Lecture05

DESIGNOFDCMACHINES

DetailstobespecifiedwhileorderingaDCmachineorconsumersspecification

1. Output:kW(forgenerators),kWorHp(formotors)
2. Voltage:Vvolt
3. Speed:Nrpm
4. Rating:ContinuousorShorttime
0 0
5. Temperaturerise: Cforanambienttemperatureof40 C
6. Cooling:Naturalorforcedcooling
7.Type:Generatorormotor, separatelyexcitedorselfexcitedshunt,series, or
compound,ifcompound typeofconnectionlongorshortshunt,type of
compoundingcumulativeordifferential,degreeofcompoundingover,underorlevel.
With or without inter poles, with or without compensating windings,with or without
equalizerringsincaseoflapwinding.
8. Voltageregulation(incaseofgenerators):Rangeandmethod
9. Speedcontrol(incaseofmotors):rangeandmethodofcontrol
10. Efficiency: must be as for as possible high (As the efficiency increases, cost of the
machinealsoincreases).
11. Typeofenclosure:basedonthefieldofapplicationtotallyenclosed,screenprotected,
dripproof,flameproof,etc.,
12. Sizeofthemachineetc.,

SizeoftheDCmachine
ThesizeoftheDCmachinedependsonthemainorleadingdimensionsofthemachineviz.,
diameter of the armature D and armature core length L. As the output increases, the main
dimensionsofthemachineDandLalsoincreases.

D
Figure.1.Armatureofadcmachine Figure.2.Yokeandpolearrangementofadcmachine

OUTPUTEQUATION

Note:Outputequationrelatestheoutputandmaindimensionsofthemachine.Actuallyitrelates
thepowerdevelopedinthearmatureandmaindimensions.

Derivation:
Nomenclature: E:emfinducedorbackemf
Ia:armaturecurrent
:Averagevalueofflux/pole
Z:Totalnumberofarmatureconductors
N:Speedinrpm
P:Numberofpoles
A:numberofarmaturepathsorcircuits
D:Diameterofthearmature
L:Lengthofthearmaturecore

3
PowerdevelopedinthearmatureinkW=EIax10

ZNP
I a 103
60A
IZ Nx103
(P) a
.......(1)
A 60

ThetermPrepresentsthetotalfluxandiscalledthemagneticloading.Magneticloading/unit
areaofthearmaturesurfaceiscalledthespecificmagneticloadingoraveragevalueoftheflux
densityintheairgapBav.Thatis,
P
B av Wb/m2ortesledenotedbyT
DL
Therefore PBavDL................(2)

Theterm (IaZ/A)representsthetotalampereconductorsonthearmatureandiscalledthe
 electricloading.Electricloading/unitlengthofarmatureperipheryiscalledthespecificelectric
loadingq.Thatis,

q Ia Z ampereconductors/m
AD
Therefore Ia Z/AqD............(3)
Substitution ofequations 2and3 in1,leadsto
N 103
kWBavDLqD 60

1.64 104B av qD2LN

C 0 D2 LN
where C0 iscalledtheoutputcoefficeintoftheDCmachineandis
equalto1.64 x104B av q.
kW
ThereforeD2L m3
4
1.64 10 B av qN
2
Theaboveequationiscalledtheoutputequation.TheD Lproductrepresentsthesizeofthe
machineorvolumeofironused.Inorderthatthemaximumoutputisobtained/kgofironused,
2
D Lproductmustbeaslessaspossible.Forthis,thevaluesofqandBavmustbehigh.

Effectofhighervalueofq
Note: Since armature current Ia and number of parallel paths A are constants and armature
diameterDmustbeaslessaspossibleorDmustbeafixedminimumvalue,thenumberof
armatureconductorsincreasesasqIaZ/ADincreases.

2
a. Asqincreases,numberofconductorsincreases,resistanceincreases,I Rlossincreases
andthereforethetemperatureofthemachineincreases.Temperatureisalimitingfactor
ofanyequipmentormachine.
b. As q increases, number of conductors increases,conductors/slot increases, quantity of
insulationintheslotincreases,heatdissipationreduces,temperatureincreases,losses
increasesandefficiencyofthemachinereduces.
c. Asqincreases,numberofconductorsincreases,armatureampereturnsperpole
ATa/pole=(IaZ/2AP)increases,fluxproducedbythearmatureincreases,and
thereforetheeffectofarmaturereactionincreases.Inordertoovercometheeffectof
armaturereaction,fieldmmfhastobeincreased.Thiscallsforadditionalcopperand
increasesthecostandsizeofthemachine.
d. Asqincreases,numberofconductorsandturnsincreases,reactancevoltageproportional
2
to(turns) increases.Thisleadstosparkingcommutation.

EffectofhighervalueofBav
a. AsBavincreases,corelossincreases,efficiencyreduces.
b. AsBavincreases,degreeofsaturationincreases,mmfrequiredforthemagnetic
circuitincreases.Thiscallsforadditionalcopperandincreasesthecostofthe
machine.

ItisclearthatthereisnoadvantagegainedbyselectinghighervaluesofqandB
2 av.Ifthevalues
selectedareless,thenD Lwillbelargeorthesizeofthemachinewillunnecessarilybehigh.
HenceoptimumvalueofqandBavmustbeselected.

Ingeneralqliesbetween15000and50000ampereconductors/m.
Lesservaluesareusedinlowcapacity,lowspeedandhighvoltagemachines.
IngeneralBavliesbetween0.45and0.75T.
2
SEPARATIONOFD LPRODUCT

KnowingthevaluesofkWandNandassumingthevaluesofqandBav,avaluefor
D2L= kW canbecalculated.
1.64104B av qN
Letitbe0.1m .3

SincetheaboveexpressionhastwounknownsnamelyDandL,anotherexpressionrelatingD
andLmustbeknowntofindoutthevaluesofDandL.
2
UsuallyavaluefortheratioarmaturecorelengthLtopolepitchisassumedtoseparateD L
product. The pole pitch refers to the circumferential distance corresponding one pole at
diameterD.InpracticeL/liesbetween0.55and1.1.

ThereforeL=(0.55to1.1)
=(0.55to1.1)D/P

IfL/=1.0andP=4,thenL=1.0D/P=1.0D/4=0.785D.
2
ThereforeD 0.785D=0.1orD=0.5m.ThusL=0.7850.5=0.395m.

2
Note:TheD Lproductcanalsobeseparatedbyassumingavaluefortheperipheralvelocityof
thearmature.

LIMITATIONSOFDANDL

Asthediameterofthearmatureincreases,theperipheralvelocityofthearmaturev=DN/60
m/s,centrifugalforceanditseffectsincreases.Thereforethemachinemustbe mechanicallymade
robusttowithstandtheeffectofcentrifugalforce.Thisincreasesthecostofthemachine.Ingeneral
fornormalconstruction,peripheralvelocityshouldnotbegreaterthan30m/sasforaspossible.

Topreventarcingbetweencommutatorsegments,voltagebetweenthecommutatorsegments
shouldnotbegreaterthanabout20Vonopencircuit.Ifasingleturncoilisusedthenthe
voltage/conductore=BavLvshouldnotbemorethan10V.
(BavAveragevalueoffluxdensityintheairgapintesla,LLengthoftheconductororgross
armaturecorelengthinmetreandvPeripheralvelocityofarmatureinm/s).e
Therefore,armaturecorelengthL=shouldnotbegreaterthan10/(0.75 30)=0.44mBavv
fornormaldesign.

Ventilatingductsandnetironlengthofarmaturecore

Tokeepdownthetemperatureriseofthemachineparts,thecoreisprovidedwithbothradialand
axialventilatingducts.Radicalductsarecreatedbyprovidingventorductspacersinbetween
corepacketsofwidth57cm.Widthoftheradialductliesbetween0.8and1.0cminpractice.

Itisclearfromthefigurethatthenetcorelength=(Lnvbv)
wherenvnumberofventilatingductsandbvwidthoftheventilatingduct.

Sincethecoreislaminatedtoreducetheeddycurrentlossandfluxtakestheleastreluctance
path,fluxconfinestotheirononly.ThereforethelengthoverwhichthefluxpassesisnotLor(L
nvbv)butlessthanthat.Generallythethicknessofinsulationonthelaminatedcorewillbe

around10%ofthegrosscorelength.Thereforethenetironlengthwillbe0.9timesthenetcore
lengthornetironlength,
Li=Ki(Lnvbv)
whereKiiscalledtheironorstackingfactorandisapproximately0.9inpractice.

Estimationofnumberofventilatingducts

Determinethenumberofductsifthelengthofarmaturecoreis35cm.

Sincethewidthofthecorepacketliesbetween5and7cm,letthewidthofthecorepacketbe6
cm.Thereforenumberofcorepacketsisequalto35/6or6say.Sixcorepacketsleadto5ducts.
Ifthewidthoftheductisassumedtobe1.0cm,thenthenetcorelengthwillbe(351 5)=30
cmandeachcorepacketafterrevisionwillbe30/6=5cminwidth.