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D.C Machines. Design of Field Poles & Field Coils Design of Commutator & Brushes. l y. h pl. Yoke. Armature Core. Flux Path. N. l c. Pole Body. h pl. S. S. N. Magnetic Circuit of 4-Pole DC Machine. Magnetic circuit . The path of magnetic flux is called magnetic circuit

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D.C Machines


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    1. D.C Machines Design of Field Poles & Field Coils Design of Commutator & Brushes

    2. ly hpl Yoke Armature Core Flux Path N lc Pole Body hpl S S N Magnetic Circuit of 4-Pole DC Machine Magnetic circuit • The path of magnetic flux is called magnetic circuit • Magnetic circuit of dc machine comprises of yoke , poles, airgap, armature teeth and armature core • Flux produced by field coils emerges from N pole and cross the air gap to enter the armature tooth. Then it flows through armature core and again cross the air gap to enter the S pole

    3. Magnetic circuit Let Bg – Max. flux density in the core Kg- Gap contraction factor lc– Length of magnetic path in the core l y – Length of magnetic path in the yoke ds - Depth of the slot dc - Depth of core hpl - Height of field pole Dm – Mean diameter of armature When the leakage flux is neglected magnetic circuit of a DC machine consists of following: • Yoke • Pole and pole shoe • Air gap • Armature teeth • Armature core

    4. Total MMF to be developed by each pole is given by the sum of MMF required for the above five sections. MMF for air gap ATg=800000 Bg Kg lg MMF for teeth ATt=att X ds MMF for core ATc=atc X lc/2 MMF for pole ATp = atp X hpl MMF for yoke ATy= atyX ly/2 att , atc , atp , aty - are determined B-H curves lc = πDm/P = π(D – 2ds – dc)/P ly = πDmy/P = π(D+ 2lg + 2hpl +dy)/P AT total =ATg + ATt + ATc + ATp +ATy

    5. Design of field system • Consists of poles, pole shoe and field winding. • Types: • Shunt field • Series field • Shunt field winding – have large no of turns made of thin conductors ,because current carried by them is very low • 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

    6. Design of field system Factors to be considered in design: • MMF/pole &flux density • Losses dissipated from the surface of field coil • Resistance of the field coil • Current density in the field conductors

    7. Design of field systemTentative design of field winding Let , ATfl-MMF developed by field winding at full load Qf - Copper loss in each field coil(W) qf - Permissible loss per unit winding surface for normal temperature rise(W/m2 ) Sf - Copper space factor ρ - Resistivity ( –m) hf - Height of winding(m) df- Depth of winding(m) S - Cooling surface of field coil(m2 ) Lmt - Length of mean turn of field winding(m) Rf - Resistance of each field coil (ohms) Tf- Number of turns in each field coil Af- Area of each conductor of field winding(m2) If- Current in the field winding (A) δf - Current density in the field winding(A/mm2 )

    8. Design of field system Cooling surface of the field winding, S=2Lmthf -- (1) Permissible copper loss in each field coil, Sqf=2Lmthfqf -- (2) Area of X-section of field coil=hfdf-- (3) Area of copper in each section=Sfhfdf-- (4) i.e, Tfaf=Sfhfdf-- (5) Copper loss in each field coil, Qf=If2Rf=If2 (TfLmt)/af i.e., Copper loss  f2(Square of the current density)

    9. Design of field system To have temperature rise within the limit, the copper loss should be equal to the permissible loss. Using Eqns. (2) & (6), 2Lmthfqf=f2Lmt(Sfhfdf) => MMF per metre height of field winding

    10. Design of field system • Normal values: • Permissible loss, qf -700W/m2 • Copper Space factor, Sf : • Small wires: 0.4 • Large round wires: 0.65 • Large rectangular conductors: 0.75 • Depth of the field winding, df :

    11. Design of field system Height of field, Total height of the pole, hpl=hf+hs+ height for insulation and curvature of yoke where, hs - Height of the pole shoe (≈0.1 to 0.2 of the pole height)

    12. Design of shunt field winding • Involves the determination of the following information regarding the pole and shunt field winding • Dimensions of the main field pole , • Dimensions of the field coil , • Current in shunt field winding, • Resistance of coil, • Dimensions of field conductor, • Number of turns in the field coil , • Losses in field coil. • Dimensions of the main field pole • For rectangular field poles • Cross sectional area, length, width , height of the body • For cylindrical pole • Cross sectional area, diameter, height of the body

    13. Design of shunt field winding • Area of the pole body can be estimated from the knowledge of flux per pole , leakage coefficient and flux density in the pole • Leakage coefficient (Cl) depends on power output of the DC machine • Bp in the pole 1.2 to 1.7 wb/m2 • Фp = Cl. Ф • Ap = Фp/Bp • When circular poles are employed, C.S.A will be a circle • Ap = πdp2 /4

    14. Design of shunt field winding • When rectangular poles employed, length of pole is chosen as 10 to15 mm less than the length of armature • Lp=L –(0.001 to 0.015) • Net iron length Lpi = 0.9 Lp • Width of pole, bp = Ap/Lpi • Height of pole body hp = hf + thickness of insulation and clearance • Total height of the pole hpl = hp + hs

    15. Design of shunt field winding • Field coils are former wound and placed on the poles • They may be of rectangular or circular cross section depends on the type of poles • Dimensions – Lmt, depth, height, diameter • Depth(df) – depends on armature • Height (hf) - depends on surface required for cooling the coil and no. of turns(Tf) • hf, Tf – cannot be independently designed

    16. Design of shunt field winding • Lmt - Calculated using the dimensions of pole and depth of the coil • For rectangular coils • Lmt =2(Lp + bp + 2df) or (Lo +Li)/2 • Where Lo – length of outer most turn & Li – length of inner most turn • For cylindrical coils • Lmt = π(dp +df) • No of turns in field coil: When the ampere turns to be developed by the field coil is known, the turns can be estimated • Field ampere turns on load, ATfl= If. Tf • Turns in field coil, Tf = ATfl/If

    17. Design of shunt field winding Power Loss in the field coil: • Power loss in the field coil is copper loss, depends on Resistance and current • Heat is developed in the field coil due to this loss and it is dissipated through the surface of the coil • In field coil design , loss dissipated per unit surface area is specified and from which the required surface area can be estimated. • Surface area of field coil – depends on Lmt, depth and height of the coil

    18. Design of shunt field winding • Lmt – estimated from dimensions of pole • Depth – assumed (depends on diameter of armature) • Height – estimated in order to provide required surface area Heat can be dissipated from all the four sides of a coil. i.e, inner , outer, top and bottom surface of the coil • Inner surface area= Lmt (hf – df) • Outer surface area = Lmt (hf + df) • Top and bottom surface area = Lmtdf Total surface area of field coil, S= Lmt (hf – df)+ = Lmt (hf + df)+ Lmtdf+ Lmtdf S= 2Lmthf +Lmtdf= 2Lmt (hf +df) Permissible copper loss, Qf=S.qf[qf-Loss dissipated/ unit area]

    19. Design of shunt field winding Substitute S in Qf, Qf= 2Lmt (hf +df).qf Actual Cu loss in field coil=If2Rf=Ef2/Rf Substituting Rf=(Lmt Tf)/ af , Actual Cu loss in field coil=Ef2 .af /(Lmt Tf) 

    20. Procedure for shunt field design Step1 : determine the dimensions of the pole. Assume a suitable value of leakage coefficient and B = 1.2 to 1.7 T Фp= Cl. Ф Ap = Фp/Bp When circular poles are employed, C.S.A will be a circle Ap = πdp2 /4 : dp =Ѵ(4Ap/π) When rectangular poles employed, length of pole is chosen as 10 to15 mm less than the length of armature Lp=L –(0.001 to 0.015) Net iron length Lpi = 0.9 Lp Width of pole = Ap/Lpi

    21. Procedure for shunt field design Step 2 : Determine Lmtof field coil Assume suitable depth of field winding For rectangular coils Lmt =2(Lp + bp + 2df) or (Lo +Li)/2 For cylindrical coils Lmt = π(dp +df) Step 3: Calculate the voltage across each shunt field coil Ef = (0.8 to 0.85) V/P Step 4 : Calculate C.S.A of filed conductor Af= ρLmtATfl/Ef Step 5:Calcualate diameter of field conductor dfc =Ѵ(4af/π) Diameter including thickness dfci= dfc + insulation thickness Copper space factor Sf = 0.75(dfc/dfci)2

    22. Procedure for shunt field design Step 6 : Determine no. of turns (Tf) and height of coil (hf) They can be determined by solving the following two equations 2Lmt(hf+ df) = Ef2af/ρLmtTf Tf.af = Sf.hf.df Step 7 : Calculate Rf and If : Rf = Tf. ρLmt /af If = Ef/Rf Step 8 : Check for δf δf = If / af δf – not to exceed 3.5A/mm2 . If it exceeds then increase af by 5% and then proceed again

    23. Procedure for shunt field design Step 9 : Check for desired value of AT ATactual= If.Tf ATdesired- 1.1 to 1.25 times armature MMF at full load When ATactual exceeds the desired value then increase the depth of field winding by 5% and proceed again.

    24. Check for temp rise: Actual copper loss = If2 Rf Surface area = S = 2Lmt (hf + df) Cooling coefficient C = (0.14 to 0.16)/(1 + 0.1 Va) m = Actual copper loss X (C/S) If temperature rise exceeds the limit , then increase the depth of field winding by 5% and proceed again.

    25. Design of Series Field Winding 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

    26. Design of Series Field Winding 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 On equating above two expressions, Tse.ase = Sfse.hse.dse hse= (Tse.ase )/(Sfse.dse)

    27. Design of commutator and brushes • Commutator and brush arrangement are used to convert the bidirectional current to unidirectional current • Brushes are located at the magnetic neutral axis ( mid way between two adjacent poles) • The phenomenon of commutation is affected by resistance of the brush , reactance emf induced by leakage flux, emf induced by armature flux.

    28. Design of Commutator and brushes Classification of commutation process • Resistance commutation • Retarded commutation • Accelerated commutation • Sinusoidal commutation • Commutator is of cylindrical in shape and placed at one end of the armature • Consists of number of copper bars or segments separated from one another by a suitable insulating material of thickness of 0.5 to 1mm • Number of commutator segments = no. of coils in the armature • Materials used : • Commutator segments: Hard Drawn Copper or Aluminum Copper • Insulation :Mica, Resin Bonded Asbestos • Brushes :Natural Graphite, Hard Carbon , Electro Graphite, Metal Graphite

    29. Design of Commutator and brushes Design formulae • No. of commutator segments, C = ½ u.Sa where, u – coils sides/slot Sa – no. of armature slots • Minimum no. of segments = Ep/15 • Commutator segment pitch = βc = πDc/C where, Commutator Diameter Dc – 60% to 80% of diameter of armature βc ≥ 4mm • Current carried by each brush Ib= 2Ia/P for lap winding Ib= Ia for wave winding • Total brush contact area/spindle Ab= Ib/δb • Number of brush locations are decided by the type of winding Lap winding: No of brush location = no. of poles Wave winding : No of brush location =2

    30. Design of Commutator and brushes • Area of each individual brush should be chosen such that , it does not carry more than 70A Let , ab – Contact area of each brush nb – Number of brushes / spindle  Contact area of brushes in a spindle, Ab = nb. ab also ab = wb.tb Ab = nb. wb.tb Usually, tb = (1 to 3) βc wb = Ab/ nb. Tb = ab/tb • Lc – depends on space required for mounting the brushes and to dissipate the heat generated by commutator losses Lc = nb(wb + Cb) + C1 + C2 where, Cb - Clearnace between brushes (5mm) C1 - Clearance allowed for staggering of brushes (10mm, 30mm) C2 – Clearance for allowing end play (10 to 25 mm)

    31. Design of Commutator and brushes • Losses : • Brush contact losses: depends on material, condition, quality of commutation • Brush friction losses Brush friction loss Pbf= μpbAB.Vc μ – Coefficient of friction pb-Brush contact pressure on commutator (N/m2) AB - Total contact area of all brushes (m2) AB =P Ab (for lap winding) = 2 Ab (for wave winding) Vc – Peripheral speed of commutator (m/s)

    32. Design of Interpoles • Interpoles: Small poles placed between main poles • Materials Used: Cast steel (or) Punched from sheet steel without pole shoes • Purposes: • To neutralize cross magnetizing armature MMF • To produce flux density required to generate rotational voltage in the coil undergoing commutation to cancel the reactance voltage. • Since both effects related to armature current, interpole winding should be connected in series with armature winding • Average reactance voltage of coil by Pitchelmayer’s Equation is, Erav = 2Tc ac Va.L .λ Inductance of a coil in armature =2Tc2 .L .λ

    33. Design of Interpoles Normally, Length of interpole = length of main pole Flux density under interpole, Bgi = ac. λ .(L/Lip) where, Lip- length of interpole In general, Bgi = 2 Iz. Zs. (L/Lip). (1/Va.Tc).λ MMF required to establish Bgi = 800000Bgi.Kgi.lgi

    34. Design of Interpoles Losses and efficiency : • Iron Loss - i)Eddy current loss ii) Hysteresis loss • Rotational losses - Windage and friction losses • Variable or copper loss Condition for maximum efficiency : Constant Loss= Variable Loss