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Electrical and Electronics Engineering Department (EEE)

ELECTRICAL MACHINE DESIGN


Design 1: DC Generator Armature Design

Submitted by:
Bacomo, Lester Allen G.
Samson, John Arnold

Submitted to:
Engr. Melodia Pahati

June 18, 2018

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

SPECIFICATION: Preliminary or
ITEM Final
SYMBOL Assumed
NO. 1550 kW ; 660/750 Volts ; 500 rpm Values
Values

ARMATURE CORE AND WINDING

1 Number of Poles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P 12 12
Frequency, Hz - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ƒ - -------- 50
2 Ratio of pole arc to pole pitch - - - - - - - - - - - - - - - - - - - - - - - - - - - - r 0.64 0.64
3 Specific Loading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - q 1,055 1,055
4 Apparent Air-gap flux density (open circuit) - - - - - - - - - - - - - - - - 𝐵𝑔′′ 62,550 70,706.506
5 Line Current (full load) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - -------- 2,348.485
6 Type of Winding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- lap
7 Armature current per circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ic 392.59
8 Output factor (laD2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- 44,481.004 50,682.602
9 Armature diameter, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D 57.34 57.34
10 Peripheral velocity, fpm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 𝜈 7,509.72 7,509.72
11 Total number of face conductors - - - - - - - - - - - - - - - - - - - - - - - - - Z 484 484
12 Number of slots - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S - -------- 20
13 Number of conductors per slot - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 24
14 Axial length of armature core; gross, in - - - - - - - - - - - - - - - - - - - - la 13.53 15.415
15 Flux per pole (open circuit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 𝜙 16.363 x106
16 Pole pitch, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 𝜏 15.012
17 Pole arc, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 𝑟𝜏 9.61
18 Area covered by pole face (rτla), sq in - - - - - - - - - - - - - - - - - - - - - - ----- 130.023 148.138
19 Dimensions of armature conductors, in. units - - - - - - - - - - - - - - - - ----- - -------- (0.185x0.345)
20 Slot pitch, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 𝜆 - -------- 9.007
21 Slot width, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - s - -------- 0.8
22 Slot depth, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - d - -------- 1.104
23 Tooth width, in. At top - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - t - -------- 8.207
At root - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 7.86
Average - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 8.034
24 Number of radial ventilating ducts - - - - - -- - - - - - - - - - - - - - - - - - n - -------- 1
25 Width of radial ducts, in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 0.375
26 Net length of armature core, in - - - - - - - - - - - - - - - - - - - - - - - - - - - ln 12.103 13.837
27 Net tooth section under pole, at center, sq in - - - - - - - - - - - - - - - - - ----- 103.718 118.577
28 Apparent density in teeth under pole, at center, sq in - - - - - - - - - - 𝐵𝑡′′ 157,770.458 91,999.51
29 Length per turn of armature coil, in - - - - - - - - -- - - - - - - - - - - - - - - - ----- - -------- 68.602
30 Resistance of one turn, ohms at 60°C - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 0.000422
31 Resistance of armature, ohms - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 0.0085
32 IR drop in armature, volts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 6.674
33 I2R loss in armature winding, watts - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 31,441.889
34 Estimated full-load flux per pole - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 16.661x106
35 Flux density in armature core below teeth - - - - - - - - - - - - - - - - - - - ----- 76,000 76,002.571
36 Internal diameter of core stampings, in - - - - - - - - - - - - - - - - - - - - - ----- - -------- 39.572
37 Weight of iron in core (without teeth), lb - - - - - - - - - - - - - - - - - - - - ----- - -------- 4,484.022
38 Weight of iron core in teeth, lb - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 665.487
39 Total weight of armature stampings, lb - - - - - - - - - - - - - - - - - - - - - - ----- - -------- 5,149.509

2
DESIGN OF ARMATURE CORE AND WINDING

Item1: Number of poles (P) and frequency (ƒ)


Referring to Art. 3, for an output of 1550 kW, a speed of up to 500 rpm and 12 poles would be
suitable for this trial design, therefore,
𝑃𝑁 12 (500)
ƒ = = = 50 Hz
120 120

Item 2: Ratio of Pole Arc to Pole Pitch


Refer to Art. 2. Since the machine will be provided with commutating poles, a suitable value for this
ratio is;
r = 0.64

Item 3: Specific Loading (q)


2,000 − 1,500 1,550 − 1,500
=
1,100 − 1,050 𝑞 – 1,050
𝑎𝑚𝑝.−𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟
q = 1,055 𝑖𝑛

Item 4: Apparent Air-gap Flux Density, open circuit (Bg’’)


63,000 − 62,500 1,550 − 1,500
=
2,000 − 1,500 𝐵𝑔’’ – 62,500
𝑙𝑖𝑛𝑒𝑠
Bg’’ = 62,550 𝑖𝑛2

Item 5: Line Current , Full Load ( IL )


𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑜𝑢𝑡𝑝𝑢𝑡 1,550,000
IL = 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑣𝑜𝑙𝑡𝑎𝑔𝑒
= 660
= 2,348.485 Amp

Item 6: Type of Winding


Simplex Lap Winding
Refer to Art. 6. Since the current per path should not exceed 250 to 300 amp, lap winding with two
parallel paths could be used for this trial design.

Item 7: Armature Current per Circuit ( Ic )


𝐼𝐿
Ic = 𝑃1
(1 + % 𝑒𝑥𝑐𝑖𝑡𝑎𝑡𝑖𝑜𝑛)

From Art. 47, % of excitation for 1000 and larger is 0.3 to 0.4, thus, 0.3 may be used.

Then,
2,348.485
Ic = 6
(1 + 0.003) = 392.59 Amp

3
Item 8: Output factor ( IaD2 )
𝑊 6.06 𝑥 108 1,550,000 6.06 𝑥 108
IaD2 = 𝑁
( "
𝐵𝑔 𝑞 𝑟
) =
500
[ (62,550)(1,055)(0.64) ] = 44,481.003 in3

Item 9: Armature Diameter (D)


Using a rectangular pole face, where k = 0.71
𝜋𝑟 𝜋 (0.64)
la = 𝑃𝑘
( 𝐷) =
12 (0.71)
(𝐷) = 0.236 D

Hence,
3
D = √44,481.003 ⁄0.236 = 57.34 in.

Item 10: Peripheral Velocity (fpm)


𝜋𝐷𝑁 𝜋(57.34)(500)
𝜈 = 12
= 12
= 7,509.72 fpm

Item 11: Total number of Face Conductors (Z)


𝜋𝐷𝑞 𝜋(57.34)(1,055)
𝑍 =
𝐼𝑐
= 392.59
= 484 conductors

Item 12: Number of Slots (S)


Assuming that there are 24 conductors per slot
𝑍 484
𝑆 = 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 𝑝𝑒𝑟 𝑠𝑙𝑜𝑡
= 24
= 20 slots

𝑆
And the Slot per Pole ( 𝑃
) would be,
𝑆 20
= = 1.67 𝑠𝑙𝑜𝑡𝑠 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒
𝑃 12
𝑆 20
= = 3.33 𝑠𝑙𝑜𝑡𝑠 𝑝𝑒𝑟 𝑝𝑎𝑖𝑟 𝑝𝑜𝑙𝑒
𝑃⁄ 6
2

Item 13: Number of Conductors per Slot ( CS )


𝑍 484
𝐶𝑠 = = = 24 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 𝑝𝑒𝑟 𝑠𝑙𝑜𝑡
𝑆 20

Item 14: Axial length of Armature Core ( la )


Solving for 𝑙𝑎 ,
𝑙𝑎 𝐷2 44,481.003
𝑙𝑎 = 2
= = 13.53 𝑖𝑛
𝐷 (57.34)2

4
Item 15: Flux per Pole, Open Circuit ( 𝜙 )
From Voltage Equation for dynamo;
𝜙𝑃𝑁𝑍
𝐸 =
𝑃1 60 𝑥 108
Solving for 𝜙,
𝐸𝑃1 60𝑥108 660 (12)(60𝑥108 )
𝜙= = = 16,363,636.36 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠
𝑃𝑁𝑍 12 (500)(484)

Item 16: Pole Pitch ( 𝜏 )


𝜋𝐷 𝜋 (57.34)
𝜏 = = = 15.012 𝑖𝑛
𝑃 12

Item 17: Pole Arc ( r 𝜏 )


𝑟𝜏 = 0.64 𝑥 15.012 = 9.61 𝑖𝑛

Item 18: Area covered by Pole Face ( 𝑟𝜏𝑙𝑎 )


𝑟𝜏𝑙𝑎 = 9.61 (13.53) = 130.023 𝑖𝑛2

Item 19: Dimensions of the Armature Conductors


Assuming k = 700,000
𝑘 𝜈 700,000 7,509.72 𝑎𝑚𝑝.
∆= 𝑞
+ 4
= 1,055
+ 4
= 2,540.94 𝑖𝑛2

Then,
𝐼𝑐 392.59
Area of Cross Section = ∆
= 2,540.94 = 0.155 𝑖𝑛2

Referring to Appendix I (Wire Table, bare and DCC Copper Ribbon), an insulated copper conductor
having a cross sectional area of 0.184 𝑖𝑛2 has a thickness of (t=0.185) and width of (w=0.345)
respectively.

Item 20: Slot Pitch ( 𝜆 )


𝜋𝐷 𝜋 (57.34)
𝜆= = = 9.007 𝑖𝑛
𝑆 20

Item 21: Slot Width ( 𝑠 )


𝐸 660
Insulation thickness = 27 + 30
= 27 + 30
= 49 mils or 0.049 in
𝑠 = 3𝑡 + 5 (𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠)
𝑠 = 3(0.185) + 5 (0.049) = 0.8 𝑖𝑛

5
Item 22: Slot Depth ( 𝑑 )
1
𝑑 = 2𝑤 + 3 (𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠) + 𝑠
3
1
𝑑 = 2(0.345) + 3 (0.049) + (0.8)
3
𝑑 = 1.104 𝑖𝑛

Item 23: Tooth Width ( 𝑡 )


At Top,
𝑡𝑇𝑜𝑝 = 𝜆 − 𝑠 = 9.007 − 0.8 = 8.207 𝑖𝑛
At Root,
𝜋 (𝐷 − 2𝑑) 𝜋 [57.34 − 2(1.104)]
𝑡𝑅𝑜𝑜𝑡 = − 𝑠 = − 0.8 = 7.86 𝑖𝑛
𝑆 20

Therefore the Average Tooth Width is,

𝑡𝑇𝑜𝑝 + 𝑡𝑅𝑜𝑜𝑡 8.207 + 7.86


𝑡𝐴𝑣𝑒 = = = 8.034 𝑖𝑛
2 2

Item 24: Number of Radial Ventilating Ducts


Refer to Art. 16. Not more than three ducts should be necessary in an armature 9 to 11 in long, with
each duct 3⁄8 in. wide.
Therefore,
Use one (1) radial ventilating duct.

Item 25: Width of Radial Duct ( 𝑙𝑣 )


𝑙𝑣 = 3⁄8 in or 0.375 in

Item 26: Net length of Armature Core ( ln )


Refer to Art. 16.
𝑙𝑛 = 0.92 (𝑙𝑎 − 𝑙𝑣 ) = 0.92 [13.53 − 1(0.375)] = 12.103 𝑖𝑛

Item 27: Net Cross Section of Teeth Under Pole

6
𝑆 20
𝑙𝑛 (𝑡𝑎𝑣𝑒 ) ( ) (𝑟) = 12.103 (8.034) ( ) (0.64) = 103.718 𝑖𝑛2
𝑃 12

Item 28: Apparent Density in Teeth Under Pole (𝐵𝑡′′ )


𝜙 16,363,636.36 𝑙𝑖𝑛𝑒𝑠
𝐵𝑡′′ = ( ) = = 157,770.458
𝑁𝑒𝑡 𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛 𝑜 𝑇𝑒𝑒𝑡ℎ 103.718 𝑖𝑛2
𝑙𝑖𝑛𝑒𝑠
But referring to the table on number 17, a 50 cycles have a 𝐵𝑡′′ of 126,000 𝑖𝑛2
and applying the
𝑙𝑖𝑛𝑒𝑠
10 % tolerance, a 50 cycles should be below 138,600 𝑖𝑛2
.

Since the preliminary value of 𝐵𝑡′′ is above the upper limit, therefore, it will be necessary to correct
(increase) the length of the armature core to bring the Flux Density down to a reasonable figure.
𝑙𝑖𝑛𝑒𝑠
Assuming 𝐵𝑡′′ = 138,000 𝑖𝑛2

16,363,636.36
Net Cross Section of Teeth = 138,000
= 118.577 𝑖𝑛2

Net Length Armature is.

𝑁𝑒𝑡 𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑇𝑒𝑒𝑡ℎ 118.577


𝑙𝑛 = = = 13.837 𝑖𝑛
𝑆 20
𝑡𝑎𝑣𝑒 𝑥 𝑥 𝑟 8.034 ( ) (0.64)
𝑃 12

To solve for the new and final value of 𝑙𝑎 ,

𝑙𝑛 13.837
𝑙𝑎 = + 𝑙𝑣 = + 0.375 = 15.415 𝑖𝑛
0.92 0.92

Then,

𝑙𝑎 𝐷 2 = (15.415)(57.34)2 = 50,682.602 𝑖𝑛3

𝑟𝜏𝑙𝑎 = (9.61)(15.415) = 148.138 𝑖𝑛2

16,363,636.36 𝑙𝑖𝑛𝑒𝑠
𝐵𝑔′′ = = 110,462.112
148.138 𝑖𝑛2
12.103 𝑙𝑖𝑛𝑒𝑠
𝐵𝑡′′ = 105,180.305 ( ) = 91,999.51
13.837 𝑖𝑛2

Now both 𝐵𝑔′′ 𝑎𝑛𝑑 𝐵𝑡′′ have an acceptable values wherein both values are within ± 10 % tolerance.

7
Item 29: Number of Radial Ventilating Ducts
By referring to Art. 16,

1.15 𝑠 1.15 (0.8)


sin 𝛼 = = = 0.102
𝜆 9.007
Then,
𝛼 = 𝑠𝑖𝑛−1 0.102 = 5.854° ; cos 𝛼 = 𝑐𝑜𝑠 38.16 = 0.995

2𝜏 2 (15.012 )
𝐼𝑐 = cos 𝛼
+ 4d + 3 = 0.995
+ 4 (1.104) + 3 = 37.772 𝑖𝑛

Therefore,

Total Length per Turn = Ic + 2 Ia = 37.772 + 2(15.415) = 68.602 𝑖𝑛

Item 30: Resistance of one turn, Ohms at 60 ℃

𝑇𝑜𝑡𝑎𝑙 𝐿𝑒𝑛𝑔𝑡ℎ 𝑝𝑒𝑟 𝑇𝑢𝑟𝑛 68.602


𝑅 = = = 0.000422 Ω
4 4
2 (𝑡 𝑥 𝑤) 𝑥 𝑥 106 2 [(0.185)(0.345)] 𝑥 𝑥 106
𝜋 𝜋

Item 31: Resistance of Armature, (𝑅𝑐 )

𝑇𝑜𝑡𝑎𝑙 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑇𝑢𝑟𝑛𝑠 484


𝑅𝑐 = 𝑅 ( ) = 0.000422 ( ) = 0.017 Ω
𝑃1 12

Finally, the Total Resistance in the Armature

1
𝑇𝑜𝑡𝑎𝑙 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = (0.017) = 0.0085 Ω
2

Item 32: IR Drop in Armature

𝑅𝑐 𝑥 𝐼𝑐 = 0.017 𝑥 392.59 = 6.674 𝑉𝑜𝑙𝑡𝑠

Item 33: I2R Loss in Armature Winding

𝐼 2 𝑅 𝐿𝑜𝑠𝑠 = 𝐼𝑐 2 𝑥 𝑅𝑐 𝑃 = 392.59 2 (0.017)(12) = 31,441.889 𝑤𝑎𝑡𝑡𝑠


8
Item 34: Full load Flux

Assuming a brush contact drop of 2 volts, and a series field and commutating-field drop of about
one-half that in the armature winding, the total generated voltage at full load must be,

𝐼𝑅 𝑑𝑟𝑜𝑝
𝑇𝑜𝑡𝑎𝑙 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑎𝑡 𝐹𝑢𝑙𝑙 𝐿𝑜𝑎𝑑 = 𝑉𝐹𝐿 + 𝐵𝑟𝑢𝑠ℎ 𝑑𝑟𝑜𝑝 + 𝐼𝑅 𝑑𝑟𝑜𝑝 +
2
6.674
= 660 + 2 + 6.674 + 2

= 672.011Volts

Therefore, the Full Load Flux must be,

𝑇𝑜𝑡𝑎𝑙 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑎𝑡 𝐹𝑢𝑙𝑙 𝑙𝑜𝑎𝑑


𝐹𝑢𝑙𝑙 𝐿𝑜𝑎𝑑 𝐹𝑙𝑢𝑥 = 𝜙 ( )
𝑉𝐹𝐿
672.011
= 16,363,636.36 ( 660
)

= 16,661,429.75 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠

Item 35: Flux density in Armature Core below Teeth

From Art. 17, the suitable density for a frequency of 50 Hz is 76,000. Bearing in mind that the air-
gap is into two equal parts below the teeth, the armature flux is one-half of the total flux. Therefore,
density in core is 76,000 𝑙𝑖𝑛𝑒𝑠⁄𝑖𝑛2 .

𝜙 16,363,636.36
𝑅𝑑 = = = 7.78 𝑖𝑛
2 𝑥 𝑙𝑛 𝑥 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝐶𝑜𝑟𝑒 2(13.837)(76,000)

And the final value of Flux Density in Armature Core below Teeth is,

𝜙 16,363,636.36 𝑙𝑖𝑛𝑒𝑠
𝐹𝑙𝑢𝑥 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝐶𝑜𝑟𝑒 = = = 76,002.571
2 𝑥 𝑙𝑛 𝑥 𝑅𝑑 2(13.837)(7.78) 𝑖𝑛2

Item 36: Internal Diameter of Core Stampings

𝐷𝑖 = 𝐷 − 2𝑅𝑑 − 2𝑑 = 57.34 − 2(7.78) − 2(1.104) = 39.572 𝑖𝑛

9
Item 37: Weight of iron Core

The weight of a cubic inch of Iron is 0.28 lb, and the total weight of iron Core below the Teeth will
be,

𝜋
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐼𝑟𝑜𝑛 𝐶𝑜𝑟𝑒 = 0.28 𝑥 𝑙𝑛 𝑥 [(𝐷 − 2𝑑)2 − (𝐷𝑖)2 ]
4
𝜋
= 0.28(13.837) ( 4 ) {[57.34 − 2(1.104)]2 − (39.572)2 }

= 4,484.022 𝑙𝑏

Item 38: Weight of iron Teeth

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐼𝑟𝑜𝑛 𝑇𝑒𝑒𝑡ℎ = 0.28 𝑥 𝑑 𝑥 (𝑡𝑎𝑣𝑒 𝑥 𝑆) 𝑥 𝑙𝑛


= 0.28 (1.069)(8.034 𝑥 20) (13.837)
= 665.487 𝑙𝑏

Item 39: Total Weight of Armature Stampings

𝑇𝑜𝑡𝑎𝑙 𝑊𝑒𝑖𝑔ℎ𝑡 = 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐼𝑟𝑜𝑛 𝐶𝑜𝑟𝑒 + 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐼𝑟𝑜𝑛 𝑇𝑒𝑒𝑡ℎ


= 4,484.022 + 665.487
= 5,149.509 𝑙𝑏

10
DESIGN SHEET FOR ARMATURE OF D-C GENERATOR (PART – 2)

SPECIFICATION: Preliminary or
ITEM Final
SYMBOL Assumed
NO. 1550 kW ; 660/750 Volts ; 500 rpm Values
Values

COMMUTATOR AND BRUSHES

40 Diameter of Commutator, in Dc --------- 36.45


41 Average volts per turn of armature winding ------- --------- 37.19
42 Number of turn between bars ------- --------- 1
43 Total number of Commutator bars ------- --------- 239
44 Bar pitch, in ------- --------- 0.479
45 Width of copper bar (on surface), in ------- --------- 0.449
46 Radial depth of bar, in ------- --------- 3.43
47 Current density at brush-contact surface, amp per sq in ∆𝑏 40 40.061
48 Contact area per brush set, sq in ------- 19.63 19.6
49 Brush arc (circumferential width), in ------- --------- 1.0
50 Axial brush length (total) per set, in ------- -------- 19.6
51 Number of brushes per set ------- --------- 31.36
52 Axial length of Commutator, in Lc --------- 22.85
53 Brush-contact drop, volts ------- --------- 2.3
54 Brush-contact loss, watts ------- --------- 9,096.684
55 Brush-friction loss, watts ------- --------- 12,684.355
56 Total brush loss, watts ------- --------- 21,781.039
57 Drawing to scale giving leading dimensional of ------- Fig. II
Armature and Commutator

11
DESIGN OF COMMUTATOR AND BRUSHES

Item 40: Diameter of Commutator (Dc)


From Art. 14, a diameter of Commutator not exceeding 80 % of the Armature Core Diameter is
𝐷
generally found practical, although a reasonably good rule to follow is to make 𝐷𝑐 = 2 + 𝑅𝑑 𝑖𝑛 .
Thus,
57.34
𝐷𝑐 = + 7.78 = 36.45 𝑖𝑛
2

This is 63.57 % of the core diameter and makes the peripheral velocity,
𝜈𝑐 = 0.6357 x 7,509.72 = 4,773.929 fpm

Item 41: Average Volts per Turn of Armature Winding


𝐸 750
= = 37.19 𝑉𝑜𝑙𝑡𝑠
𝑍⁄ 484⁄
2𝑃1 2(12)

Item 42: Number of Turns between Bars


One (1)

Item 43: Total Number of Commutator Bars


𝐶𝑠 24
𝐶=( 𝑥 𝑆) − 1 = ( 𝑥 20) − 1 = 239 𝐶𝑜𝑚𝑚𝑢𝑡𝑎𝑡𝑜𝑟 𝐵𝑎𝑟𝑠
2 2

Item 44: Bar Pitch


𝜋 𝐷𝑐 𝜋 (36.45)
= = 0.479 𝑖𝑛
𝐶 239

Item 45: Width of Copper Bar (On Surface)


Using 0.03 in mica for insulation, the width of copper bar = Bar Pitch ― 0.03, therefore, 0.479―
0.03 = 0.449in at the Commutator surface.

Item 46: Radial Depth of Bar


Since the Peripheral Velocity is less than 4,500 fpm, the Radial Depth of the Commutator Segment
should be about,
𝐷𝑐 + 15 36.45 + 15
ℎ= = = 3.43 𝑖𝑛
15 15

12
Item 47: Current Density at Brush-Contact Surface (∆𝑏 )
𝑎𝑚𝑝. 𝑎𝑚𝑝.
The Current Density over the Brush Contact Surface is about 30 to 50 𝑖𝑛2
, taking 40 𝑖𝑛2
as
preliminary value.

Item 48: Contact Area per Brush Set


𝑃𝐼𝑐 12(392.59)
= = 19.63 𝑖𝑛2
(𝑃⁄2)(∆𝑏 ) 6(40)

Item 49: Brush Arc (Circumferential Width)


1.0 inch

Item 50: Axial Brush Length per Set


𝐶𝑜𝑛𝑡𝑎𝑐𝑡 𝐴𝑟𝑒𝑎 19.63
= = 19.63 𝑖𝑛
𝐵𝑟𝑢ℎ 𝐴𝑟𝑐 1.0

Item 51: Number of Brushes per Set


The actual area per Brush Set is,
𝐴𝑥𝑖𝑎𝑙 𝐵𝑟𝑢𝑠ℎ 𝐿𝑒𝑛𝑔𝑡ℎ 𝑥 𝐵𝑟𝑢𝑠ℎ 𝐴𝑟𝑐 = 19.63 𝑥 1.0 = 19.6 𝑖𝑛2

From Art. 34, the usual width of Brush is something between the limits 5⁄8 in and 1 1⁄4 in., and as
a further check on the desirable dimensions, the width should not exceed one-tenth of the pole
pitch referred to the Commutator surface. Thus, use a Brush of 5⁄8 in. width.
Then,
19.6 19.6
𝑁𝑜. 𝑜𝑓 𝐵𝑟𝑢𝑠ℎ𝑒𝑠 𝑝𝑒𝑟 𝑆𝑒𝑡 = = = 31.36 𝐵𝑟𝑢𝑠ℎ𝑒𝑠
5⁄ 0.625
8
The Current Density will be increased slightly to;
19.63 𝑎𝑚𝑝.
40 ( ) = 40.061
19.6 𝑖𝑛2

Item 52: Axial Length of Commutator (Lc)


In addition to the 19.6 in which must be provided for the four 5⁄8 in Carbon Brushes, the Axial
Length of the Commutator Face must allow for the following:
a. Brush holder and clearances = 4 5⁄16 = 5⁄4 𝑖𝑛

b. Staggering of (+) and (-) Brushes = 5⁄8 𝑖𝑛


c. End clearance for Brushes = 1 in
d. End Play = 3⁄8 𝑖𝑛

13
Total Length will be,

5 5 3
𝐿𝑐 = 19.6 + + + 1 + = 22.85 𝑖𝑛
4 8 8

Item 53: Brush Contact Drop


𝑎𝑚𝑝.
Referring to Fig. 38, the Brush Contact Drop for Hard Carbon at about 40. 𝑖𝑛2 is 2.085 volts.
Allowing the 10 % of roughness, chipping and irregularities, thi drop will be about
2.3 volts.

Item 54: Brush Contact Loss


Brush Contact Drop x P x Ic = 2.3 (12 x 329.59) = 9,096.684 watts

Item 55: Brush Friction Loss


For a peripheral speed greater than 4,000 fpm, use c = 0.25 for hard carbon; P = 2 𝑙𝑏⁄𝑖𝑛2

𝑐𝑃𝐴𝑁𝐷𝑐 𝜋 𝑥 746 0.25(2)(19.6𝑥12)(500)(36.45) 𝜋 𝑥 746


𝑊𝑓 = = = 12,684.355 𝑤𝑎𝑡𝑡𝑠
12 𝑥 33,000 12 𝑥 33,000

Item 56: Total Brush Loss

𝑇𝑜𝑡𝑎𝑙 𝐵𝑟𝑢𝑠ℎ 𝐿𝑜𝑠𝑠 = 𝐵𝑟𝑢𝑠ℎ 𝐶𝑜𝑛𝑡𝑎𝑐𝑡 𝐿𝑜𝑠𝑠 + 𝐵𝑟𝑢𝑠ℎ 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝐿𝑜𝑠𝑠


= 9,096.684 + 12,684.355
= 21,781.039 𝑤𝑎𝑡𝑡𝑠

Item 57: drawing to Scale giving leading Dimensions of Armature and Commutator

3 𝑂𝑢𝑡𝑝𝑢𝑡 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑆ℎ𝑎𝑓𝑡 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0.84 √
𝑁

3 1,550.000
= 0.84 √ 500

= 12.25 𝑖𝑛

14

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