Course Title: Design of Electrical Machine

Introduction to Electrical Machine

Dr. Sulieman Eldoud Bashir

DESIGN OF ELECTRICAL
MACHINES

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Introduction

2
🞂 Engineering Design
 an application of Science & Technology and

Invention to produce Machines

 to perform specified tasks with optimum
economy and efficiency

3
Major Consideration to Evolve a Good Design

 Cost
 Durability
 Compliance with Performance Criteria

4
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.

IM : 20 to 30 Years - Low Initial Cost

SM & Trs : Designed with Reliability and Durability Low Initial
Cost

5
Classification of Design Problem

Basic components of design of electric machine

 Design Factors

Basic structure of Rotating Electrical Machines

 Magnetic Circuit
 Electric Circuit
 Dielectric Circuit
 Thermal Circuit
 Mechanical Parts

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Magnetic Circuit
Provide path for
 magnetic flux an consist of Air gap
 Stator and Rotor Teeth and
 Stator and Rotor Core(yokes)
Electric Circuit
 Stator and Rotor Winding
 Winding of a Trs., Rotating M/c. conveys energy and
is concerned with Production of emf and
Development of mmf.

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Dielectric Circuit
 To isolate one conductor from another conductor and also
the windings from the core.
 Insulating Materials are Non –Metallic, Organic,
inorganic, natural or Synthetic.
Thermal Circuit
Mode and Media for dissipation of heat produced inside the
machine on account of losses.

Mechanical Parts
Frame, Bearings and Shaft

** A successful Design brings out an economic compromise for

space occupied by iron, copper, Al., insulation and coolant.

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Limitation in Design
 Saturation
 Temperature Rise
 Insulation
 Efficiency
 Mechanical Parts
 Commutation
 Power Factor
 Consumer Specifications
 Standard Specifications

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Constraints of Design (Limitation)
Saturation
Electrical M/c use Ferro Magnetic materials -Bmax – Increased
Excitation resulting in higher cost for the field system.
Temperature Rise
 Cooling and ventilation –required to keep the temperature rise
in safe limits.
 Coolant become excessive.
Insulation
 Able to withstand the electrical, mechanical and thermal
stresses.
 Type of insulation – decided by maximum temperature.
 size of insulation - decided by maximum voltage stress and
mechanical stress.

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Efficiency
The capital cost of a M/C designed for high efficiency is high while
its running cost is low.
Mechanical Parts
 Mechanical stresses at the bottom of rotor teeth do not exceed the
maximum allowable limit – Turbo Alternator.
 Air gap length as small as possible to maintain high power factor- IM

 Bearings of rotating M/Cs are subjected to the action of rotor weight,

external loads, Inertia forces.
Commutation
Commutation conditions limit the maximum output.
Power Factor
Poor PF results in larger values of current for the same power – larger
conductor sizes have to be used.
Size and cost of IM reduced by using Bmax which leads to saturation
of iron parts and poor PF.

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Consumer’s Specification
Specification laid down in the consumer’s order have to be met and
the design evolved should be satisfies all the specifications and also
the economic constraints imposed on the manufacture.
Standard Specification
These specifications are the biggest strain on the design because the
manufacture as well as the consumer cannot get away from them
without satisfying them.
Modern Machine Manufacturing Techniques
**Wide range of power output
Small size Machines – M/cs having power o/p of 750watts.
Medium size Machines - power o/p of few KW to 250KW.
Large size Machines - power o/p of 250KW to 5000KW.
Larger size Machines - power o/p as high as hundreds of megawatt.

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🞂 Trend to build machines which are smaller in size.
Using lesser materials without sacrificing their
efficiency and capacity.
 Modern M/c – Magnetic materials having high permeability,
low iron loss and high mechanical strength.
 improvement in the insulating materials
 Marked with the use of higher electro magnetic loadings for
active parts and increased mechanical loadings
 Different and refined manufacturing techniques are used
for individual machine parts.
 M/cs are operates satisfactorily under the desired
environmental conditions.
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 According to Size:
◦ Small Size : up to 750 Watts
◦ Medium Size : up to 250 KW
◦ Larger Size : 250 KW to 5000KW
 According to speed:
◦ Low speed : < 500 r.p.m.
◦ Medium speed: 500 to 1000 r.p.m.
◦ High speed / Turbo: > 1000 r.p.m.
🞂 SIEMENS
🞂 ABB
🞂 KIRLOSKAR
🞂 GEC
🞂 BHEL
🞂 INDO TECH
🞂 GD Electricals
 Dimensions and Rating of Machines
Output Equation
 The output equation for DC and AC machines is derived in the following sections.
 The output equation relates the main dimensions of any rotating machine to its power
rating.

DC Machine
 In general, the output power developed by a DC machine is given by

 Emf induced in armature of DC machine is given by

where φ – flux, p – number of poles, Z – number of armature conductors, N – speed in r.p.m,
n – speed in r.p.s, A – number of parallel paths in which conductors are connected.
Also, current in each conductor is given by
where Ia – Total armature current
Substituting Eqs.

Rewriting the above equation, we get

From the above equation, the terms ‘ pφ ’ and ‘ IzZ ’ can be related to specific
magnetic, which is defined as average flux density over the air gap of an electric
machine and specific electric loading, which is defined as total number of
armature ampere conductors per metre of armature periphery at the air gap of
an electric machine by
Substituting Eqs.

where Co = π2Bav ac and is called the output coefficient. Equation is the output
equation of DC machine.
Total Magnetic loading
Total flux around the armature periphery at the air gap.
= PØ

Total Electric loading

Total [Link] armature conductors around the armature
periphery.

= IzZ
 AC Machine
 In general, the output power developed by a three-phase AC machine is given by

 From machine design point of view, it is required to express the above equation in terms
of main dimensions [diameter, D and length, L], specific electric and magnetic
loading and speed of operation.
 Emf induced per phase of three-phase AC machine is given by

where f – frequency, φ – flux, Tph – total number of turns per phase,

Kws – winding factor.
Consider number of parallel paths, A = 1,
Substituting Eqs.

Substituting Eq. in the above equation, we get

 Rerranging the terms in the above equation, we get

From the above equation, the terms ‘ pφ ’ and ‘ IzZ ’ can be related to specific magnetic and
specific electric loading by
Specific magnetic loading,

Specific electric loading,

Substituting Eqs

where Co = π2Bavac Kws and is called the output coefficient. Equation is the output equation
of AC machine.
🞂 Every section of armature is capable of carrying certain
amount of current. Hence ampere- turn per unit section of
armature periphery is an important parameter to estimate the
intensity of electric loading

ac =(Total Armature ampere conductors) / Armature periphery

at air gap
= (Iz Z)/πD
🞂 Copper loss: Higher the value of ac
- larger will be the number of armature of conductors which
results in higher copper loss.
- This will result in higher temperature rise and reduction in

efficiency.

Voltage: A higher value of ac

- can be used for low voltage machines

- since the space required for the insulation will be smaller.

🞂 Synchronous reactance: High value of ac leads to
- higher value of leakage reactance and armature reaction and
hence higher value of synchronous reactance.
- Such machines will have
poor voltage regulation,
lower value of current under short circuit condition
low value of steady state stability limit and
small value of synchronizing power.
🞂 Stray load losses: With increase of q =>stray load losses will increase.

Values of specific magnetic and specific electric loading can be selected from
Design Data Hand Book for salient and non salient pole machines
🞂 Each unit area of armature surface is capable of receiving a
certain magnetic flux. Hence Ф/A is an important parameter to
estimate the intensity of magnetic loading.

Bav = Total flux around the air gap/Area of flux path at the air
gap
= PØ/πDL
🞂 Iron loss: A high value of flux density in the air gap leads to higher value of
flux in the iron parts of the machine which results in
- increased iron losses and
- reduced efficiency.

🞂 Voltage: When the machine is designed for higher voltage

- space occupied by the insulation becomes more
- making the teeth smaller and hence
- higher flux density in teeth and core.
🞂 Transient short circuit current: A high value of gap density results in
- decrease in leakage reactance and hence
-increased value of armature current under short circuit conditions.
🞂 Stability: The maximum power output of a machine under steady state
condition is indirectly proportional to synchronous reactance.
- If higher value of flux density is used it leads to smaller number of
turns per phase in armature winding.
- This results in reduced value of leakage reactance and hence
increased value of power and hence increased steady state stability.
🞂 Parallel operation: The parallel operation of synchronous generators depends
on the synchronizing power.
- Higher the synchronizing power higher will be the ability of the
machine to operate in synchronism.
-The synchronizing power is inversely proportional to the
synchronous reactance and hence the machines designed with higher
value air gap flux density will have better ability to operate in parallel
with other machines
Electrical Engineering Materials
Electrical Engineering Materials
Material serving as electrical conductors can be divided
into 2 groups
 High Conductivity Materials
 High Resistivity Materials
High Conductivity Materials
Used for making windings required in electrical Machines,
apparatus Devices and Transmission & Distribution of
Electrical Energy.
Least possible Resistivity
High Resistivity Materials
Used for making Resistances and Heating Devices
Constituent materials of an electric machine
🞂 To avoid any electrical activity between parts at
different potentials, insulation is used
🞂 Properties:

• High Dielectric strength

• High resistivity
• Good thermal conductivity
• High degree of thermal stability
• Low dielectric loss
• Good mechanical properties
• Ability to withstand moisture, chemical, heat etc.,
Properties of insulating materials
Class Temperature (o C)
Limit
Y 90
A 105
E 120
B 130
F 155
H 180
C > 180
🞂 Class Y :Cotton, Silk, Paper, Cellulose, Wood
🞂 Class A :Cellulose esters, Insulating Oil,
Laminated Wood, Varnished paper
🞂 Class E :Synthetic resin enamels, Cotton & Paper
laminates with fromadehyde bonding
🞂 Class B : Mica, Glass fibre, Asbestos with bonding
and laminates
🞂 Class F : Materials of class B with suitable bonding of
higher thermal stability
🞂 Class H : Mica, Glass fibre and Asbestos with silicon
resins.
🞂 Class C : Ceramics, Quartz
 Magnetic Materials
 Magnetic materials are an integral part of any
electric machine, used in electro-mechanical/
magnetic energy conversion.
 They also provide structural strength to the
electric machine.
 Magnetic materials are classified based on the
relative permeability (μn) or magnetic
susceptibility (Xm) into three broad categories.
Ferromagnetic materials
 The relative permeability is largely greater than one (μn >> 1) very large positivesusceptibility, e.g., iron, nickel,
cobalt, alnico.
 Magnetization of these materials is easy and retain considerable amount of it when removed from magnetic
field.
 They are affected by high temperatures and they have nonlinear B-H curve.
 Ferromagnetic materials are of great significance in contribution towards manufacturing of electric machines.

Diamagnetic materials
The relative permeability is less than or equal to one (μn ≤ 1), i.e., very small negative susceptibility, e.g., copper,
silver, gold.

Paramagnetic materials
The relative permeability is slightly greater than or equal to one (μn ≥ 1), i.e. very small positive susceptibility, e.g.,
air, platinum, tungsten. Paramagnetic materials are temperature dependent.
Note: Diamagnetic and paramagnetic materials have linear B-H characteristics and are largely non-magnetic.
Classification of magnetic materials based on hysteresis loop
Types of Duties and Ratings
 Duty is defined as the load(s) to which the machine is subjected, including, if
applicable starting, electric braking, no-load and rest and de-energized
periods, and their durations and sequence in time.
 The types of duties as per IS 4722-1968
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