A Strong Partner for Sustainable Development

Module
In
EE 514

ELECTRICAL MACHINE DESIGN

College of Engineering
BSEE
WPU-QSF-ACAD-82A Rev. 00 (09.15.20)
 Module No. 1

Design of Armature for

DC Generator

1st Semester 2020-2021

ARMAN M. ARANGORIN
Assistant Professor I
arman.arangorin@wpu.edu.ph

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Table of Contents

Contents Page

Cover Page i

Title Page ii

Table of Contents iii

Instruction to the User iv

Introduction v

Chapter 1 1

Title Chapter 1

Overview 1

Learning Outcomes 1

Pre-test 2

Specific learning outcomes 2

Time Allotment 2

Discussion 4

Activities/Exercises 24

Rubrics 25

Evaluation/Post-test 27

References 29

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 INSTRUCTION TO THE USER

This module would provide you an educational experience while

independently accomplishing the task at your own pace or time. It aims as
well to ensure that learning is unhampered by health and other challenges. It
covers the topic about sample Design of DC armature.

Reminders in using this module:

1. Keep this material neat and intact.

2. Answer the pretest first to measure what you know and what to be
learned about the topic discussed in this module.
3. Accomplish the activities and exercises as aids and reinforcement for
better understanding of the lessons.
4. Answer the post-test to evaluate your learning.
5. Do not take pictures in any parts of this module nor post it to social
media platforms.
6. Value this module for your own learning by heartily and honestly
answering and doing the exercises and activities. Time and effort were
spent in the preparation in order that learning will still continue amidst
this Covid-19 pandemic.
7. Observe health protocols: wear mask, sanitize and maintain physical
distancing.

Hi! I’m Blue Bee, your WPU Mascot.

Welcome to Western Philippines University!

Shape your dreams with quality learning experience.

STAY SAFE AND HEALTHY!

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Introduction

Electrical Machine Design

This module will serve as an alternative learning material to usual way of

classroom teaching and learning delivery. The instructor will facilitate and explain the
module to the students to achieve its expected learning outcomes, activities and to
ensure that they will learn amidst of pandemic.

This material discusses about the sample Design of Armature of DC Generators,

it covers also the armature construction in real dc machines, commutation, problems
with commutation, internal generated voltage and induced torque equation,
construction of dc machines and power flow and losses in dc machines

It is very important that the learner will cooperate in by using this module page
by page and completing all the activities asked. At the end learning outcome is
evaluated based the different task given to you. Through your cooperation in this kind
of flexible learning delivery, understanding and designing of DC armature, AC
armature and transformer is very much possible. It is expected that after using this
module you will become more prepared to the next lesson about the AC armature and
transformer designing.

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Chapter I

Design of Armature for DC generator

Overview

An electrical generator is a machine which converts mechanical energy into

electrical energy.

DC generators are used to provide direct current to specific loads. The

armature, mounted on the rotor, is driven through the magnetic poles which is
developed by the electromagnetic fields. The generated AC voltage is actually induced
into the armature, and then mechanically rectified by the commutator and brush
assembly. Brush polarity is established in a self-excited generator by the magnetic
polarity of the poles and the direction of rotation. Voltage output is determined by the
speed of rotation and the strength of the magnetic field.

The basic structural features of a D.C. machine are:

• Stator - The stator carries the field winding. The stator together with the rotor
constitutes the magnetic circuit or core of the machine. It is a hollow cylinder.
• Rotor - It carries the armature winding. The armature is the load carrying
member. The rotor is cylindrical in shape.
• Armature Winding - This winding rotates in the magnetic field set up at the
stationary winding. It is the load carrying member mounted on the rotor. An armature
winding is a continuous winding; that is, it has no beginning or end.

Depending on the manner in which the coil ends are connected to the
commutator bars, armature windings can be grouped into two: lap windings and wave
windings. Wave winding gives greater voltage and smaller current ratings while the
lap winding supplies greater current and smaller voltage ratings.

The following are the applications of DC machines:

Rolling mills Lathes
Elevators Machine tools
Conveyors Blowers and Fans
Electric locomotives Cranes and hoists
Rapid transit systems

Learning Outcomes

After studying this course, the student should be able to

➢ Design a DC armature for DC generator

➢ Design an AC armature for AC generator
➢ Design a transformer

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Pre-Test

Select the correct answer for each of the following statements and place the
corresponding letter in the space provided.

1. A generator __________
a. changes electrical energy to mechanical energy.
b. changes mechanical energy to electrical energy.
c. is always self-excited.
d. is always separately excited.

2. One of the following is not essential in generating a DC voltage: __________

a magnetic field c. slip ring
a conductor d. relative motion

3. Commutating poles are __________

a. fastened to the center of the commutator.
b. located midway between the main poles.
c. secondary poles induced by cross magnetizing the armature.
d. used to regulate the voltage at the armature.

4. what part of the generator that carries the armature winding.

a. Rotor c. Brush
b. stator d. pole

5. what part of the Generator does not form the electrical circuit.
a. armature c. conductors
b. yoke d. commutator

6. what do you call the one that houses the armature conductors or coils and causes
them to rotate and hence cut the magnetic flux of the field magnets.
a. armature core c. field coils
b. yoke d. commutator

7. the purpose of using laminations in the armature is.

a. to reduce the loss due to eddy currents
b. to increase the field current
c. to decrease the speed of the commutator
d. to increase the loss due to eddy currents

8. Wave winding gives greater voltage and ______ current ratings.

a. varying c. smaller
b. greater d. decreasing

9. The function of the commutator is to _______

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 a. facilitate collection of current from the armature conductors.
b. the normal voltage regulation for a shunt generator
c. to collect current from commutator
d. to reduce the loss due to eddy currents

10. which of the following is not included in the applications of dc machines.

a. elevators
b. conveyors
c. water heater
d. rolling mills

Specific learning outcomes

After studying this unit, the student should be able to

➢ Compute the required parameter of armature core

➢ Compute the required parameter of armature winding
➢ Compute the required parameter of commutator

Time Allotment: 48 hrs.

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Design computation

In this module we will discuss and explain how to solve the parameters required
to Design an Armature suitable for a dc generator provided with commutating poles,
to run at 1,200 rpm and develop 230 volts on open circuit and 250 volts at full-load
output of 300 kw.
It is advisable to follow the design sheet (see the table below) for us not to be
confused in the computation of the parameters required. And also to facilitate the step
by step procedure that will guide us through the design itself.

DESIGN SHEET FOR ARMATURE OF D-C GENERATOR (PART 1)

Item Specifications: 300 kw; 230/250 Symbol Preliminary Final Values

No. volts; 1200 rpm or Assumed
Values
Armature Core and Winding
1 Number of Poles 𝑃 6 6
Frequency 𝑓 60
2 Ratio of Pole Arc to Pole Pitch 𝑟 0.64 0.64
3 Specific Loading 𝑞
4 Apparent Air-gap Flux Density (Open 𝐵𝑔 "
Circuit)
5 Line Current (full load) 𝐼
6 Type of Winding
7 Armature Current per Circuit 𝐼𝑐
8 Output Factor (𝑙𝑎 𝐷2 )
9 Armature Diameter, in. 𝐷
10 Peripheral Velocity 𝑣
11 Total Number of Face Conductors 𝑍
12 Numbers of Slots 𝑆
13 Number of Conductors per Slot
14 Axial Length of Armature Core; gross in. 𝑙𝑎
15 Flux per Pole (Open Circuit) 𝜑
16 Pole Pitch, in. 𝜏
17 Pole Arc, in. 𝑟𝜏
18 Area Covered by Pole Face (𝑟𝜏𝑙𝑎 ), sq. in.
19 Dimensions of Armature Conductors, in.
units
20 Slot Pitch, in. 𝜆
21 Slot Width, in. 𝑠
22 Slot Depth, in. 𝑑
23 Tooth Width, in.
At top 𝑡
At root
Average
24 Number of Radial Ventilating Ducts 𝑛
25 Width of Radial Ducts, in.
26 Net Length of Armature Core, in. 𝑙𝑛
27 Net Tooth Section under Pole, at center,
sq. in.
28 Apparent Density in Teeth Under Pole, at 𝐵𝑡 "
center, sq. in.
29 Length per Turn of Armature Coil, in.
30 Resistance of One Turn, ohms at 60°𝐶

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 31 Resistance of Armature, ohms
32 IR Drop in Armature, volts
33 I2R Loss in Armature Winding, watts
34 Estimated Full-load Flux per Pole
35 Flux Density in Armature Core Below
Teeth
36 Internal Diameter of Core Stampings, in.
37 Weight of Iron in Core (without teeth), lb
38 Weight of Iron Teeth, lb
39 Total Weight of Armature Stampings, lb

Computation

For the armature core and armature winding we should follow and compute for
the item number and the required parameter. The book Electrical Machine Design of
Alfred Still and Charles Siskind will be use as the reference for more clear explanation
about the formulas, constant values and tables that are used in this design. In the
computation we will input the value of the required parameter being solve on the
design sheet.

Item no. 1 Number of Poles and Frequency

Refer to Article 3. The selection of a suitable number of poles will be influenced

by considerations of frequency and pole pitch. The frequency of currents in the
armature conductors and of flux reversals in the armature core generally lies between
30 and 60 cycles per second in continuous – current generator. The frequency is,
Refer to article 3 page 13 of Electrical Machine Design for the formula;

120 𝑓
P= 𝑁

where
F = frequency (60 Hertz) here in the Philippines
P = number of poles
N = rpm

120 𝑥 60
P= 1,200
= 6 poles

(check your computed value on the table on page 16)

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Item no. 2 Ratio of Pole Arc to Pole Pitch

Refer to article 2 page 12 of Electrical Machine Design

The quantity of r which is the ratio of pole arc to pole pitch usually has a value
between 0.6 and 0.8, a common value being 0.7. when the machine is provided with
commutating interpoles, ratio of pole arc to pole pitch must be small in order to make
room for the interpole. In this case a figure between 0.6 and 0.64 would be selected as
a suitable value for r.
r = 0.64

Item nos. 3 Specific Loading

For the 300 kW, the value of q = 850

If the load assigned is not available in the table interpolation is required to

obtain the value of q, please show how you interpolate.

Example if the load assigned is 550 kW

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Output q
750 950
550 x
500 900

By interpolation method,
750−500 950−900
=
750−550 950−𝑥
Solving for the value of x, x will be the value of q
𝑥 = 910 = q
Thus, 𝑞 = 910
Item no. 4 Air-gap Density

Refer to article 2 from the table on page 11 of Electrical Machine Design

Select B”g = 57,500 for the load 300 kW, again If the load assigned is not available in
the table interpolation is required to obtain the value of B”g, please show how you
interpolate.

Item no. 5 Line Current (I)

𝑜𝑢𝑡𝑝𝑢𝑡 𝑖𝑛 𝐾𝑤
I = 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑣𝑜𝑙𝑡𝑎𝑔𝑒

300 000 𝑤
I= = 1,200 amps
250 𝑉

Item no. 6 Type of Winding

Refer to article 6 page 20 of Electrical Machine Design

Since the current per path should not exceed 250 to 300 amp it is clear that a
lap winding must be used in this case. (a wave winding with two parallel paths would
make Ic about 1,200/2 = 600 amp)

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 therefor we use Lap Winding in the design
In lap winding the number of parallel paths is = p x plex or the multiplicity of
the winding
For simplex lap, plex = 1
For duplex lap, plex = 2
For triplex lap, plex = 3

If we are going to use simplex lap the parallel path is = 6 x 1 = 6

Ic = 1,200 amps/ 6 = 200 amps

Item no. 7 Armature Current per Circuit

The current in each armature circuit will be one sixth of the line current if the
shunt exciting current is neglected. A table giving the usual value of shunt field current,
expressed as a percentage of the output current, will be found on page 121.

Ic = (I/parallel path) (1+ % shunt field current)

= (1200/6) (1+ 0.007)
= (200) (1.007)
= 201.4 amps

Select shunt field exciting current = 0.7% for the load 300 kW, again If the load
assigned is not available in the table interpolation is required to obtain the value of
shunt field exciting current, please show how you interpolate.

Item no. 8 output factor (laD2)

Refer to article 2 by formula 7 page 10 of Electrical Machine Design

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 𝑊 6.06 𝑥 108
laD2 = ( )
𝑁 𝐵"𝑔 𝑥 𝑞 𝑥 𝑟
Where
W = output in watts (300,000)
N = rpm (1,200)
B”g = apparent airgap flux density (57,500)
q = specific loading (850)
r = laD2 ratio of pole arc to pole pitch (0.64)
300,000 𝑤𝑎𝑡𝑡𝑠 6.06 𝑥 108
laD2 = ( ) = 4,850
1200 57,500 𝑥 850 𝑥 0.64

Item no. 9 armature diameter (D)

Refer to article 2 page 13 by formula 8

𝜋𝑥𝐷𝑥𝑟
la = 𝑃 𝑥 𝑘
Where
D - armature diameter
la - length of armature
r - ratio of pole arc to pole pitch (0.64)
P - number of poles (6)
k - is constant (0.71)
- ratio of pole arc/armature length

Substitute the value to the formula

𝜋 𝑥 0.64
la = 6 𝑥 0.71 D
la = 0.472 D

Substitute the value of la to the formula of laD2

laD2 = 4,850
(0.472D) D2 = 4,850
0.472 D3 = 4,850
D3 = 4,850/0.472
3 4,850
D = √0.472

D = 3√10,275.4237
D = 22 inches

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Item no. 10 Peripheral velocity (fpm)

The peripheral velocity of the diameter computed is

𝜋𝑥𝐷𝑥𝑁
v= 12
Where
v - peripheral velocity
D – diameter (22 inches)
N – rpm (1200)

𝜋 𝑥 22 𝑥 1,200
v= = 6, 900 fpm
12

Note: from table on page 14 the ampere conductor per pole (ZIc/p)

100-500 KW ---- 10,000 – 15,000 (ZIc/p)

𝜋𝑥𝐷𝑥𝑞
Z= 𝐼𝑐

Substitute value of Z to (Zic/p)

𝜋𝑥𝐷𝑥𝑞 𝜋 𝑥 𝐷 𝑥 𝑞 𝑥 𝐼𝑐 𝜋𝑥𝐷𝑥𝑞
( 𝐼𝑐
) (Ic/p) = =
𝐼𝑐 𝑥 𝑝 𝑝
𝜋 𝑥 22 𝑥 850
= = 9,800 ampere conductor per pole
6

The value is below the upper limit the design may proceed to the basis of six
poles and 10,000 – 15,000 is the range of upper limit.

Item no. 11 total no. of face conductors

The total no. of face conductor is therefor from the formula on article 2 on page
10.
𝜋𝑥𝐷𝑥𝑞
Z= 𝐼𝑐

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Where
Z = total no. of face conductor
D = diameter of the armature (22)
Ic = current per path (201.4 amps)
q = specific loading (850)

𝜋𝑥𝐷𝑥𝑞 𝜋 𝑥 22 𝑥 850
Z= = = 291.7 ≈ 292 face conductors
𝐼𝑐 201.4
Item no. 12 number of slots (S)

Assuming that we have 4 conductors per slot

S = Z/4

Where S = no of slot
Z = no of conductors
= 73 slots

Then the slot pitch (λ = π x D/S)

0.95 see article 12 this value is reasonable

Compute for no. of slots per pole = S/p

S/p = 73/ 6 = 12.17

However, since it is desirable to have an odd integer of slots per pair of poles
the slot per pole should be an integer plus 1/2

Slot per pair of poles = odd integer

= 73/3 = 24.33

to make it odd integer make the slot per pole plus ½

slot per pole = 12.17 ≈ 12.5 = S/p
S = 12.5 x p
S = 12.5 x 6
S = 75 slots

Check
slot per pair of poles = S/ (pair of poles)
= 75/3 = 25 odd integer

Therefor the change in the value of S the value of Z will also change
Z = S x no. of conductors per slot
Z = 75 x 4 = 300 final value of face conductors

Then the value of q will be from formula on page 10

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 𝑍 𝑥 𝐼𝑐
q = 𝜋𝑥𝐷
300 𝑥 201.4
= 𝜋 𝑥 22
= 874.2 ≈ 875 final of q

Item no. 13 Number of conductors per slot

Therefore, from the assumption that we use for the number of conductors per
slot is 4 from item no. 12. Then the number of conductors per slot will be 4.

Item no. 14 axial length of armature core (la)

This may be determined from the final value of the output factor (laD2) since it
is inversely proportional to q.
laD2 = 4,850 x (850/875)
laD2 = 4,710
la = 4,710/D2
= 4,710/ (22) 2
la = 9.77 ≈ 9.75 inches

However, this is subject to correction if later the flux density calculations

indicate whether desirable or not.

Item no. 15 flux per pole on open circuit(Ф)

Using the value of Z determined in item no. 11 from formula 2 on page 8.

ФpNZ E x 60 x p1 x 108
E = 60 x p1 x 108 , Ф = pNZ
where
E - open circuit voltage (230 v)
f – frequency (60)
p1 - parallel path – 6
p- number of poles (6)
N – rpm (1200)
Z – total number of face conductor (300)

Therefore,
E x 60 x p1 x 108
Ф= = 3,833,000 maxwells
pNZ

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Item no. 16 pole pitch (t)

The formula for the pole pitch (t)

𝜋𝑥𝐷
t= 𝑝
Where:
D – diameter of armature (22in)
p – number of pole (6)
𝜋𝑥𝐷 𝜋 𝑥 22
t= 𝑝 = 6
= 11.5 in

Item no. 17 pole arc (rt)

The pole arc = rt

Where:
t – pole pitch (11.5)
r – ratio of pole arc to pole pitch (0.64)

rt = 0.64 x 11.5
= 7.37 in

Item no. 18 area covered by pole face (rtla)

The area covered by pole face is = rtla

Where:
la – length of armature (9.75)

rtla = 0.64 x 11.5 x 9.75

= 71.8 sq. in.

The apparent air gap flux density can now be computed

𝛷 3,833,000
B”g = 𝑎𝑟𝑒𝑎 𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝑏𝑦 𝑝𝑜𝑙𝑒 𝑓𝑎𝑐𝑒 = 71.8 =

= 53,400 lines per sq. in.

Item no. 19 dimensions of armature conductors (in)

From formula 17 on page 36 the book electrical machine design

𝑘 𝑣
Δ= 𝑞 + 4

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Where
Δ – ampere per sq. in.
k – is constant between 400,000- 700,000
q – specific loading
v – peripheral velocity

𝑘 𝑣 700,000 6,900
Δ= + = + = 2,525 amp. per sq. in.
𝑞 4 875 4
𝐼𝑐
The area of cross section =
𝛥

𝐼𝑐 201.8
= 2,525 = 0.080 sq. in.
𝛥

𝜋𝑥𝐷
The slot pitch (λ) =
𝑛𝑜. 𝑜𝑓 𝑠𝑙𝑜𝑡 (𝑆)
𝜋 𝑥 22
= 75 = 0.922 in.

In order to determine the actual dimensions of the armature conductors, it will

be first convenient to assume a width of slot.

assume 0.4 inches from the range 0.3 -0.5 on article 12 page 31.

it will make the ratio of tooth width to slot width from the range of 1.1 – 1.5 to
obtain the proper flux density on article 12 from page 31.

since a wire with an area of 0.08 sq. in. is heavy and difficult to bend and shape
it is desirable to use two conductors in parallel.

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 This arrangement may be used from the possibility of having either twice as
many commutator segments as slots

It is necessary now to find by trial the best arrangement of 300 conductors item 11
and 75 slots item 12.

The slot pitch refer to art. 12

𝜋𝑥𝐷
The slot pitch (λ) =
𝑛𝑜. 𝑜𝑓 𝑠𝑙𝑜𝑡 (𝑆)
𝜋 𝑥 22
= = 0.922 in.
75

Then the ratio of tooth width/slot width should be within the range of 1.1 – 1.5
Assume slot width = 0.4
Tooth width = 0.922 – 0.4 = 0.522

Then the Ratio of tooth width/ slot width = 0.522/0.4 = 1.305

If we check the range 1.305 is within the prescribed value.

Since a wire with an area of 0.08 sq. in. is heavy and difficult to bend and shape
it is desirable to use two conductors in parallel.

Area of conductor
0.08 sq. in

Arrangement of 4 conductors per slot slot width s = 0.4

If the assume slot width s = 0.4
The width of the conductor is the space left in the slot that is being compute
0.4 −(3 𝑥 0.016)−(2 𝑥 0.035)
= slot insulation=35 mils
4
= 0.07in

Cotton covering= 16 mils

slot width s = 0.4

For the length of the conductor
Since the copper area of two conductors is 0.08 sq. in. it follows that each
conductor will have a length of
length of conductor= 0.08/ (2 x 0.07) = 0.571 ≈ 0.58 in
Dimension = 2 x (0.07 x 0.58)

0.07 in
WPU-QSF-ACAD-82A Rev. 00 (09.15.20)
Item no. 21 slot pitch

𝝅𝑥𝐷
The slot pitch (λ) =
𝑛𝑜. 𝑜𝑓 𝑠𝑙𝑜𝑡 (𝑆)

𝜋 𝑥 22
=
75
= 0.922 in

Item no. 21 slot width, s

The slot width will be s = 0.4 in. as what we have assumed

From article 12 page 31 the slot width should range from 0.3 – 0.5 in

S = 0.4

Item no. 22 slot depth, d

The slot depth = thickness of hard wood (0.135 in) + insulation spaces above,
below and between the coils (35 mils) + length of conductor (0.58 in)
d = 0.135 + (3 x 0.035) + (2 x 0.58)
= 1.4 in

insulation spaces above, below and between the coils (35 mils)

thickness of hard wood = 0.135 in.

d = 1.4 in

L = 0.58 in

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Item no. 23 tooth width, in
The width of the top of the tooth = λ – s = 0.922 – 0.4 = 0.522 in

The width of the tooth at the root = ((π x (22-2.8))/75) – 0.4)= 0.405 in

the average tooth width = (0.522 + 0.405 )/ 2 = 0.463 in

λ slot

tooth
s

Item no. 24 number of radial ventilating ducts

Refer to art. 16

the ventilating spaces in self-cooling machines consist of radial ducts provided

by inserting special ventilating plates at interval of 2 – 4 inches and so dividing the
armature core into sections around which the air can circulate.

no. of radial vents = la/ (2-4)

where la = 9.75 in

= 9.75/ 4

no. of radial vents = 2.43 ≈ 3

Item no. 25 Width of radial ducts

Refer to art. 16 page 39

the width of those ventilating spaces (measured in a direction parallel to the

axis of rotation) is rarely less than 3/8 or more than ½ in. in machine without forced
ventilation.

width = 3/8 = 0.375 in

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Item no. 26 net length of armature core (ln)

Refer to art. 16 on page 39 formula 20

ln = 0.92 (la – lv)

Where

la = is the gross length of the armature(item # 14)

lv = is the total width of all vent ducts

ln = 0.92 (9.75- (3 x 0.375))

ln = 7.935 in Item no 26
Item no 25

Item no 27 Net cross section of teeth under pole

net cross section = ln x ave. tooth width x (S/P) x r

Where

ln = net length of armature Item no 26

Item no 23
r = ratio of pole arc/pole pitch

S = no. of slot
Item no 2
P = no. of pole

net cross section = 7.94 x 0.463 x (75/6) x 0.64

net cross section = 29.4 sq. in.

Item no 28. flux density in teeth

Refer to article 17

the apparent flux density at the center of tooth, under open circuit condition is,

= flux per pole on open circuit/ cross section of iron under pole
Item no 27
= 3,833,000/29.4

= 130,374 lines/ sq. in. Item no 15

Note that this value is above the upper limit given in the table on page 40 for
60 cycles. It will therefore, be necessary to correct or increase the length of the
armature core to bring the flux density down to a reasonable figure.

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 upper limit from the table

60 cycles --- 123,500 density --- 130, 374 greater than the upper limit

Lets assume about 123,100 and used it as our new value

123,100 = 3,833,000/x Our final value for the item no

x = 3,833,000 / 123,100 28, flux density in teeth

x = 31.137 sq. in.

Then recompute for ln

31.137 = ln x ave. tooth width x (S/p) x r

ln = 31.137/(0.463 x (75/6) x 0.64)

ln = 8.406 in.

Finally recompute for la

ln = 8.406 = 0.92 (la- (3x0.375))

la = (8.406/ 0.92) + (3 x 0.375)

la = 10.261 in

Item no 29 length per turn of armature coil

Refer to art. 16 formula 18 on page 38

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 lc = length of coil curve From item no. 16
2t
lc = (cos∝) + 4d + 3
From item no. 22
solve for sine α
1.15 𝑠 1.15 (0.4)
sine α = , α = arc sin =0.5 Final value of la from
𝝀 0.922
item no. 28
and cos α = cos 0.5 = 0.866
Therefore
2 (11.5)
lc = + 4(1.4) + 3
0.866
lc = 35.16 in
The total length = lc + 2(la) =35.16 + 2(10.261) = 55.682 in

Item no. 30 armature resistance of one turn ohm at 60ᴼ

The resistance at one turn ohm is

𝑙
R= ρ𝑎
Resistance of copper ρ = 1 ohm per cir. mil inch
4
1 sq. in. = ( ) 𝑥 106 cir. Mils From item no. 29
𝜋
𝑙𝑐
R=ρ
𝑎
56
= (1 ohm per cir. mil inch) 4
2(0.07𝑥0.58)𝑥 ( 𝜋 ) 𝑥 106

R = 5.416 x 10-4
From item no. 19
R = 0.0005416 ohm

Item no 31 resistance of armature, ohms

No. of turns = face conductor/2

= 300/2

= 150

Resistance per circuit = resistance of one turn x (no of turns/ parallel path)

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Resistance/circuit = 0.0005416 x (150/6)

= 0.01354 ohms

The total resistance of the armature = one sixth of the resistance per circuit

= 1/6 x 0.01354

= 0.0023 ohms

Item no 32 IR drop in armature, volts

From item no. 7
The IR drop = I x R

= 201.4 x 0.01354 Resistance per circuit

= 2.71 volts from item no. 31

Compare the percent of IR drop to full load voltage from the table on art. 16 page 38

% IR drop = (2.71/ 250) 100 = 1.08 %

Item no 33 I2R loss in armature winding; watts

The watts loss in the armature winding is

= IR x (I x 6)

= 2.71 volts (201.4 x 6)

= 3,274 .76 watts

Item no 34 full load flux

It is necessary to develop or generate enough voltage to overcome the internal

resistances

brush contact drop = 2 volts (constant)

series field and commutating field drop = ½ of IR drop

IR drop = 2.71 volts

1
the total generated voltage at full load = 250 + 2 + 2 (2.71) + 2.71

= 256.065 V

full load flux = 3,833,000 X (256.065/230)

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 = 4,267,000 maxwell

Item no 35. flux density in armature core below teeth

Refer to table on art. 17 page 40

Frequency density in core
60 Hz 73,000 Maxwell per sq. in.
Assume 73,000

Item no 36 internal diameter of core stampings

The armature-core flux is ½ of the total flux.

From item no. 26
Rd x ln x 73,000 = Ф/2

Ф
Rd =
2 𝑥 ln 𝑥 73,000
From item no. 9
4, 267,000
=
2 𝑥 8.4 𝑥 73,000 From item no. 22
Rd = 3.48 in ≈ 3.5 in

The internal diameter of the core stampings = 22 – (2 x3.48) – (2 x 1.4)

= 12.2 in

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Item no 37 weight of iron in core

The weight of a cubic inch of iron is 0.28 lb. From item no. 36
the total weight of iron below the teeth is

= 0.28 lb/in3 x ln x (π/4)((D-(2xd))2-(internal diam of core)2)

= 0.28 lb/in3 x 8.4 in. x (π/4) ((22-(2x1.4))2 - (12.2) 2 )

= 406.03 lbs. From item no. 22

From item no. 26 From item no. 9

Item no 38 weight of iron in teeth

The weight of iron in teeth is

= 0.28 lbs./ in3 x d x ave. tooth width x ln x no. of teeth

= 0.28 lbs./ in3 x 1.4 in x 0.463 in x 8.4 in x 75

= 114.34 lbs. From item no. 12

From item no. 22 From item no. 23

Item no 39 total weight of armature stampings

The total weight of armature stampings is

= weight of iron in teeth + weight of core stampings

= 114.34 lbs. + 406.03 lbs.

= 520.37 lbs.

note: continuation of item 40-57 will follow.

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Activities/Exercises

Activity 1. Compute the following:

Item # 1 -39 and fill up the table for the corresponding item.

note: For the computation of your design problem please refer to the table below. Just
change the load output with the load given with your name.

Design an Armature suitable for a dc generator provided with commutating

poles, to run at 1,200 rpm and develop 230 volts on open circuit and 250 volts at full-
load output of 300 kw.

NAME Load (KW)

BACULPO, JOSSUA LATUBE 100

BADUA, BERNARD MALON 200

DELA PEÑA, ALDRIN ABOABO 400

DIAZ, CHRISTIAN ALINDAJAO 500

GONZAGA, JENO LIMUS 600

HALANI, RASUL ABDULKADIL 700

MENDIGORIA, BRYAN JOSEPH LACASANDILE 800

ULANDAY, JOHN MARLOU EVANGELIO 900

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Rubrics for Timeliness
CRITERIA LEVELS OF PERFORMANCE/ SCORE

Submission on or before deadline Accepted with (10)

Submission 2 weeks after deadline Accepted with (8)

Submission 1 month after deadline Accepted with (6)

Submission 2 months after deadline Accepted with (4)

Late submission beyond 2 months Accepted (2)

Total 10

Rubrics for Drawings

LEVELS OF PERFORMANCE/
CRITERIA
SCORE

Drawings/illustrations are complete, neat and

Very Satisfactory (20)
clear with specifications/details

Drawings/illustrations are complete, with

Satisfactory (15)
specifications/details

Drawings/illustrations are complete, with

Fair (10)
missing specifications/details

Drawings/illustrations are incomplete with

Needs improvement (5)
missing specifications/details

Total 20

Computation of grades for Design 1, 2 & 3

Description Criteria rating

Timeliness Format Drawings Content total

Design # 1 10% 10% 20% 60% 100% 40%

Design # 2 10% 10% 20% 60% 100% 30%

Design # 3 10 10% 20% 60% 100% 30%

total 100%

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Requirement (Design compilation)

Title page
Table of contents
WPU mission vision
CET mission vision
CET goals & objectives
EE objectives

Introduction – as a whole for Electrical Machine Design

Chapter I Design no. 1 – Design of an armature of a DC generator
Introduction – About DC generator
Objectives- To design an armature of a DC generator…
Design problem – How to design an armature of a DC generator…
Drawings
Computation
Tables
Chapter II Design no. 2 – Design of an armature of AC generator
Introduction – About AC generator
Objectives - To design an Armature of AC generator…
Design problem – How to design an armature of AC generator…
Design Sheet
Computation
Drawings
Tables
Chapter III Design no. 3 – Design of Transformer
Introduction – About Transformer
Objectives - To design a Transformer …
Design problem – How to design a Transformer…
Design Sheet
Computation
Drawings
Tables
Chapter IV problems encountered
Chapter V summary, conclusion & recommendation
Chapter VI References
Still A. Siskind C.S. (1954), Elements of Electrical Machine Design. Third
Edition. McGraw-Hill

Siskind C.S. (1966), Electrical Machines, Direct and Alternating. Second

Edition. McGraw-Hill

Note:
All chapter & computation hand written, drawings (armature winding) -
AutoCAD, tables used – may be photocopied as attachment.

Deadline for design # 1 - January 5, 2021.

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Post Test

Select the correct answer for each of the following statements and place the
corresponding letter in the space provided.

1. A generator __________
a. changes electrical energy to mechanical energy.
b. changes mechanical energy to electrical energy.
c. is always self-excited.
d. is always separately excited.

2. One of the following is not essential in generating a DC voltage: __________

a magnetic field c. slip rings
a conductor d. relative motion

3. Commutating poles are __________

a. fastened to the center of the commutator.
b. located midway between the main poles.
c. secondary poles induced by cross magnetizing the armature.
d. used to regulate the voltage at the armature.

4. what part of the generator that carries the armature winding.

a. Rotor
b. stator
c. Brush
d. pole

5. what part of the Generator does not form the electrical circuit.
a. armature c. conductors
b. yoke d. commutator

6. what do you call the one that houses the armature conductors or coils and causes
them to rotate and hence cut the magnetic flux of the field magnets.
a. armature core c. field coils
b. yoke d. commutator

7. the purpose of using laminations in the armature is.

a. to reduce the loss due to eddy currents
b. to increase the field current
c. to decrease the speed of the commutator
d. to increase the loss due to eddy currents

8. Wave winding gives greater voltage and ______ current ratings.

a. varying c. smaller
b. greater d. decreasing

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

9. The function of the commutator is to _______
a. facilitate collection of current from the armature conductors.
b. the normal voltage regulation for a shunt generator
c. to collect current from commutator
d. to reduce the loss due to eddy currents

10. which of the following is not included in the applications of dc machines.

a. elevators
b. conveyors
c. water heater
d. rolling mills

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

References:

BOOKS

Siskind C.S. (1966), Electrical Machines, Direct and Alternating. Second Edition.
McGraw-Hill

Still A. Siskind C.S. (1954), Elements of Electrical Machine Design. Third Edition.
McGraw-Hill

Keljik J. (2009) Electricity 3. Power Generation and Delivery, Ninth Edition. Delmar.

WEB

https://www.generatorsource.com/Understanding-Generator-Labels.aspx

ARTICLES

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

Congratulations for completing this module!

Student’s Information

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Program:
Year and Section:
Contact No.:
E-mail address:
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Messenger Account:

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)

 Vision 2020
WPU: the leading knowledge center for sustainable
development of West Philippines and beyond.

Mission
WPU commits to develop quality human resource and green
technologies for a dynamic economy and sustainable
development through relevant instruction,
research and extension services.

Core Values (3CT)

Culture of Excellence
Commitment
Creativity
Teamwork

WPU-QSF-ACAD-82A Rev. 00 (09.15.20)