Session SP25 Semester VI
EE465 Electrical Machine Design
Module 1
I. DESIGN OF MACHINES
Design may be defined as a creative physical realization of theoretical concepts. Engineering
application of science, technology and invention to produce machines to perform specified tasks
with optimum economy and efficiency.
The major considerations to evolve a good design are :
1. Cost
2. Durability
3. Compliance with performance criteria as laid down in specifications.
II. DESIGN FACTORS
The mechanical force required for movement in rotating electrical machines can be produced both
by electrostatic and electromagnetic fields since both the fields store energy.
In electrostatic machines, the energy density is limited by the dielectric strength of the medium
used. For example, if air is used as the dielectric medium, the maximum value of electric intensity
that can be used is 3 MV/m (on account of dielectric breakdown) which corresponds to an energy
density of about 40 J/m3.
In electromagnetic machines, magnetic effect is used for production of force and there is no
comparable restriction in magnetic fields. However, the maximum value of flux density that can be
used is about 1.6 Wb/m, because beyond this value magnetic saturation sets in the ferromagnetic
materials required to complete the magnetic circuit of the machine.
The basic structure of an electromagnetic rotating electrical machine is shown in Fig. 1.1. The
machine consists of the following parts :
1. Magnetic Circuit.
It provides the path for the magnetic flux and consists of air gap, stator and rotor tceth and stator
and rotor cores (yokes).
Fig. 1 Basic constructional details of a rotating machine.
2. Electric Circuit
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It consists of stator and rotor windings. The winding of a transformer or a rotating machine conveys
electrical energy to or from with the working region and is concerned production of emf and
development of magneto-mechanical force.
[Link] Circuit.
The dielectric circuit consists of insulation required to isolate one conductor from another and also
the windings from the core. The insulating materials are essentially non-metallic and may be
organic or inorganic, natural or synthetic.
[Link] Circuit.
The thermal circuit is concerned with mode and media for dissipation of heat produced inside the
machine on account of losses.
5. Mechanical Parts.
The important mechanical parts of a machine are its frame, bearings and shaft.
III. LIMITATIONS IN DESIGN
1. Saturation.
Electromagnetic machines use ferro-magnetic materials. The maximum allowable flux density to
be used is determined by the saturation level of the ferro-magnetic material used.
A high value of flux density results in increased excitation resulting in higher cost for the field
system.
2. Temperature rise
The most vulnerable part of the machine is its insulation. The operating life of a machine is depends
upon the type of insulating materials used in its construction and the life of the insulating materials
which in turns depends on the temperature rise of the machine. If an insulating material is operated
beyond the maximum allowable temperature, its life is drastically reduced. Proper cooling and
ventilation techniques are required to keep the temperature rise within sate limits.
3. Insulation.
The insulating materials used in a machine should be able to withstand the electrical, mechanical
and thermal stresses which are produced in the machine. The type of insulation is decided by the
maximum operating temperature of the machine parts where it is put. The size of insulation is not
only decided by the maximum voltage stress but also by the mechanical stresses produced.
4. Efficiency.
The efficiency of a machine should be as high as possible to reduce the operating costs. In order to
design a highly efficient machine, the magnetic and electric loadings used should be small and this
requires the use of large amount of material (both iron. as well as copper/aluminium). Therefore, the
capital cost of a machine designed for high efficiency is high while its running cost is low.
5. Mechanical parts.
The construction of an electrical machine has to satisfy numerous technological requirements. The
construction should be as simple as possible and also it is technologically good if it is carried cut
using simple and economical means with as little labour as possible.
6. Commutation
The problem of commutation is important in the case of commutator machines as commutation
conditions limit the maximum output that can be taken from a machine. For example, at present the
maximum power output of a single unit d.c. machine is approximately 10 MW and this limitation is
solely on account of commutation difficulties.
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7. Power factor :
Low power factor results in larger values of current for the same power and, therefore, large
conductor sizes has to be used.
8. Consumer's Specifications. The limitations imposed by consumer's specification on the design
of electric machinery are obvious. The specifications as laid down in the consumer’s order have to
be met and the design evolved should be such that it satisfies all the specification
and also the economic constraints imposed on the manufacturer.
9. Standard Specifications.
These specifications are the biggest strain on the design because both the manufacturer as well as
the consumer cannot get away from them without satisfying them.
IV. MODERN TRENDS IN DESIGN OF ELECTRIC MACHINES
The design of electrical machines is both a science and an art. A "science", because it follows
established and universally accepted physical and mathematical principles which have been verified
by the experimental methods and an "art" in that the knowledge of these principles is often
insufficient to produce a correct and economic design.
The process of design of a single machine may be divided into three major design problems,
such as:
(i) electromagnetic design, (ii) mechanical design, and (iii) thermal design.
V. MODERN MACHINE MANUFACTURING TECHNIQUES
1. Important feature of modern electrical machine manufacture is the trend to build machines which
are smaller in size and therefore involve the use of lesser material and at the same time have the
same efficiency and overload capacity.
2. The second important factor in the manufacture of modern machines is the use of magnetic
materials which have a high permeability, a low iron loss and a high mechanical strength. The
material permit use of the high values of flux density and therefore reduction in the size of the
machine and promote the extension of the power output.
3. There has been a significant improvement in the insulating materials and newer materials are
increasingly being used in the present day machines. These insulating materials are able to
withstand much higher temperatures. Since, the rating of the machine mainly depends upon the
insulating materials used in it, greater outputs are possible with the use of these insulating materials.
In other words, the use of better class of insulating materials allow the smaller machine sizes to be
used for the same output ratings.
4. Different improved and refined manufacturing techniques are used for individual machine parts
which expedite the process of machine manufacturing.
Optimisation:
Optimization is used in electrical machine design to achieve the best possible performance while
satisfying various constraints and requirements. The goal of optimization in electrical machine
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design is to find the most efficient and cost-effective solution that meets specific performance
criteria. Here are some key reasons why optimization is employed in electrical machine design:
Efficiency Improvement: Optimization helps in maximizing the efficiency of electrical machines.
Higher efficiency means that the machine can convert more of the input electrical power into useful
mechanical power or vice versa, resulting in reduced energy losses and improved overall
performance.
Cost Reduction: Optimization helps in minimizing material usage and manufacturing costs while
maintaining or improving performance. This is important for making electrical machines more
economically competitive in the market.
Size and Weight Reduction: Optimization can be used to design machines with reduced size and
weight without compromising performance. This is particularly important in applications where
space and weight constraints are critical, such as in electric vehicles or portable devices.
Meeting Design Constraints: Designing electrical machines involves dealing with various
constraints such as temperature limits, mechanical stresses, and magnetic field requirements.
Optimization techniques help in finding solutions that satisfy these constraints, ensuring the
machine's reliability and durability.
Customization for Specific Applications: Different applications may have specific performance
requirements. Optimization allows designers to tailor the machine's characteristics to meet the
unique needs of a particular application, whether it's high torque, high speed, or a combination of
different performance parameters.
Reducing Noise and Vibration: Optimization can be used to minimize noise and vibration levels
in electrical machines, which is crucial in applications where quiet operation is essential, such as in
household appliances or electric vehicles.
Environmental Considerations: Optimized designs can lead to more energy-efficient machines,
contributing to a reduction in overall energy consumption and environmental impact. This is
increasingly important as energy efficiency and sustainability become key considerations in
engineering design.
Different optimisation techniques are, Genetic Algorithm, Particle Swarm Optimisation
Reference:
Sawhney, A. K., and A. Chakrabarti. Course in electrical machine design. Dhanpat Rai, 2006.