A Laboratory Manual for

AC Machine Design (3170909)

B.E. Semester VII (Electrical Engg.)

Directorate of Technical Education, Gandhinagar,

Gujarat
 Certificate

This is to certify that Mr./Ms. ___________________________________

Enrollment No. _______________ of B.E. Semester _____ Electrical
Engineering of this Institute (GTU Code: _____ ) has satisfactorily completed
the Practical / Tutorial work for the subject : AC Machine Design
(3170909 ) for the academic year ________________ .

Place: __________
Date: __________

Name and Sign of Faculty member

Head of the Department

 Preface

Main motto of any laboratory/practical/field work is for enhancing required skills as well as
creating ability amongst students to solve real time problem by developing relevant
competencies in psychomotor domain. By keeping in view, GTU has designed competency
focused outcome-based curriculum for engineering degree programs where sufficient weightage
is given to practical work. It shows importance of enhancement of skills amongst the students
and it pays attention to utilize every second of time allotted for practical amongst students,
instructors and faculty members to achieve relevant outcomes by performing the experiments
rather than having merely study type experiments. It is must for effective implementation of
competency focused outcome-based curriculum that every practical is keenly designed to serve
as a tool to develop and enhance relevant competency required by the various industry among
every student. These psychomotor skills are very difficult to develop through traditional chalk
and board content delivery method in the classroom. Accordingly, this lab manual is designed
to focus on the industry defined relevant outcomes, rather than old practice of conducting
practical to prove concept and theory.

By using this lab manual students can go through the relevant theory and procedure in advance
before the actual performance which creates an interest and students can have basic idea prior to
calculation & design . This in turn enhances pre-determined outcomes amongst students. Each
experiment in this manual begins with competency, industry relevant skills, course outcomes as
well as practical outcomes (objectives). The students will also achieve safety and necessary
precautions to be taken while performing practical.

This manual also provides guidelines to faculty members to facilitate student centric lab
activities through each experiment by arranging and managing necessary resources in order that
the students follow the procedures with required safety and necessary precautions to achieve the
outcomes. It also gives an idea that how students will be assessed by providing rubrics.

The knowledge of electrical machines design is essential for manufacturing as well as the pre-
installation performance analysis. The design is also essential for the practicing engineers in the
research and development field. This subject deals with design of electrical machines including
basics of computer aided design.

Utmost care has been taken while preparing this lab manual however always there is chances of
improvement. Therefore, we welcome constructive suggestions for improvement and removal
of errors if any.

1
 Practical – Course Outcome matrix

Course Outcomes (COs):

1.Select appropriate design parameters according to applications and rating of electrical machines
2. Design the AC machines as per the given specifications
3. Evaluate the performance parameters of electrical machines using design parameters
4. Formulate the optimum design problem and solve it with computer aided tools

Sr. CO CO CO CO CO
Objective(s) of Experiment
No. 1 2 3 4 5
Study and demonstration of different cooling methods
1. √
used in power transformer
Study and demonstration of different types windings
2. √
used in power transformer
√
3. Design of 3 phase Transformer √ √

√
4. Design of 3 phase Induction Motor √ √

√
5. Design of 3-phase Alternator √ √

6. Computer aided design procedure flowcharts & problems √ √

7. Optimization techniques used in Electrical machine √ √

design.

8. Study of FEM for Electrical Machine Design √

9.

10.

11.

12.

13.

14.

2
Industry Relevant Skills

The following industry relevant competency are expected to be developed in the student by
undertaking the practical work of this laboratory.
1. Demonstrate an ability to select optimal design scheme for further development
2. Demonstrate an ability to advance an engineering design to defined end state

Guidelines for Faculty members

1. Teacher should provide the guideline with demonstration of design calculation for
AC machine to the students with all features.
2. Teacher shall explain basic concepts/theory related to the design problem to the students
before starting of design calculations. l
3. Involve all the students in performance of each design and give different rating of AC
machine batch vise for design.
4. Teacher is expected to share the skills and competencies to be developed in the
students and ensure that the respective skills and competencies are developed in the
students after the completion of the experimentation.
5. Teachers should give opportunity to students for hands-on experience after the
demonstration.
6. Teacher may provide additional knowledge and skills to the students even though not
covered in the manual but are expected from the students by concerned industry.
7. Give practical assignment and assess the performance of students based on task
assigned to check whether it is as per the instructions or not.
8. Teacher is expected to refer complete curriculum of the course and follow the
guidelines for implementation.

Instructions for Students

1. Students are expected to carefully listen to all the theory classes delivered by the faculty
members and understand the COs, content of the course, teaching and examination
scheme, skill set to be developed etc.
2. Students shall follow the design procedure, tables and datasheet given in book
, “A Course in Electrical Machine Design”, by A. K. Sawhney ,Dhanpat
Rai and Sons,
As a solved design problem of AC machine , organize the work in the group and make
result data sheet at the end of design of machine
3. Students shall develop software skill as expected by industries.
4. Student shall attempt to develop related hand-on skills and build confidence.
5. Student shall develop the habits of evolving more ideas, innovations, skills etc. apart from
those included in scope of manual.
6. Student shall refer technical magazines and data books.
7. Student should develop a habit of submitting the experimentation work as per the schedule
and s/he should be well prepared for the same.

3
 Index
(Progressive Assessment Sheet)

Sr. Objective(s) of Experiment Page Date of Date of Assessme Sign. of Remar

No. No. perform submiss nt Teacher ks
ance ion Marks with date
Study and demonstration of different cooling 5
1
methods used in power transformer
Study and demonstration of different types 10
2
windings used in power transformer
Design of 3 phase Transformer 12
3
Design of 3 phase Induction Motor 27
4
Design of 3-phase Alternator 42
5

Computer aided design procedure flowcharts & 55

6 problems
58
7 Optimization techniques used in Electrical
machine design.
Study of FEM for Electrical Machine Design 66
8

Total

4
 Experiment No: 01

Study and demonstration of cooling systems of Power Transformer

Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical
Machines

Objectives: (a) To obtain the knowledge about different methods available for cooling of Power
Transformer
(b) To carry out selection of type of effective cooling system out of available for Power
Transformer used.

Equipment/Instruments:
1. Cut section view of Power and Distribution Transformer
2. Charts showing cooling methods of of 3 phase Power & Distribution Transformers

Theory :

METHODS OF TRANSFORMER COOLING

The cooling system plays an important role in handling destroyers of transformers caused by heat. The
generation of heat in the transformer is caused by internal losses like hysteresis, eddy current, iron, and
copper loss, or loading, high ambient temperature, and solar radiation. If the temperature continues to
climb rapidly, it will damage the various parts and failures of the transformer.

Removing and decreasing the heat of the transformer is useful for the efficient working, longer life, and
higher efficiency of the transformer. The cooling system is equipped with various coolants as air,
synthetic oils, mineral oils, gas, water.The transformer is divided into two types: dry and oil
transformer. There are the cooling methods as follows:

1. Air Natural

2. Air Blast or forced

3. Oil Natural Air Natural

4. Oil Natural Air Forced

5. Oil Forced Air Forced

5
6. Oil Natural Water Forced

Dry Type Transformer

Air Natural (AN)

Basically, due to Air Natural Method When the temperature of the transformer rises higher comparing to
the temperature of the surrounding air, the heated air is cooled by the circulation of natural air. This
method, called a self-cooled method, is used for cooling the smaller output transformer rating (up to 1.5
MVA).

Air Forced (AF) or Air Blast

Regarding this method, the temperature of the transformer decreased by the forced air circulation method.
The high velocity of air is forced on the core and the windings of the transformer by fans and blowers.

the fans and blowers are switched ON automatically if the alarm of the standard safe level of the
transformer is activated. This solution is used for transformers rating up to 15MVA.

Oil-Immersed Type Transformer

Oil Natural Air Natural (ONAN)

The temperature of the transformer is cooled by the Natural convection process. The core and windings
are designed in the oil-immersed tank. Due to the heat of the core and the windings, the temperature of
the oil in the transformer rises. Then, the oil moves upward and flows from the upper portion of the
transformer tank. This hot oil dissipates heat in the air by conduction process and natural convection, the
oil is cooled by the circulation of natural air and passes through the radiator again for the use of the
transformer. This method is used for the transformer rating up to 30 MVA.

Oil Natural Air Forced (ONAF)

With this method, the forced air is used for the purpose of cooling the transformer. The oil cooling will
be faster if the tank area of the transformer is increased, resulting in an increase in the degree of heat
dissipation. When fans and blowers are installed, a high velocity of air is forcefully applied to the radiator
and cooling tower, which will help cool the oil more quickly and efficiently.

Its cost is higher than another process in which the circulation of oil and air is done spontaneously
because a fan and blower are attached as an additional cooling device. ONAF method is used for the
transformer rating up to 60 MVA.

6
Oil Forced Air Forced (OFAF)
With this method, both oil and air are forced to cool the transformer. with the help of a pump,
Heat exchangers are installed through which hot oil is circulated. Air is forced to pass through
the heat exchanger with the help of a high-speed fan.Like ONAN method, because of a low load
on the transformer, cooling is done using the simple ONAN method. However, as soon as the
load is increased, more heat will be generated and therefore the sensor will give a warning that
the heat dissipation has exceeded a safe value and the fan and pump are turned on automatically
as a result. Therefore, the cooling takes place by the OFAF method.

Oil Natural Water Forced (ONWF)

In the Oil Natural Water Force cooling method, the transformer core and the windings are placed in the
oil tank. A radiator is installed outside the tank, as the temperature goes up and the oil heats up and
moves upward, the heat is dissipated by the natural process of convection, and oil is passed through the
radiator, but the water is pumped and passed through the heat exchanger for cooling of the oil.

Oil Forced Water Forced (OFWF)

A heat exchanger is installed through which both water and oil are passed with the help of a pump. The
pressure and level of the oil are always kept higher than that of water so that if any leakage occurs in the
system the oil mixes with the water, but water is not mixed up with the oil.

This type of method suits for large capacity of the transformer having a rating of several hundred MVA
or where banks of transformers are installed. Importantly, this type of cooling is done for the transformer
installed at the hydropower plant.

7
Quiz:
1. Why cooling system required in Transformer.

2. List out diff. cooling systems available for Power & Distribution Transformer

3. What is selection criteria of cooling system for rated transformer.

4. Compare diff. cooling systems in Transformer

8
Suggested Reference :

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

Dhanpat Rai and Sons

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

9
 Experiment No: 02

Study and demonstration of different windings of Power & Distribution

Transformer
Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical
Machines

Objectives: (a) To obtain the knowledge about different types of windings available for Power and
Distribution Transformer
(b) To carry out selection of type of effective windings for primary & secondary
windings out of available for Transformer used.

Equipment/Instruments:
3. Cut section view of Power and Distribution Transformer
4. Charts showing different types of windings available for Power and Distribution Transformer

Theory :

Types of Transformer Windings:

Cylindrical, Helical, Crossover & Disc Winding

Core and Windings of Three Phase Core Type Transformer:

There are different types of windings used for different kinds of applications and
arrangements. Windings are the conductors wrapped in various forms like helical, disc,
cylindrical, crossover which generates MMF that is carried by the core to other windings for
having the different levels of voltages there are two types of transformer:
1. Core type transformer
2. Shell type transformer
In core type, we wrap the primary, and secondary windings on the outside limbs, and in shell
type, we place the primary and secondary windings on the inner limbs.

We use concentric type windings in core type transformer. We place low voltage winding near
to the core. However, to reduce leakage reactance, windings can be interlaced. Winding for

10
core type depends on many factors like current rating, short circuit withstands capacity, the
limit of temperature rise, impedance, surge voltage, transport facilities, etc.

Types of Winding used for Core Type Transformer

Cylindrical Windings
These windings are layered type and uses a rectangular or round conductor. The conductors
are wound on flat sides shown in Fig.(c) and wound on the rib side in .

Uses of Cylindrical Windings

Cylindrical windings are low voltage windings used up to 6.6 kV for kVA up to 600-
750, and current rating between 10 to 600 A.

We often use cylindrical windings in its multi-layer forms. We use rectangular

conductors in two-layered type because it is easy to secure the lead-out ends. Oil
ducts separate the layers of the windings this arrangement facilitates the cooling
through oil circulation in the winding.

In multi-layered cylindrical windings, we use circular conductors, wound on

vertical strips to improve cooling conditions. The arrangement creates oil ducts to
facilitate better cooling. We use this types of winding for high voltage ratings up to
33 kV, 800 kVA and current ratings up to 80 A. The maximum diameter we use for a
bare conductor is 4 mm.

Helical Windings
We use helical windings low voltage, high capacity transformers, where the current
is higher, at the same time windings turns are lesser. The output of the transformer
varies from 160 – 1000 kVA from 0.23-15 kV. To secure adequate mechanical
strength the cross-sectional area of the strip not made less than 75-100 mm square.
The maximum number of strips used in parallel to make up a conductor is 16.
There are three types:

• Single Helical Winding

• Double Helical Winding
• Disc-Helical Winding
•
Single Helical Windings consist of winding in an axial direction along a screw line
with an inclination. There is only one layer of turns in each winding. The advantage
of Double Helical Winding is that it reduces eddy current loss in conductors. This is
11
on account of the reduced number of parallel conductors situated in the radial
direction.

In Disc-Helical Windings, the parallel-connected strips are placed side by side in a

radial direction to occupy the total radial depth of winding.

Multi-layer Helical Winding

We use it commonly for high voltage ratings for 110 kV and above. These types of
winding consist of several cylindrical layers concentrically wound and connected
in series.

We make the outer layers shorter than the inner layers to distribute capacitance
uniformly. These windings primarily improve the surge behavior of transformers.

Crossover Winding
We use these windings for high voltage windings of small transformers. The
conductors are paper covered round wires or strips. The windings are divided into
a number of coils in order to reduce the voltage between adjacent layers. These coils
are axially separated by a distance of 0.5 to 1 mm. The voltages between adjacent
coils should not be more than 800 to 1000 V.

The inside end of a coil is connected to the output side end of the adjacent one as
shown in the above figure. The actual axial length of each coil is about 50 mm while
the spacing between two coils is about 6 mm to accommodate blocks of insulating
material.
The width of the coil is 25 to 50 mm. The crossover winding has a higher strength
than cylindrical winding under normal conditions. However, the crossover has
lover impulse strength than the cylindrical one. This type also has higher labor
costs.

Disc and Continuous Disc Winding

Primarily used for a high capacity transformer. The winding consists of a number of
flat coils or discs in series or parallel. The coils are formed with rectangular strips
wound spirally from the center outwards in the radial direction as shown in the
figure below.

12
The conductor can be a single strip or multiple strips in a parallel wound on the flat
side. This makes robust construction for this type of windings. Discs are separated
from each other with press-board sectors attached to vertical stripes.
The vertical and horizontal spacers provide radial and axial ducts for the free
circulation of oil which comes in contact with every turn. The area of the conductor
varies from 4 to 50 mm square and limits for current are 12 – 600 A.
The minimum width of the oil duct is 6 mm for 35 kV. The advantage of the disc
and continuous windings is their greater mechanical axial strength and cheapness.

Windings for Shell Type Transformer:

Sandwich Type Winding

Allow easy control over the reactance the nearer two coils are together on
the same magnetic axis, the greater is the proportion of mutual flux and the less is
the leakage flux.

Leakage can be reduced by subdividing the low and high voltages sections. The end
low voltages sections contain half the turns of the normal low voltage sections
called half coils.

In order to balance the magneto motive forces of adjacent sections, each normal
section whether high or low voltage carries the same number of ampere-turns. The
higher the degree of subdivision, the smaller is the reactance.

Advantages of Shell Type Windings in Transformers

The advantages of shell-type windings include:

• High short-circuit withstand capability

• High mechanical strength
• High dielectric strength
• Excellent control of leakage
• Efficient cooling capability
• Flexible design
• Compact size
• Highly Reliable Design

13
Quiz:
1. Why H.V. winding in always on outer side ?

2. List out diff. types of winding available for Transformer.

3. What is selection criteria of Primary & Secondary winding of Power Transformer ?

4. 4. Explain types of conductors used for Primary & Secondary winding of Power Transformer ?

14
Suggested Reference :

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

Dhanpat Rai and Sons

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

15
 Experiment No: 03
Design of 3 phase Transformer
Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical machines
2. Design the AC machines as per the given specifications
3. Evaluate the performance parameters of electrical machines using design parameters

Objectives: (a) To obtain the knowledge about different methods available for cooling of Power
Transformer
(b) To carry out selection of type of effective cooling system out of available for Power
Transformer used.
Equipment/Instruments:
1. Cut section view and charts showing cooling methods of of 3 phase Power Transformers

DESIGN PROBLEM
.Design a 200 KVA 11000/415 V , 50 Hz, Delta / Star, core type, oil immersed, , natural
cooled, distribution Transformer . The transformer is provided +/- 2.5 to +/- 5 % tappings
on H.V. winding, The maximum temperature rise not to exceed 450 C with mean
temperature rise of oil 350 C.,

Design Procedure :
Core Design :
First select the value of K from table 7.2 for distribution transformer. K = ____________

Calculate voltage/ turn Et =K√Q .= ___________

"' E,
Flux in core = Øm = / ( 4.44 x f ) = ________________- wb
lli

For core , Hot rolled silicon still grade 92 is used and flux density 1.0 Wb/m2 assumed

Ai = __________________

16
 Find net iron area Ai = _____________________________ = _____________ mm2

Using a cruciform core .

Net iron area Ai = 0.56 d2 =

Dia of of circumscribing circle d= = _______ mm

Calculate widths of laminations: a = 0.85 d = ___________ mm & b = 0.53 d =

_______________ mm

Select standard size a & b of lamination a = _______ mm & b = ___________ mm

Window Dimensions :

The wimhw space factor for small transformer is Kw .= KVA / (30+kV).

.". Kw = ___________ .

The current density in winding is taken 2·3 A/mm2

From output equation of transformer Q, = ____________________________

find window are Aw = ______________mm2

Taking the ratio height to width of window = 2·5,

Hw x Ww -..,= Aw = _____________________________

Find Width and Height of window Ww = __________ mm & Hw =________ mm

Area of window provided Aw = Hw * Ww = __________ mm2

Distance between adjacent core centre D= Ww.+d= __________ mm.

17
Yoke De■ign.

The area of yoke is taken as 1 . 2 t i m e s o f c o r e l i m b s

S o , Flux density in yoke = _________ Wb/m1.

Net area of yoke= __________mm2 &

Gross are of Yoke = _________ mm2.

Taking the section of the yoke a rectangular.

Depth of yoke .Dy = a = ___________ mm & height of yoke Hy = _________ mm

Overall Dimensions of Frame

Height of frame H = Hw + 2Hy = __________ mm

Width of frame W = 2D+ a = __________ mm.
Depth of Frame Dy = a = ___________ mm.

L.V. Winding:

Secondary line voltage = _________ V

Connectioo=star.

Secondary Phase Voltage = _________ V.

Number of turns per phase Ts = Vs ,/Et = _____

Secondary phase current I s = = = A.

18
 Current density 2·3 A/mm2 is used.

Area of secondary couductor as = ___________ mm2

From Table 17. I (IS; 1897-1982 ),using bare conductor ,

select area of bare conductor = _______ mm2

Current density iu secondary winding = ________ = 2 23 A/m1.

The conductors are P V C c o v e r e d The increase in dimensions on account

of paper covering is 0.5 mm.

Dimensions of insulated c o n d u c t o r = _ _ _ _ _ _ _ _ _ _ _ _ _ _ mm2 •

Using three ( 3) layers for LV winding.

Helical w i n d i n g i s u s e d . .

There fore space has to be provided for _______ turns along the axial depth.

Axial depth of LV winding Lcd ,= ___ X axial depth of conductor = ___________

mm.

The height of window is _ _ _ _ _ _ _ m m. This leaves a clearance of

_ _ _ _ _ _ _ _ _ m m on each side of LV winding. . (The minimum clearance should be 6
mm for windings having voltage below 500 V.)

Using 0.5 mm pressboard cylinder between the layers .

Radial depth of of LV winding

b, = number of layers X radial depth of conductor + insulation between layers

= _________ mm.

Below Fig. shows a cross- section through l.v coil.rnm

19
 Pru, boarif

L.V. winding (all dimensions in mm).

Diameter of circumscribing circle d = _________ rnm.

Using pressboard wraps wraps 1·5 mm thick as a insulation betweeu I v.

winding and core.

Laminated diameter of LV winding = _________mm .

Outside diameter of LV winding = _______ mm

H. V. winding

Primary line voltage = _________ V. Primary connection = Delta

Primary phase voltage = primary line voltage = _____________ V .

:. Number of turns per phase Tp , = _ _ _ _ _ _ _ _ _

As ± 5% Tapping to be provided so, no of turns increased to Tp= 1.o5 * V

The voltage p e r c o i l c oil is

about 1500 V.

Voltage per coil= Vp /8= _

:. li!iing 8 roih.
____

Turns pt•r coil-515fl/H;:64!.

20
Using 7 normal coils of ___________ turns and one rainforced coil of
__ turns

Total h.v. turns provided Thv = _____________ .

Taking 24 layers per coil. Turns per layer = ________

Maximum vo1tage between layers = _________ V,

Which is below allowable limit

. .

H.V. winding phase = = _______ A.

cu rrent Ip
\

As the current is below 20 A , cross,over coils are used for H.V.

winding

Taking a current density 2.4 A/mm2

Area of h v concductor = _______ mm2

Diameter of bare conductor = __________ mm.

21
 Using paper covered conductors. From table 17.4

Nearest standard conductor size

bare diameter = ______ mm, & insulated diameter = ____________ mm

Modified are of conductor ap = _____________________ = _________________

mm2 .

Actual value of current density used δp= _________ A/mm2 .

Axial depth of one coil = = ________ mm.

The spacers med between adjacent coils are 5 mm in height.

Axial depth of HV winding Lcp = number of coils X axial depth of each coil
+ depth o f s p a c e r s = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ mm. 1

The height of hv winding = _______.and there fore space left =___ _ mm. This is
occupied by insulation and axial b r a c i n g o f _ _ _ _ _ _ _ . The clearance l e f t on
each side i s _ _ _ _ m m, which is sufficient for I I kV t r a n s f o r m e r .

The insulation med between layers is 0·3 mm t h i c k paper.

So, radial depth h.v. coil b,= mm.

From Eqn. 1·22 the thickness of insulation b e t w e e n h.v. and l.v. winding is

____________ mm. This includes the width of oil duct a l s o

The insulation between h.v. and l v. winding is 5 mm thick

backelised paper cylinder The h.v. winding i, wound on a former 5 mm thick and the
duct is 5 mm wide, making

the total insulation b e t w e e n h.v. and l.v. windings = __________m.

Inside diameter of of h.v. winding

= outside diameter l.v. winding+ 2 x thickne1s of insulation = _____________ m. --f•

Outside diameter of h.v. winding = = _____________ mm.

22
 Clearance between two adjacent limbs = ______________________________

= ________________ mm.

Resistance : -
Mean length of primary winding = _________ ___ mm.

Length of mean turn of primary winding = Lmtcp = _______________ = ___________ m.

Resistance of Primary winding = ________________ Ohm

Mean diameter of secondary winding = ________________

________________________________
_____________mm.

Length of mean turn of secondary winding = Lmts = ___________ =

________________m

Resistance of secondary winding = ______________ Ohm

Total resistance referred to primary side Rp = _________________ Ohm

P.U. resistance of transformer € r = (Ip x Rp) /Vp = _______________

Mean diameter of windings = = ___________mm.

Length of mean turn Lmtc = _ = ________m.

Height wincling Lc = = _________________ mm.

Leakage rcactann of transformer referred to primary side Xp =

P.U. leakage reactance €x = __________________________________

La a_- :i •
.
= _____________ .

P.U. impedance Z = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ = _________ .

Regulation

P.U. Regulation = R = € r Cos + €x Sin Ø =_____________ ____________

. :

23
 :.P.U Regulation at Unity p.f. = ___________________________________ = ____________

P.U. Regulation at 0.8 p.f. lagging = _______________________________ _ = ___________

Losses : · ·
I2 R loss \

I2R loss at 75°C, = ____________ w.

Taking stray load loss 15% of above.

Total I 2 R loss including stray load loss Pc= ___________________ = _______ W.

Core loss

Taking the density of laminations as 7·6 X 10' kg/m3,

weight of 3 limbs- = _________________________________________= __________ kg

;:

Taking flux density in the limbs is 1 Wb/m2 & corresponding to this specific core loss

Specific core loss 1·2 W/kg for 92 grade laminations

Core loss in limbs = _____________________________________= _______________ W

Weight of two yoke s = ____________________________________ Kg

Corresponding to a ftux density of __________ w b / m 2 i n y o k e ,

The specific core loss = ___________________ W/Kg

Core loss in yoke = _____________________________________ = ___________ W'.

Total core losses Pi = __________ =

_ _ _ _ _ _ _ _ _ W.

24
 Efficiency :

Total losses at full load = _____________________ __ = _________________ W.

Efficiency at full load and unity p.f = _______________________________ = ___________ %

For max. efficiency x2 Pc = Pi

Thus maximum e fficiency occurs at _ _ _ _ _ _ _ _ _ % of full load

This is good figure for distribution transformer .

.
No load current:
Corresponding to flux density _____ Wb/m2 . in core and ___________ Wb/ m2 in
yoke ,

Core mmf atc = _________________ A/m & Yoke mmf aty = ___________________ A/m

Total magnetizing mmf =_______________________________ =

____________________ A.

Magnetizing mmf per phase AT0 = ___________________ = __________________ _ A.

Magnetizing current C = AT0 / (√2 x Tp ) + _____________ A

loss component of no load current I L = _ _ _ _ _ _ _ _ _ _ _ =

___ A

'No load current I 0 = √ Im2 + I L 2 = _____________________ A.

No load current as a percentage of full load current = __________ %

Allowing for joints etc. the no load current wil be about 2 . 5 % of full load current

Tank

25
 Height over yoke H= _________________ mm Allowing _ _ _ _ _ mm at base and
about ___________ mm for oil.

Height of oil Level = ____________ mm. Allowing another _ _ _ _ _ _ _ _ _ _ _ _ mm

height for leads etc.,

height of tank B,= ____________ mm.

The height of tank is taken as __________ or Hi = _________________m.

Assuming a clearance of 40 mm along the width on each side

Width of tank Wt=2D+D,+2l-= _____________________________ = ______m..

'
The width of tank Wt is taken as _______________ m.

The clearance along the length of the transformer is greater than that
along the width. This is because additional space is needed along the length to
accommodate tapping etc. The clearance used is
approximately________________mm on each side.

:. Length of tank = ___________ mm.

The length of tank Lt is taken as = __________________ m.

Total loss dissipating surface of tank Si =_______________________________=

____ m2

Total specific heat dissipation due to radiation and convection is 12.5 W/m2 0c

:. Temperature rise = _____________ °C

This is below 55°C and therefore plain tank is sufficient for cooling and no tubes
are required.

26
Result:
DESIGN SHEET

1. Material 0·3S mm thick 92 Grade

2. Output co efficient K
3. Voltage per turn E,

4. Circumscribing circle diameter d

5. Number of steps
6 Dimensions
a _______mm
b ________mm
7. Net iron area _________mm2
8. Flux density D,,. _______ Wb/m2

9. Flux ___________ Wb

10. Weight kg
11. Specific iron loss _________ W/kg
12. Iron loss ____________W
Yoke
I. Depth of yoke ___________ mm
2 . Height of yoke ____________mm
,. Net yoke area ________________ mm2
4 . Flux density ____________ Wb/m2
,. Flux 10-135 m Wb

6. Weight _____________Kg
7. Specific: iron loss 0·8 W/Kg
8. Iron loss __________ W
Windows
I. Number 2 0·1s
2. Window space factor
,. Height or window _______mm
4. Width of window
________ mm
'
Window area
Frame
________ mm2

1. Distance between adjacent D ___________ mm

Limbs
__________ mm
,2.. Height of frame
Width of frame ___________ mm

... Depth of frame ___________ mm

27
 ----•-..-
Winding L.V. H.V.
·
1. Type of Winding Helical Cross-over
2. Connection Star Delta
3. Conductor
Dimensions -bare _________mm' mm
insulated mm =____ mm
Area of conductor mm2 mm2
Number in parallel None None
2
4. Current density 2·23 A/mm A/mm2
s. Turn, per phase Nil
6. Coil
total number
per c:ore lea
7. Turn
per coil •
turns
per layer
8. Number of layers
9. Heiaht of winding mm mm
10. Depth of winding mm mm
11. Insulation
Between layers O·5 mm press board 0·3 mm paper
Between coils
1'2. Coil Diame,cn
· Inside mm mm
Outside mm mm
13. Length of mean turn m m
14. Resistance at 7S°C A A

Insulation
t. Between l.v. winding and core = press board wraps ___________ mm
2. Between l.v. windins and h.v. winding = bakclized paper ____________ mm
3. Width of duct between l.v. and h.v ·== _______ mm

Tank
1. Dimension,
_________ ,m
Height He _________ m
Length L,
__________ m
width w, _________ m
2. Oil Level Nil
___________________ 0
3. Tube c
4. Temperature rise
Impedance

1. P.U. Resistance __________________

2. P.u. Reactance _________________
3. P.U. Impedance ___________________

Losses

28
 1. Total core loss ___________ W

2, Total copper loss __________W

3. Total losses at full load ___________ W

4. Efficiency at full load ___________ %

***********************************************************************************

Quiz:
1. Explain: (1) Window space factor (2) Stacking factor.

2. Why circular coils are preferred in transformer winding?

3. a. Give reasons for following:

1) Why are tapping provided on HV winding ?

29
 2) Why cores of transformers are stepped?.

4. Explain design difference between power transformer and distribution transformer.

Suggested Reference :

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

Dhanpat Rai and Sons

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

30
 Experiment No: 04
Design of 3 phase Induction Motor
Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical machines
2. Design the AC machines as per the given specifications
3. Evaluate the performance parameters of electrical machines using design parameters

Objectives: (a) To obtain the knowledge about different parts of 3 ph Induction Motor.
(b) To carry out selection of required parameters for design of 3 phase Induction Motor.
(c) To develop the skill to make design of Induction motor as per requirement.

Equipment/Instruments:
1. Cut section view of 3 phase Induction Motor ( Squirrel cage )
2. Charts showing construction & parts of different types of rotors of 3 phase Induction Motor

Design Problem

Design a 5 KW/HP., 415 V, 3 ph., 50 Hz, 1460 RPM speed, sq. cage Induction Motor. The
m/c is to be started by star-delta starter. The efficiency is 0.88 and p.f. is 0.85 at full load.
The temp rise is not to exceed 50 oC
Solution :
Find Synchronous speed ns = ______________ rps & No. of poles P = ________

Assume suitable Bav & ac from table given in book w.r.t. rating of I.M. Tate Kw = 0.955

Output co efficient Co = 11 x Bav xacx Kwx10 -3 = ____________

KVA input Q = ( KW ) / ( p.f. x efficiency ) = _________

Calculate D2L = Q / ( ns x Co ) = ____________

Depends on design criteria select ratio L / Ʈ = _________ ( from 1.0 ,1.2, 1.5 , 2 etc. )

Fro relations D2L & ratio L / Ʈ , Calculate D = _________ m & L = _________m & pole pitch
Ʈ = __
31
If length of core L is > 0.125 m , then provide radial ventilating ducts.

Net iron length Li = 0.9 x L = ______ m

Use 0.5 thick silicon laminations for stator core

STATOR Design :

M/c is designed for Delta winding on stator & started by star elta starter.

Stator voltage / ph = __________ V

Flux per pole = Bav x L x Ʈ = _______ _______ Wb

Calculete Stator turn / ph Ts = ______________

Take slot pitch between 15 to 25 mm and slo/ pole/ phase = qs =2 ,

Calculate Total stator slots Ss = _________ , stator slot pitch Yss = ___________ mm

Total stator conductors Z= 6 Ts = _____________

Stator conductor / slot = _____

Mush winding in tapered semi enclosed slot used

Coil span = slots / pole = __________ ( but coil span should not even integer , so short pitched
winding is used )

Calculate short pitc factor Kp = ________________________________________ &

distribution factor for slo/ pole/ phase 2 = Kd = ________________________________________

So, stator winding factor Kw = Kp x Kd = _______________

Stator current Is = ________________________ A

For sator current density = 4 A/mm2 , area of stator conductor = ___________ mm2
32
Dia of bare conductor d = _____________________ mm

From table 17.7 , diameter of standard bare conductor d = ______________ mm

Actual area of stator conductor As = _________________________________ mm2

Current density in stator conductor = _________________ A/mm2

Dia. of enemalled conductor ( medium covering ) d1 = ______________ mm ( from table 17.7 )

Slot dimensions :

Space required by conductor in slot = Zss x ass = __________________ mm2

Taking space factor 0.4 , area of each slot = _____________________ mm2

Considering maximum flux density in teeth , calculate minimum width of teeth in stator

Wts min = ______________________________ = __________________________ mm

Find all required dimensions of stator slot and mention in figure ( lip, wedge, upper width, bottom width
etc … )

Calculate length of mean turn Lmts = ________________________________________________ mm

STATOR CORE :

33
Flux in stator core = _________________________ Wb

Assuming 1.2 Wb/ m2 flux density , area of stator core = _________________________________ m2

Depth of stator core dsc = _______________________ m

Find flux density in stator core Bsc = _________________________________ Wb/ m2

Find outer dia. f stator core lamination Ds = D + 2 dsc + 2 dss = ____________________ mm

ROTOR DESIGN :

Length of air gap lg ( referring to table 10.2 ) = _____________ mm ( nearer to 0.3 mm )

Dia. Of.Rotor Dr = ____________________ mm

No. of rotor slots taken as pole pair smaller than stator slots.

No. of stator slots Ss = ____________ So, no. of rotor slots Rs = ________________

Rotor slot pitch Yrs = ____________ mm

Calculate Rotor bar current Ib = = _____________ A

For high starting torque , use 6 A/mm2 current density for rotor bars.

Area of rotor bar ar = _________________ = ________________________ mm2

From table 17.1, select rotor bar diameter size _________________________mm

Actual area of rotor bar ar = __________________ mm2

With above , dimensions of rotor slot ( semi closed slot )

Width of slot Wrs = ___________________ mm, & depth of rotor slot drs = __________mm

Flux density at rotor teeth at root should be checked and it should be within limit.

Flux density at root of teeth Btrs = = ______________ Wb/ m2

Slot pitch at bottom of teeth = ___________________ mm

34
Tooth width at bottom = _________________ mm

Flux density at root of rotor teeth Btr = = ____________

Wb/m2

Bars are skewed by one slot pitch . So length of each bar lb = _______________________ mm

Resistance of rotor bar Rb = = _____________ ohm

Total copper loss in bars = = __________________ W

END RING

Current in end ring Ib = Sr.Ib/( π P ) = _______________________________________ A

Taking current density 6 A/mm2 in end ring, area of end ring ae = _________________________________ mm2

Selecting standard section of end ring ________________ mm2

, find depth of end ring de = ______________________ mm & thickness te = ___________________mm

Find, oter dia. Of end ring = _________________ mm & Inner dia. Of end ring = ___________________
mm

Mean dia. Of end ring = ______________________ mm

Resistance of each end ring Re = = _________________ ohm

Copper loss in two end rings = = ________________W

Total copper loss of rotor = = _________________ W

Full load slip S = = _________________

Depth of rotor core dr = _________________________ equal to depth of stator core ds =

_____________mm

Find flux density in rotor core Brc = ____________________________ wb/ m2 &

Inner dia. Of rotor core = =_______________ mm

35
NO LOAD CURRENT

Calculate the mmf required for various parts of magnetic circuit

mmf required for air gap ATg = = _____________ A

Calculation :

Kcs = gap contraction factor for stator slots =

Kcr = “ rotor “ =

Gap contraction factor Kc = Kcs x Kcr = ____________________

Effective length of air gap lg += _____________ mm

Bg 60 = ____________________ wb/mm2

b. mmf required for stator teeth ATs = =

_______________A

c. mmf required for stator core ATsc = = ______________

A

d. mmf required for rotor teeth = = ______________A

e. Mmf required for rotor core ATrc = = __________________A

Total mmf required for magnetic circuit AT = _____ + ____+ _____ + ___ +____ = ____________ A

Magnetising current per phase Am = = ________ A

36
LOSS COMPONENT
a. Iron loss in stator teeth = _____________ W
Calculation :

b. Iron loss in stator core = ______________ W

Calculation :

Total iron loss = _________ + _____________ = ____________ W

Actual iron loss = Total iron loss x 2 = __________________ W

Friction & windage loss = ____________________ W

Total no load loss WNL = Actual iron loss + Friction & windage loss = _________________ W

Loss component of no load current / phase IL = Total no load loss / (3 x VL) = _________________ A

No load current I0 = √ (Im + IL ) = __________________ = ________________ A

% of no load current of full load current = ___________ %

No load p.f. Cos Ø0 = _______________ = __________

Phase angle of no load p.f. Ø0 = _____________ = ____________

SHORT CIRCUIT CURRENT :

Calculate Leakage reactance for
37
 1. Stator slots :

2. Rotor slota :

3. Overhang leakage :

4. Zigzag leakage :

Total leakage reactance per phase referred to stator = ________+ _________+ ________ +
_______

Xs = ________________ ohm

RESISTANCE :

Calculate total resiatance per phase referred to stator = _______ =_________ ohm

Rs = ____________ ohm

Total impedance at stand still Zs = = √ (Rs + Xs ) = _____________ ________ = ______ ohm

38
Short circuit current / phase ( Rotor blocked ) Isc = ________________ = _____________ A

Short circuit p.f. . Cos Øsc = ___________________ = ____________

Phase angle at short circuit Øsc = __________________ = ____________

LOSSES & EFFICIENCY :

Stator l copper loss = _____________________ =_________________________ W

Rotor copper loss = _____________________ =_________________________ W

Total iron loss = _____________________ =_________________________ W

Friction and windage loss = _____________________ =____________________ W

Total losses at full load = ______________________ _______________ = _______________ W

Efficiency at full load Ƞ = ____________________________________ = ________________ %

Steps to draw Circle Diagram of an Induction Motor:

• Take the phasor voltage V1 along the y-axis.

• Choose a convenient current. With O as origin, draw a line OO’ = I0 at an angle ϕ0 with V1.
• Draw the line OKN perpendicular to V1. Similarly, draw a line O’D perpendicular to V1.
39
 • From point O draw the line equal to the blocked rotor current I1BR to the same scale as I0. This line lags
behind V1 by the blocked rotor power factor angle ϕ1BR.
• Join O’F and measure its magnitude in amperes. The line O’F represents I’2BR.
• From point F, draw a line FMN parallel to V1. This line is perpendicular to O’D and ON.
• Calculate MS = I’22BRR1/V1 and locate point S. Join O’S and extends it to meet the circle at J.
• Draw the perpendicular bisector of the chord O’F. This bisector will pass through the center of the circle
at point C. Now with the radius CD’ or CD draw the circle.

Result Obtained from the Circle Diagram :

Assume that the line current I1 is known. With the centre at O, draw an arc with the radius I1. This arc
intersects the circle at the operating point E. Draw the line EK and locates the point H, L, G.

The following results are obtained from the circle diagram shown above.

2. Input power = 3V1 KE = ____________ ____________ = __________________

3. Rotational losses = 3V1 KH = ________________________ = ___________________

4. Stator copper loss = 3V1 HL = ________________________ = ___________________

5. Rotor copper loss = 3V1 LG = ________________________ = ____________________

6. Output power = 3V1 GE = _______________________ = ___________________

7. Output torque = 3V1 LE/ωs = ________________________________ =

__________________________

8. Starting torque = 3V1 SF/ωs = ________________________ = ____________________

9. Slip = LG/LE = ________________________ = ____________________

10. Speed = GE/LE X ns = ________________________________ =

________________________

11. Efficiency = GE/KE = _______________________ = ___________________

12. Power factor = KE/OE = ________________________ = __________________

Max. torque
➢ Ratio ----------------------- = -------------------------------- = __________________
Full load torque

Max. power output

40
 ➢ Ratio ----------------------------- = ---------------- ---------- = __________________
Full load power output

TEMPERATURE RISE

Calculate for temperature rise in machine & it should be within limit of 50 0 C

Calculation :

Result :

Prepare data sheet of design of 3 phase Induction Motor Alternator

Parameter Symbol Result

41
42
43
Conclusion:
______________________________________________________________________________

______________________________________________________________________________

_______________________________________________________________________________

______________________________________________________________________________

_______________________________________________________________________________

Quiz:
1. Why semi-enclosed slots are usually preferred for induction motors

2. Discuss the effect of “skewing” on the performance of three phase induction motor

44
 3. Briefly discuss factors affecting determining air gap length in induction motor design.

4. State the rules for the selection of rotor slots in 3-phase squirrel cage induction motor.

Suggested Reference :
“A Course in Electrical Machine Design”, by A. K. Sawhney ,
Dhanpat Rai and Sons

45
References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

46
 Practical No : 05
Design of 3 Phase Alternator ( Cylindrical )
Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical machines
2. Design the AC machines as per the given specifications
3. Evaluate the performance parameters of electrical machines using design parameters

Objectives:
(a) To obtain the knowledge about different parts of 3 ph Induction Motor.
(b) To carry out selection of required parameters for design of 3 phase Induction Motor.
(c) To develop the skill to make design of Induction motor as per requirement.

Equipment/Instruments:
1. C/S view of 3 phase Synchronous Generator ( Cylindrical type )
2. Charts showing construction & parts of different types of rotors of 3 phase Alternator

C/S view of 3 phase Synchronous Generator ( Cylindrical type )

DESIGN PROBLEM : Design of 3 Phase Alternator ( Cylindrical )

Design a 3 MVA , 11 KV, 50 Hz,3 ph, 3000 rpm, air cooled Turbo alternator . The load
power factor is 0.8.
Solution :

MAIN DIMENSIONS :

Synchronous speed ns = ______________ =_________ No of poles = _________________ = ______

Assuming specific magnetic loading Bav = 0.55 Wb /m2 , winding factor Kw = 0.955 &

Specific magnetic loading ac = 54000 amp. cond/m

Output co efficient Co = ___________________________________________ = ________________

So, product D2L = Q / (Co x ns) = ____________________________ = ________________

Assuming peripheral speed of rotor π D ns = 130 , So Stator bore dia. D = ________________ m

Pole pitch Ʈ = π D / p = ____________________ _______ = _________________

47
Length of core L = ______________________ ___________= ____________m

LENGTH OF AIR GAP

Armature mmf per pole ATa = ac Ʈ / P = _________________________ =_______________________ A

Assuming short circuit ratio SCR = 0.55

No load fielf mmf ATfo = SCR x Ata = _______________________ =___________________

Taking mmf for air gap is 80 % of no load field mmf,

Mmf for air gap ATg = 0.8 x ATfo = _____________________________________ = ________________ A

Taking air gap contraction factor = 1.1 ,

Length of air gap lg = _________________________________________________ = ______________

Dia. Of rotor Dr = D- 2 lg = ________________________________ = ____________________ m

Peripharal speed of rotor Vn = π Dr ns = ____________________________ m/s

STATOR DESIGN

Flux per pole Ø = Bav x Ʈ x L = _______________________ = ________ Wb

Voltage / ph Vph = _____________________ V

Turns per phase Tph = ______________________________ = ____________________

Conductor per phase Zph = 2 x Tph = ___________________________ = __________________

Total armature conductors Z = 3 x Zph = ____________________

Assume no of slots Ss = ______________

Slot/ pole/ phase q = Ss / ( 3 P ) = _____________________ = __________________

Conductors / slot = ________________________

Stator slot pitch Yss = π D / Ss = ________________________ = ____________________ mm

48
Single layer concentric with 3 plane overhang winding is used and semi enclosed slots are used.

Magnetic Circuit :

Using combined radial and axial ventilating ducts , calculate Total core length Lc =

____________________________________________________________________

Gross iron length Ls = ________________________________________ = ____________ m

Net iron length of stator Li = ___________________ = _____________________ m

Flux in stator core Øs = ________________ = __________________ wb

Taking stator core flux density 1 Wb/ m2, area of stator core Ass = __________________ =
______________

Depth of stator core dss = ________________________ = ___________________ m

Ventilating Holes :

Considering overall efficiency = ____________ %

Output of machine = KVA rating x p.f. = ______________________ =_____________ KW

Total losses at full load = ( 1- efficiency ) x KW output = ______________________ = _____________

Calculate total area of ventilating holes in stator to keep temp .rise within limit.

49
------------------------------------------------------------------------------------------------------------------------------------------
Slot dimensions :

To control short circuit current in m/c, high leakage reactance is required & it is possible by deep slots.

Minimum width of teeth should be such that flux density should be 1.8 Wb/m2 in stator teeth.

Calculate dimensions depth and width of slot at stator core .

50
------------------------------------------------------------------------------------------------------------------------------------------
ROTOR Design :

Calculate armature mmf per pole AT a = __________________________________________ = __________A

The field mmf should be twice the armature mmf / pole,

So, Full load field mmf ATFL = ________________________________________ = __________________ A

Taking 2.5 A/mm2 current density in field winding conductor ,

Area of field winding conductor per pole = 2 x ATF / 2.5 = ______________________ mm2

No of rotor wound slots = 70 % of total rotor slots (Sr)

Calculate no. of rotor slos = ________________________________

Rotor slot pitch Ysr = π Dr / Sr = ____________________ mm

ROTOR WINDING :

Take exciter voltage = 220 V DC

Keeping 20 % voltage reserve, voltage across field coils = __________________

voltage across each field coil Ef = voltage across field coils / 2 = __________________ V

Length of mean turn of field coil Lmtf = __________________________________

______________________________________ m

Area of each field conductor af = _____________________ __________

= _____________ mm2

Area of each field conductor per pole af = _____________________ __________

= ________ _____ mm2

Wound slots / pole = ____________________________

51
Conductors / slot =_____________________________

Turns per pole Tf = _______________________________

Resistance of each field winding Rf = _________________________ = __________________Ω

Current in field winding Rf = ____________________________ = ____________________ A

So, Mmf provoded per pole = _______________________________ = ____________________ A

ROTOR SLOT DIMENSIONS :

Calculate rotor slot width :

______________________________________

____________________________________

____________________________________

_____________________________________

____________________________________

_ ______________________________________

Total slot width Wsw = ________________________

Calculate rotor slot Depth :

______________________________________

____________________________________

____________________________________

_____________________________________

____________________________________

_ ______________________________________

52
Total slot Depth dsw = ________________________

ROTOR VENTILATING HOLES :

________________________________________________________________________

_________________________________________________________________________

__________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

____________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

_________________________________________________________________________

__________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

Total area of holes in rotor = _________________________________ mm2

Result: Prepare data sheet of design of 3 phase Alternator

STSTOR side design parameters

Parameter Symbol Result

53
54
55
Conclusion:
______________________________________________________________________________

______________________________________________________________________________

_______________________________________________________________________________

______________________________________________________________________________

_______________________________________________________________________________

Quiz:

1. Define SCR and its importance in designing of synchronous machine..

56
2. Explain the difference between turbo and hydro alternator in a point of view of design.

3. What is the role of damper winding in (i) synchronous generator and (ii) synchronous motor?.

4. Explain design considerations to eliminate harmonics in synchronous machines..

57
Suggested Reference:

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

Dhanpat Rai and Sons

References used by the students: (Sufficient space to be provided)

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

58
 Experiment No: 06

Study of Computer aided design of Electrical machines

Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical
Machines
2. Formulate the optimum design problem and solve it with computer aided tools

Objectives:
(a) To obtain the knowledge about Computer aided design of Electrical machines
(b) To develop the skill of Computer aided design of Electrical machines

Equipment/Instruments:
Open source software
1. CAD-CAM
 CAD of electrical machines and power equipments
2. MATLAB

Theoty :
Various methods for Computer aided design of Electrical machines with flowcharts :

COMPUTER AIDED DESIGN OF ELECTRICAL APPARATUS

INTRODUCTION
1 Various computational tools available for the design of electrical apparatus.
• CAD-CAM
• CAD of electrical machines and power equipments
• MATLAB
2 Comprision between conventional and computer aided design of electrical apparatus.
CONVENTIONAL APPROACH CAD
DESIGN
Only 2D design is possible. Two and three dimensional can be
designed.
Storage space required is more. Reduced storage space.
Errors can happen while designing. Errorless design in electrical apparatus.
3 Limitations of conventional approach.
• Only 2D design is possible.
• Storage space required is more.
• Errors can happen while designing.
4 Major considerations for design of electrical machines.
• Specification
• Choice of materials.
59
 • Assumption of basic design parameters.
• Design process.
• Performance calculation.
• Comparison.
5 Various method of design.
• Analysis .
• Synthesis.
• Hybrid process.

The process of design by CAD follows:

1. Analysis 2.Synthesis 3.Hybrid Process

ANALYSIS:

In this process the dimensions of the machine are estimated by experience selecting
suitable volume making use of output equation and thus estimating all the dimensions of
the m/c and the performance by known methods. The performance so estimated is
compared with the desired result as specified and any divergence is eliminated by
successive iterations by making small changes in dimensions. Here computer is used as a
calculating aid.

60
 SYNTHESIS:

The process of synthesis is the exact opposite of the Analysis. Here the starting point is
the desired performance and the computer is required to work backward and determine
the optimum machine dimensions. The process involves the formulation of suitable
inverted performance equations which are differential equations connecting the
performance to the various design parameters like length, diameter, air-gap, current
density etc. The designer is also required to feed in the boundary conditions or constraints
of the equations.This method makes full use of the logic abilities of the computer and
theoretically the most desirable method for design using computer.

HYBRID PROCESS:
It is a combination of the Analysis & Synthesis and involves partial synthesis using the
standard frames, slots & conductors decided on the basis of availability in the market. It is a
practical method because it makes possible the use of standardization which is important
for economic and practical design. Since the synthesis methods involve greater cost, the
major part of the program is based upon analysis with a limited portion of the program
being based upon synthesis. This approach makes the design more practical and
economical
61
Quiz:
1. Compare convensional and computer aided design of Electrical apparatus.

2. Lists the design consideration of electrical Machines.

3. List the various computational tools available for the design of electrical apparatus.

4. Write the limitations of conventional approach of design.

5. Explain the different approaches of computer aided design of electrical apparatus

62
Suggested Reference :

“Computer Aided Design of Electrical Machines”, By K. M. V. Murthy, B.S.

Publications, 2015.

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

63
 Experiment No: 07

Study of optimization techniques in design of electrical machines

Date:

Competency and Practical Skills:

Relevant CO:
1. Select appropriate design parameters according to applications and rating of electrical
Machines
2. Formulate the optimum design problem and solve it with computer aided tools

Objectives:
(a) To obtain the knowledge of about available optimization techniques in design of electrical
machines
(b) To develop the skill of optimum design of Electrical machines

Equipment/Instruments:
Open source software
1. CAD-CAM
 CAD of electrical machines and power equipments
3. MATLAB
.
Theory :
Design Optimization of Electrical Machines
1 Introduction
Basic Procedure for Design Optimization of Electrical Machines The general process of design optimization
of electrical machines includes two main stages, design and optimization. The main aim of the design stage is
to find the feasible scheme (or several schemes) and design for a given application through the expert
knowledge and investigation of different materials and dimensions, motor types and topologies, and multi-
disciplinary analysis, etc. The analysis of this stage will provide information on the performances of the
proposed design for the development of optimization models that will be used in the optimization stage. The
main target of the optimization stage is to improve the performance of the motor proposed in the design stage
through optimization algorithms and methods. As the outcome, an optimal solution will be obtained for the
single objective design situation,
Design Optimization of Electrical Machines and some non-dominated solutions (called Pareto optimal
solutions) will be gained for a multi-objective design situation after the completion of this stage. There is no
fixed procedure for the design optimization of electrical machines. However, there are some common steps
to be followed. These steps are briefly described as follows which may also interact with each other.
Step 1: Determine the specifications from the application.
The performance requirement of the application may include the speed range, output torque/power, and
working condition, etc. These specifications will provide the instructions for the design scheme selection.
Step 2: Select/determine possible initial designs including motor types, topologies, and materials
qualitatively according to the specifications of the application. The main aim of this step is to obtain various
motor options that may be suitable for a specific application. This process is also the dimension reduction
64
process based on the expert system for the following optimization. Because the initial design is given by
going through the possible designs for an application quantitatively, the computation burden is usually
heavy. Therefore, there is a high requirement for the designer experience and the expert system on
determining the limited initial designs effectively according to the application requirement.
Step 3: Implement multidisciplinary modeling and analysis for the potential designs and evaluating the
performance included in the objectives and constraints. This process is coupled with the initial design
proposing. Due to the multidisciplinary property, the performances in terms of different disciplines have to
be investigated in this step which mainly includes electromagnetic, thermo tics reliability. economics,
mechanics , dynamics, and acoustics.
Step 4: Model the optimization problem according to the design specifications, initial designs, and
multidisciplinary performance modeling. Quantitively define the objectives and constraints and select the
design variables.
Step 5: Conduct optimization and obtain an optimal solution or some optimal solutions. The implementation
covers optimization algorithms and methods. For the optimization algorithm, the global optimum searching
ability and convergence speed are generally.
Due to the complexity of the optimization modeling and computation burden, optimization strategies and
methods are also required as effective complements for the algorithm. After the optimization, compare all
designs and output the best one with detailed design parameters and the simulated performances.
Step 6: Validate the design with prototypes and experiment results. The results will provide the verification
of the optimization and basis for the model modification for the next loop of optimization containing the
above steps until determining the final optimal design.
We conclude the design optimization into the mathematical model which can be expressed as
min : f (x)
s.t. gj (x)  0, j = 1, 2,, m
xl  x  xu

where x ,f and j g are the design parameter vector, objectives and constraints, and l x and u x are the lower
and upper boundaries of the design variables, respectively. As written with different colors, we separate the
optimization problem into four main steps, i.e. determination of the initial design, definition, and calculation
of objective and constraints, selection of design variables, optimization by algorithms. The following
introduction is about the problems in this procedure.
Selection of Design Optimization Variables Parametric optimization is widely adopted for the design
optimization of electrical machines. After the topology of the initial design is proposed, the geometry is
parameterized at first. Theoretically, all material parameters and dimensions used in the design stage can be
optimized as the design variables, such as eminence, length, width and height of PMs, radiuses of rotor and
stator, number of turns of winding and the length of the air gap, etc. optimization of the electrical machines is
to find the optimal combination of the design parameters. Even though this design variable definition method
is generally used, the drawback of the parametric optimization is obvious. On one hand, to describe a design,
there are usually tens of parameters required. The sampling number of this high dimension design problem is
huge which leads to a high computation burden. On the other hand, the optimization of freedom is limited.
Once the geometry of the initial design is parameterized,
For example, holes cannot arise in the rotor if no relevant geometry parameters are defined. Therefore, the
experience of the designer or expert knowledge is also important in this case. This problem can be made up
to some extent by defining the geometry parameters in more detail. However, the design parameter may
increase further which leads to the computational burden in the optimization process. Compared with
parametric optimization, topology optimization is regarded as the nonparametric optimization method which
aims to optimize the material layout of the initial design.
The topology optimization based on FEM takes the material property of each element as the design variable
for higher optimization freedom.
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Popular Algorithms
Optimization Algorithms
Sequential quadratic programming algorithm
Intelligent Optimization Algorithms
Gradient based Algorithms
GAs Conjugate gradient algorithm
Multi-objective optimization algorithms
PSO Algorithm,
EDAs, ant colony,
immune algorithm, and others
Evolutionary algorithms Evolution programming evolution strategy DEAs MOGA, NSGA, NSGA II,
MPSO, and others Popular optimization algorithms for the optimization of electrical machines.
The optimization algorithm is the program conducted iteratively for the optimal solution with the best
objective performance subject to the constraints. The criteria to judge the effectiveness of the optimization
algorithms includes the convergence speed and global
convergence ability.

Figure shows some popular optimization algorithms for the design optimization of electrical
machines as well as other electromagnetic devices. As shown, there are two main types, i.e. gradient-based
algorithms and intelligent optimization algorithms. As a kind of deterministic algorithm, the iteration of the
gradient-based algorithm is driven by the gradient information obtained from the objective functions and
constraints by the analytical calculation or the difference method
Generally, deterministic algorithms can quickly convergence to the local extreme point in a small number of
iteration steps. The ability to search for the global optimal solution of the deterministic algorithms cannot
generally be promised. Since the optimization problem of electrical machines belongs to the multi-objective
nonlinear mathematical programming problem, and each objective is normally a non convex function with
multiple extreme points, the stochastic algorithms or also named intelligent algorithms with the ability of
global convergence are widely utilized. First of all, various scalar or single objective intelligent optimization
algorithms have been employed for the optimization of electrical machines in the past several decades, such
as the evolutionary algorithms (EAs), particle swarm optimization (PSO) algorithms, estimation of
distribution algorithms (EDAs), immune algorithm, and ant colony algorithm, and their improvements . For
the widely used genetic algorithm (GA) and differential evolution algorithms (DEAs), they are two of four
major subclasses of EAs. The other two subclasses are evolution programming and evolution strategy. Even
though with the ability of global convergence, the convergence speed is slow compared with the gradient-
based algorithms since various iteration steps are required for global optimum searching. To solve the multi-
objective problem, the objectives are normally summed in one objective function with the weighting factor
or reflected in the constraints. Furthermore, multi-objective optimization algorithms can be applied directly.
They can provide a Pareto solution set with a single run. This solution set consists of many non-dominated
optimal design solutions for the designer to select based on a specific application
Some popular multi-objective optimization algorithms are originated from GA and PSO , such as multi-
objective GA, non dominated sorting GA (NSGA) and its improvements (NSGA II) and multiobjective PSO
algorithm
The gradient-based algorithms show faster convergence speed but poorer global convergence ability
compared with intelligent algorithms. The sensitivity of the objectives and constraints with respect to the
design variables are required for the application of the algorithms. Based on the general motor modeling
method such as FEM without explicit analytical expression, the sensitivity analysis is complex. If a
differential method is applied, the number of the FEM for each iteration should be conducted is twice of the
number of the design variables which increases the computation burden from the aspect of performance

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calculation. When some fast analytical or coarse models are applied for the optimization, the computation
time for a single sample can generally be ignored. Considering the above-mentioned reasons, the application
of pure gradient based algorithms is relatively less. The utilization of gradient-based optimization can be
found in the design problem of a very high dimension such as topology optimization. Different from
conventional gradient-based algorithms, the implementation of intelligent optimization algorithms does not
depend on the mathematical properties of the optimization models.
For example, the functions of objectives are not required to be continuous and differentiable, and to have
analytical expressions. Compared with conventional ones, intelligent optimization algorithms have many
advantages, such as global optimizing, stronger robustness and parallel searching capability. There are three
main steps in the implementation of intelligent optimization algorithms. They are population initialization
and algorithm parameter determination, individual updating and population regeneration.
Different algorithms have different algorithm parameters and strategies for individual updating and
population regeneration. However, the convergence speed is normally low for these algorithms because of
the huge amount of iterations. Moreover, we can see the works for improving both types of algorithms by
taking advantage of each other i.e. the hybrid algorithms. For example, the gradient algorithm
. For the conduction of the optimization for electrical machines, besides selecting rational performance
calculation model and optimization algorithms, the optimization methods or strategies are also important for
improving the optimization efficiency.

Conjugate gradient algorithm

Gradient
based Algorithms Sequential quadratic
programming algorithm

GAs

Evolution programming

Evolutionary algorithms
evolution strategy

optimization
DEAs
PSO Algorithm, EDAs, ant
Intelligent Optimization colony, immune algorithm,
Algorithms and others

Multi-objective optimization MOGA, NSGA, NSGA II,

algorithms MPSO, and others

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Quiz:
1. Write the optimization techniques can be used in design of electrical machines

Suggested Reference :

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

Dhanpat Rai and Sons

68
References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

69
 Experiment No: 08

Study of FEM for design of Electrical machines

Date:

Competency and Practical Skills:

Relevant CO:
1. 3D visualization of various electrical machine using open source software

Objectives:
(a) To obtain the knowledge about 3D visualization of various electrical machine using FEM
(b) To develop the skill for study & analysis of various electrical machines by 3D visualization of
using open source software

Equipment/Instruments:
1. Open source software

Theoty & practice :

PHILOSOPHY OF FEM

• The finite element method is a very versatile numerical technique and is a general purpose
tool to solve any type of physical problems.
• It can be used to solve both field problems (governed by differential equations) and non-field
problems.
• There are several advantages of FEM over FDM. Among them, the most important advantage
is that FEM is well suited for problem with complex geometries, because no special
difficulties are encountered when the physical domain has a complex geometry.
• The other important advantage is that it is easier to write general purpose computer codes
for FEM formulations.
Three different approaches are being used when formulating an FEM problem. They are:
1. Direct Approach
2. Variational Approach
3. Weighted Residual Method
Direct Approach:
The direct approach is related to the “direct stiffness method” of structural analysis
and it isthe easiest to understand when meeting FEM for the first time. The main advantage of
this approach is that you can get a feel of basic techniques and the essential concept involved
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in the FEM formulation without using much of mathematics. However, by direct approach we
can solve only simple problems.
Variational Approach:
In variational approach the physical problem has to be restated using some variational
principle such as principle of minimum potential energy. It is widely used for deriving finite
element equations whenever classical variational statement is available for the given problem.
A basic knowledge of calculus of variations is required to use variational approach. The major
disadvantage of the variational approach is that there exist many physical problems for which
classical variational statement may not be available. This is the case with most of the
nonlinear problems.In such cases variational approach is not useful. The Rayleigh-Ritz
method is an approximate method based on the variational formulation.
Weighted Residual Method:
Weighted residual method (WRM) is a class of method used to obtain the approximate
solution to the differential equations of the form

In WRM, we directly work on differential equation of the problem without relying on any
variational principle. It is equally suited for linear and nonlinear differential equations.
Weighted residual method involves two major steps. In the first step, we assume an
approximate solution based on the general behavior of the dependent variable. The
approximate solution is so selected that it satisfies the boundary conditions fo rφ. The
assumed solution is then substituted in the differential equation.

71
7.Discuss shape function.
• The shape function is the function which interpolates the solution between the discrete values
obtained at the mesh nodes.
• Therefore, appropriate functions have to be used and, as already mentioned, low order
polynomials are typically chosen as shape functions. In this work linear shape functions are used.
• For three-dimensional finite element simulations it is convenient to discretize the simulation
domain using tetrahedrons, The linear shape function of the node has the form

where i=1.2….. The coefficients, ai,bi,ci and di for each nodal basis function of the tetrahedral element

can be calculated considering the condition.

As a result, a system of equations for the unknown coefficients is obtained. This procedure has to
be repeated for all tetrahedrons of the mesh, so that the basis functions of all grid nodes are determined.
.

The calculations can be significantly simplified by carring out a coordinate transformation. A

tetrahedron in a transformed coordinate system is shown in Figure (b). Each point (x,y,z) of the

tetrahedron in the original coordinate system can be mapped to a corresponding point in the
transformed coordinate system.

which in matrix form leads to the Jacobian matrix

In this way, the nodal basis functions for the tetrahedron in the transformed coordinate system are
given by

72
These shape functions are rather simple, so that the derivatives and integrals required for
the finite element formulation can be readily evaluated in the transformed coordinate
system. Given a function f(x,y,z), the gradient in the transformed coordinates is of the

form

where the derivatives are calculated via the chain rule by

These equations can be expressed in matrix notation as

or

where is the transpose of the Jacobian matrix. Thus, the gradient in the original
coordinate system can be calculated using the transformed coordinate gradient by

Performing such a coordinate transformation significantly simplifies the practical

implementation of the FEM. The nodal shape functions in the transformed coordinates
are fixed and known in advance, thus, it is not necessary to solve the system of equations
for each element of the mesh. Only the Jacobian matrix has to be determined, and the
required calculations for the finite element formulation can be easily evaluated.
The principle of finite difference methods is close to the numerical schemes Used
to solve ordinary differential equations. It consists in approximating the differential
operator by replacing the derivatives in the equation using differential quotients. The

73
 domain is partitioned in space and in time and approximations of the solution are
computed at the space or time points.
In applying the method of finite differences a problem is defined by:
• A partial differential equation such as Poisson's equation
• A solution region
• Boundary and/or initial conditions.
An FDM method divides the solution domain into finite discrete points and replaces the
partial differential equations with a set of difference equations. Thus the solutions obtained
by FDM are not exact but approximate.
Few analytical methods for field computation.
• Time varying field in conductors.
• Charge relaxation
• Propagation of EM waves

The finite element method has its origin in the field of structural analysis. The finite elements
analysis of any problem involves basically four steps:
(A) Discretizing the solution region into a finite number of sub regions or elements ,
(B) Deriving governing equations for a typical element ,
(C) Assembling all the elements in the solution region, and
(D) Solving the system of equations obtained.

Quiz:

1. What are the advantages of FEM over FDM?

2. Compare diff. methods used for 3D visualization of Electrical Machines

74
 3. List out applications of FEM

4. Mention few analytical methods for field computation.

5. List out the general steps of finite difference method.

Suggested Reference :

75
References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

76
 AC Machine Design
3170909

Lab Manual prepared by

Prof. G.A.Patel
Asso. Prof. Electrical
G.E.C. Patan

Branch Coordinator
Dr. J.R.Iyer
Professor, Electrical Engineering
L.D. College of Engineering
Ahmedabad

Committee Chairman
Dr N M Bhatt
Professor of Mechanical Engineering
L. E. College, Morbi

77