in be used. This
results in reduction
lower. Hence loading can
machines is electric
reduction in specific electric
necessitate a machine.
general, the size of the
used if the
loading ac.
value of electric loading may be
value of ac , results in large A high of
Capacity: larger machine is small. The value
. Overload
phase. Which in turn increase
the cooling coefficient of the
ventilation
number of turns per the
reduces the coefficient depends upon
of the machine, cooling
leakage
reactance
machines will
the machine. conditions in the
machine. High speed
overload capacity of value of ac can
and so higher
Permissible Temperature
Rise have better ventilation
4.
e Temperature rise be used.
Let
S Dissipating surface 5. Size of Machine
Q Loss dissipated is clear that ac depends on
From the equation (1.6) it
machines the
c Cooling Coefficient the dimension of the
slot. For large
higher values
8 Current density depth of the slot will be greater and so

if the current density and

p Resistivity of ac can be used. Actually
assumed constant, then
Loss dissipated per x Resistance the slot space factor are
current)' x No.of conductors to the diameter
specific electric loading proportional
unit area of Surface
armature
area of is
armature surface
as slot depth usually depends
upon the diameter.
ZxpL/a
TDL 6. Current Density

.. (1.5) equation, q ac ð p it is clear that a higher

x
TD p ac sp
From the
=

az be used in
value of specific electric loading can a

where, machine which employs lower current density in its

conductors. (because ac = q/ö p).
Also Q/S

density are in the range of 2

values of current
i

The temperature rise, 0 =

Typical
to 5 A/mm. The temperature rise is usually 40°C
9 6/C
(above ambient) for normal applications and cooling

ac p c coefficient is between 0.02 and 0.035°C W-m?

 Machine: value of fiux density in tE
Ee Is hot
.Factors Affecting Size of a Rotating maximum value of flux density in the exceeded. The
exceed
teeth is betv
Speed: machine 1.7 to 2.2 Wb/m.
to the output equation
of a rotating
According 2. Magnetizing Current
with agiven value of kVA rating
Q CDLn, The magnetizing current of a machine ne isis din
directh
proportional to mmf. The mmt is directly proporti
D'L Represent the volume of machine to specific magnetic loading. large value oHence proportional
specific magnetic loading results in increased value of
Speed, n, DL magnetizing mmf and magnetizing current.
The value of magnetizing Current is not
usual
It is clear from outputequation that the volume of active serious design consideration in dc machines. Butin
in
parts is inversely proportional to the speed. Increase increased value of
speed means less volume (smaller size) that is low cost.
induction motors an
magnetprina
current results in low power factor. Hence
Output Co-Efficient: specift
magnetic loading in induction motors is lower than in
According to the output equation of a rotating machine
dc machines. For synchronous machiens the
with a given value of speed
magnetizing current is not so critical and the value of
Q CD Ln,
Output Co-efficient, specific magnetic loading is intermediate between that
of dc and induction machines.
CoD'L 3. Core Loss
t is clear from output equation that the volume of active The loss in any of the
core
part magnetic circuit is
parts is inversely proportional to the value of output
coefficient Co- speed. So Increase
directly proportional to flux density for which it is
in value of co results in
reduction in size and cost of the going to be designed. The flux density is directly
machine...
Co = Output co-efficient proportional to the specific magnetic loading. Hence
the core loss in machine varies
1.16 CHoICE OF SPECIFIC LOADINGS a
directly as the specific
magnetic loading. Thus a
large value of specifc
116.1 Choice of Specific Magnetic Loadings_ magnetic loading results in increased
The choice if specific core loss and
magnetic loading is influence by consequently decreased
certain factors. Some are
general in nature and apply to all
a
efficiency and an increased
types of machines and some are temperature rise.
specific and apply to
individual machines. With a given specific
magnetic loading, the core los
Some general factors are: increases as the frequency of flux
reversals is increased
1 Maximum flux This is because the
density in iron parts of machine hystersis loss is directy
2 Magnetizing current proportional to the frequency and
eddy current loss is
3 Core losses proportional to the square of the
1 that for high speed dc
frequency. It follows
Maximum Flux Density in Iron machines, or high frequency ac
The maximum flux machines, specific magnetic
density in any iron part of machine
must be below a certain in order
loadings must be reduced
limiting value. The maximum achieve lower iron loss.
to
flux density occurs in
stator core).
the teeth of the
armature (or 1.16.2
1.16.2 Choice of
of Specific Electric
Specific Electric Loading
Loading
[Teeth are the portion of the core 1.
between slots]. in Copper Loss and Temp Rise:
large value of ac, needs
The flux greater amount of copper, results in
density in the teeth
is directly losses and large higher copper
specific magnetic loading. Hence the proportional to temperature rise
choice of specific 2.
loading should be such that the Voltage: for high voltage machines, less value of ac
maximum
density in the teeth is not exceeded. value of flux should be chosen,
because it needs large space ro
The maximum insulation.
S p e c i t i C

It is efined as the ratio of total number of ampere Output

Alternating Current Machines
Equation:"Expressed in te
of its main
conductors and the ature periphery at the air gap. dimensions, specific loadings and
Total number of ampere conductors speed."
ac
Consider, m number of phases and having 1 circuit
Armature periphery gap at the air
(parallel path) per phase
The typical values of specific magnetic loading and kVA
alectric loading for various types of rotating machines
rating of machine
Q no. of phases x
o/p voltage/ phasex
are listed in Table 1.1
current/ phase x 10
Table 1.1
mEphlph x103
Machine Specific Magnetic Specific Electric Terminal voltage/phase may be taken to induced
loading Bav in
as equal
Loading acin EMF/phase.
Wblm2 amp.cond.m We have,
0.4 to 0.8 15000 to 50000
DC machine Eph 4.44f6TphKw
Inducton motor 0.3 to 0.6 5000 to 45000 Q m x
4,44f¢TphK x Iph 10 x

SynchronouS machine 0.52 to 0.65 20000 to 40000 But, f p.n/2

Turbo-altemator 0.52 to 0.65 50000 to 75000 Q = mx444 TpnK.Jph x 10

1.15 OUTPUT EQUATION 1.11 k (po 2m Iph Tph) n, 10 x

in terms of its main dimensions, specific Current in each conductor 1, = Iph (as only one
Expressed
loadings and speed." circuit/phase)
Direct Current Machines Total no. of armature conductors

developed by armature in kW Z = no. of phases x (2 x turns per phase)

Power level
= 2mlph
Pa generated EMF x armature current
Total electric loading = 1,2 = 2mlph ph
x 10
= E.l, x 10 Hence, Q 1.11 K(po)l,Z)n,x10
1.11K,(total magnetic loading) (total
But, E 0 Z n electric loading) (synchronous speed)
x10
P Z nx 10 But, po TDL-Bav and I1,Z =tD-ac
Q 1.11 K (TDL-B,) (7D-ac)n, x 10
(p nx 103 since!, = (1.117* Baackx 10 )D'Ln,
(11 Bavack, x 10 )D' Ln,
=
(P ) , Z) nx 10r CD Ln,
Hence, Pa (total magnetic loading) (total electric
where, Co 118aacKw x10
loading) (speed in rps) x 10 = Output co-efficient

P
Specific magnetic loading Bav T-D.L The capacity of usually given either
motor is in horse
O power (h.p) or in Kw.But this has to
be changed in kVA

p 0 T D L Bv kW
Input kVa, Q n coso
*

By substituting these values we get,

The rating of induction motor is given in Horse Power

Specificelectric loading ac = or Z= T.D. ac

HPx0.746
n cos
P =( D L B,) (T D ac) nx10
Full load p.f. usually lies 0.82 to 0.92
= CD Ln
High p.f. is generally obtained with high speed motor.
where, Co B v acx10 The full load efficiency is usually varies between 0.82 to
Co Output co-efficient 0.93
 DIMENSIONS OF ROTATING
1.12 MAIN Motor
MACHINE diameter of stator o
stahs
pert is cyndncal
in tere mn
rairc~acines the actve
sepe Tre voume o te ayinder is Civen b te Stator core length m

s D s the = Speed ps
area o oross seCiO andengn
ard s e eng oi ginder,
ten tihe
s
syinchreneus speed. res
diaerer L

are
DUme s gve by TL4 Theretore D and L No. of voles
sefed s man dimersions Total ne of armature or
statr
cornducters

T= Pole pitch, m

T Tums per vhase

Statur- = Current in each conductor Amp

= Winding factor,
Current per phase. Amp
Induced EME per phase Volt
E
Q = kVA rating of machine
machines
Fig 14 Main damensions of rotating AND RATING OF THE
o d machine D represent the diameter of
1.13 DIMENSIONS
c2se
in MACHINE
aUre and Lr e p r e s e n t the length oi armature
machines is related to its maim
c2se of ac machine D reoresen: the inner diameter of The power rating of rotating
dimensicns namely the armature diameter and amature
represent the length of staror core The
s end L

Fg 5 shows the mein dmensions of roteting length. A few equations are developed are
general
applicable to all types of rotating machines like DC
reites
induction and synchronous machines However it must b=
D. = Diameter ci rotor
mentioned that the design process of ditferent machine
rgh cga cannot be demonstrated with a set of few genern
equetions

1.14TOTAL LOADINGS
Total Magnetic Loading
The Total fiux around the stator periphery at the
gap is called the total magnetic loading
Total magnetic load = po

(a) Main dimensions of DC machines

Total Electric Loading:
The total number of ampere conductors around
t
stator periphery is called the total electric
loading.
Total electric loading = ,Z

Specific Magnetic Loading

u
The Average flux density over the air gap of a machin
is known as specific magnetic loading and it is a
defined as the ratio of total flux around the air gap
a
the area of flux path at the air gap.
(b) Main dimensions of AC machines
Total flux around the air gap
p
Fig. 1.5: Main dimensions of rotating machiness aArea of flux path at the air gap DL
 action between them, while there
to each other, thus a 90°,sin 90° 1 force of repulsion between them if
perpendicular
=
= is a
re
they carry
F B1 Newton currents in the opposite directions.
The value of the flux
density, at the position or
conductor carrying current I2
N Due to current I is
O Flux density B uH =

2D
Electromagnetic force
F BIl
(a) (b)
F 2TD

F
2D hh Newton

(c)
Fig. 12: Force carrying conductor situated
on a current

perpendicular to a magnetic field (Interaction law)

In Fig. 1.2 (a), B represents the flux density of
an

undisturbed (original) magnetic field. The introduction

of a current carrying conductor introduces new
due to
magnetic field. The original field and the field
Conductor combine to produce a resultant field as
shown in (b). The resultant field is distorted in
Fig. 1.2
the neighbourhood of the conductor, the resultant flux (a) Attraction (b) Repulsion
carrying conductor
density being greater on one side and lesser on the
current
Fig. 1.3: Forces between
other and this results production of an
in 3. Alignment
Electromagnetic force in the direction indicated. In field exists in permeability medium lik
a low
ase the increase in flux density on one side is equal to
If a magnetic
air and if piece of high permeability material is placed
the reduction on the other side, the electromagnetic experiences a force which tries to alic
this field, the latter
force is given by Eq. 1.3. that it occupies
it with the direction of field in such away
when either the direction of the current or
the position of minimum reluctance. The principlee
of
direction of the magnetic field is reversed. However, IT is used in reluctan
production of torce due to alignment
e directions of both the current as well as the
motors
agnetic field are reversed, the direction of the force
 Total tlUX n k l g
IN.
PROCEDURE N d , + N,V2 + N,b, N, p.
DESIGN
10 GENERAL
hine has two windings
any elec
trir al ma

n general
has primary
and serondary winding N D (1
The ansformer machine has l
and synhronous
dmahine link with flux
The
The induc tion machine has N,The number of turns which
amature and field winding
in the value of th
there is a change e fu
stator and rotor winding In this caSe
of all electrical linkages of the coil an induced emf is produced is givenb
basic principle of opIation
The
law of induction
machine is governed by faraday's d' Volt
1he energy is (12
in electrical machine dt
Also every
field Hence
transferned through the mAgneti for the ()sign indicates
that the direction of the induced em-
(an be developed
(Jeneral design proc edure
The Change in Flux Linkages can be Caused in Thre
elelktrical machines
designof
is to telate the Main
Ways:
The general design procedule
flux and the fi
imentions of the machine to
its Iated power output The coil is stationary with respect to
certain with respect to time.
machine is designed to deliver a magnitude
An electrical varies in
The rated power
amount of power called rated power 2 The flux is constant with respect to time and
the maximum power
utput of a machine is defined as through it.
can be delivered by machine safely
In de machine stationary and the coil moves

hat 3 Both the changes mentioned above occur togethe

in kW and in ac machine
e power tating is expressed
kVA In Case of motor the output power is expressed (ie)the coilthrough a time varying field.
moves

HP Method 1:Where the coil is stationary and the flux is tim

electrical machines the core and winding of the or pulsational em
varying, an emf called transformer
chine are together called active part. (Because the produced. No motion is involved. There is no enerqy
rgy conversion takes place only in all active part of conversion. The process that really takes place is energ
machine) transference. This principles used in transformers.
eneral output equation can be developed for de
ine which relates the power output to volume of
Method 2: The flux cutting rule can be employedt
illustrate the emf generated in a conductor moving in
part (D'L), speed, magnetic and electric loading.
constant stationary field. The emf generated in a conducto
orly a general output equation can be developed
length moving at right angles to a uniform, stationay
machine which relates kVA rating to volume of
time invarying magnetic field.
part (D'L), speed, magnetic and electric loading.
e BlvVolt
SIC PRINCIPLES B- flux density wb/m (T)
of electromagnetic machines can be related to I = length of conductor (m)
principles which are,
ction
v
linear velocity of conductors (m/s)
The generated
emf in this case is called a "motioned emf
action
Emf generated due to motion of conductor ,since motion s
ment
involved in the production of this emf,the process invoves
Low of Electromagnetic Induction electromechanical energy conversion.
tates that emf induced in a closed electric
This principle is utilize in rotating machines ike D
ual to the rate of change of flux linkages induction machines, synchronous machines.
SW=Ndb Method 3: A conductor
berof turns in a coil
or coil is moving across
stationary time varying magnetic field (flux)and therelore
g with all of them
both transformer as well as motional emf are produced
flux D does not link with all the turns orthe conductor or coil This process involves botn
turns do not link with the same flux. transformer and energy conversion.
 MACHINE

Specitications
RIN.OF
ELEC.

Issued for
Electrical IS4722 1992
Specifications
Standard machines.
rise measurement of
The Temperature
Machines : IS 12802 1 9 8 9
of machines rotating electrical machines
Standard ratings of efficiency
Types of enclosure IS 4889 1968
Method of determination
conductors to be used electrical machines.
dimensions of of rotating of
Standard details and application
ratings and
n a m e plate Guide for selection
Method of marking IS 13555 1993 of driven
used for different types
specifications to be
induction
Performance
three phase
temperature
insulation and permissible equipment.
Types of testing Synchronous
-1973 : Guide for
IS 7132
rise
Permissible losses
and range of efficiency machines.

of machine parts
and
IS 5422
-
1996: Turbine type generators.
Procedure for testing ac and
IS 7572 1974 Guide for testing single-phase
machines
to be provided
universal motors.
Auxiliary equipments characteristics
be adopted IS 8789 1996 Values of performance
Cooling methods to induction motors.
Indian standards (BIS) has laid for three phase
Bureau of for
In India the induction motors
various products. The Three phase
down their
specification (IS) for IS 12066 - 1986
in order to
amended time to time, machine tools.
standards will be outdoor 3-phase
for
developments in technology. IS 1180- 1989 Specifications
include the latest and Non-
machine has to bear transformer 100 kVA. [Sealed
distribution
The name plate of the rotating
ISI specifications. sealed type)
the following details as per transformers.
KW or KVA rating of
machine IS 2026 1994: Specifications of power
transformers.
Rated working voltagge IS 11171 1985 Dry type power
1969 Continuously variable
voltage auto
IS 5142 -

Operating speed
transformers
Full load current
10028 -1985 Code of practice for selection
IS
Class of insulation
installation and maintenance
of transformers.
for power
Frame size IS 10561 1983 Application guide
-

Manufacturers name transformers.

Serial number of the product transformers.
IS 13956 1994 Testing
-

Some of the Indian

Standard Specifications IS 9678 1980 Methods of measuring temperature
1.9.2
Numbers along with Year
of Issue for rise of electrical equipment.
of protections
Electrical Machines are Listed Here IS 12063 1987: Classification of degree
electrical equipment.
for three phase
induction provided by enclosures of
I S 325 1996: Specifications dimensions of rectangular
IS 3855 1966 Standard -

motor. enamelled Copper conductor.

for foot mounted
IS1231- 1974 Specifications IS 449 1962, Standard dimensions of enamelled
induction motor. round Copper conductor (oleo resinous enamel).
Guide for testing three phase
IS 4029- 1967 IS95 1960 Standard dimensions of enamelled round
induction motor.
copper conductor (synthetic
enamel).
and
Specifications for single phase
cc
IS 996 1979 IS 1897 1962: Standard dimensions of bore copper
universal meter.
strip
IS 1885 1993 Specifications for electric and magnetic IS 1666 1961 Standard dimensions of paper covered
Circuits rectangular copper conductor for transformer windings
electric and IS 2068 1962 Standard dimensions of cotton
IS 9499 1980 Conventions concerning

magnetic circuits. covered rectangular copper conductor for transformer

induction
IS 7538 1996 Specifications ofthree phase windings.
applications. IS 3454 1966 Standard dimensions of paper covered
motor centrifugal pumps and agricultural
efficient round conductors used for transformer windings.
IS 12615 1986 Specifications for energy
IS 450 1964 Standard dimensions of cotton covered
induction motor
IS 9320 1979 Guide for testing dc machines round conductors for transtormer Nindings.
 DESJGN : Ihe specifications as lait
PAIAN LEC
MACHINI
9 Consumer's Specifications
in the consumer's order have to and th
be met
down
naulatran

should be such that it satisfied all e

design evoived
sipecificatrons
and also the economic constraints
Mer tanir al parte the
manufacturer
mposed on
specifications ara
Specifications: This the-
eTtstigh

10. Standard because both

Pew fartr on the design the
stran
bvggest
o n t m e r spegifitntign consumer cannot qet awae
manufacturer as
well as the ay
them
30S1anciaredspTifiratior
from thenm
without satisfying
lectreriagrietic rrshine
Saturation 1.9 STANDARD SPECIFICATIONS
mavimum
aliovWBble fluv
materials The
ferrmagnet saturation standard organization to fix standar
determined by the (ountry has
cdersity te be used i Every The specification
material used A high value for the manufacturer
specifications
ipvel of the ferrpmagnetic arnd m a n u f a c t u r e r s to produce economi-
loss
guidelines for the
increased core
results in
flus density
of
in higher tost or the without compromising
quality
increasecd excitation resulting products
are compiling with standardes
introduces harmorucs manufacturer who
feld aystem I1 also The
for their products. The
reduces the a certification
current density and will be rssued
Current Density : Higher
2
the loBses and
certified products will be periodicall
volue of copper but increases
quality of the

monitored by the standard organization

temperature
most important parts of the Standardization and Standards
Temperature Rise: The machine
1.9.1
machne 18 insulatuon
The operating life of a Standardzation and standard specifications play
used in
of insulat1ng materials choice, design manufacture anc
depends upon the types important part in the
materials in turn
The life of insulating
ts constructton operation of any apparatus.
of the machine
the temperature rise fx
depends upon standards organization to
and ventilation techniques are required Every country has a
Proper cooling standard specifications for the
manufacturers.
rise within safe
lumits
tokeep tihe temperature the manufacturer
materials used in a machine The specficaton are guidelines for
Insulation The insulatron
the electrical ,mechan1cal to produce economic products without compromisin
shouic be able to withstand

and tihermastesses which are produced

in the quality
the who compiling with the
machines Yhe type of insulation is decided by The manufacturers are

axinum opeiatng temperature of the machine parts will be 5sued à certification for then
standards
where it is put And also the size of the insulation is
products
decided by maximum voltage stres5 and mechanical The quality of the certufied products will be periodicaile
slresses produced monitored by the standard organization
5 ffficiency: The effiCiency of the machine should be as Advantages of Standardization
ugh as passiDie to reduce the operat1ng costs
To manufacturer
6Mechanical Parts: of mechanical
The construction wne
Reduction in economy resuits
cost as
parts shouid De as Simple as possible and also it is number of objects are built at the same time
lechnologically good The design of mechanical part is
paricularly important in case of higth speed machines Easy to production pianning

Commutation The problem of commutation s Stream-ining the a production ine.

mponant in the case of commutator machines To user
Standardization means interchangeability
Commuialion condituon lmit the maximum output that
Can be laken from a machine equipments and spares
To designe
Power Factor Poo power factor results in larger
values ot (uilent far the same power and therefore t means Rigidity
ialge ionducio Ses nave 1o De used Poner tactor
naian standards tnese are ssued by Bureau o
Zafar
pClel 1 parti uially nputant in case of nauction Standards (6!S), Manak Bhavan, Bahadur Shah
New Dein
The Basic Structure gn or an electrical
of Electrical Machines chine invo solution of
many complex and
It consists of following parts
The Design
engineering problems.
1. Magnetic circuits Problems may be Classified under the
2 Electric circuits Following Four Headings.
1. Electromagnetic design
3 Dielectric circuits
2. Mechanical design
4 Thermal circuits
5. Mechanical parts
3 Thermal design
4 Dielectric design
Cores Frames Each problem
Windings may be solved Separately and the results
are combined to give overall solution. Each of these
three major problems may be further divided into
simple problems and solutions of
Shaft Bearing are
individual problem
combined to give the solution of a
problem. major design
1. Electromagnetic Design
The
electromagnetic design problem in rotating
Rotor machines involves the
Air design of stator & rotor core
gap
dimensions, stator & rotor teeth dimensions,
Stator-
air-gap
length, stator and rotor windings. In transformer, it is
the problem of
designing the core and the windings.
Fig. 1.1: Basic constructional details of rotating machines 2. Mechanical Design
L
Magnetic Circuits: It provides the
path for the
The mechanical
design in rotating machine involves
magnetic flux and the design of frame
consists of air gap. stator and rotor (enclosure), shaft and bearings. In
teeth and stator and rotor cores
(yokes) transformer, it is the design of tank (i.e.,
core and
housing for
2. Electric Circuits: consists of stator and rotor
It winding assembly)
3. Thermal Design
winding, winding of transformer. It should ensure that
required emf is induced with no complexity in winding The thermal design in rotating machine involves the
arrangement. design of
cooling ducts in core and cooling fans. In
3. Dielectric Circuits : The case of large machines coolants like
dielectric circuit consists of air or hydrogen
insulation required to isolate one conductor from may be forced to circulate in the ducts and
air-gap. In
another and also the transformer, it involves the design of cooling tubes or
windings from the core. The
radiators.
insulating materials are essentially- non-metallic and
4. Dielectric Design
may be organic or
inorganic ,natural or synthetic. Another important design problem, that
4 Thermal Circuits: The thermal circuits is concerned may require
with mode and media for dissipation of heat great attention is the design of insulations (Dielectric
produced design). Dielectric materials are used to insulate one
inside the machine on account of losses.
conductor from other and also the
windings from the
5. Main Mechanical Parts core.The dielectric materials are
designed to withstand
Frame high voltage stresses. The breakdown of dielectric
materials may lead to failure of machine.
Bearings
Shaft 1.8 LIMITATIONS IN DESIGN
A successful design brings out an economic Following are the limitations for design:
iron, copper 1. Saturation
compromise space occupied by
for
be air, 2. Current Density
(aluminum) insulation and coolant (which may
hydrogen, water or oil) 3 Temperature rise
 called stator and the rotating electromagnet is cal
of the transformer are is called
constructional elements
The tubes or radiators.
rotor.
core, tank and cooling
windings, The basic constructional
he Dasic constructional elements of aa ro
A simple transformer
vwindings
has two and they are
electrical machine are stator and rotor. In de machin rotating
and low voltage winding
called high voltage winding the stator consists of field core and
winding. The rotor
connected to supply and it is and winding, In
One of the winding is comprises of
armature core
ac
is connected to load
Called primary The other winding machines the stator has armature core and windina
9
and it is Called secondary The rotor consists
of field core and winding
constructions
The two different types of transformer The constructionalelements of various electrical
core type transtormer
are core type and shell type In machines are listed
here.
the windings surround the core and in shell type Constructional Elements
of DC Machine
ransformer the core surround the windings.
The core 1.
Rotor
tank. Cooling Stator
and winding assembly is housed in the Armature core
the tank Yoke or Frame
1ubes or radiators are provided around
effective cooling Armature winding
surface in order to increase the Field winding
Commutator
surface Poles
Others Brush
5 CONSTRUCTIONAL ELEMENTS OF Pole shoe
Brush holder
ROTATINGMACHINE Field winding interpole
converts electrical Constructional Elements of Salient Pole Synchro
The rotating electrical machines 2.
or vice-versa. The energy nous Machine
energy to mechanical energy
conversion takes place through magnetic field. Every Rotor
Stator
three quantities.
rotating machine have the following Frame Field pole,
The presence of any two quantities, will produce the
Armature core Pole shoe.
third quantity
Armature winding Field winding
Magnetic Field (Field)
Magnetic field (Armature) Damper winding
3. Constructional Elements of Cylindrical Rotor Syn-
Mechanical force
chronous Machine
In generator the armature is rotated by a mechanical
force inside a magnetic field or the magnetic field is Stator Rotor
rotated by keeping armature stationary. By Faraday's Frame Solid rotor
law of induction, an emf is induced in the armature. Field conductors or
Armature core
When the generator is loaded, the armature current
bars
flows,which produce another magnetic field (armature
magnetic field). Hence in a generator, by the presence Armature winding
of a magnetic field and mechanical force, an another 4. Constructional Elements of Squirrel Cage Induc
magnetic field is produced. tion Motor
The mechanical force developed by the motor is due
Stator Rotor
o the reaction of two magnetic fields, A current
arrying conductor has a magnetic field around it. Frame Rotor core
Vhen it is placed in another magnetic field it Stator core Rotor bars
periences a mechanical force due to the reaction of
Stator winding End ring
vo magnetic field. Hence in a motor by the presence
two magnetic fields a mechanical force is 5. Constructional Elements of Slip-Ring Induction
veloped Motor
Dm discussion it is clear that any rotating
the above
Stator Rotor
chine requires two magnetic field and one of the
dis
rotating. Hence a rotating
machine will havea Frame Rotor core
Ionary and rotating electromagnet, ea
consisting9 Stator core Rotor winding
Core and winding. The
stationary electromagnet
is
Stator winding Slip ring
 is to determine the dime
Aim of design 1.3 DESIGN FACTORS
the material specification, prepare
part of the rnachine, for movement in rotating
units. The mechanical force required
the dravwings and furnish to manufacturing
in view the electrical machines can be produced both by
Design has to be carried out keeping
volume and weight and at the 1. Electrostatic fields
optimizing of the cost,
same time achieving the
desired performance as per 2. Electromagnetic fields
specification. Knowledge of latest technological trends
Both the fields stores some energy
to supply a competitive product
is a must. Design
1. Electrostatic Fields
should conform to stipulations specified by
is limited
International / National standards. Design is the most In electrostatic machines, the energy density
For Air
important activity. by the dielectric strength of the medium used.

The designer should be familiar with the following dielectric medium the energy density about 40J/m.
aspects: Voltages that can be developed and used by normal
of international/national forces produced by electrostatic effects are
Thorough knowledge means, the

standards. very weak.

Properties ofgood electrical materials (like 2. Electromagnetic Fields

copper), magnetic materials (like silicon steels), In electromagnetic machines, magnetic effect is
used
mechanical
insulating materials (like Epoxy mica), for production of force and there is no comparable
and metallurgical properties of all types of steel.
restriction in magnetic fields. Maximum value of flux
laws of electrical circuits.
Governing density that can be used is about 1.6wb/m.
Laws of heat transfer. A small current can produce large mechanical force by
exchange rates,
Prices of materials used, foreign electromagnetic means and therefore all the modern
types of duties levied on products. electrical machines are electromagnetic type
Labour rates of both ski lied and unskilled labour ELEMENTS OF
1.4 CONSTRUCTIONAL
Knowledge of competitor's products. TRANSFORMER
1.2 DESIGN OF MACHINE The transformer is a static electromagnetic device used

is defined a creative physical realization of to transfer electrical energy from a high potential
Design as

theoretical concepts. (voltage) circuit to low potential (voltage) circuit or

1.2.1 Engineering Design vice-versa.

It consists of two or more windings which link with a

Engineering Design is application of science, technology
a
common magnetic field. An iron core serves as a path
and invention to produce machines to perform specified
tasks with optimum economy and efficiency. for magnetic flux.

(1.1)