Machine Construction

Construction of Induction
and Synchronous Machine

by
Sikandar Ali Khan
3 Phase Induction Machine : Exploaded View
Single Phase Induction Machine : Exploaded
View
Synchronous Machine : Exploaded View
Stator
• Stator is the stationary part of the
machine which carries the
distributed winding.
• It is made up of thin laminations
and the slots are punched on the
inner periphery.
• Stator structure is same for both
induction machine and
synchronous machine.
• Stator slots carry three phase
balanced winding.
Rotor
• Rotor is the rotating part of the machine.
• Rotor structure is different for induction machine and synchronous
machine.
• Following two types of rotor structure are used for induction machine :
1. Squirrel Cage rotor
2. Wound rotor or Slip ring rotor
• Following two types of rotor structure are used for synchronous
machine :
1. Cylindrical rotor
2. Salient pole rotor
Rotor : Induction Machine
Squirrel Cage Rotor
• In the rotor slots, copper or

aluminum bars are placed.
• Rotor bars are short circuited at
both ends by the end ring.
• This type of rotor is very rugged
and require very little
maintenance.
Rotor : Induction Machine
Wound Rotor
• In the rotor slots, three phase winding

is present.
• Rotor winding is star connected and
closed through slip rings.
• This type of rotor require maintenance
due to the presence of slip ring and
brushes.
• Due to presence of brushes, this type
of motor can not be used in explosive
environment such as mines, oil rigs etc.
Rotor : Synchronous Machine
Cylindrical Rotor
• In this type of construction, rotor is slotted on

the outer periphery but only two third of the
rotor periphery is slotted so as to form rotor
pole arc.
• This type of construction is used in alternators
with high rating (several hundred MW).
• Steam turbine is used as a prime mover for this
type of construction.
• This construction is used for 2 or 4 pole
alternators.
• The rotors have long axial length and small
diameter.
Salient Pole Rotor
• In this type of construction, rotor poles are

radially protruding from rotor core.
• This rotor is used where prime mover
speed is low such as in hydro power plants.
• No. of poles in this construction are
normally greater than 4.
• A concentrated winding is placed on the
rotor poles which is energized by a dc
supply.
• This type of rotor has small axial length
and large diameter.
11-01-2022 EED,DTU 11
Armature Winding
• Armature winding is one in which
main voltage is induced.
• In synchronous machine, armature
winding is placed on stator.
• Armature winding is 3 phase, space
displaced, balanced winding which
is placed in stator slots.
• Armature winding can be a single
layer or a double layer winding.
• A detailed description of armature
winding is given later in this
presentation.
Armature Winding
• Some terms and definitions common
to armature winding are discussed
below :
1. Conductor : A length of wire which

takes active part in the energy
conversion process is called a
conductor.
2. Turn : One turn consists of two
conductors.
3. Coil : One coil may consist of any
number of turns.
4. Coil – side : One coil with any
number of turns has two coil-sides.
5. Winding : An arrangement of coils
in different slots is called a winding.
Armature Winding
6. Single- layer and double layer
windings :
Single- layer winding :

One coil-side occupies the total
slot area
Used only in small ac machines
Double- layer winding :

Slot contains even number (may
be 2,4,6 etc.) of coil-sides in two
layers
Double-layer winding is more
common above about 5kW
machines.
Armature Winding
• The advantages of double-layer winding over single layer winding are as
follows:
Easier to manufacture and lower cost of the coils

Fractional-slot winding can be used
Chorded-winding is possible
Lower-leakage reactance and therefore , better performance of the machine
Better emf waveform in case of generators
Armature Winding
7. Pole – pitch : A pole pitch is
defined as the peripheral
distance between identical
points on two adjacent poles.
Pole pitch is always equal to
180o electrical.
8. Coil–span or coil-pitch : The
distance between the two coil-
sides of a coil is called coil-span
or coil-pitch. It is usually
measured in terms of teeth,
slots or electrical degrees.
Armature Winding
9. Full Pitch and Short Pitch Coil :
Full Pitch Coil : if the coil-span is equal

to the pole-pitch, then the coil is termed
as a full pitch coil.
Short Pitch Coil : in case the coil span is

less than the pole – pitch, then it is called
chorded, short-pitch or fractional pitch
coil.
Armature Winding
10. Integral Slot Winding and
Fractional Slot Winding :
Integral Slot Winding : If the number

of slots per pole per phase is an
integer, the winding is called integral
slot winding.
𝑆
𝑞 = 𝑚×𝑃 = 𝑎𝑛 𝑖𝑛𝑡𝑒𝑔𝑒𝑟
Fractional Slot Winding : If the

number of slots per pole per phase is
not an integer, the winding is called
fractional slot winding.
𝑆
𝑞= ≠ 𝑎𝑛 𝑖𝑛𝑡𝑒𝑔𝑒𝑟
𝑚×𝑃
Armature Winding
• Phase Spread : phase spread is
the angular spread in electrical
degrees corresponding to number
of slots belonging to only one
phase under one pole pair.
Armature Winding
11-01-2022 EED,DTU 20
Armature Winding
11-01-2022 EED,DTU 21
Field Winding
• Field winding is one which produces
the main magnetic field in the
machine.
• In cylindrical rotor construction,
winding is distributed on the rotor
periphery but the turns are
connected in series to form the field
winding.
• In salient pole rotor construction,
concentrated field winding is used.
• Field winding is energized by a dc
supply to produce a space
distributed mmf waveform.
Field Winding
11-01-2022 EED,DTU 23
Field Winding
11-01-2022 EED,DTU 24
Field Winding
11-01-2022 EED,DTU 25
Field Winding
11-01-2022 EED,DTU 26
Field Winding
11-01-2022 EED,DTU 27
Exciter
• There are two ways in which the field winding can be excited.
• One way is to use slip – rings and brushes to connect the field winding to DC
voltage source.
• Slip rings are metal rings completely encircling the shaft of a machine but insulated
from it.
• One end of the dc rotor winding is tied to each of the two slip rings on the shaft of
the synchronous machine, and a stationary brush rides on each slip ring.
• A "brush" is a block of graphite like carbon compound that conducts electricity
freely but has very low friction, so that it doesn't wear down the slip ring.
• If the positive end of a dc voltage source is connected to one brush and the negative
end is connected to the other, then the same dc voltage will be applied to the field
winding at all times regardless of the angular position or speed of the rotor.
Exciter
• Slip rings and brushes increase the amount of maintenance required on the
machine, since the brushes must be checked for wear regularly.
• In addition, brush voltage drop can be the cause of significant power losses
on machines with larger field currents.
• Despite these problems, slip rings and brushes are used on all smaller
synchronous machines, because no other method of supplying the dc field
current is cost-effective.
• Second method is to use a specialized system to circulate field current which
is located on the shaft of the alternator.
• It consists of two parts namely,
1. Main exciter
2. Pilot exciter
Exciter
• The main exciter is a small ac
generator with its field circuit
mounted on the stator and its
armature circuit mounted on the
rotor shaft.
• The three-phase output of the
exciter generator is rectified to
direct current by a three-phase
rectifier circuit also mounted on
the shaft of the generator, and is
then fed into the main dc field
circuit.
• By controlling the small dc field
current of the exciter generator
(located on the stator), it is
possible to adjust the field current
on the main machine without slip
rings and brushes.
Exciter
• To make the excitation of a
generator completely independent
of any external power sources, a
small pilot exciter is often included
in the system.
• A pilot exciter is a small ac
generator with permanent magnets
mounted on the rotor shaft and a
three-phase winding on the stator.
• It produces the power for the field
circuit of the exciter, which in turn
controls the field circuit of the main
machine.
• If a pilot exciter is included on the
generator shaft, then no external
electric power is required to run the
generator.
Motor Manufacturing and Assembly Video
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You

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Construction of Induction

and Synchronous Machine

• In the rotor slots, copper or

• In the rotor slots, three phase winding

• In this type of construction, rotor is slotted on

• In this type of construction, rotor poles are

1. Conductor : A length of wire which

Single- layer winding :

Double- layer winding :

Easier to manufacture and lower cost of the coils

Full Pitch Coil : if the coil-span is equal

Short Pitch Coil : in case the coil span is

Integral Slot Winding : If the number

Fractional Slot Winding : If the

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