DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC.

PROF/EEE

OUTPUT EQUATION

The output of a machine can be expressed in terms of its main dimensions, specific magnetic and
electric loadings and speed; the equation describing this relationship is known as output equation.

----- (1)

----( 2)

NOTE:

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

ESTIMATION OF P
a

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

MAIN DIMENSIONS

MAGNETIC CIRCUIT CALCULATIONS

CONCEPT OF MAGNETIC CIRCUIT

❖ The path of the magnetic flux is called a magnetic circuit.

❖ A magnetic circuit is analogous to an electric circuit.
A review of laws of magnetic circuits is given below. Let

Φ = magnetic flux, Wb; A = area of the magnetic path, m2;

= length of magnetic path, m; B = flux density, Wb/ m2 (Tesla);
l μ=μ
H = at =magnetic force, (Amp.turns/length) A/m; AT= total mmf, A; r

μ = absolute permeability of the magnetic material, H/m;

o

μ = permeability of free space = 4π x 10 -7 H/m; μ = relative permeability

o 1 r
S = reluctance, (mmf/flux) A/Wb; Λ= S= permeance, (flux/mmf) Wb/A
In an electric circuit Ohm’s law expresses a relationship between current, emf and resistance. While
in a magnetic circuit, a similar relation exists relating flux, mmf and reluctance.
This relation is:
mmf
flux=
relutance
AT
Ф=
S
Ф = AT х Λ

The reluctance of the magnetic material can be estimated using the following equation.
length
Reluctance=
area х permeability

--- (3)
l
S=
Aμ
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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

The strength of the magnetic field is measured by the term magnetizing force, H. It is the mmf
required to establish flux in a unit length of magnetic path.

magnetising force = flux x reluxtance per unit length

⎛ ⎞
l
⎜ ⎟
⎝Aμ⎠
H=Ф
l
H=Ф
1 l Aμ
Ф1
H=
Aμ

B
H=
μ

For the case of a material of length l , and carrying a uniform flux, the total mmf (AT) is:
AT=H × l='at' × l

In a series magnetic circuit, the total reluctance is the sum of reluctance of individual parts.
S = S1 + S2 + S3 + ....
where S = total reluctance
and S1 + S2 + S3 + .... = reluctance of individual parts.

The total mmf acting around a complete magnetic circuit is then by

AT=H x l='at' x l
S = S1 + S2 + S3 + ....
AT = ФS = Ф(S1 + S2 + S3 +....) AT = ФS1 + ФS2 + ФS3
+....
AT=AT +AT +AT +....
AT=at1l1 + at21l2 + at23l3 +....3 … (4)
... (5)
∫
AT= 'at '.l
Equations (1) and (2) represent the circuital law for magnetic circuits where at , at , at etc., are the
1 2 3
mmfs per metre for individual part and l1 and l2 ,l3.... etc., are corresponding lengths of parts connected in
series.

In parallel circuits, the same mmf is applied to eac of the parallel paths and the total flux divides
between the paths in inverse proportion to their reluctances, as in corresponding electric circuits.

Ф = Ф1 + Ф2 + Ф3 +....

Dividing by AT, the applied mmf, we get

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Ф Ф1 Ф2 Ф3
= + + + ....
AT AT AT AT
1 1 1 1
S = +S + + ....
1
S2 =Λ +SΛ
Λ 3 + Λ + ....
1 2 3

where S = total reluctance of magnetic circuit

S , S , S … etc. = reluctance of individual parts, and

1 2 3

Λ 1
= total permeance of magnetic circuit =
S
while Λ1 + Λ2 + Λ3 +....etc. are permeance of individual parts.

The magnetic circuits of various electrical machines are shown in fig. 1

Fig. 1 Magnetic circuit of various electrical machines

The similarities and the differences between electric and magnetic circuits are presented in table 1
and 2 respectively.

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Table 1 Similarities in electric and magnetic circuits

ELECTRIC CIRCUIT MAGNETIC CIRCUIT

The emf circulates current in a closed path. The mmf creates flux in a closed path.
Flow of current is opposed by resistance of the The creation of flux is opposed by reluctance of the
circuit. circuit.
The path of current is called electric circuit. The path of flux is called magnetic circuit.
ρl l
Resistance R= Reluctance S=
A Aμ

emf mmf
current = resistance Flux = reluctance
current Flux
current density = Flux density =
area of cross section area of cross section
Table 2 Differences between electric and magnetic circuits

ELECTRIC CIRCUIT MAGNETIC CIRCUIT

Current actually flows in the electric circuit. Flux does not flow, but it is only assumed to flow.
When current flows, the energy is spend Energy is needed only to create the flux but not to
continuously. maintain it.
Resistance of the electric circuit is independent of Reluctance of the magnetic circuit depends on total
current strength. flux or flux density in the material.

MAGNETIC CURVE (B-H CURVE)

In magnetic materials, the magnetizing force required to establish a given flux density depends on
the saturation of the material. If the material is not saturated, then a small increase in magnetizing force will
result in a proportional increase in flux density. But when the material is saturated, a large increase in
magnetizing force will result in a small increase in flux density. Therefore, the permeability of the magnetic
material is not constant.

In a non-magnetic materials like air, copper, etc. there is no such phenomena of saturation. Hence
the permeability of non-magnetic material is constant and the relation between B and H is linear. Therefore
the B-H curve will be straight line passing through origin.

In magnetic materials, the relation between the flux density B and the magnetizing force H is non-
linear. Hence, it is difficult to express the relation in terms of mathematical equation. Therefore, to calculate
mmf per metre of flux path for a given flux density the B-H curve is employed.

The manufacturers of stamping or laminations for transformer, induction motor, ac machines etc will
supply B-H curve. These curves are used to estimate magnetizing force and core loss for a given flux density
or for a required flux density in any part of the machine.

By using digital computers, the analytic relations between B and H prove more convenient. Two of
the most used mathematical relationships are give below.
aH
B= …. (6)
1+bH

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a +a H+a H2 +...
and o 1 2 …. (7)
B= 1+b1H+b H2 +...
2
where a, b, a ,a ,b ,b ,a ,b …. are constants.
o 1 o 1 2 2

Equ. (6) gives reasonable and approximate values while Equ. (7) is better overall fit. If alternating
magnetization is used, only odd powers of H must be used to Equ. (7)

For air or any other non-magnetic material the mmf per meter

B
B =8,00,000B ... (8)
H= μ = 4π x
10-7

MAGNETIC LEAKAGE

It is impossible to confine all the magnetic flux to a given path ( there being no magnetic insulator),
and therefore the designer’s problem becomes that of providing a path of low reluctance to that
comparatively little flux leaks away from the path and then supplying a somewhat larger mmf to compensate
for the flux which leaks away. This flux which strays away completes its circuit by paths which prevent its
utilization in the functioning of the apparatus or machinery.

For the operation of electric machinery, some air gaps are necessary in the magnetic paths but these
air gaps should be kept to a minimum of length and maximum of cross-section so as to reduce their
reluctance. A long air gap of small cross-section would require a large mmf resulting in large coils of many
turns and would also result in a tendency for the flux to wander away from its main path. This flux which

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

strays away from the main path is called the leakage flux. The leakage flux does not contribute to either
transfer or conversion of energy.

However, the leakage flux affects the performance of rotating machines and transformers. The
leakage flux affects the excitation demands of salient pole machines, the leakage reactance of windings on
which the performance of the a.c. machines is primarily based, the forces between windings especially under
short conditions, voltage regulation of a.c. generation and transformers, commutation conditions in d.c.
machines, stray load losses, circulating currents in transformer tank walls and several other performance
indices of importance.

For magnetic circuit calculations, a term ‘leakage co-efficient’ is introduced in order to take into
account the leakage flux. The value of this leakage co-efficient is defined as

Leakage co-efficient, useful flux + leakage flux total flux …(9)

Cl = useful flux = flux
useful

TYPES OF LEAKAGE FLUX

The armature leakage fluxes affects most of the performance of rotating machines Hence the
different types of armature leakage fluxes are discussed in this section. The different types of armature
leakage fluxes are:

❖ Slot leakage flux

❖ Tooth top leakage flux
❖ Zigzag leakage flux
❖ Overhang leakage flux
❖ Harmonic or differential leakage flux
❖ Skew leakage flux
❖ Peripheral leakage flux

Slot leakage flux

The fluxes that cross the slot from one tooth to the next and
returning through iron are called slot leakage flux. They link the
conductors below them, as shown in fig. 3

Fig. 3. Slot leakage flux

Tooth top leakage flux

The flux flowing from top of the one tooth to the top of
another tooth as shown in fig. 4 is called tooth top leakage
flux. This leakage flux is considered only in machines having
large air-gap length like DC machines and synchronous
machines. Since in induction machines the air-gap length is
very small the tooth top leakage flux is negligible.
Fig. 4 Tooth top leakage flux
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Zigzag leakage flux

The flux passing from one tooth to another in a

zigzag fashion across the air-gap as shown in fig.
5 is called zigzag leakage flux. The magnitude of
this flux depends on the length of air-gap and the
relative positions of the tips of rotor an stator
teeth.

Fig. 5 Zigzag leakage flux

Overhang leakage flux

The end connections (the conductor which connects the

two sides of a coil) are called overhang. The fluxes
produced by the overhang portion of the armature
winding are called overhang leakage flux as shown in
fig 6. It depends on the arrangement of overhang and the
nearby metal parts (for eg. Core stiffness and end
covers)

Fig. 6 Overhang leakage flux

Harmonic ( or Differential or Belt) leakage flux

The harmonic leakage flux is due to dissimilar mmf distribution in the stator and rotor. Actually
the difference in the harmonic contents of stator and rotor mmfs produces harmonic leakage fluxes. In
squirrel cage induction motor the rotor current is exactly balanced by stator current and so there is no
harmonic leakage flux.

Skew leakage flux

A twist provided in the rotor of induction motors to eliminate harmonic torques and noise is called
skewing. The skewing reduces the mutual flux and thus creating a difference between total flux and mutual
flux. This difference is accounted as skew leakage flux.

Peripheral leakage flux

The fluxes flowing circumferentially round the air-gap without linking with any of the windings
are called peripheral leakage flux. Usually this leakage flux is negligible in most of the machines.

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

RELUCTANCE OF AIR-GAP IN MACHINES WITH SMOOTH ARMATURE

Let
L = length of core lg = gap length Ws =

ys = slot pitch width of slot Wo = slot

Wt = width of tooth opening

nd = number of radial ducts Wd = width of each duct

The iron surfaces around the air gap are not smooth and so the calculation of mmf for the air gap by
ordinary methods gives wrong results. The problem is complicated by the fact that:

❖ One or both of the iron surfaces around the air gap may be slotted so that the flux tends to
concentrate on the teeth rather than distributing itself uniformly over the air gap.

❖ There are radial ventilating ducts in the machine for cooling purposes which affect in a similar
manner as above.

❖ In salient pole machines, the gap dimensions are not constant over whole of the pole pitch.

Consider the iron surfaces on the two sides of the air gap to be smooth as shown in fig. 7. The flux is
uniformly spread over the entire slot pitch and goes straight across the air gap. Fig. 7

Fig. 7 Fig. 8

If we confine our attention to only one slot pitch, the reluctance of air gap

lg
l … (10)
Sg= μ A μo Ly
o

= S
RELUCTANCE OF AIR-GAP IN MACHINES WITH OPEN ARMATURE SLOTS

In armature with open and semi enclosed slots, the flux will flow through the teeth of the armature.
Hence the effective area of flux path is decreased, which results in increased reluctance of air gap.

Reluctance of air-gap neglecting fringing effect

Consider the armature with open type of slots as shown in fig. 8. Here the flux is only confined to
the tooth width. Hence the area of cross-section of the air gap through which the flux passes is L(ys -ws ) or
Lw t .
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Reluctance of air gap of a slotted or open type armature

lg … (11)
Sg=
μ oL(y -WS )
S

Reluctance of air-gap including the effect of fringing

In armature with open slots the flux would fringe around the tooth and this fringing would increase
the area of cross section of flux path.

Consider the open type slot of armature shown in fig. 9. Here the fringing of flux can be accounted
by increasing the area of cross-section of flux path by δwS as shown in fig. 10.

Fig. 9 Fig. 10

The reluctance in this case is more than that of a air-gap in smooth armature but lesser than that of
the case where the whole flux is assumed to be confined over the tooth width.

A simple method to calculate reluctance in this case is to assume that the air gap flux is uniformly
distributed over the whole of slot pitch expect for a fraction of slot width as shown in fig.(b). This fraction
depends on the ratio of slot width to air gap length. Thus the flux of one slot is distributed over Wt + δWS .

Effective or contracted slot pitch

y ' = W + δW
s t S

On adding and subtracting, Ws and replacing Wt + WS = yS , we get

y ' = W + W + δW − W
S t S S S

y = y + δW − W
'
S S S S

y = y − (1− δ)W
'
S S
y SS' = y − KS W …. (12)
CS S

slot
Where K CS is the Carter’s gap co-efficient which depends upon the ratio:
gap length
width
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An empirical formula which gives the value of KCS directly is

1
K CS …. (13)
l
1+ 5 g
= WS

Another useful relationship which can be used for calculation of Carter’s co-efficient for parallel
sided open slots is:

2⎡ 1 …. (14)
K CS =⎢ tan⎥ −1 y π− log (1+ y2 )
⎤ π ⎣ ⎦
where WS
y=
2lg

The value of KCS can also be determined from the standard curve shown in fig. 11

Fig. 11 Fig. 12
Reluctance of air gap with slotted armature
lg
Sg=
μ oyS' L

lg
Sg= …. (15)
μ oL( y − K
S W )
CS S

Let ratio of reluctance of air gap of slotted armature to reluctance of air gap of smooth armature be
KgS . Therefore, from equ. (15) and (10).
lg

K gS = μo L( yS − KCSWS )
l g

μo LyS

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yS
K gS …. (16)
yS− K WCS
S
=
where KgS is called the gap contraction factor for slots.

EFFECT OF VENTILATING DUCTS ON RELUCTANCE OF AIR-GAP

The provision of radial ventilating ducts results in contraction of flux in the axial direction as shown
in fig. 12. It is clear that the effective axial length of the machine is reduced owing to presence of ducts and
this result in an increase in the reluctance of air gap. We can derive a similar expression for ventilating ducts
by treating stacks of laminations as teeth and the ducts as slots.

Contracted or effective axial length

L' =L - K cdn W
d …. (17)
d

where Kcd is the Carter’s co-efficient for ducts.

Let the ratio of reluctance of air gap with ducts to reluctance of air gap without ducts be Kgd .
L
K gd …. (18)
L - Kcdn W
d

= d
Kgd is called gap contraction factor for ducts.

Let the ratio of reluctance of air gap of a slotted armature with ducts to reluctance of air gap of a
smooth armature without ducts be Kg .

K =K K …. (19)
g gS gd

where Kg is called total gap contraction factor for slots and ducts.

MMF CALCULATION FOR VARIOUS TYPES OF ELECTRICAL MACHINES

Estimation of total mmf

The magnetic circuit calculations involve estimation of reluctance, flux density and mmf for various
sections of magnetic circuit. The ultimate aim of magnetic circuit calculation is to estimate the total mmf
required to establish the desired flux in a magnetic circuit.

The magnetic circuit is split into convenient parts (sections) which may be connected in series or
parallel. Then the reluctance, flux density and mmf for every section of the magnetic circuit is estimated.
The summation of mmf of all sections in series gives the total mmf for the magnetic circuit.

The following procedure can be used to estimate the mmf of a section of magnetic circuit.

❖ Determine the flux in the concerned section from the knowledge of flux per pole.

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❖ Calculate the area of cross-section of the section from the specified dimensions.

❖ The ratio of flux and area of cross-section will give the flux density, B in this section.

❖ For the calculated flux density, B, determine the mmf per unit length from the B-H (or B-at) curve.

❖ The mmf for the concerned section is given by the product of length of the section and mmf per unit
length.

The method looks quite simple but there are some parts in the magnetic circuit like air-gap and
tapered teeth which present complex magnetic problems. The reluctance of the air-gap is modified or
affected due to slots, radial ventilating ducts, and non-uniform air gaps. Hence the calculation of mmf for
air-gap cannot be generalized and so the calculation of reluctance should be attempted for each type of
machine.

The dimension of the tooth depends on the types of slot. Also, the dimensions of the teeth is not
uniform, hence the reluctance of the teeth is non-uniform. Hence special methods are needed for estimating
the mmf for teeth.

MMF FOR AIR-GAP

Non-magnetic materials (like air, copper etc.,) have a constant value of permeability and so the B-H
curve for them is straight line passing through the origin.

mmf per metre for air gap

ATg = 800,000 B …. (20)

MMF OF AIR-GAP IN MACHINES WITH SMOOTH ARMATURE

mmf required for air gap having a length lg , with smooth armatures,

AT = 800,000 B l
g g
…. (21)

MMF OF AIR-GAP IN MACHINES WITH OPEN ARMATURE SLOT AND RADIAL

VENTILATING DUCTS
mmf required for air gap, having a length lg with slotted armature with ventilating ducts

AT = 800,000 K B l (22)
g g g
….

where Kg = KgS Kg d = Total gap contraction factor for slots and ducts

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EFFECT OF SALIENCY ON THE MMF FOR AIR GAP

In the case of salient pole machines, the length of air gap is not constant over the whole pole pitch.
This gives rise to different values of air gap density over the pole pitch. Thus to know the value of reluctance
of the air gap, it is necessary to know the distribution of magnetic field in air gap. Fig. 13 shows a typical
flux distribution curve for a salient pole machines.

Fig. 13

Fig. 13 (a) shows the flux tubes passing from field to armature. Fig. 13 (b) shows an actual flux
distribution curve. The equivalent electric circuit for this magnetic circuit is a number of resistances
connected in parallel with each resistance representing a flux tube. In parallel electric circuits, it is sufficient
to know the value of only one resistance and the current flowing through it in order that the voltage across
the circuit be known.

Similarly, by analogy, we have only to know the reluctance of one flux tube and the flux flowing
through it in order to find the mmf required for air gap.

mmf required for air gap of a salient pole machine

ATg = flux in a flux tube x reluctance of flux tube

Let us consider a flux tube at the centre of the pole

Flux in the flux tube at the centre = flux density x area of flux tube
= Bg x area of flux tube

effective length
μo x area of tube
of flux air gap at the
at the centre
centre
Reluctance of flux tube at the centre =
Kg l g
=
4π x 10 -7 x area of flux tube at the centre
Kg l g
ATg B
= x area of flux tube at the centre x 4π x 10 -7 x area of flux tube at the centre
g

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ATg = 800,000 Bg Kglg …. (23)

where Kg = gap contraction factor for a gap length at the centre of the pole.

The value of Bg can be calculated after determining the value of field form factor Kf . Fig. 13 (c)
shows an approximate flux distribution curve fro salient pole machine.

The field form factor Kf is defined as:

average gap density over the pole pitch

K f= maximum flux density in the gap

B …. (24)
f av
K = Bg

we have Bav = flux per pole = Φ =

area per pole τL ⎛
Φ πDL
⎞ ⎜
⎝ ⎟
p
πD
where τ = pole pitch = ⎠
p
pole arc
also Kf =ψ
pole pitch …. (25)

The assumption Kf = ψ is fairly correct for machines with normal proportions and a fair degree of
saturation.

NET LENGTH OF IRON

The cores of magnetic circuits are build up with laminated steel plates wherever required. These
laminations or stampings are insulated from each other by paper, stuck to one side of the lamination, kaolin
clay or enamel. Moreover, in order to have an effective cooling of the machine, the length of the core is
divided into packets of about 40 to 80 mm width separated by vent spacers. These vent spacers form
ventilating ducts through which air is circulated. These ducts are radial and their width normally varies from
8 to 10 mm.

From above it is clear that whole of the length is not occupied by iron: some part of the length is
taken up by ventilating ducts and some part by insulation between steel laminations and air spaces created by
irregularities in thickness of laminations.

It is usual to define iron space factor, called stacking factor, as the ratio of actual length of iron in
a stack of assembled core plates to total axial length of stack.

Gross iron length

LS = length of slot portion conductor
= core length - length of ventilating ducts
LS = L - n d Wd …. (26)

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Net iron length

L =K(L-n W )
i i d d
….(27)

where Ki = stacking factor for iron which largely depends upon thickness of plates and the type of
insulating material employed. The manufacturers specify the stacking factor for a single
lamination. The stacking factor for build up cores is smaller and an average value of 0.9
may be assumed for all practical purposes.
MMF FOR TEETH

The calculation of mmf necessary to maintain the flux in the teeth is difficult owing to the
following complex problems.

1. The teeth are wedge-shaped or tapered when parallel sided slots are used. This means that the
area presented to the path of flux is not constant and this gives different values of flux density
over the length of teeth.

2. The slot provides another parallel path for the flux, shunting the tooth. The teeth are normally
worked in the saturation region and therefore their permeability is low, and as a result an
appreciable portion of the flux goes down the depth of the slots. The presence of two parallel
paths, the reluctance of one part depending upon the degree of saturation in the other, makes
the problem intricate.

Tapered Teeth: The mmf required for teeth can be easily calculated whatever may be their shape,
if the flux going down the slot is neglected. The correction, to take slot flux into account, can be
incorporated later on.

Following are the methods usually employed for the calculation of mmf required for tapered teeth.

(a) Graphical Method:

The mmf per metre (H or ‘at’) for the whole length of tooth is not uniform as the flux density is not
the same everywhere. Therefore, to obtain correctly the value of total mmf, it is necessary to construct a
graph showing the manner in which ‘at’ varies over the length of the tooth. The mean ordinate of this graph

H dl
∫
gives the equivalent ‘at’ for the whole of the tooth. The total mmf for the teeth is given by , the
integration being carried out for the complete height of tooth.
Therefore, total mmf required for the tooth, ATt = mean ordinate x height of tooth

ATt = atmean x lt = atmean x dS … (28)

The height of tooth lt is equal to dS , the depth of slot.

To determine this atmean , it is necessary to construct first a graph showing the manner in which the
flux density varies. From the known value of flux per tooth, the flux density is evaluated for a number of
sections along the length of the tooth from tip to root as shown in fig. 14. The corresponding values of ‘at’
are found from the B-‘at’ curve of the material and are plotted. The value of atmean is obtained from the
graph, as shown.

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Fig. 14 Fig. 15

(b) Three ordinate Method (Simpson’s rule):

This method can be applied to teeth of very simple form and of a small taper and is based upon the
assumption that the curve relating ‘at’ with flux density, is a parabola. In this method, values of ‘at’ are
obtained at three equidistant points, the ends of the tooth and its centre.

The mean value of ‘at’ is given by:

at mean = at1 + 4at2 + at3 …. (29)

6

where at1 , at2 , at3 are the values of ‘at’ for three sections shown in fig. 15.

(c) B method:
t1/3

This method is applied to teeth of small taper and is based upon the assumption that value of ‘at’
obtained for flux density at a section 1/3 of tooth height from the narrow end is the mean of ‘at’ for whole of
the tooth. This method is the most simple of all the methods and results are sufficiently accurate if the teeth
are worked at low saturation.
Let B = flux density at 1/3 height from narrow end,
t1/3

at = value of mmf per metre for B as obtained from B-‘at’ curve

t1/3
1/3

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Total mmf for teeth

ATt = at1/3 x lt = at1/3 x dS …. (30)

REAL AND APPARENT FLUX DENSITIES

The flux entering an armature from the air gap flows in teeth. If the flux density in the teeth is very
high then the mmf acting on the teeth is high. Since the slots are in parallel with teeth, this mmf will act on
the slots also. Thus some of the fluxes pass through slots. At higher flux densities the flux passing through
the slots becomes large and cannot be neglected.

Hence the real flux passing through the teeth is always less than the total or apparent flux. As a
result, the real flux density in the teeth is always less than the apparent flux density.

Fig. 16 shows slot flux due to saturation of teeth.

The apparent flux density is defined as

Total flux in a slot pitch

B =
app
Tooth area

The real flux density is defined as

Actual flux in a tooth

B =
Fig. 16 real
Tooth area

In an actual machine, there are two parallel paths for the flux over one slot pitch.

They are i) iron path of tooth and ii) air path of slot

Bapp = Total flux in a slot pitch = Total flux in a slot pitch

Tooth area Iron area over a slot pitch

Bapp
Φ Φ+Φ
= ASi = i Ai a

where Φi = flux passing through iron over a slot pitch

Φa = flux passing through air over a slot pitch
⎡ Φ ⎤
Φ A ⎢ Φi = B real Aa ⎦ ⎥
Φ
reali
Φ Φ + Aa . a
a
)
B app
A=i +A a =B A+ a = real &B=
i i a ⎣ A a
B
i
A i
… (31)
B = B +B K
app real a

Ba = flux density in air = μo H=4π x 10 'at' -7

real

where 'at'real =mmf per metre across the tooth for tooth density Breal
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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Aa air area total area - iron area total area A

K= = = = −1 i
iron area iron area iron area

core length x slot pitch Ly ⎛ ⎞

K= - 1 =S - 1 = KS -1 ⎜ K S = LyS
net iron length x tooth width L W ⎝ i ⎟
i LW
∴B =B +4 x 10 -7
'at' (K t t⎠
-1)
app real real S
B =B − 4π x 10 -7 'at'(K … (32)
-1)
real app real S

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 01

Given data

Ws = Wt = 12mm lg = 2mm nd = 0

Solution

EXAMPLE: 02

Given data

L = 0.32m nd = wd = 10mm τ= ys = 65.4mm wo = ws = 5mm lg = 5mm Φ = 52mWb

4 0.19mm
Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 03

Given data
L = 0.25m Ss = 90 Wo = Sr = 120 Wor = 3mm lg = 0.95mm Kcd = 0.68
D = 0.65m
3mm nds = ndr = 3 Wd = 10mm
Kcs = 0.46

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 04

Given data

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 05

Given data

Solution

EXAMPLE: 06

Given data

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Solution

EXAMPLE: 07

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 08

Given data

L = 0.33m nd = 3 wd = 10mm K i = 0.9 ys= 25mm ws = 14mm Bapp = 2.3Wb

/ m2
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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Solution

Li = Ki (L − nd wd )

EXAMPLE: 09

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Given data

wt = 12mm
s w = 10mm L = 0.32m nd = 4 w =d 10mm Breal = 2.2Wb / K i = 0.9
μreal = 31.4×10 H / m m2
−6

Solution

Li = Ki (L − nd wd )

EXAMPLE: 10

Given data

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 11

Given data

Breal = 2.15Wb / ys= 28mm ws = 10mm L = 0.35m nd = 4 w = d10mm

2
m
at = 55000A/ m Ki = 0.9

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

SUMMARY OF DESIGN EQUATION

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

SELECTION OF NUMBER OF POLES

The selection of number of poles depends on

(i) Frequency (ii) Weight of iron parts (iii) Weight of copper
(iv) Length of commutator (v) Labour charges (vi) Flash over (vii) Distortion of field form

2. Weight of iron parts

The number of poles affects the weight of the various parts of the magnetic circuit as explained
below.
a) Yoke area. The flux carried by yoke is inversely proportional to number of poles. Therefore by
using greater number of poles, the area of cross section of yoke is proportionately decreased.
b) Armature core area. By increasing the number of poles the weight of iron in the armature core
can be decreased.
c) Overall diameter. The overall diameter of the machine decreases as the number of poles is
increased.
From above it is clear that the total weight of iron required by the machine decreases with an
increase in number of poles.

3. Weight of copper

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

GUIDING FACTOR FOR SELECTION OF NUMBER OF POLES

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

Note:

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

SEPERATION OF D AND L FOR DC MACHINES

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 01

Given data

P = 5kw V = 250V N = 1500rpm Bav = 0.42wb η= L

/ m2
ac =15000a / m τ = 0.66
0.87
Solution

P
Pa = η

EXAMPLE: 02

Given data
p = N = 600rpm Vt = 220V Bmax = 0.83Wb / ac = 30000a /
P = 50kW
m2 m
4
Voltage drop = 3%Vt I f = 1%I L L
τ = 0.66
Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

E = Vt + Aramature
drop

IL = P
V

I f = 1%IL

Ia = IL + I f

EXAMPLE: 03

Given data

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - II D. RAJASEKARAN ASSOC. PROF/EEE

EXAMPLE: 04

Given data

Solution

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