UNIT – 2

Optimal design of DC machine

Unit-02/Lecture-01

Construction of DC Machine- [RGPV/ June 2013/ 10 Marks]

The sectional view of a 4-pole D.C machine with complete magnetic path is shown in figure
below. The length of the machine is perpendicular to the paper. Stator has got 4 numbers of
projected poles with coils wound over it. These coils may be connected in series in order that
consecutive poles produce opposite polarities (i.e., N-S-N-S) when excited from a source.

Sectional Diagram of a DC Machine

Structurally and construction wise a direct current motor is exactly similar to a DC generator,
but electrically it is just the opposite. Here we unlike a generator we supply electrical energy to
the input port and derive mechanical energy from the output port.

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 1) Yoke of DC Motor-
The magnetic frame or the yoke of dc motor made up of cast iron or steel and forms an integral
part of the stator or the static part of the motor. The outer frame or yoke serves double
purpose :
i) It provides mechanical support for the poles and acts as a protecting cover for the
whole machine.
ii) It carries the magnetic flux produced by the poles.
In small generators where cheapness rather than weight is the main consideration, yokes are
made of cast iron. But for large machines usually cast steel or rolled steel is employed.

2) Poles of DC Motor-
The magnetic poles of DC motor are structures fitted onto the inner wall of the yoke with
screws. The construction of magnetic poles basically comprises of two parts namely, the pole
core and the pole shoe stacked together under hydraulic pressure and then attached to the
yoke. These two structures are assigned for different purposes, the pole core is of small cross
sectional area and its function is to just hold the pole shoe over the yoke, whereas the pole
shoe having a relatively larger cross-sectional area spreads the flux produced over the air gap
between the stator and rotor to reduce the loss due to reluctance.

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 3) Field Winding of DC Motor-
The field winding of dc motor are made with field coils (copper wire) wound over the slots of
the pole shoes in such a manner that when field current flows through it, then adjacent poles
have opposite polarity are produced.When current is passed through these coils, they electro-
magnetise the poles which produce the necessary flux that is cut by revolving armature
conductors

4) Armature Core –
It houses the armature conductors or coils and causes them to rotate and hence cut the
magnetic flux of the field magnets. In addition to this, its most important function is to provide
a path of very low reluctance to the flux through the armature from a N-pole to a S-pole. It is
cylindrical or drum-shaped and is built up of usually circular sheet steel discs or laminations
approximately 0.5 mm thick.

5) Armature Winding of DC Motor-

The armature winding of dc motor is attached to the rotor, or the rotating part of the machine,
and as a result is subjected to altering magnetic field in the path of its rotation which directly
results in magnetic losses. For this reason the rotor is made of armature core, that’s made with
several low-hysteresis silicon steel laminations, to reduce the magnetic losses like hysteresis
and eddy current loss respectively. These laminated steel sheets are stacked together to form

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the cylindrical structure of the armature core.

6) Commutator of DC Motor-
The commutator of dc motor is a cylindrical structure made up of copper segments stacked
together, but insulated from each other by mica. The function of the commutator is to facilitate
collection of current from the armature conductors; it rectified i.e. converts the alternating
current induced in the armature conductors into unidirectional current in the external load
circuit. It is of cylindrical structure and is built up of wedge-shaped segments of high-
conductivity hard-drawn or drop forged copper. The number of segments is equal to the
number of armature coils. Each commutator segment is connected to the armature conductor
by means of a copper lug or strip. As far as the dc motor is concerned, Its main function is to
commute or relay the supply current from the mains to the armature winding housed over a
rotating structure through the brushes of dc motor.

7) Brushes of DC Motor-
The brushes of dc motor whose function is to collect current from commutator are made with
carbon or graphite structures, making sliding contact over the rotating commutator. The
brushes are used to relay the electric current from external circuit to the rotating commutator
form where it flows into the armature winding. So, the commutator and brush unit of the dc
motor is concerned with transmitting the power from the static electrical circuit to the
mechanically rotating region or the rotor.The number of brushes per spindle depends on the
magnitude of the current to be collected from the commutator

S.NO RGPV QUESTIONS Year Marks

Q. 1 Show the complete magnetic path in a sketch of a 4-pole DC June 2013 10 Marks
machine.

Department of Electrical & Electronics Engineering, OIST, Bhopal

 Unit-02/Lecture-02

Design of DC Machine:

The aim of designing the DC machine is to obtain the complete dimensions of various parts of
the machine as listed below

Armature Design : [RGPV/ June 2012/ 20 Marks]

The armature of a dc machine consists of core and winding. The armature core is cylindrical in
shape with slots on the outer periphery of the armature. The core is formed with circular
laminations of thickness 0.5mm. The winding is placed on the slots in the armature core. The
design of armature core involves the design of main dimensions D & L, number of slots, slot
dimensions and depth of core. In the overall design of armature, the equation for armature
design as well as the design of armature winding is to be considered.

Specific Magnetic and Electric Loadings :

[RGPV/ June 2013/ 10 Marks, RGPV/ June 2009/ 10 Marks]

The specific electric loading (usually denoted by the symbol (q), the A standing for Amperes) is
the axial current per metre of circumference on the rotor. In a slotted rotor, the axial current is
concentrated in the conductors within each slot, but to calculate q we picture the total current
to be spread uniformly over the circumference.

Many factors influence the values which can be employed in motor design, but in essence the
specific magnetic and electric loadings are limited by the properties of the materials (iron for
the flux, and copper for the current), and by the cooling system employed to remove heat
losses.

The specific magnetic loading does not vary greatly from one machine to another, because the
saturation properties of most core steels are similar. On the other hand, quite wide variations
occur in the specific electric loadings, depending on the type of cooling used.

Despite the low resistivity of the copper conductors, heat is generated by the low of current,
and the current must therefore be limited to a value such that the insulation is not damaged by
an excessive temperature rise. The more effective the cooling system, the higher the electric
loading can be. For example, if the motor is totally enclosed and has no internal fan, the current

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density in the copper has to be much lower than in a similar motor which has a fan to provide a
continuous flow of ventilating air. Similarly, windings which are fully impregnated with varnish
can be worked much harder than those which are surrounded by air, because the solid body of
encapsulating varnish provides a much better thermal path along which the heat can low to the
stator body. Overall size also plays a part in determining permissible electric loading, with large
motors generally having higher values than small ones.

Equation for Armature Design (Output Equation):

[RGPV/ June 2013/ 10 Marks, RGPV/ June 2009/ 10 Marks]

Output equation expresses the relationship between the output of the machine and the main
dimensions of the armature in terms of specific magnetic and electrical loadings. The output
equation of a dc machine is given as power developed by armature in kW.

E : emf induced or back emf

Ia : armature current
f : Average value of flux / pole
Z : Total number of armature conductors
N : Speed in rpm
P : Number of poles
A : number of armature paths or circuits
D : Diameter of the armature
L : Length of the armature core

Power developed in the armature in kW =

The term Pf represents the total flux and is called the magnetic loading. Magnetic loading/unit
area of the armature surface is called the specific magnetic loading or average value of the flux
density in the air gap Bav. That is,

Therefore,

The term (Ia Z/A) a represents the total ampere-conductors on the armature and is called the

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electric loading. Electric loading/unit length of armature periphery is called the specific electric
loading q. That is,

Therefore,

Substitution of equations 2 and 3 in 1, leads to

Where C is called the output coefficient of the DC machine and is equal to

Therefore,

The above equation is called the output equation. The D2L product represents the size of the
machine or volume of iron used. In order that the maximum output is obtained/kg of iron used,
product must be as less as possible. For this, the values of q and Bav must be high.

Effect of higher value of q:

Since armature current Ia and number of parallel paths A are constants and armature diameter
D must be as less as possible or D must be a fixed minimum value, the number of armature
conductors increases as increases.

i) As q increases, number of conductors increases, resistance increases, I2R loss increases

and therefore the temperature of the machine increases. Temperature is a limiting
factor of any equipment or machine.
ii) As q increases, number of conductors increases, conductors/slot increases, quantity of
insulation in the slot increases, heat dissipation reduces, temperature increases, losses
increases and efficiency of the machine reduces.
iii) As q increases, number of conductors increases, armature ampere-turns per pole AT /
pole = (Ia Z / 2 A P) increases, flux produced by the armature increases, and therefore
the effect of armature reaction increases. In order to overcome the effect of armature
reaction, field mmf has to be increased. This calls for additional copper and increases
the cost and size of the machine.

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 iv) As q increases, number of conductors and turns increases reactance voltage
proportional to (turns) increases. This leads to sparking commutation.

Effect of higher value of Bav :

i) As Bav increases, core loss increases, efficiency reduces.

ii) As Bav increases, degree of saturation increases, mmf required for the magnetic circuit
increases. This calls for additional copper and increases the cost of the machine.

It is clear that there is no advantage gained by selecting higher values of q and Bav. If the values
selected are less, then D2L will be large or the size of the machine will unnecessarily be high.
Hence optimum value of q and Bav must be selected.

S.NO RGPV QUESTIONS Year Marks

Q. 1 Explain the Detailed Procedure for Armature design of a DC June 2012 20 Marks
machine
Q. 2 Define Specific magnetic loading and Specific electric loading June 2013 10 Marks
and obtain an expression for the output coefficient of a DC June 2009
machine.

Department of Electrical & Electronics Engineering, OIST, Bhopal

 Unit-02/Lecture-03

Factors influencing the choice of Number of Poles:

[ RGPV/ June 2014/7 Marks , RGPV/June 2011/ 10 Marks, RGPV/June 2009/ 10 Marks]

In order to decide what number of poles (more or less) is to be used, let the different factors
affecting the choice of number of poles be discussed based on the use of more number of
poles.

(i) Frequency of flux reversal :

As the number of poles increases, frequency of the induced emf f =PN /120 increases,
core loss in the armature increases and therefore efficiency of the machine decreases.
However, in DC machines the iron losses taking place in armature core and armature
teeth depends upon the frequency of flux reversal. Thus, the choice of number of poles
should be such, as to keep the iron losses within limits. The frequency of flux reversal
usually ranges from 25 to 50 Hz for DC machines. This would normally form the basic
consideration for deciding the number of poles.

(ii) Weight of iron parts:

Since the flux carried by the yoke is approximately /2 and the total flux T =
pis a constant for a given machine, flux density in the yoke

It is clear that Ay is 1/P. as By is also almost constant for a given iron. Thus, as
the number of poles increases, Ay and hence the weight of iron used for the yoke
reduces.

(iii) Overall size of machine

The height of the pole decreases with increased number of poles. Thus, overall outside
diameter of the machine will decrease, as the number of poles is increased.
Moreover, the overhang of the armature winding is reduced as the number of poles
increases and as a result, the overall length of armature will be reduced. Hence, the size
of the machine is reduced with increased number of poles.

(iv) Weight of copper :

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 For a given active length of the coil, overhang pole pitch D/P goes on
reducing as the number of poles increases. As the overhang length reduces, the
weight of the inactive copper used at the overhang also reduces.

(v) Overall diameter:

When the number of poles is less, ATa / pole and hence the flux, produced by the
armature is more. This reduces the useful flux in the air gap. In order to maintain a
constant value of air gap flux, flux produced by the field or the field ampere-turns must
be increased. This calls for more field coil turns and size of the coil defined by the depth
of the coil df and height of the coil hf increases. In order that the temperature rise of the
coil is not more, depth of the field coil is generally restricted. Therefore height of the
field coil increases as the size of the field coil or the number of turns of the coil
increases. As the pole height, is proportional to the field coil height, height of the pole
and hence the overall diameter of the machine increases with the increase in height of
the field coil.

Obviously as the number of poles increases, height of the pole and hence the overall

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 diameter of the machine decreases.

(vi) Commutator length:

Since each brush arm collects the current from every two parallel paths, current /
brush arm = 2 Ia / A and the cross sectional area of the brush / arm Ab = 2Ia /
Ab = 2Ia / Pb 1 / P reduces as the number of poles increases.

As Ab = tbwbnb and tb is generally held constant from the commutation point of

view, wbnb reduces as Ab reduces. Hence the length of the commutator Lc = (wbnb
+ clearances) reduces as Ab reduces or the number of poles increases.

Where, Wb – width of the brush,

tb – thickness of the brush,
nb – number of brushes per spindle

(vii) Labour charges:

As the number of poles increases cost of labour increases as more number of poles are
to be assembled, more field coils are to be wound, placed on to the pole, insulate,
interconnect etc. It is clear that, when the number of poles is more, weight of iron used
for yoke and armature core, weight of inactive copper, overall diameter, length of
commutator and effect of armature reaction reduces. On the other hand efficiency
reduces chances of flash over increases and cost of machine increases. Since the
advantages outnumber the disadvantages, more number of poles is preferable.

Thus, though more number of poles is preferable, it is not advisable from the cost point
of view. In general the number of poles should be so selected that good operating
characteristics are obtained with minimum weight of active material and minimum cost

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 of construction

(viii) Flash-over between brushes:

As the number of poles increases, voltage between the segments increases.

Because of the increased value of Eb and carbon dust collected in the space where the
mica is undercut, chances of arcing between commutator segments increases. The arc
between the segments in turn may bridge the positive and negative brushes leading to a
dead short circuit of the armature or flash over.

S.NO RGPV QUESTIONS Year Marks

Q. 1 Discuss the various factors that influence the choice of June 2014 7 Marks
number of poles and main dimensions of a DC machine. June 2011 10 Marks
June 2009

Department of Electrical & Electronics Engineering, OIST, Bhopal

 Unit-02/Lecture-04-05

Design of Armature winding: [RGPV, June 2014/ 7 Marks]

The armature winding of dc motor is attached to the rotor, or the rotating part of the machine,
and as a result is subjected to altering magnetic field in the path of its rotation which directly
results in magnetic losses. For this reason the rotor is made of armature core, that’s made with
several low-hysteresis silicon steel laminations, to reduce the magnetic losses like hysteresis
and eddy current loss respectively. These laminated steel sheets are stacked together to form
the cylindrical structure of the armature core.

The armature core are provided with slots made of the same material as the core to which the
armature winding made with several turns of copper wire distributed uniformly over the entire
periphery of the core. The slot openings a shut with fibrous wedges to prevent the conductor
from plying out due to the high centrifugal force produced during the rotation of the armature,
in presence of supply current and field.

The armature winding can broadly be classified as concentrated and distributed winding. In
case of a concentrated winding, all the conductors / pole is housed in one slot. Since the
conductors / slot is more, quantity of insulation in the slot is more, heat dissipation is less,
temperature rise is more and the efficiency of operation will be less. Also emf induced in the
armature conductors will not be sinusoidal. Therefore

a) Design calculations become complicated (because of the complicated expression of

non-sinusoidal wave).
b) Core loss increases (because of the fundamental and harmonic components of the non-
sinusoidal wave) and efficiency reduces.
c) Communication interference may occur (because of the higher frequency components
of the non-sinusoidal wave).

Hence no concentrated winding is used in practice for a DC machine armature. In a distributed

winding (used to overcome the disadvantages of the concentrated winding), conductors / pole
is distributed in more number of slots. The distributed winding can be classified as single layer
winding and double layer winding.

In a single layer winding, there will be only one coil side in the slot having any number of
conductors, odd or even integer depending on the number of turns of the coil. In a double layer
winding, there will be 2 or multiple of 2 coil sides in the slot arranged in two layers. Obviously

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conductors / slot in a double layer winding must be an even integer.

Since for a given number of conductors, poles and slots, a single layer winding calls for less
number of coils of more number of turns, reactance voltage proportional to (turn)2is high. This
decreases the quality of commutation or leads to sparking commutation. Hence a single layer
winding is not generally used in DC machines. However it is much used in alternators and
induction motors where there is no commutation involved. Since a double layer winding calls
for more number of coils of less number of turns/coil, reactance voltage proportional to (turn)2
is less and the quality of commutation is good. Hence double layer windings are much used in
DC machines. Unless otherwise specified all DC machines are assumed to be having a double
layer winding.

The principal purpose of the armature winding is to connect the armature conductors together
in such a way that a desired resultant e.m.f. can be maintained between two points which are
connected to an external circuit. In the design of armature winding, the aim is to obtain the
following details regarding the winding based on the given specifications and dimensions of the
armature.

1. Number of Conductors on the Armature

Since the emf induced or back emf

Number of armature conductors where

For a preliminary design emf induced can be taken as the terminal voltage in case of a
generator and back emf can be taken as the applied voltage in case of a motor.

The number of armature conductors can also be calculated by considering the specific
electric loading. In that case. The number of conductors must be an even integer.

2. Number of Armature Slots

In order to decide what number of slots (more or less) is to be used, the following
merits and demerits are considered.

a) As the number of slots increases, cost of punching the slot increases, number of coils

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 increases and hence the cost of the machine increases.
b) As the number of slots increases, slot pitch decreases and hence the tooth width
reduces. This makes the tooth mechanically weak, increases the flux density in the tooth
and the core loss in the tooth. Therefore efficiency of the machine decreases.

If the slots are less in number, then the cost of punching & number of coils decreases,
slot pitch increases, tooth becomes mechanically strong and efficiency increases,
quantity of insulation in the slot increases, heat dissipation reduces, temperature
increases and hence the efficiency decreases. It is clear that not much advantage is
gained by the use of either too a less or more number of slots.

As a preliminary value, the number of slots can be selected by considering the slot pitch.
The slot pitch can assumed to be between (2.5 and 3.5) cm. (This range is applicable to
only to medium capacity machines and it can be more or less for other capacity
machines). The selection of the number of slots must also be based on the type of
winding used, quality of commutation, flux pulsation etc.

When the number of slot per pole is a whole number, the number slots embraced by
each pole will be the same for all positions of armature. However, the number teeth per
pole will not be same.

This causes a variation in reluctance of the air gap and the flux in the air gap will pulsate.
Pulsations of the flux in the air gap produce iron losses in the pole shoe and give rise to
magnetic noises. On the other hand, when the slots per pole is equal to a whole number
plus half the reluctance of the flux path per pole pair remains constant for all positions
of the armature, and there will be no pulsations or oscillations of the flux in the air gap.
To avoid pulsations and oscillations of the flux in the air gap, the number of slots per
pole should be a whole number plus half. When this is not possible for other reasons,
the number of slots per pole arc should an integer.

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 3. Dimensions of Armature Conductors

Since the armature conductors are connected in series in any of the parallel paths of dc
machine, maximum value of the current to be carried by the conductor is Ia / A and the
cross sectional area of the conductor a = Ia / A mm2. The current density lies
between 4.5 and 7.0 A / mm2 in practice.

As the current density increases, cross sectional area decreases, resistance of the
conductor increases, I2R loss increases and temperature of the machine increases. If the
cooling facility is not good, temperature rise will unnecessarily be high. Hence higher
value of current density should be used in machines where the peripheral velocity or
speed of operation is high or where cooling facility is good. For the calculated area ‘a’, a
round, square or rectangular section conductor can be used. (Trapezoidal section
conductor is also used but only in case of squirrel cage rotor of an induction motor for
increasing the starting torque).

4. Conductor and Slot Insulation:

Conductor insulation:

Separates the wires and turns of a coil. Usually, standards are not as high for conductor
insulation as they are for slot liner insulation, and therefore the former is usually
notably thinner than the latter. Consequently a conductor or turn to turn insulation is
usually, and in small machines in particular, a varnishing on the wire.

Slot Insulation:

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 Width and depth of the slot depends on the number of conductors per slot, cross
sectional area of the conductor, rated voltage etc. The insulation within the slot can be
roughly divided into two main categories: ground wall or slot liner and that associated
with conductor insulation and their arrangement in the slot.

Slot liner protects the winding insulation against any mechanical damage due to
roughness of the slot walls and insulates the armature. It also galvanically separates the
coil from the iron core of the machine. Materials used generally are Leatheroid, Melinex
polyester films, horn fiber etc.

Separator separates and insulates the two layers. Leatheroid, horn fiber, micanite etc.,
are used.

5. Dimensions of slot

The dimensions of the slot are slot width and depth. Usually the slot area is estimated
from the knowledge of conductor area and slot space factor. The slot factor lies in the
range of 0.25 to 0.4 & the value depends on the thickness of insulation.
Slot area = (Conductor Area)/(Slot space factor)

The following factors can be considered before finalizing the slot dimensions.
i) Flux density in tooth
ii) Flux pulsations
iii) Deep slots cause Eddy current loss in conductors
iv) Slot opening should be narrow to reduce the flux pulsation and hence to reduce
eddy current losses
v) Reactance voltage
vi) Fabrication difficulties

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 6. Details of insulation:

Desirable properties of a good insulator:

i) Should have a high dielectric strength.
ii) Should withstand a high temperature
iii) Should have a high resistivity
iv) Should not absorb moisture
v) Should have a low dielectric hysteresis loss
vi) Should withstand vibration, abrasion, bending
vii) Should be flexible and cheap.

No insulating material in practice satisfies all the desirable properties. Therefore

materials which satisfy most of the desirable properties must be selected. Based on the
temperature withstanding ability, the insulating materials have been classified
according to ISI (now BIS) – 1271, 1985, first revision as Class Y, Class A, Class E, Class B,
Class F, Class H, Class C.

S.NO RGPV QUESTIONS Year Marks

Q. 1 Discuss how the armature winding of a DC machine is June 2014 7 Marks
designed.

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Department of Electrical & Electronics Engineering, OIST, Bhopal
 Unit-02/Lecture-06-07

Design of the Field System: [RGPV/ Dec. 2009/10 Marks]

When a dc machine operates at no load, the only mmf that exists is due to the field system
(Main poles) which creates the main flux, ф. However, under loaded conditions, appreciable
current flows through the armature winding, which would produce the magnetic flux linking it.
Hence armature mmf is originated under the loaded condition of the d.c. machines. The
armature mmf has a considerable influence on the behavior of dc machines. The effect of
armature mmf upon the distribution of flux under the main poles of the field system is called
the armature reaction. Armature reaction weakens the main flux. In case of generator,
weakening of the main flux reduces the generated voltage. Armature reaction distorts the main
flux, hence the position of M.N.A. gets shifted (M.N.A. is perpendicular to the flux lines of main
field flux). Brushes should be placed on M.N.A., otherwise it will lead to sparking at the surface
of brushes. So, due to armature reaction, it is hard to determine the exact position of M.N.A.
The field system consist of
(i) Poles
(ii) Pole shoes
(iii) Field winding

1. Dimensions of the Pole:

Earlier solid poles of circular cross section made of forged steel and bolted to the frame
were normally used for large dc machines. With circular cross section of the poles, the
mean length of the turn is minimum and thus results in saving of the costly copper
material and reduction of the field copper losses. Solid pole body was being used,
because the flux in the pole body is of constant nature and as such iron losses do not
occur in the pole body. However, iron losses will occur in the pole shoe, because of the
alternating flux in the air gap of the machine. Thus, pole shoe must be laminated to
minimize the eddy current losses occurring. The laminations of the pole shoes are
insulated from each other by thin coat of varnish. These laminations are riveted and the
pole shoe is fixed to the pole body by countersunk screws.

Main poles are the solid poles of fabricated steel with seperate/integral pole shoes are
fastened to the frame by means of bolts. Pole shoes are generally laminated. Sometimes
pole body and pole shoe are formed from the same laminations. Stiffeners are used on
both des of the laminations. Riveted through bolts hold the assembly together. The pole
shoes are shaped so as to have a slightly increased air gap at the tips.

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 Inter-poles are small additional poles located in between the main poles. These can be
solid, or laminated just as the main poles. These are also fastened to the yoke by bolts.
Sometimes the yoke may be slotted to receive these poles. The inter poles could be of
tapered section or of uniform cross section. These are also called as commutating poles
or compoles. The width of the tip of the compole can be about a rotor slot pitch.

The present practice is generally to use laminated poles with pole shoe forming the part
of the same lamination for all ratings of the dc machine because
a) Use of laminated poles improves the commutation to a certain extent; especially in
wide speed range d.c. motors fed from static thyristor converters.
b) It reduced the overall cost of the machine, due to standardization. The same
standard laminations can be used in variety of dc machines, changing the
assembled dimensions according to the requirements of the field systems.

Based on the above fundamentals regarding the poles, the dimensions of the rectangular poles
are calculated as discussed below:

i) Axial length of the pole:

The axial length of the pole body can be taken normally 1 to 1.5 cm less than the gross
length of the armature. So as to permit end play and to avoid magnetic centering of the
armature.

ii) Width of the pole:

For laminated poles, flux density on full load, may be assumed as 1.5 to 1.7 Tesla for
medium and large dc machines. For smaller machines, flux density in the pole may be
assumed 1.4 to 1.5 Tesla. An appreciable portion of the total flux passing down the
poles does not enter the armature, but completes its magnetic circuit from pole to pole
through air. Such a flux is known as leakage flux.
The leakage factor may be taken about 1.15 to 1.2 for dc machines.
As the laminations of the pole are quite thick, iron factor for the poles may be taken as
0.95.
Thus flux in the pole body, фp = 1.15 to 1.2 ф
Net cross sectional area of the pole

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 iii) Height of the pole
The height of the pole should be selected in such a way that it can conveniently
accommodate the total ampere turns to be provided on the pole in the form of exciting
coil. Total field ampere turns per pole needed by the field system to produce the useful
flux, ф at full load and the height of the pole are inter related. Thus, the ratio between
the full load ampere turns per pole ATf to the armature full load ampere turns per pole
ATa can be assumed as guide line.

For non-inter pole machines = 1.1 to 1.3

For inter- pole machines = 0.7 to 1.0

The approximate height of the field coil can be calculated as

Height of pole body hp = hf + thickness of insulation and clearance

Total height of the pole hpl = hp + hs

2. Dimensions of the yoke

The dimensions of the yoke can be found out based on the flux carried by the yoke
section, which is approximately half the pole flux i.e.
Flux in yoke section,

Normally, cast steel yokes are used for DC machines, for which the flux density may be
assumed varying from 1.0 to 1.3 Tesla. Choosing a proper flux density in the yoke, cross
sectional area of the yoke is given by,
Cross sectional area of the yoke,

Moreover, Axial length of the yoke x depth of the yoke.

Axial length of the yoke may be taken approximately 1.5 times the gross length of the
armature, in order to account for the overhang of the armature.
Thus, depth of the yoke,

Knowing the depth of the yoke, height of the pole and external diameter of the
armature, outer diameter of the yoke can be calculated.

3. Ampere turns for the Iron Parts of the Magnetic Circuit

Department of Electrical & Electronics Engineering, OIST, Bhopal

 The different parts of the dc machine magnetic circuit / pole are yoke, pole, air gap,
armature teeth and armature core. Therefore, the ampere magnetic circuit is the sum of
the ampere
That is,
(i) Calculation of the ampere turns for the yoke
To calculate the ampere turns for the yoke, find out the ampere turns per
meter of flux path length, Hy corresponding to yoke flux density. By using
magnetization curve of the material of the yoke (cast steel) as shown below

Next step is to calculate the mean diameter of the yoke, Dmy, calculate the
mean flux path in the yoke and find out the total no. of ampere turns.

(ii) Calculation of the ampere turns for the pole

To calculate the ampere turns for the pole, find out the ampere turns per
meter of flux path length, Hp in the pole corresponding to pole flux density.
By using magnetization curve of the material of the pole (cast steel) as
shown in the figure.
Now calculate the length of magnetic flux path in the pole lp= hp. and find out
the total no. of ampere turns for the pole.

4. Length of Air Gap

The radial length of the air-gap between stator and rotor is usually made as small as
possible in dc motors. With consideration given to the overall size of the motor, the
manufacturing process and the tolerance on the assembly determine what the smallest
length can be to ensure that the rotor does not rub against the stator. The advantage of a

Department of Electrical & Electronics Engineering, OIST, Bhopal

 short air-gap is a lower reluctance value since the air-gap constitutes the major part of the
total circuit reluctance. In very small motors, it is not unusual to have air-gaps less than
0.01 inch.

It is also important to make the air-gap uniform around the complete periphery of the
rotor. Any asymmetry would result in unequal forces, radial and axial, around the rotor
and cause additional losses and mechanical vibration.

S.NO RGPV QUESTIONS Year Marks

Q. 1 Develop an algorithm for designing the field system of a DC Dec. 2009 10 Marks
machine. How are the parameters selected for optimal
design?

Department of Electrical & Electronics Engineering, OIST, Bhopal

 Unit-02/Lecture-08-09

Design of the Field Winding:

[RGPV/June 2014/ 7 Marks, RGPV/June 2012]
The field winding of dc motor are made with field coils (copper wire) wound over the slots of
the pole shoes in such a manner that when field current flows through it, then adjacent poles
have opposite polarity are produced. The field winding basically form an electromagnet, that
produces field flux within which the rotor armature of the dc motor rotates, and results in the
effective flux cutting.

1. Design of shunt field winding

The shunt field winding consists of large number of turns made of thin conductors,
because the current carried by them is very low. The series field winding is designed to
carry heavy current and so it is made of thick conductors.

(i) Cross sectional area of conductor:

The dimensions of the conductor are area of cross section and diameter. The area of
cross section of the field conductor can be estimated from the knowledge of field
current (If) & current density (δf). The usual range of current density in the field
conductor is 1.2 to 3.5 A/mm2.
area of cross section of the field conductor for the exciting coil can be found as
resistance of shunt field exciting coil,

Thus, cross sectional area of the conductor,

Where,
= Mean length of the turns of shunt exciting coil
total field ampere turns per exciting coil on no load i.e. ATfo
voltage across shunt field exciting coil.

(ii) Dimensions of field coil

The field coils are former wound & placed on the poles. The field coils may have
rectangular or circular cross-section, depending on the type of poles. The
dimensions of the field coil are depth, height & length of mean turn of field coil.

(iii) Current in the winding i.e. Shunt field current

Department of Electrical & Electronics Engineering, OIST, Bhopal

 The shunt field current can be estimated from the knowledge of voltage across field
coil and the resistance of field coil. Each pole of a dc machine carries one field coil
and all the field coils are connected in series to form shunt field winding. Hence the
voltage across each field coil is given by voltage across each field coil, Ef =voltage
across shunt field winding.
Number of poles field current= Ef/Rf

(iv) Number of turns in the winding

When the ampere turns to be developed by the field coil is known the turns can be
estimated from the knowledge of field current. Total number of turns in each
exciting coil can now be calculated from the total ampere turns of the exciting coil,
ATf and the shunt field current Ish.

(v) Proper arrangement of the field winding

Total turns in the exciting coil are properly arranged and in the first step, find out
the bare diameter of conductor using standard specification and design data for
paper covered round conductors according to the sectional area, ash of the
conductor. Now find out the diameter of the insulated conductor di from the same
data and calculate the number of turns in the height of the exciting coil hf.

(vi) Resistance of the winding

The resistance of the field coil can be estimated from the knowledge of resistivity of
copper, length of mean turn of field coil and area of cross section of field conductor.
Resistance of the shunt field winding is given by

Where,
= Mean length of the turns of shunt exciting coil
total no. of turns in shunt field winding
Sectional area of the conductor.

(vii) Copper losses in the winding

Shunt field copper losses can be calculated as
Shunt field copper losses = × number of exciting coils, Watts.

Shunt field current should be modified, as per the resistance calculated and

Department of Electrical & Electronics Engineering, OIST, Bhopal

 modified value should be used in the above equation.

(viii) Power loss in the field coil

The power loss in the field coil is copper loss which depends on resistance and
current. Heat developed in the field coil due to this loss and heat is dissipated
through the surface of the coil. If there is no sufficient surface for heat dissipation
then heat accumulates, which may lead to damage (or burning) of the coil. In field
coil design the loss dissipated per unit surface area is specified and from which the
required surface area can be estimated. The surface area of field coil depends on
length of mean turn, depth and height of field coil. Usually the length of mean turn is
estimated in order to provide the required surface area. The heat can be dissipated
from all the 4 sides of a coil i.e., inner, outer, top & bottom surface of the coil.

2. Design of series field winding

Series field winding is designed to carry heavy current and so it is made of thick
conductors/strips. Field coils are formed, insulated and fixed over the field poles. The
steps involved in the design of series field winding are listed below.
Step 1: Estimate the AT to be developed by series field coil,
AT /pole = (Iz . (Z/2))/P
For compound m/c, ATse = (0.15 to .25) (Iz . Z)/2P
For series m/c, ATse = (1.15 to 1.25) (Iz . Z)/2P
Step 2: Calculate the no. of turns in the series field coil,
Tse = ATse/Ise (Corrected to an integer)
Step 3: Determine cross sectional area of series field conductor,
ase = Ise /δse
Normally, δse - 2 to 2.3 A /mm2
Step 4 : Estimate the dimension of the field coil
Conductor area of field coil = Tse.ase
Also Conductor area of field coil = Sfse.hse.dse
When circular conductors are used
Sfse = 0.6 to 0.7
For rectangular conductors, Sfse – depends on thickness and type of insulation

Department of Electrical & Electronics Engineering, OIST, Bhopal

 On equating above two expressions,
Tse.ase = Sfse.hse.dse
hse= (Tse.ase )/(Sfse.dse)

S.NO RGPV QUESTIONS Year Marks

Q. 1 Explain the design procedure for the design of field winding of June 2014 7 Marks
a DC machine. June 2012 10 Marks

Department of Electrical & Electronics Engineering, OIST, Bhopal

Flowchart for optimal design of DC machine: [RGPV/ June 2011,
Dec. 2009]

Department of Electrical & Electronics Engineering, OIST, Bhopal

S.NO RGPV QUESTIONS Year Marks
Q. 1 Draw flowchart for optimal design of DC machine. Discuss June 2011 10 Marks
how the objective function and constraint function is Dec 2009
formulated.

Department of Electrical & Electronics Engineering, OIST, Bhopal

Department of Electrical & Electronics Engineering, OIST, Bhopal