SETHU INSTITUTE OF

TECHNOLOGY

15UEE504-Electrical Machine Design

Presented by
C.Shiva
Assistant Professor/EEE

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Unit – I

Introduction:

Major considerations in Electrical Machine Design - Electrical Engineering

Materials – Space factor – Choice of Specific Electrical and Magnetic loadings
– Thermal considerations - Heat flow – Temperature rise - Rating of machines –
Standard specifications.

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Unit-II
DC Machines:

Output Equations – Main Dimensions -Magnetic circuit calculations – Carter’s

Coefficient - Net length of Iron –Real & Apparent flux densities – Unbalanced
Magnetic Pull- Selection of number of poles – Design of Armature – Design of
Field winding - Design of commutator and brushes – performance prediction
using design values.

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Unit - III

Transformers:

Output Equations – Main Dimensions - KVA output for single and three
phase transformers – Window space factor - Overall dimensions – Operating
characteristics – Regulation – No load current – Temperature rise in
Transformers – Design of Tank - Methods of cooling of Transformers.

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Unit - IV

Induction Motors:

Output equation of Induction motor – Main dimensions –Length of air gap-

Rules for selecting rotor slots of squirrel cage machines – Design of rotor bars
& slots – Design of end rings – Design of wound rotor -– Magnetic leakage
calculations – Leakage reactance of polyphase machines- Magnetizing current
- Short circuit current –Operating characteristics.

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Unit-V

Synchronous Machines:

Output equations – choice of loadings – Design of salient pole machines –

Short circuit ratio – shape of pole face – Armature design – Armature
parameters – Estimation of air gap length – Design of rotor –Design of damper
winding – Determination of full load field mmf – Design of field winding –
Design of turbo alternators – Rotor design.

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Text Books

1. Sawhney A.K, “A Course in Electrical Machine Design ”,

Dhanpat Rai& Sons, Sixth edition
2010.
2. Sen S.K., “ Principles of Electrical Machine Designs with
Computer Programmers ”, Oxford
and IBH Publishing Co. Pvt. Ltd, 2006.

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Reference Books

1. Shanmugasundaram A., Gangadharan and Palani R, “Electrical Machine

Design Data
Book ”, New Age International Pvt. Ltd., 2007.
2. Upadhyay K.G., “ Design of Electrical Machines”, New Age International
Pvt. Ltd., 2008
3. Agarwal R.K., “Principles of Electrical Machine Design ”, S.K.Kayaria&
Sons , 2007
4. Eclayton A. and NNHancock, , “The performance and Design of Direct
current Machines ”,
CBS & Distributors Pvt.Ltd, 2004.

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WHAT IS DESIGN?

Design is defined as a creative physical realization of theoretical concepts.

Engineering Design is application of science, technology and invention to

produce machines to perform specified tasks with optimum economy and
efficiency.

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Design Process?

The process of design involves following circuits,

Electrical Circuit
Dielectric Circuit
Magnetic Circuit
Mechanical parts
Thermal Circuit

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Major Considerations in Electrical Machine

Design:

Cost
Reliability / Durability
Specifications Of Performance
Limits

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IM : 20 TO 30 Years - Low Initial Cost

SM & Trns : Designed with Reliability and Durability
Less emphasis on Initial Cost

Electrical Machines:
Static Machines - Transformers
Rotating Machines- Generators & Motors
Conversion in any electrical M/C takes place through magnetic field.
Magnetic Field produced by an EM which require core and
winding.

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Electrical Engineering Materials

Electrical Engineering
Materials

High Conductivity High Resistivity

Materials Materials

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Used for making all types of windings

All types of apparatus and devices

High
Conductivity
materials
Used for transmission and Distribution of
electric energy

Least possible resistivity

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Used for making resistances

High
Resistivity
materials
Used for making heating devices

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High Conductivity Materials:

Fundamental Requirements to be met are
Highest possible conductivity
Least possible temperature co-efficient of resistance
Mechanical strength
High tensile strength and absence of brittleness
Rollability and Drawability
Weldability and Solderability
Adequate resistance to corrosion.

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High Resistivity Materials:

Resistivity
Specific weight
Density
Resistance temperature co-efficient
Co-efficient of thermal expansion
thermal conductivity
Specific heat
Tensile strength
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COPPER
Properties:
High electrical conductivity.

Excellent Mechanical Properties.

Immunity from oxidation and corrosion.

Ductile metal.

Can be forged, rolled, drawn, machined.

Most electrical machines employ windings of annealed high conductivity copper.

Hard drawn copper wire – used in electrical machines as wires.

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ALUMINIUM
Aluminium is available in abundance on earth’s surface.
Softer than Copper

Can not be drawn into fine wires due to low mechanical strength
Machines have to be redesigned for larger slots to accommodate aluminium wires.
For induction motors with power outputs upto 100 kW – Aluminium used as bars
and Squirrel cage.
Super enamelled aluminium wires - used as Stator Windings of small induction
motors.
Aluminium used as Transformer tank because of its light weight.

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Item Copper Aluminium

Cost 1 0.49*pc/pa
Cross-Section 1 1.62
Diameter 1 1.27
Volume 1 2.04
Weight 1 0.49
Breaking Strength 1 0.64
*pc= unit price by weight of copper
pa= unit price by weight of aluminium

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Characteristics Copper Aluminium

Density,kg/m3 8900 2700
Melting point, ∘C 1083 660
Thermal Conductivity 350 200
W/m-∘C
Restitvity,Ωm 0.01724×10-6 0.0287×10-6
Resistance temperature 0.00393 0.0039
co-efficient at 20∘C,-1∘C
Co-efficient of thermal 16.7×10-6 25.5×10-6
expansion at 20∘C/∘C
Specific heat,J/kg-∘C 390

Specific strength MN/m2 220-250 920

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IRON AND STEEL

Iron and Steel:

Steel alloyed with chromium and aluminium is used for making
starter rheostats.

Cast iron is used in the manufacture of resistance grids to be used in

the starters of large motors.

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ALLOYS OF COPPER
Bronze:
Copper based alloys containing tin, cadmium , beryllium and other metals are
called bronze.

Used as high conductivity materials.

Possess high mechanical strength as
compared with copper, but have higher
resistivities.

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Beryllium Copper:
Used for carrying springs, brush holders, sliding contacts and knife switch blades.
Resistivity 3 to 6 times that of copper.

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Cadmium Copper:

Copper alloys containing 1.1 percent cadmium give wires which are stiffer, harder
and of high tensile strength than hard-drawn copper.
Used for making contact wires and commutator segments.
It is also used for cage windings.

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Brass:
It contains 66% of copper and 34% of zinc. High
mechanical strength.
Wear resistance.
Lower conductivity than copper.
Easily shaped by press forming methods.
Good weldability and solderability.
Fairly resistance to corrosion.
Used in the manufacture of electrical apparatus as
current carrying and structural materials.

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Thank
You

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