Jon Gabriel C.

Gonzales 03/22/2025
BSEE 4-2 Elective 3 – Machine Design

Design of Dynamic Field Magnets & Windings

Relation between Air-gap Density and Ampere-turns for Air Gap and Teeth

Outside diameter of armature core, D = 28.1 in. Slot pitch, λ = 1.051 in.
Gross length of armature core, la = 10.9 in. Number of face conductors, z = 336
Net length of armature core, La = 9.0 in. Number of poles, p = 8
Depth of slot, d = 1.40 Armature current per circuit, Ic = 251.25
Width of slot, s = 0.40 in Air-gap flux density, B”g = 54,000
Width of slot at top, t = 0.651 in.

336 𝑥 251.25
Air-gap: 𝛿 = = 0.195 𝑖𝑛

}
8 𝑥 54 000
0.21 in.
𝛿 = 0.04√28.1 + 3 = 0.223 𝑖𝑛

1.051
Equivalent 𝛿𝑒 = = 0.195 in.
0.651 1 0.40
Air-gap: ( 0.210) + 2 log [ (
𝑒 2 0.21 ) + 1]

Four section te, tooth top: 0.651 in.

of tooth: tr, tooth root: 0.530 in.
tm, tooth average: 0.59 in.

At middle At root At top H

Bg Formula (TI)t
Bt Hm Bt Hr Bt He
42
10 000 21 700 440 24 200 1 100 19 700 220 513 1 440
9 000 19 800 220 22 000 500 18 000 100 247 69
7 000 15 500 27 17 300 58 14 000 14 30 84
5 000 11 300 7 12 600 9 10 300 6 7 20

de = (1.40 + 0.195) – 0.21 = 1.385 in.

Design of Poles, Yoke, and Windings

Given Data
1. Number of Main Poles, p = 8
2. Number of Commutating Poles = 8
3. Diameter of Armature Core, D = 28.1 in.
4. Axial length of Armature Core, Ia = 10.9 in.
5. Ratio of Pole Arc & Pole Pitch, r = 0.7
6. Air gap under center of pole, δ = 0.195 in.
7.Leakage Factor, If = 1.15
Item 7: Leakage Factor

* According to Art. 46, for a 500 kW generator, use leakage factor of 1.09 to 1.18 *
We use 1.15 in this design.

Items 8 & 9: Cross section of Pole Core

Recall: Full load flux per pole, 5 085 000 maxwells

Based on B-H curve, 95,000 line per sq. in. will not require an excessive number of ampere turns

5.09 𝑥 106 𝑥 1.15

𝐴𝑐 = = 61.6 sq. in.
95 000
Icore = 10.9 – (1.5 x 0.195) = 10.6075 ≈ 10.60 in.

61.60
𝑊𝑐𝑜𝑟𝑒 = = 5.81 ≈ 5.80 in
10.60
Item 10: Length of Winding Space on Pole

Use tentative value of 6.5 in.

Items 11, 12 & 13: Flux Density in Frame

Use tentative value of 90 000 lines per sq. in. for flux density in yoke ring

5.09 𝑥106 𝑥1.15

𝐴𝑦 = = 32.50 sq. in. ⃪ 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑦𝑜𝑘𝑒 𝑟𝑖𝑛𝑔
2 𝑥 90 000
Preliminary values of:

Yoke overhang = 2 in
Yoke extension = 14 in

32.50
𝑌𝑜𝑘𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠: 𝑊𝑦𝑜𝑘𝑒 = = 2.32 ≈ 2.35 𝑖𝑛.
14
(7.75 − 5.80)
𝐴𝐵 𝐿𝑒𝑛𝑔𝑡ℎ = = 0.975 𝑖𝑛.
2
0.15 𝑥 5 085 000 0.975
∅𝑥 = ( )+( 𝑥 5 085 000) = 830 000 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠
4 7.75
830 000
𝑥= = 0.824 ≈ 0.825 𝑖𝑛.
10.60 𝑥 95 000
Items 14 to 17: Ampere – turns per pole for total Magnetic Circuit

∅𝑎𝑣𝑔 = 1.125 ∅, since lf = 1.15

∅ ∅
𝐵𝑔𝑒" = =
[(0.85 𝑥 0.7) + 0.15]11 𝑥 10.9 89.33

Referring to Fig 66, note the following

1.) Shunt field ampere-turns per pole on open circuit (230V) = 4080 AT
2.) Shunt field ampere-turns per pole at full load (250V) = 4440 AT
3.) Total ampere turns for shunt-and series-field coils (256.1 V) = 4915 AT
 4.) Series-field ampere-turns @full load = 4915-4440 = 475 AT

Items 18 to 22: Shunt field Winding

Insulation = 0.5 in
Length of winding space = 6 in

* Shunt Coil = (4440/4915)6 = 5.5 in. + series coil of ½ in *

* Insulation space of 0.25 in between coils & pole core *
* Inside Dimensions of the shunt and series coils: 5.5 x 10.125 in.*
* Assume initial thickness of winding of w = 1.5 in. , the mean length per turn
will therefore be: 2(5.5 + 10.125) + ( 1.5 π) = 35.96 ≈ 36 in

36 𝑥 4080 𝑥 8
𝑠𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒: = 6010 𝑐𝑖𝑟. 𝑚𝑖𝑙𝑠
0.86 𝑥 230
Referring to wire table II, next highest up use AWG #12 wire or 3.5 mm2

12 AWG → 7 630 cir. Mils & 119 turns per sq. in.
→ Resistance: 1.65 Ω/ 1000 ft @ 75° C
→ Resistance @ 60°C = 1.65 (234.5 + 60/234.5+75) = 1.57 Ω/ 1000 ft

* There will be 5.5 x 11 = 60.5 ≈ 61 wires per layer and 1.5 x 11 ≈ 17 layers

Allowance for manufacturing tolerances: 60 x 17 layers = 960 turns per coil

36 𝑥 960 𝑥 1.57
𝑅 𝑝𝑒𝑟 𝑐𝑜𝑖𝑙 = = 4.52 𝛺
12 𝑥 1000
230 𝑥 0.85
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 @ 𝑛𝑜 𝑙𝑜𝑎𝑑 = = 5.41 𝐴
8 𝑥 4.52
250
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 @ 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 = 𝑥 5.41 = 5.88 𝐴
230
Check AT:

@ no load: 5.41 x 960 = 5193

@ full load: 5.88 x 960 = 5644

} Adjust AT to match values

Current Density @ full load:

5.88
4
= 981 A/ sq. in., which is reasonable
7630/(𝜋 𝑥106 )

Items 23 to 26: Series Field Coils

Total length for series-field copper:

(8 x ½ x 36) + 50 = 194 in.

Total series-field resistance:

194
𝑅𝑠𝑒𝑟𝑖𝑒𝑠 = = 2.03 𝑥10−4 𝛺
4 6
0.75 𝑥 𝜋 𝑥10
 Total Copper loss in the series field:

I2R = (1203.8)2 x 203 x10-4 = 294.17 W

Item 27: Temperature Rise of Field Coils

Total cooling Surface of Winding / pole = 2 (8+1.5) x 36 = 684 sq. in.

Watts lost in shunt & series coils on one pole:

294.17
+ (5.88)2 𝑥 4.52 = 193 𝑊
8
Coefficient of cooling = 0.0087

193
𝑡= = 32.43 °𝐶
0.0087 𝑥 684
Jon Gabriel C. Gonzales 03/28/2025
BSEE 4-2 Elective 3 – Machine Design

Losses, Ventilation & Temperature Rise

Calculation of Armature-core Losses

Losses in Core below teeth

5 085 000
𝐹𝑙𝑢𝑥 𝐷𝑒𝑛𝑠𝑖𝑡𝑦: = 80 700 𝑙𝑖𝑛𝑒𝑠 𝑝𝑒𝑟 𝑠𝑞. 𝑖𝑛.
2 ( 9.0 𝑥 3.5)

Watts per pound cycle: 0.1

Total Loss in the core (excluding teeth) = 0.1 x 60 x 615 = 3690 watts

Losses in Teeth
Get length @ bottom of slot: 0.53 + 1/3 (0.651 – 0.53) = 0.570 inches

5 085 000
𝐵𝑔" = = 60 200 𝑙𝑖𝑛𝑒𝑠 𝑝𝑒𝑟 𝑠𝑞. 𝑖𝑛. ← 𝑎𝑣𝑒. 𝑎𝑖𝑟 𝑔𝑎𝑝 𝑓𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
10.9 𝑥 7.75
Bg” (max) = 60 200 x 1.2 = 72 200 lines per sq. in.

= 11 200 gauss

Corresponding tooth density = 23 400 gauss

@ tm = 0.59

Cross-section of tooth 1/3 of the distance from the bottom of the slot:

0.59
𝐵𝑡 = 23 400 𝑥 = 24 200 𝑔𝑎𝑢𝑠𝑠 𝑜𝑟 156 000 𝑙𝑖𝑛𝑒𝑠 𝑝𝑒𝑟 𝑠𝑞. 𝑖𝑛.
0.57
Total loss in teeth:

0.33 x 60 x 175 = 3465 watts

Total Loss in Armature Stampings

LossT = 3690 + 3465 = 7155 watts

Calculation of Commutator Losses

Assumed Brush Pressure = 1.515 per sq. in.

Brush-resistance Losses @ 40A using soft graphitic carbon: ≈ 1.38 V x 1.1 = 1.52 ≈ 1.50 V
I2R = 1.5 x 2000 = 3000 watts

Brush Friction Losses:

Peripheral velocity @ commutator surface:

(𝜋 𝑥 18 𝑥 900)
𝑉𝑐 = = 4 200 𝑓𝑝𝑚
12
Coefficient of friction of soft graphitic carbon: C = 0.18
 (0.18)(1.5)(8𝑥10)𝑥 4 200 𝑥 746
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝐿𝑜𝑠𝑠: 𝑊𝑠 = = 2050 𝑤𝑎𝑡𝑡𝑠
33 000
Total Commutator Losses: 3000 watts + 2050 watts = 5050 watts

Temperature Rise of Commutator

Total Width of B brush holders per set: 12 in

Number of Brush Sets: 6
Radial depth of exposed ends of copper bars: 1.5 in

De = 18-3 = 15 in
Dr = 18+4 = 22 in

𝜋 𝑥 18 𝑥 900
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑐𝑜𝑚𝑚𝑢𝑡𝑎𝑡𝑜𝑟: = 4200 𝑓𝑝𝑚
12
𝜋 𝜋
𝑆 = [(𝜋 𝑥 18 𝑥 14.5) + (22)2 − (18)2 ] + [(182 ) − (15)2 ] + (2 𝑥 12 𝑥 8)
4 4
S = 1145 sq. in.

4200
𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡, 𝑐 = (0.025 + ) = 0.067 𝑤𝑎𝑡𝑡 𝑝𝑒𝑟 𝑠𝑞. 𝑖𝑛. 𝑝𝑒𝑟 𝐶 ° 𝑟𝑖𝑠𝑒 𝑖𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
100 000
5050
𝑡= = 65 °𝐶 𝑢𝑝𝑝𝑒𝑟 𝑙𝑖𝑚𝑖𝑡 𝑣𝑎𝑙𝑢𝑒
0.067 𝑥 1145
Decrease De to 14 in. → s = 1169

5050
𝑡= = 64 °𝐶 𝑎 𝑚𝑜𝑟𝑒 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑣𝑎𝑙𝑢𝑒
0.067 𝑥 1169

Temperature Rise of Dynamo Armature

Iron Losses = 7155 watts

Losses to be dissipated

Tooth and Copper Loss

2 𝑥 10.9
𝑥 5708 = 2260 𝑤𝑎𝑡𝑡𝑠 → 𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑠𝑠: 7155 + 2260 = 9415 𝑤𝑎𝑡𝑡𝑠
55
Cooling Surfaces

Sc = π x 28.1 x 10.9 = 962 sq. in. ⃪ outside cylindrical surface

Si = π x 17.6 x 10.9 = 602 sq. in ⃪ inside cylindrical surface

Sd = π/4 [ (28.1)2 = (17.6)2] x 8 = 3015 sq. in ⃪ area of both side of ventilation ducts and armature

Temperature Rise

17.6
𝑉𝑖 = 𝑥 6620 = 4150 𝑓𝑝𝑚
28.1
Cooling coefficient for the cylindrical surfaces & ventilating ducts
 1500 + 6620
𝐶𝑜 = = 0.081
100 000
1500 + 4150
𝐶𝑖 = = 0.057
100 000
6620
𝐶𝑑 = 3 = 0.022
100 000
Watts that can be dissipated per degree rise in temperature are:

Outside cylindrical surface = 0.081 x 962 = 77.92

Inside cylindrical surface = 0.057 x 602 = 34.31
ducts and end surfaces = 0.022 x 3015 = 66.33
total = 178.56

9415
𝑡= = 52.73 °𝐶
178.56
Efficiency of Generator

500kW Shunt field current @FL = 5.88 A

230/250 V I2R loss in series field = 294.17 W
900 rpm Core Losses = 7155 W
25 – 150% of rated load Brush I2R loss @FL = 3000 W
I2R Loss = 5708 W Brush Friction Loss = 2050 W

25 50 75 100 125 150

Output, kW 125 250 375 500 625 750
Terminal Voltage 235 240 245 250 252.5 255
Amperes: ↓531 ↓1042 ↓1530 ↓2000
Line.. 2475 2941
Shunt field.. 5.53 5.64 5.76 5.88 5.94 6.00
Armature.. 536.53 1047.64 1535.76 2005.88 2480.94 2947.00
Losses, kW
Armature.. 0.40 1.55 3.34 5.71 8.74 12.35
Series Field.. 0.021 0.080 0.172 0.294 0.450 0.634
Commutating Field.. 0.037 0.140 0.301 0.514 0.787 1.109
Shunt Field.. 1.00 1.353 1.411 1.470 1.500 1.530
Brush I2R.. 0.808 1.579 2.314 3.022 3.739 4.441
Brush Friction.. 2.050 2.050 2.050 2.050 2.050 2.050
Core.. 7.155 7.155 7.155 7.155 7.155 7.155
Friction and Windage... 4.400 4.400 4.400 4.400 4.400 4.400
Stray.. 1.250 2.500 3.750 5.000 6.250 7.500
Total.. 17.421 20.807 24.893 29.615 35.071 41.168
Input, kW 142.421 270.807 399.893 529.615 660.071 791.168
Efficiency 0.878 0.923 0.938 0.944 0.947 0.950
Efficiency of Generator

lb per 1000ft of #12 AWG: 19.8 lb I2R loss @ armature: 7155 watts
# of face conductors: 336 Cooling Surface: 3015 sq. in. ⃪ armature & ventilating ducts
Length per turn: 55 in. Cooling coefficient: 0.067 per watt per sq. in per ˚C
Total Length of Wire: 18 480 in → 1540 ft
Total Weight: 30.5 lbs

7155
𝑡= = 35.42 °𝐶
0.067 𝑥 3015

Time required to raise the temperature at the coil to 35.42˚C

57 𝑥 35.42 37.2
𝑥 = 32 𝑠𝑒𝑐𝑜𝑛𝑑𝑠
7155 0.32

The temperature is not that high to warrant concern in it reaching maximum temperature in that amount of time.

Temperature Rise in Armature Conductors

Thickness of slot insulation = 0.054 in.

Outside Dimension of the two insulated coil side = 1 x 0.5 in.
Total Cross-section of slot = 0.40 in.
Current Density = 1000 A/ sq in.
k = 0.003

1 0.054
𝑅𝑛 @ 𝑙𝑖𝑛 𝑐𝑜𝑛𝑑 = 𝑥( )= 6
0.003 3

Heat path length = 0.054

Area of heat path = 3 sq. in.

W = I2R = (1000)2 x (0.84 x10-6) x (1 x 0.4) = 0.336

td = 6 x 0.336 = 2.016

td = 2.02˚C