CERTIFICATION OF APPROVAL

DESIGN DIRECT-CURRENT (DC) MOTOR USING MATLAB

By

Syahrul Ashikin Azmi

A project dissertation submitted to the

Electrical & Electronic Engineering Programme
Universiti Teknologi PETRONAS
In partial fulfillment of the requirement for the
Bachelor of Engineering (Hons)
(Electrical & Electronics Engineering)

Approvol ~
/W~'-
-----~"'----Nursya.rinl Mohd Nor
Lecturer
Mr. Nursyarizal Mohd. Nor Eie.ctric~l. Engineering Deputment
Umverslti Teknologi PETRONAS
31750 Tronob
Project Supervisor Pf!ri\k

UNIVERSITI TEKNOLOGI PETRONAS

TRONOH, PERAK

June 2004
 CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the

original work is my own expect as specified in the references and acknowledgements,

and that the original work contained herein have not been undertaken or done by

unspecified sources or persons.

I
 ABSTRACT

Electrical machine is a practical and dominant medium for achievement of productivity

improvement. DC motor is defined when a machine reverses the conversion process to
absorb energy in electrical form and reformat the energy to mechanical form on a
sustained basis. As the field of industrial application of direct current is very wide, DC
machine are produced both generators and motors, which suit for a large range of output
powers, voltages, speeds and other. Therefore, an adequate design in de motor is
essential in order to meet the industrial practitioners' requirement. This study basically
deals in designing de motor based upon the customer specification using interactive
computer software, MATLAB programming. The student is acted as the designer whom
is requested by the customer to design a de motor which produce correct simulation
outcomes in order to meet the desired specifications. The project mainly concentrates
on performing and formulating the required MATLAB programming added with C++
coding. The generated programs will demonstrate the plot-curves analysis of shunt
excited de motor design. An accurate de motor design is reflected from the curves
performed, whether it meet the performance specification or otherwise. MATLAB is
fully utilized as the main tool to complete this area of study. As the initial stage of the
study, iterative procedures have to be followed in designing the motor. The calculations
for all parameters in each design stages need to be performed using the correct
equations. The frame designation and units are referred to international standardization,
which is NEMA MG-1 Standard. In order to enhance understanding of the conceptual
design, literature review and theory is conducted concurrently with endeavor MATLAB
programming. As continuous from preliminary stage, the study then focuses on
application using MATLAB in order to perform the required analysis. Compared to
previous design of de motor, the NEMA frame designation and field winding
arrangement play significant roles in differentiating the desired plot-curve
representation.

11
 ACKNOWLEDGEMENT

Firstly, I would like to express my gratitude to God, for His grace I was able to
accomplish this project. I believe He has blessed me with sufficient strength and
wisdom for me to carry out and complete this project.

My heartfelt thank goes to my supervisor, Mr, Nursyarizal Mohd. Nor for his
continuous guidance and outstanding support that lead to the accomplishment of this
project. Under his supervision, I was able to learn many new things especially on the
subject regarding my project. I am very much indebted to him for the resources and
precious time that he had provided me throughout the year. Truly, his generous
guidance and help has put a light on my path in carrying out the project. Your sharing of
knowledge, kindness and patience will always be appreciated.

My sincere thanks to Mr. Russin Ibrahim ofUTP Information Resource Center for his
willingness to help me in finding materials regarding my project despite of his busy
schedule. Special thanks to Mr. Yassin ofUTP Power System Lab for his cooperation
and teaching me about the construction of DC machine and also for sharing his
information on the project topic.

I wish to thank my best friend Nukman Hussain, my roommates Suraya Hanim

Abdullah Sani, my family, my housemates and my classmates who showed their
concern and willingness to help for the success of my project from the beginning until
the end. Your prayers, words of wisdom, encouragement and support have helped me
through times where the path seemed to lead to a dead end. From deep inside my heart,
thank you.

I would like to thank individuals such as the lab technicians, other lecturers and students
whose names are not mentioned but involved directly or indirectly in the success of my
project.

111
 TABLE OF CONTENTS

CERTIFICATION .

ABSTRACT. 11

ACKNOWLEDGEMENT . l1l

TABLE OF CONTENTS IV

LIST OF FIGURES . Vlll

LIST OF SYMBOLS IX

CHAPTER!: INTRODUCTION . 1
1.1 Background of Study . 1
1.2 Problem Statement 2
1.3 Objectives and Scope of Study 3

CHAPTER2: LITERATURE REVIEW AND THEORY 5

2.1 DC Motor Construction 5
2.2 Torque. 8
2.3 Torque, voltage and current relationship
of motor operation 9
2.4 Production of magnetic field . 9
2.5 Magnetic Behaviour of ferromagnetic
Materials 11

IV
CHAPTER3: METHODOLOGY I PROJECT WORK 14
3.1 Research 14
3.1.2 Research on DC Motor Design Theory 14
3.2 Perform Calculations of All Parameters for Every
Design Stages 14
3.3 Discussion with Supervisor 14
3.4 Implementation (MATLAB Programming) 14
3.5 Descriptions of Each DC Motor Design Stages 17
3.5.1 1st stage: Specification 17
3.5.2 2nd stage: Volume and Bore Sizing 17
3.5.3 3'd stage: Armature Design 17
3.5.4 4th stage: Field Pole Design 17
3.5.5 5th stage: Saturation Curve Analysis 17
3.5.6 6th stage: Field Winding Analysis 18
3.5.7 7th stage: Performance Analysis 18
3.5.8 8th stage: Mechanical Classification 18
3.6 Tool Required. 19
3.6.1 MATLAB Software 19

CHAPTER4: RESULTS AND DISCUSSION 20

4.1 Specification 21
4.2 1st stage: Volume and Bore Sizing 21
4.2.1 Developed Rated Torque (tdR) 21
4.2.2 Armature Diameter (d) 22
4.2.3 Armature Stack Length (/a) 22
4.3 Armature Design 23
4.3.1 Number of Armature Slots 24
4.3.2 Voltage and Torque Constant. 25
4.3.3 Rated Current and Flux per Pole 26
4.3.4 Slot Design 27
4.3.5 Coil Characteristic 29

v
 4.3.6 Flux Density Check 32
4.3.7 Commutator Design 35
4.4 Field Pole Design 37
4.5 Magnetic Circuit Analysis 40
4.5.1 B-HCurves 41
4.5.2 Magnetization Curve of DC Motor 43
4.6 Field Winding Design 45
4.7 Performance Analysis 47
4.7.1 MATLAB Outcomes for Performance
Analysis 47
4.8 Discussion 50
4.8.1 Motor Characteristic 51
4.8.2 DC Shunt Motor Performance 51
4.8.3 Speed-Torque Characteristic Curve 52
4.8.4 Speed-Current Characteristic Curve 54
4.8.5 Speed-Output Power Performance Curve 55
4.8.6 Speed-Efficiency Performance Curve. 56

CHAPTERS: CONCLUSION AND RECOMMENDATION 57

REFERENCES 59

APPENDIX A 60

APPENDIXB 61

APPENDIXC 62

APPENDIXD 63

APPENDIXE 69

Vl
APPENDIXF 70

APPENDIXG 71

APPENDIXH 73

APPENDIX I 75

Vll
 LIST OF FIGURES

Figure 2.1: DC Motor Construction 5

Figure 2.2: Concept of a Commutator 6
Figure 2.3: DC Motor Stator Construction 6
Figure 2.4: DC Motor Rotor Construction 7
Figure 2.5: Commutator of a Large DC Motor 8
Figure 2.6: Magnetic Core. 10
Figure 2.7a: DC Magnetization Curve for Ferromagnetic Core 13
Figure 2.7b: Magnetization Curve of Flux Density vs. Magnetizing Intensity 13
Figure 2.8: Magnetization curve a typical piece of steel 16
Figure 3.1: Logic flowchart of de motor design 12
Figure 4.1: Armature Slot Section View 27
Figure 4.2: Armature Coil End Tum 30
Figure 4.3: Field Pole Span of Teeth 33
Figure 4.4: Commutator Design from End View and Side View . 35
Figure 4.5: Frame Section 37
Figure 4.6: Field Pole Shape 39
Figure 4.7: Magnetization Curve for M-22 ESS, 26-gage 42
Figure 4.8: Magnetization Curve for AISI 1010 Steel Frame 42
Figure 4.9: Experimental Setup for Armature Reaction Determination 44
Figure 4.10: OCC Showing Armature Reaction for 1200 rpm Speed 44
Figure 4.11: Magnetization Curve of DC Motor 45
Figure 4.12: MATLAB Speed vs. Torque Curve 47
Figure 4.13: MATLAB Speed vs. Armature Current Curve 48
Figure 4.14: MATLAB Speed vs. Output Power Curve 48
Figure 4.15: MATLAB Speed vs. Efficiency Curve 49
Figure 4.16: Shunt DC Motor Equivalent Circuit . 50

Vlll
 LIST OF SYMBOLS

Developed Torque
K e.m.f constant or torque constant
<Pp Total magnetic flux flowing from a field pole to armature core
fa Armature current
H Magnetic field intensity produced by the current Iaet
dL Differential element of length along the path of integration
lc Mean path length of the core

f1 Magnetic permeability of material

B Resulting magnetic flux density produced
dA Differential unit of area
A Cross-sectional area of the core
v, Rated Terminal Voltage
hpR Rated Output Power
Speed at rated load

1'/R Goal Design Efficiency

nm Maximum speed at rated load

f Frequency
p Number of poles
Developed rated torque
d Armature diameter

a Armature stack length

Outside frame diameter
Frame thickness
Normalized sizing value.
N Number of armature slots
Number of multiple per slot.
Total conductors for the armature winding
Voltage constant
Torque constant

IX
a Number of lap winding
faR Rated condition current

cp pR Rated condition flux per pole

Sa Stator conductor cross-section area

a Typical value of allowable stator current density for air-cooled machine
b, Armature slot width
Armature conductor with bare copper width
d, Slot depth
Gap between each adjacent coil
Armature coil depth at lower end-tum
Armature coil depth at upper end-tum
Width of each coil
Gap between coil at lower end-tum
Armature coil span for each tum
a Angle of end-tum overhang
OH Complete end-turn overhang
MLTa Mean length tum of an armature coil
Ra Armature Resistance
p Copper resistivity
T Estimated average conductor temperature
Bcm Apparent flux density at the tooth root
w,, Width of armature tooth
SF Stacking factor
1Jf Pole arc-to-pole pitch ratio
<p Number of armature slots spanned by the pole arc
m An integer (1,2,3, ..... )
,\ Armature slot pitch
Kc Number of commutator bars
de Commutator brush surface diameter
tb Brush dimension
W& Width of a single brush

X
 b Brush current density for rated load
nb Number of brushes per set
c5 Air gap length
c5e Effective length of the air gap
LF Leakage factor.
B1 Field flux density
A1 Cross-sectional area of frame perpendicular to flux flow
w1 Armature coil overhang
fJ Frame thickness
hp Height of field pole
"' Pole shank of field pole shape
sh Pole shoe length of field pole shape
w,k Width of pole shank
Ba Apparent tooth flux density at tooth ferromagnetic material
k, Permeability of the parallel air path
A3 Slot pitch at one-third the tooth depth
w13 Tooth width at one-third the tooth depth
mmJ;, Magnetomotive per pole
MLT1 Mean length turn ofthe field winding

Rfp Field resistance per pole

Rf Field resistance of a series connection

If Field current
Nf Number of field turns
TFW Friction and windage torque
Wm Motor Speed
PFw Mechanical rotational losses
Ea Internal generated voltage
'find Induced Torque
Pin Input Power
Pout Output Power

Xl
 CHAPTER!

INTRODUCTION

1.1 Background of study

The electric machine age can be traced to 1831 with the invention by Michael Faraday
of the disk machine-a true de machine. Electric machines remained largely a laboratory
and demonstration curiosity until the 1870s when Thomas Edison began commercial
development of the de generator to support house electrical power distribution. A major
milestone in the history of electric machine was the patent of the three-phase induction
motor by Nikola Tesla in 1888. Practical electric machines are bilateral energy
converters that use an intermediary magnetic field link. When a machine reverses the
conversion process to absorb energy in electrical form and reformat the energy to
mechanical form on a sustained basis, it is called a motor.

DC machines can be thought of as a dying breed, but death will come slowly. Prior to
the development of reliable, high-power solid-state switching devices, the de motor was
the dominant electric machine for all variable-speed motor drive applications. Even
though "power electronic revolution" has led a significant shift from de motor to
adjustable-speed induction motor, this scenario not in possession of the facts that de
motor still become a machine of choice. Electric motors exist to convert electrical
energy into mechanical energy. This is done by two interacting magnetic fields -- one
stationary, and another attached to a part that can move. DC motors have the potential
for very high torque capabilities (although this is generally a function of the physical
size of the motor), are easy to miniaturize, and can be "throttled" via adjusting their
supply voltage. DC motors are also not only the simplest, but the oldest electric motors.
Due to the wide spear application of de motor, it is crucial to comprehend the
construction and underlying basis of the machine. Thus, designing de motor is an
eminent stage to allow concise presentation of basic processes and procedures
underlying.

I
The designing process comprehends MATLAB programming as an essential tool in
developing the design based on specification given. MATLAB is an integrated teclmical
computing environment with combinations of numeric computation, advanced graphics
and visualization, and a high-level programming. This software handles tedious
calculation arising in electrical machine analysis. As a consequence, more exact de
motor design can be retained for analysis rather than the approximate design commonly
introduced for the sake of computational simplicity. The MATLAB software will be
programmed to generate outcomes result-plot in speed-torque, speed-line current,
speed-output power and speed-efficiency curves of de motor design to allow assessment
with regard to performance specification. In preliminary stage, a literature review of the
project is conducted as the initial cornerstone or underlying concept for development of
de machine. Subsequently, this study concentrates in performing calculations for each
stage of design. A good understanding of the relationship and characteristic of the
applied equations has to be achieved throughout the project. All the design procedures
have to follow a standard guideline which is National Electrical & Manufacturer
Association (NEMA) Standard MG-1. These guidelines can be organized into
nameplate, environment and mechanical subdivisions. NEMA frame designations
standardize envelopes and mounting dimensions, assuring interchangeability of motor.
After completing all those phases, MATLAB programs are formulated to produce plot-
curves analysis by associating all the parameters in each de motor design phase.

1.2 Problem statement

DC machine turns out to be the most economical choice in the automotive industry for
cranking motors, windshield wiper motors, blower motors and power window motors.
DC machines already installed in areas where they are not presently the choice for new
installations, yet still have many years of service life remaining. Thus, study on de
machine design is in order for enhancing acquaintance in the teclmical field. Besides of
that, due to it's widely application in the industry, lots of demand on purchasing the
machine still on-going. Therefore, in this. project, a good invent of de motor is needed to
be performed and significantly has to fulfill industrial practitioners' requirement. The

2
student act as the developer or designer to design de motor based on the performance
specifications which are given by the customer or user. In addition, the design of the
motor must meet international standardization, NEMA MG-1 and IEEE standards. The
outcome of the design will be interpreted using MATLAB programming. MATLAB is a
tool to ease the analysis intensity without a sacrifice in accuracy. The significant of the
project is to ease to user to view and make analysis using MATLAB based upon the
specifications that being given to the developer. Besides, it also provides an adequate
reference for future developers in designing and makes comparison, as well as enhances
improvement of the current design.

1.3 Objectives and Scope of Study

The objectives of this project are:

1. To study on basic processes and procedures underlying in designing a de
machine.
2. To perform required calculations for each design stages for MATLAB data
input.
3. To design a de motor that meets the specifications given and also follows
national standardization (NEMA Standard MG-1) frame designation.
4. To generate programming or coding that engenders the required de motor
analysis using MATLAB software.
5. To simulate plot-curves result of the design to allow assessment with regard to
the performance specifications.

The scope of this project is to study on the procedures required to design a de motor. A
logic flowchart is illustrated in Figure 3.1 as a basic guideline is used throughout the
designing process. The procedures include volume and bore sizing, armature design,
field pole design, magnetic circuit analysis, field winding design and finally
performance analysis. Each design stages have its parameters that have to be understood
and calculated. All calculations accomplished in each stage is included and tested in
computer aided tool, namely MATLAB. The comparison between the manual and
MATLAB calculations are compared respectively to check error if any. There are some

3
assumptions need to be considered in conjunction with result a good design practice.
Besides, general understanding on standardization of overall design and also on the
specific components in constructing de motor is essential to make the design successful.
The major part in this project is to formulate MATLAB programs to generate the
correct plot-curves which suit the performance specifications. If the result does not meet
the desired performance, the design then must be iterated by doing modification in the
previous design stages.

Due to MATLAB application, therefore familiarization and learning process on

MATLAB are done concurrently with the literature review of de motor. Trial and error
method also used in generating the coding if there is error happened. The MATLAB
program will plot the speed-efficiency, the speed-torque, the speed-current and
magnetization curves for the motor design to allow assessment based on the
performance specification given by the user. Thus, MATLAB program with addition of
C++ language has to be generated successfully to produce the outcome stated above.
Furthermore, the project has become feasible to be carried out in the scope and
timeframe given.

In addition, in accomplishing this project, problems such as absence or inadequacy of

equipment or tools is barely possible as the project focuses mainly on design study and
programming using MATLAB, in which the software is readily available.

4
 CHAPTER2

LITERATURE REVIEW AND THEORY

2.1 Construction of DC Motor

The stator of the DC motor has poles, which are excited by DC current to produce
magnetic fields. The rotor has a ring-shaped laminated iron-core with slots. Coils with
several turns are placed in the slots. The distance between the two legs of the coil is
about 180 electric degrees. Figure 2.1 illustrates a typical de motor construction that
includes rotor, brush, stator with poles and field winding arrangement.

Held

LJ~~~~~l...:~ S'tzrtor with

Brush with pates

Figure 2.1: DC Motor Construction

The coils are connected in series. To keep the torque on a DC motor from reversing
every time the coil moves through the plane perpendicular to the magnetic field, a split -
ring device called a commutator is used to reverse the current at that point. The
commutator illustrates in Figure 2.2 consists of insulated copper segments mounted in a
cylinder. The electrical contacts to the rotating ring are called "brushes" since copper
brush contacts were used in early motors. Modem motors normally use spring-loaded
carbon contacts, but the historical name for the contacts has persisted. Two brushes are

5
pressed to the commutator to permit current flow. The brushes are placed in the neutral
zone (magnetic field is close to zero) to reduce arcing.

I_

I
Insulator

[+

Figure 2.2: Concept of a Commutator

Figure 2.3 illustrates the stator of a large DC machine with several poles. The interpoles
reduce the field in the neutral zone and eliminate arcing of the commutator. A
compensation winding is placed on the main poles to increase field during high load.
The iron core is supported by a cast iron frame.

Intel pore

C:omp~nsa.tiOn
wihding

Figure 2.3: DC Motor Stator Construction

6
The following Figure 2.4 illustrates the rotor of a DC machine. The rotor iron core is
mounted on the shaft. Coils are placed in the slots. The ends of the coils are bent and
tied together to assure mechanical strength. The commutator mounted on the shaft
consists of several copper segments, separated by insulation.

Figure 2.4: DC Motor Rotor Construction

Figure 2.5 illustrates the commutator of a large DC machine. The segments are made
out of copper and mica insulation and placed between the segments. The end of each
segment has a flag attached. The coil endings are welded to these flags. An insulated
ring is placed on the coil ends to assure proper mechanical strength.

7
 Figure 2.5: Commutator of a Large DC Motor

A DC motor is rarely installed in a situation where it is required to run at constant speed

under constant load, since an AC induction motor performs such duties satisfactorily,
costs only a fraction of the price of a DC machine of equal power and speed and
requires minimal maintenance.

Many simple variable-speed systems are inherently stable in operation, so that the
steady-state behaviour of a DC motor is frequently all that an engineer needs to take
into consideration. For simple systems, a DC shunt motor excited from a single source
is often satisfactory and provides a reasonable range of adjustable speed and torque. [1]

2.2 Torque

Magnetic lines of force flow in a direction of north to south between the poles of the
stationery magnet. When magnetic lines of flux flow in the same direction, they repel
each other. When they flow in opposite directions, they attract each other. The magnetic
lines of flux around the conductors cause the loop to be pushed the direction shown by
the arrows. This pushing or turning force is called torque and is created by the magnetic
field of the pole pieces and magnetic field of the loop or armature.

8
Two factors determine the amount of torque produced by a direct current motor:
1. Total magnetic flux flowing from a field pole to armature core
2. Armature current of the respective pieces

The developed torque, <d, is represented in a given formula:

l"d = KfP p/a • ............................................. (2.1)
Where:
K e.m.f constant or torque constant
(/>P Total magnetic flux flowing from a field pole to armature core
Ia Armature current
One characteristic of a direct current motor is that it can develop torque at 0 rpm. [2]

2.3 Torque, voltage and current relationship of motor operation

If a load is connected to the motor, it must furnish more torque to operate the load. This
causes the motor to slow down. When the motor speed decreases, the rotating magnetic
field cuts the rotor bars at a faster rate. This causes more voltage to be induced in the
rotor and therefore, gained more current. The increased current flow produces a stronger
magnetic field in the rotor, which causes more torque to be produced. The increased
current flow in the rotor also causes an increased current flow in the stator. This is why
motor current will increase as load is added. [2]

2.4 Production of magnetic field

The basic law governing the production of a magnetic field by a current is Ampere's
Law:
f H. dL = lnet ......... ..................................... (2.2)
Where:
H Magnetic field intensity produced by the current Inet
dL Differential element oflength along the path of integration

9
In SI units, I and H are measured in ampere and ampere-turns per meter respectively.
Figure 2.6 shows a rectangular core with a winding of N turns of wire wrapped about
one leg of the core. If the core is composed of iron or other similar metals, essentially
all magnetic field produced by the current will remain inside the core, so the path of
integration in Ampere's Law is the mean path length of the core lc. The current passing
within the path of Inet is Ni, since the coil of wire cuts the path of integration N times
while carrying current i. Thus, the law becomes:
Hlc = Ni .. ................................................. (2.3)

H =z: ...................................................
Ni
(2.4)

t'tu\'\--~.l<'d)1Jlkt!
;tre.: A

Figure 2.6: Magnetic Core

The magnetic field intensity H is in sense a measure of the effort that a current is
putting into the establishment of a magnetic field. The strength of magnetic flux
produced in the core also depends on the material of the core which typically
ferromagnetic material. The relationship between H-field and the resulting magnetic
flux density, B produced within a material is given by:

B =pH ................................................. (2.5)

10
Where:
H Magnetic field intensity
f.1 Magnetic permeability of material
B Resulting magnetic flux density produced

By combination of equation (2.4) and (2.5), the magnetic of flux density, B, is given by:
,uNi
B=,ull=- .......................................... (2.6)
[c

The total flux in a given area is indicated by:

rjJ = fB.dA .. .............................................. (2.7)

A

Where:
dA Differential unit of area

If the flux density vector is perpendicular to a plane of area A, and if flux density is
constant throughout the area, then this equation reduces to:
r/J=BA ................................................... (2.8)

Thus, the total flux in the core due to the current in Figure 2.1 due to the current, i, in
the winding is given by:
,uNiA
r/J=BA=- .......................................... (2.9)
[c

Where:
A Cross-sectional area of the core.
lc Mean path length of the core. [3]

2.5 Magnetic Behaviour of Ferromagnetic Materials

The magnetic permeability was defined by equation (2.5) explained that the
permeability of ferromagnetic materials is very high, up to 6000 times the permeability
of free space. The behaviour of magnetic permeability in a ferromagnetic material is
illustrated by applying a direct current to the core shown in Figure 2.6. The current

11
started with 0 A and slowly working up to the maximum permissible current. When the
flux produced in the core is plotted versus the magnetomotive force producing it, the
resulting plot looks like Figure 2.7a. This type of plot is called a saturation curve or a
magnetization curve. At first, a small increase in the magnetization force produces a
huge increase in the resulting flux. After a certain point, though, further increases in the
magnetomotive force produce relatively smaller increases in the flux. Finally, an
increase in the magnetomotive force produces almost no change at all. The region of
Figure 2.7a in which the curve flattens out is called the saturation region, and the core is
said to be saturated. In contrast, the region where the flux changes very rapidly is called
the unsaturated region of the curve, and the core is said to be unsaturated. The transition
region between unsaturated and saturated region is often called the knee of the curve.
On the other hand, Figure 2.7b illustrates a plot of magnetic flux density B versus
magnetizing intensity H. From the plot, it is clearly visualize that magnetizing intensity
is directly proportional to magnetomotive force and magnetic flux density is directly
proportional to flux for any given core. Therefore, the relationship between B and H has
the same shape as the relationship between flux and magnetomotive force. Figure 2.8
illustrates a magnetization curve for a typical piece of steel which plotted more detail
and with magnetizing intensity on a logarithmic scale.

The advantage of using a ferromagnetic material for cores in electric machines is that it
gain more flux for a given magnetomotive force with iron compared to air. Since real
motors and generators depend on magnetic flux to produce voltage and torque, they are
designed to produce as much as flux as possible. As a result, most machines operate
near the knee of magnetization curve and the flux in their cores is not linearly related to
the magnetomotive force producing it. [3]

12
 8, T I
Saturation region Saturation region

Linear region

1
A-turns H. A-tumslm

1a1

Figure 2.7a: DC Magnetization Curve for Ferromagnetic Core

Figure 2.7b: Magnetization Curve of Flux Density versus Magnetizing Intensity

2.0

E LK
~ L6
·,;:
~ 1.4
~ L!
:£
LO
O.H

0.6

OA
0.2
0
IO 20 J() 50

Figure 2.8: Magnetization curve a typical piece of steel

13
 CHAPTER3

METHODOLOGY I PROJECT WORK

3.1 Research Study

To accomplish this project, it has to begin with information gathering activity. The
resources for this research include books, journals, articles, reports and the internet.

3.1.2 Research on DC Motor Design Theory

This method is the essential part for the project as it implies lots of courage and effort to
gain well-understanding and familiarization of the topic proposed. A study has being
performed, in order to understand the underlying basis and also the equations in
designing de machine. This study also includes on the theoretical part of de motor and
also identifies all the parameters needed in each design phase.

3.2 Perform calculations of all parameters for every design stages

After all the parameters required being identified, calculations have been performed.
The formulas of all calculated parameters were found from the books and paper work.
To ensure the accuracy of the calculation, MATLAB program is formulated for
comparison. The parameters of each stage are used as data input for MATLAB
programmmg.

3.3 Discussion with supervisor

This approach act is the crucial part for the project progress. With the assistance of the
supervisor, all the finding and the problem face could be discuss and being evaluate
together in order to achieve the solution. The discussion also provides the platform for
the idea brainstorming, which help on the progress made on the project.

3.4 Implementation (MATLAB programming)

Since the project mainly involve programming using MATLAB software, therefore the
familiarization stage is beneficial in order to implement the coding design of the project.
This method is essential and important in order to produce the desired result. The

14
software is a tool to ensure that the design platform accommodate with the specification
given by the supervisor. Furthermore, several trial programming are beneficial to be
performed for preliminary understanding on the project. Trial-and-error also one of
alternative that will be accommodate whenever there is any error occurred in the
program. However, this alternative is based on knowledge and discussion with
supervisor and who are expert in the field of study. The programs basically formulated
by extracted some of the parameters in the design process to generate the specific
outcome. Different outcome might need different data to be accommodated within it.

As a clearer view of procedure identification of the project, a graphical logic flowchart

and brief descriptions of each phase is stated in Figure 3.1.

15
 Specification

Volume and bore sizing

N
Armature design

y
Field pole Field pole design
problem?

Saturation curve analysis

Field winding design

Performance analysis

Mechanical design

Figure 3.1: Logic flowchart of de motor design

16
3.5 Description of each de motor design stages

3.5.1 1''stage: Specification

1. The specification is given the customer and for frame designation of the
design must followed NEMA MG-1 standard.
3.5.2 2"d stage: Volume and Bore Sizing

1. The initial sizing process of de motor design is to set the outside frame
diameter (DJ) which in this project NEMA frame designation, D1 = P.
2. The design procedure starts with three important parameters namely
armature diameter, rated developed torque and armature stack length.

3.5.3 3rd stage: Armature design

1. In this stage, some calculations have to be performed such as calculate

the number of armature slots, voltage and torque constants, rated current
and flux per pole and slot design.
2. These calculations are essential in order to proceed to the next stage.

3.5.4 41h stage: Field pole design

1. To design of actual field pole, two items must be addressed which are air
gap length and frame thickness.
2. Based on the satisfied result, the reluctance of magnetic circuit around
flux path remains nearly constant regardless of armature position.

3.5.5 51h stage: Saturation cnrve analysis

1. This stage is the major role in the design process where all the data
correlate in above stages are formulated in Matlab program to produce
magnetization curve of de motor. An analysis of the design begins at this
point.
2. The open-circuit saturation curve ( <Pp vs mmfp) must be determined prior
to the analysis. The field winding cannot be designed for the rated point
of operation until the mmfrequirement is satisfied. Using Matlab,
magnetization curve and B-H curve have to be performed.

17
3.5.6 61h stage: Field winding design
1. The field winding arrangement is designed to fit into the available space
surrounding field pole physically. In the project, the field winding
arrangement is shunt excited de motor.
2. A layout drawing of field pole and frame is necessary to determine space
availability.

3.5. 7 71h stage: Performance analysis

1. At this stage, all the calculation involved in the previous stages also are
formulated in MATLAB software. The analysis continued with
performance analysis of the design whether meet the performance
requirement or otherwise.
2. The expected outcomes are plot-curves of speed-torque, speed-line
current, speed-output power and speed-efficiency of shunt de motor. All
these curves have to be understandable and analyze their characteristic
with respect to the selected field winding arrangement.
3. The MATLAB program is formulated by modification of the required
design to read OCC (open-circuit circuit) that has been saved by the last
run of the program. The simulation of the result will predicted the
performance of designed motor whether suit the specification or
otherwise.

3.5.8 81h stage: Mechanical classification

1. Basically in this stage, the prototype of the motor will be made with
associated by mechanical department.
2. The design of DC motor is successfully completed.

18
3.6 Tool required

3.6.1 MATLAB software

The main and only tool that is required for this project is MATLAB software. For the
project, MATLAB version 6.5 is being used. MATLAB is a robust simulation which
utilizes mathematical equations to generate the outcome. In order to achieve the
objectives of the project, pure progrannning is used instead of simulation. This required
basic knowledge and exposure on the software application.

19
 CHAPTER4

RESULT AND DISCUSSION

4.1 Specification

Specification is the first constituent encountered in the flow chart illustrated in

methodology. The outcome of designing processes is considered success if it can meet
the specification given. The specification for de motor design is stated as below.
1. Rated Terminal Voltage, V1 =415 v.
2. Rated Output Power, hpR =400hp.
3. Speed at rated load, nmR = 1 800rpm.
4. Goal Design Efficiency, 1'/R =95%.
5. Maximum speed at rated load, nmax =3 000 rpm.
6. NEMA Frame designation = 583-AT.
7. Frequency,/ =50 Hz.
8. Number ofpole,p =4.

A standard of the National Electrical Manufacturers Association (NEMA) defines a

product, process, or procedure with reference to one or more of the following:
1. Nomenclature.
2. Composition.
3. Construction.
4. Dimensions.
5. Tolerances.
6. Safety.
7. Operating characteristics.
8. Performance.
9. Ratings.
10. Testing.
11. The service for which it is designed.

20
The standards play a vital part in the design, production, and distribution of products
destined for both national and international connnerce. Sound technical standards
benefit the user, as well as the manufacturer, by improving safety, bringing about
economies in product, eliminating misunderstandings between manufacturer and
purchaser, and assisting the purchaser in selecting and obtaining the proper product for
his particular need. The basic NEMA frame dimensions is illustrated in Appendix I.
Specific dimension values for a selected group of frames that being used in de motors
over range from 5 to 800-hp motors are also found in Appendix A. For this project, 583
AT frame designation are selected.

4.2 I st stage: Volume and Bore Sizing

The design procedure starts with Volume and Bore Sizing. In this stage, there are three
important elements that must be accomplished in order to complete this stage, namely:
1. Developed rated torque ('tdR)
2. Armature diameter (d)
3. Armature stack length (fa)

4.2.1 Developed rated torque (TdR)

The rated output power and full-load speed are used to calculate rated condition shaft
torque or full-load torque, rdR, for a de motor, given in equation (4.1 ):

rdR = 5250hp, ft.lbs ............................. (4.1)

nmR

Where:
h pR Rated output power (unit in hp)

nmR Speed at rated load (unit in rpm)

The rated developed torque is under reasonable assumption of 5 percent rotational

losses. This torque is required to keep the load running continuously at a fixed speed.

From equation (4.1 ), the developed rated torque, TdR is:

21
 r = 5250 x 400 ft.Ibs
dR 0.95 X 1800
TdR = J 228.07 jt-/b

4.2.2 Armature diameter (d)

In sizing process of de motor design, one of the important parameter is to set the outside
frame diameter (DJ)- Thus, by referring to NEMA frame designation (583AT) which D1
is equal toP, in the respective table illustrated in Appendix A. Usually, adequate frame
thickness (t1) and radial depth to accommodate field pole design results if the armature
diameter is taken to be in range of:
0.55DJ~ d ~ 0.65DJ.. ................................. (4.2)

From the table, the frame designation being used is 583AT frame where DJ = P= 29.00
inch. Using mean value of equation (4.2),
0.55(29.00) ~ d ~ 0.65(29.00)
15.95 ~ d ~ 18.85
d = 0.6D1= 0.6 (29.00) = 17.4 in

4.2.3 Armature stack length (Ia)

In order to minimize sizing value, the values of current density and flux density are
maintained at the limit allowed by the ability to cool armature conductors and by
saturation limits imposed in ferromagnetic material. Therefore, the formula to calculate
armature stack length, la:
d 2l
--" =constant= Vr . ................................. (4.3)
rdR

Where:
vr Normalized sizing value.
d Outside frame diameter (unit in inch).

22
The sizing value vr must be increased as the machine size decreases to allow for
acceptable tooth root flux density. The graph in Appendix B represents the values of vr
used for initial sizing of de motor depending on the method of cooling. The graph is
valid for rated speed of approximately 1800 rpm. The value of vr is inversely
proportional to the speed. Based on the graph, the approximate vr is 1.91 in3/ft.lb.

Thus,

d 21
Ia = ---:j'- ............................................. (4.4)
d

I = 2 345.6137
a 17.4 2

Ia= 7.7474 in

4.3 Armature Design

Armature Design is the 2"d stage of designing de machine. In this stage, certain
parameters have to be calculated which are:
1. Number of armature slots.
2. Voltage and torque constant.
3. Rated current and flux per pole.
4. Slot design.
5. Coil characterization.
6. Flux density check.
7. Commutator design.

A flowchart for armature design also include in Appendix C for clearer view of the
process.

23
4.3.1 Number of armature slots

In order to minimize flux pulsation along the pole face and produce a slot width that
allows for good slot wedge integrity, the armature slot pitch (Jc) should typically be in
the range:

1 :o; A- = Jid :o; 1.5 inch ................................ (4.5)

N

Where:
d Outside frame diameter (unit in inch).
N Number of armature slots

Ford<:: 20 inch, the lower end of the range usually results in better design.
If slot pitch A.= 1, the equation above gives:
N=7r:d
Jc
;rx17.4
1
= 54.66 slots"' 54 slots
Use N= 54 slots. With N chosen,

--i=;rx17.4
54
= 1.0123 in

Since the armature lamination stack experiences a reversing flux, the number field poles
should be selected to give a cyclic frequency in the range of 45 to 70Hz for operation at
rated speed.

45 :o; pnmR :o; 70Hz ................................. (4.6)

120

Where:
p Number of poles.
nmR Speed at rated load (unit in rpm).

24
From the specification, the design motor should be 4-pole machine, therefore the cyclic
frequency is:

pnmR = 4x1800
120 120
=60Hz

This value is within the acceptable range for acceptable core losses. In addition, a good
design practice is to select the number of armature slots (N) as an integer that falls in the
range:
11.5p:SNS15.5p ................................. (4.7)

55
N = =13.75
p 4

Thus, the value lies within the acceptable range for slots per pole.

4.3.2 Voltage and torque constant

In this design, the consideration is taken in a case where a simplex winding (a=p).
Integral horse-power de machine commonly has a single-tum armature coil with
multiple coils per slot (nc) with two or three coils per slot being typical values. The total
conductors for the armature winding, Z, is given by:
Z = 2ncN ........................................... (4.8)

Where:
nc Number of multiple coils per slot.
(3 coils per slot for design trial for 3-phase de motor).

Thus, the total armature conductors are:

Z = 2 x 3 x 54 = 324 conductors

F
U}.\ i ·,i -E t:~'~Ti 'l
25
The voltage and torque constants, kE and kT (unit in flux) are given by, respectively in
equation (4.9) and (4.10):
pZ
kE = ••.•••••••.••••••••••••••.•.••••.•••••• (4.9)
a60x10 8
Where:
a Number oflap winding (consider simplex winding, a=p=4)

4x33
kE = = 5.5 x 10 -8 .
V/lme.rpm
4x60x10 8

pZ
kT = •••••••.••••.••••...••••••.•.•.•••••• (4.10)
a8.525 x 10 8

4 330
k = x 3.871x10-8 ft-lb/line.A
T 4x 8.525 X 10 8

4.3.3 Rated current and flux per pole

The rated condition current, IaR, is calculated using equation (4.11 ).

I R = 746hP. .................................... (4.11)

a TJRV,
Where:
lJ • Design goal efficiency (unit in%).

V, Rated Terminal Voltage (unit in Voltage).

I = 746x400 756.88A
aR 0.95 X 415

If reasonable value rotational losses are 5 % of the machine power rating, the rated
condition flux per pole, <I> pR is:

10 95
<I>P• = ',• · lines ................................ (4.12)
kT/aR

26
 <)) = 1228.07
pR 3.871x10- 7 x756.88
= 4.1915 Megalines

4.3.4 Slot design

After rated armature current and rated flux per pole is established, the armature slot,
tooth and coil can be seized as shown in Figure 4.1.

Sl<>l wedge

b,
d,
C<>il
separator

Coil side
(eondoctor)

Figure 4.1: Armature slot section view

In de machine design, it is rarely to find a standard square wire size compatible with the
selected slot dimensions. However, magnet wire manufacturers readily supply
rectangular conductors drawn to desired dimension and served with film insulation.

The value of stator conductor cross-section area, sa, is given as follows:

Sa= faR ............................................. (4.13)

a11.

Where:
1'1a Typical value of allowable stator current density for air-cooled machine.

27
The acceptable range for Lla is:
500 ::0 Lla::; 800 A/cm2 or 3200 :::; Lla::; 5200 A/in2

In this design, consideration has been made that the machine is a self-ventilated which
will fall in the mid-range of 3200 :::; Lla::; 5200 A/in2 • Let Lla = 4000 A/in2 • thus the stator
conductor area, sa, is:
756 88
s = · 0.0473 in 2
a 4x4000

For good design, the armature slot width, b, is selected such that:
0.4A.:::: b,:::: 0.5A. ....................................... (4.14)

In an attempt to have an armature slot width, b, in the midrange of equation (4.14), an

armature conductor with bare copper width, We, is selected equal to 0.110 inch. The
armature conductor will be insulated with a high temperature fihn wrap to a thickness of
0.003 inch. Therefore, conductor height, he, is:

h, =!.E._ ............................................... (4.15)

w,
Where:
sa Armature conductor area (unit in inch2)
We Armature conductor with bare copper (unit in inch)

h = 0.0473 = 0.43in
c 0.110
The slot depth, d, on the other hand falls in the range of:
2b,::; d,:::: 4b, ..... .................................... (4.16)

In addition to containment of two coil sides, the slot must assure adequate insulation
between coil sides and accept a means of retaining the coil sides (slot separator) and
accept a means of retaining the coil sides (slot wedge) as illustrated in Figure 4.1.

28
Allowing for irregularity in material, d, is chosen as 1.150 inch. The slot depth-to-width
ratio is:

E.,_= 1.1 50 = 2.55

b, 0.450

From calculated slot depth-to-width ratio, d,lb,, it is found that the ratio falls within the
range suggested by equation (4.16).

4.3.5 Coil characteristic

Coil is one or more turns of wire grouped together and mounted on the drum-wound
armature in order to cut lines of flux. According to the degree of closure produced by
winding, there are 2 types of armature winding:
1. Open coil winding is when winding does not close on itself and usually
employed in ac machine.
2. Closed-coil winding is when winding which closes on itself. DC machine
employ only this winding in order to provide for the commutation of the coils.

The winding may be lap windings or wave windings. As mention earlier, lap winding is
used due to its capability in producing more parallel paths for large current application.
In lap winding, the finish of each coil is connected to the start of next coil so that
winding or commutator pitch is unity. In a simple lap winding, front and back pitches
are always odd and differ by 2, while the average pitch is an even number. In a one tum
winding, the total number of segments required is equal to one-half the number of
armature conductors, since each commutator segment is connected to two conductors.

The end-tum layout of an armature coil is shown by Figure 4.2. The end-tum projection
of armature coil is directly impacts the axial length of armature assembly, therefore it is
desirable to hold the projection to as small a value as practically possible.

29
The design objective is usually accomplished if the following dimensions of Figure 4.2
are maintained:
I. Gap between each adjacent coil, Se = 0.125 to 0.250 inch.
2. Armature coil depth at lower end-turn, be= 0.50 to 1.00 inch.
3. Armature coil depth at upper end-tum, ge = d,
4. Width of each coil, de= Se + b,
;r(d-d)
5. Gap between coil at lower end-turn, A = '
' N

6. Armature coil span for each turn, r, =integer N x A,

p

7. Angle of end-turn overhang, a = sin_, ~

A,

.I
Figure 4.2: Armature coil end turn

Complete end-turn overhang, OH for each turn, is given by:

OH =be+~ tana+ge····························· (4.17)

For the coil end-turn overhang ( OH) calculation, let:

se = 0.125 inch.
be= 0.50 inch.

30
 ge = ds =1.150 inch.
de= 0.125 + 0.45 = 0.575 inch.

A- =;r(l 7 .4-1.1 5) 0.9454in

' 54
54
r, =integer x 0.9454 = 12.7629 in
4

. -1 0.575
a=sm = 37.46"
0.9454

Using all the parameters calculated above, the complete end-tum overhang, OH is
calculated by equation (4. I 7):
12 7629
OH = 0.50 + · tan 37.46" + 1.15
2
= 6.5396 inch

The mean length tum (MLTa) of an armature coil can be determined as:

MLTO = 2(~+2b,
cos a
+ 2g, +Ia) .................... (4.18)

12 7629
MLT, =2( · +1+2.3+7.7474]
cos37.46°

= 54.252 I inch

Then, the value of resistance for armature circuit can be calculated using equation
(4.19):
MLT.(Z/2)
Ra = P 2
•• •••••••••••••••••••••••••••• (4.19)
a sa

Where:
p Copper resistivity (equivalent value is 0.69 X 10"6 n. inch at 20°C).

31
The value must be adjusted to the anticipated operating temperature (T) of armature
winding by equation (4.20):
234 5
P= · + r (o.69 x 1o- 6 ) ............................ ( 4.20)
254.5

= 234.5+150r0. 69 x 10 _6 )
p 254.5 ~
= 1.042 x 10-6 Q.inch

Where:
T Estimated average conductor temperature, T= l50"C.

Therefore, the armature resistance, Ra, is calculated using equation (4.19):

R =1. 042 xlo- 6 (54.2521x162)

a 4 2 x0.04505
= 0.0127 Q

4.3.6 Flux density check

Prior to begin the commutator design, critical flux density for armature tooth root
should be checked. The apparent flux density at the tooth root, B 1ra, of Figure 4.1 is
given by:
cj) pR X p
B, = .......................... (4.21)
'" lj/XNxw,, xla xSF
Where:
W 1r Width of armature tooth (unit in inch).

w" = [ ll'(d ~d,) ]-b,

7 23
= [ ll'(l ·:4- )]- 0.45 ......................... (4.22)

= 0.4285 inch

<DpR Rated flux per pole (unit in Megalines).

Ia Armature stack length (unit in inch).
SF Stacking factor.

32
p Number of pole.
N Number oftums.
VI" Pole arc-to-pole pitch ratio.

The value of stacking factor (SF) is in range of 0.94:S SF :S 0.97, and depends on the
lamination thickness as well as the axial assembly pressure of the armature lamination
stack. In this design, the value of stacking factor is assumed to be 0.96. The next step is
to find pole arc-to-pole pitch ratio (VI") per unit field. The range should be in range of
0.65 to 0. 70.

TPP
VI"=- ............................................. (4.23)
Jill

This ratio is stated as approximation to the number of armature slots sparmed by the
pole arc, Tp. The common design practice is to select a pole arc, Tp such that:
TP 1
- = m+- ........................................... (4.24)
A- 2

Where:
m An integer (1,2,3, ..... ).
,( Armature slot pitch (unit in inch).

Figure 4.3: Field pole span of teeth

33
When equation (4.24) is satisfied, the situation per pair of poles of the de motor is
illustrated in Figure 4.3. The reluctance of magnetic circuit around a complete flux path
remains nearly constant regardless of armature position. However, there can be some
reluctance variation as the leading edge of a pole tip approaches a tooth while the
trailing pole tip exits a tooth. This is due to different dimension of slot width and tooth
width.

To ensure pole arc-to-pole pitch ratio ( (!') in the acceptable range, the value of m is

selected is 9. Thus, by substituting the values, equation (4.24) becomes:

rP I
-=9+-
A. 2
rP=9.5xA.
= 9.5 x 1.012 = 9.614 inch

The value of rP is then substitute into equation (4.23) to find pole arc-to-pole pitch

ratio, If! is shown as below:

9.614x 4
!!' = 0.703
JrX 17.4

These parameters finally complete the equation of apparent flux density at the tooth

6
B = 4x4.1915xl0
tm 0. 703 X 54x 0.4285 X 7. 747 X 0.96
= 138.588 kilolines I in 2
=2.15 T

For a good design, the value of Btra must be< 170 kilolines/in2 which is equal to 2.6T
(measure in Tesla). If Btra is unacceptably large, action should be taken to decrease the
slot width or change the number of armature slots. If an acceptable B,,. cannot suit the
requirement, then e, must be increased. Since Bu·a is within acceptable limits, no
refinement of dimension is required.

34
4.3.7 Commutator design

Brush
,,
"''..:;
- ,..--'
t~ " '"~""

-~"'"

<1, ,-, ::::, __ ,_.. -

--
,,,

~---
",

= --.--
1

••

"'• 1-
Figure 4.4: Commutator design from end view and side view

The commutator side and end view is shown in Figure 4.4. The number of commutator
bars (Kc) for a two-layer winding is equal to the number of armature coils. Thus, for
number of commutator bars, K, is:
Kc = nc xN ......................................... (4.25)
Where:
nc Number of multiple coils per slot.
N Number of armature slots.
Kc = 3 x 54= 162 bars

The carbon brushes typically offer acceptable service life if the commutator surface
speed does not exceed 9000 ft/min. The use of copper brushes is made for large current
at low voltage machine.

Thus, the commutator brush surface diameter, de, should satisfy equation (4.26):

d, ~ 9000(12) 34000 ............................ (4.26)

Jr nm nm
Where:
nm Maximum rated speed (unit in rpm).

35
 d = 34 OOO = 11.333 inch
' 3 000

The carbon brushes should have a thickness chosen so that the brush spans n, + 0.5
commutator bars insofar as standard 0.125-in increments in brush dimension allow.
Thus, brush dimension, fbis calculated using equation (4.27):

tb = ":, (n, + 0.5) ................................ (4.27)

'
tb = K X 11.333 (3 +0.5 ) =0.7 69 2mc
. h
162

As the commutator reaches the wear limit, the brush span of bars increased, thus 0.125-
in increment below 0.7692 in should be selected, or use tb=0.673 in.

Modem electro-graphite brushes exhibit life expectancy with a current density of !'J.b =

80A/in2 . The total width of nb brushed per set is found as:

2JaR
nb wb = ...................................... (4.28)
p!'J.btb

2x756.88 . h
nbwb = =7. 03 me
4x80x0.673
Where:
wb Width of a single brush. It should lies in the range 1 inch :; wb :; 2 inch. For this
design, wb is assumed to be 1.5 inch.
!'J.b Brush current density for rated load (unit in A/in\

Once equation (4.28) being evaluated, then the number of brushes per set, nb can be
readily determined.
7 03
nb = · = 4.6867 inch
1.50
Therefore, the number ofbrushes per set, nb is 4.6867 inch.

36
4.4 Field Pole Design

Figure 4.5: Frame section

Figure 4.5 illustrates the frame section of de motor that associated in field pole design.
Field pole design is the 3'd stage that needs to be accomplished in de motor design. Prior
to design of actual field pole, two items must be addressed which are air gap length and
frame thickness. The air gap length (o) increases with armature diameter and can be
decided by:
0 = 0.0335-.Jd ...................................... (4.29)

o= 0.0335 ..J 17.4 = 0.14 inch.

Due to reluctance variation of armature teeth, the effective length (Oe) of the air gap
used in magnetic circuit calculations is greater than the tooth-to-pole face diameter
determined by equation (4.30).
.It (50+ b,)
c>, = 2 c) ................................. (4.30)
.11 (5o+ bJ- b,

Where:
b, Armature slot width (unit in inch).
A Armature slot pitch (unit in inch).
o Air gap length (unit in inch).

37
 0
= 1.012(5x0.14+0.45)
014
' J(5x0.14+0.45)-0.45 2 .
= 0.17 inch

The frame of a de motor must carry 0.5 ([JP plus any leakage flux that passes between
adjacent field pole structures. The typical value for field pole leakage flux are in range
of 10-20 percent of flux per pole and can be adequately accounted for with the use of
leakage factor (LF) that in range of 1.1 :S LF :S 1.2. In order to avoid an excessive mmf
requirement for frame flux path, the frame flux density (B1) should not exceed 100
kilolines/in2 . Consequently, the cross-sectional area of frame perpendicular to flux flow,
A1 as illustrated by Figure 4.5 and determined using equation (4.31):

LF<f> R
2000~0 ··························· (4 .31 )

Where:
LF Leakage factor.
B1 Field flux density (unit in kilolines/in2).

Since the value of'¥ is equal to 0.703 which had been determined in subsection 4.3.6-
Flux density check, the field pole tips are reasonably close so that field pole leakage
flux will be on the upper end of typical condition. Thus, leakage factor is chosen as
LF= 1.2. Thus, cross-sectional area of frame perpendicular to flux flow, A1 is as follows:

A = 1.2x4.27xl0 6
f 200 000
= 25.62 in'

The frame can maintain a uniform thickness that extends to half of the armature coil
overhang, Wf· Thus,
w1 =!a+ OH ..................................... (4.32)

w1= 7.747 + 6.5396 = 14.2866 in

38
The necessary frame thickness, t1 is determined as:
A!
tf = - .................................................. (4.33)
WI

25.62
t = 1.7933 inch
J 14.286

With oand If are determined, the height of field pole, hp shown in Figure 4.6 can be
calculated in the equation (4.34).
1 .
hP =-z(D1 -26-2t 1 -d) ............................ (4.34)

hp = _!_(29- 2(0.14)- 2(1.7933) -17.4)

2
= 3.8667 inch

The pole shank (fsk) and pole shoe length (fsh) of field pole shape of Figure 4.6 have the
reasonable values of:

fsh"' 0.1 hp · ··· ··· ··· ···· ·· ···· (4.35)

e,k"' 0.9(3.8667) e,h"' 0.1(3.8667)

"'3.48 in. "' 0.38667 in.

Ftdd

t.,T
l
w

{~-.<:
I
,,
l h,

-~

f
s

Figure 4.6: Field pole shape

39
Acceptable magnetic circuit performauce aud adequate space for the field winding
usually results if the pole shank width is sized so that the flux density is 110
kilolines/in2 .

Hence, width of pole shank, Wsk is stated as below:

LF<'P pR
w,k = ..................................... (4.36)
llO 000/aSF

1.2 X 4.27 X 10 6
w,k = llO OOOx 7.747x 0.96
= 6.2634 inch

4.5 Magnetic Circuit Analysis

Magnetic circuit aualysis is the 41h stage of de motor design. Since the value of flux per
pole, <Pp may well be adjusted in chauge of operating points for a de machine, the open-
circuit saturation curve ( <Pp vs mmJ;, ) must be determined prior to aualysis at other thau
the rated point. Moreover, the field winding cannot be designed for the rated point of
operation nntil the mmf requirement for that point is known.

The armature teeth are tapered by nature so that the flux density at the tooth root (width
w1r) may experience significaut saturation. When the tooth root area reaches saturation,
flux tends to travel along a path radially outward aud parallel to the tooth sides. A
computer interface method which is MATLAB software used to computationally haudle
the analysis when tooth root saturation occurs. A Ba - H curve for use in the tooth area
aualysis is constructed that accounts for parallel permeauce path through slot area. It is
where apparent tooth flux density (Ba) at each point is calculated as though the flux
were confined only to the tooth ferromagnetic material by:
Ba=B+k,H ........................................ (4.37)

The constant k, is the permeability ofthe parallel air path given by:
k1 =3.2 (SFxA. 3 / w13-1) ............................... (4.38)

40
Where:
AJ Slot pitch (unit in inch).
w13 Tooth width (unit in inch).

Both parameters are calculated at one-third the tooth depth from the bottom. The
MATLAB program has been formulated to calculate the necessary values and plot the
magnetization curve ( cJ>p vs mmJ;,) for a de machine with winding and dimensional data
inserted in the program. The program assumes that the field pole and armature
ferromagnetic material is M-22, 26-gage ESS and the frame is AISI 1010 steel. If the
resulting magnetization curve displays saturation problem, then the offending portion of
magnetic structure must be identified and corrective action taken as indicated in the
Methodology section where illustrated logic flow diagram of de motor design.

The comparing results between calculated and using MATLAB tool (<Info.m>) also
included in Appendix D. Based on the result, the outcome through MATLAB provides
more efficiency in term on number of decimal places compared to the calculated
outcome. Although that, the differences between the results are slightly small and can
be ignored.

4.5.1 B-H Curves

The <Hm22.m> and <Hx.m> programs were developed in order to perform B-H curves
for field pole and armature ferromagnetic material is M -22, 26-gage ESS and AISI 1010
steel armature frame. With regard to the reference curves as illustrated in Figure 2.7b,
some modifications were made and finally the programs were successfully run and
produce the saturation curves as illustrated in Figure 4.7 and 4.8. The expected result
from both programs are directly proportional curve which become constant when reach
the operating point. The linear part of the curve represent the unsaturated section where
else the constant part is the saturated region.

The MATLAB programs are attached in Appendix E & F and plot results are as
follows.

41
 ' ' ' ' ' '
-------L-------L-------L-------
1 ' '
-------~-------l-------~------
' ' '

------r-------r-------r-------r-------+-------+-------t-------t------
0

------r-------r-------r-------r-------,-------r-------r-------,------
I I

o
I I I I I I

' '
------r--·----r-------r-------r-------T-------T·-----·y·------T----
' '
1 ' ' '

' ' ' ' ' ' ' '

------~-------~-------~-------~-------·-------·-------+-------·------
' ' ' '

Figure 4.7: Magnetization Curve for M-22 ESS, 26 gage

Magn

-------r--------r--------r--------,--------r--------
' ' '
o
' '

••••••-•L--------L•••----
0

'
'
I '
'0 'I '
--r--------~--------~--------~--------~--------~--------~-------
.
I

1 1 I I I

-------L---••••• --------L•••-----L-----•••L--------L-----•••L-------

-------r--------r--------r--------,--------r--------r--------r-------
I ' I

o
I I I

0
I

Figure 4o8: Magnetization Curve for AISI 1010 Steel Frame

42
4.5.2 Magnetization Curve of DC Motor

The MATLAB program <Magnetcurve.m> has been formulated to calculate the

necessary values and plot magnetization curve ( <Pp vs mmJ;, ) for a de machine with
winding and dimensional data read from <Info.m>. Besides, the program also called the
previous two programs, which are <Hm22.m> and <Hx.m> that contain the B-H curves
of these two materials as illustrated in Figure 4.8 & 4.9. The MATLAB source codes
are attached in Appendix G.

If the resulting magnetization curve displays saturation problem, then the offending
portion of magnetic structure must be identified and corrective action should be taken as
indicated by Figure 3.7: Logic flowchart of de motor design in Methodology section.
The final action taken by <Magnetcurve.m> is to form the open-circuit characteristic
(OCC) curve for the de machine and save the file for later use. OCC is a plot of no-load
terminal voltage, V, versus field current, It where all data is recorded for a constant
value of speed. OCC indicates phenomenon known as armature reaction which means
that flux per pole, <Pp is reduced in value with regard of armature mmf Fa effect.
Consideration of armature reaction is an analytical challenge owing to the nonlinearities
involved. Without knowledge of armature winding data, experimental work can be
conducted to determine the effects of armature reaction on the cemf E at several load
current conditions. An experimental setup for armature reaction evaluation is illustrated
in Figure 4.9. A small value of V, may be recorded for 11 =0 owing to a slight residual
magnetism present in the ferromagnetic structure. In the design, the number of field
turns per pole (N1) is not known, therefore the horizontal axis is simply plotted as field
current (11) knowing that the result is only a scaling factor different from mmf source, Fp
(Fp=Nj1). Since speed is held to a constant value for all data points, the vertical axis is
only a scaling factor (Kw =Kwm) different from <Pp. The actual value of E with armature
reaction is determined by:
E = V1 + JaRa ....................................... (4.39)

However, the setup is not being done by the student since the main concern is to
develop the MATLAB program to generate such output illustrated in Figure 4.10.
Figure 4.10 displays a typical plot of E vs. It with Ia as a parameter.

43
Figure 4.9: Experimental Setup for Armature Reaction Determination

600

'"'
f400
'3
.;>-

'E'
-=
\::;i

Figure 4.10: OCC Showing Armature Reaction for 1200 rpm Speed

44
Figure 4.11 illustrates magnetization curve for de motor by including B-H curves of
these two materials as illustrate in Figure 4.7 & 4.8 added with winding and
dimensional data from each design stages. Figure 4.11 is used to determine the
magnetomotive force (mmfp) requirement for the rated flux per pole (<Pp).

iil;.4U'UU.~-------- ~------ -------~--------~--------L--------L••••••••i•••••••

I I I I

' I
I
I
I
I
I
I
I
'
' '
'
'
'
'I 'I
-----r--------r--------r--------r--------r·-------r-------
I I I I

I I I I I

•••----L--------L--------i--------i--------i·-------i•-•••••
I I I I I I
I I I I I
I I I I I
I I I I
I I I I

' '
I I I
''
I I
''
I
'''
I
----r--------r--------r--------r--------r--------r--------r-------
' I I I I I I
I I I I I
I I I I I
I I I I I
I I I I I
1 I I I I
I I I I I

Figure 4.11: Magnetization Curve of DC Motor

4.6 Field Winding Design

Once the magnetization curve has been calculated, the value of mmfp to produce <PpR
can be determined. At least 1.05 mmfp should be used as mmfpR in field winding design
to allow for armature reaction. Any field winding arrangement can be designed to
produce mmfpR as long as the winding physically fit into the available space surrounding
the field pole. A layout drawing of field pole and frame is usually necessary to
determine space availability. The space available is further diminished with the addition
of the interpoles and their associated windings.

45
After execution of <Magnetcurve.m> with the values for the design entered in
<Input.m>, Figure 4.11 results. Figure 4.11 illustrates magnetomotive per pole mmf of
the de motor design with reference of calculated flux per pole <PpR is equivalent to
4.1915 kilolines. It is found that mlr![p = 5060 A-t to produce rated flux per pole.
Assuming the annature reaction increases the field mmf requirement by 10 percent, the
shunt field should be designed to produce mmfpR = (1.10)5060 = 5566 A-t. Without the
benefit of a layout, it is assumed that a field winding of average width of 2.50 inch and
a height of 0.85isk =0.85(3.48) =2.96 inch can be fitted into the interpolar space. The
2
area of the field winding cross section is (2.50)(2.96) = 7.40 in • If No. 14 square wire
insulated with heavy film over double glass is selected for the field conductor, 1100
turns (NJ) can be fitted into the available area.

The mean length turn of the field winding, MLTfis:

MLT1 = 2[1. + w,k + 2(2.5)] . ....................... (4.40)
MLT1 = 2[7. 747 + 6.2634 + 2(2.5) j
= 38.02 inch

Where:
fa Armature stack length
Wsk Width of pole shank

No. 14 square magnet wire has a resistance of 5.25 n per 1000 ft for a temperature of
160°C. Thus, the resistance per pole, Rfp is:

R = NJMLTJ (5.25) = 1100(38.02) (5.25) = 18.2971 Q

fp 1000(12) 1000(12)

Where:
Hj Number of field turns
MLTj Mean length turn of the field winding

46
For a series connection of all field poles, R1 :
R1 = pRiP = 4(18.2971) = 73.1885 Q

Where:
RiP Field resistance per pole
p Number of poles

Full voltage across the field winding yields field current, ljof:
v,
11 =-=
415
=5.6703A
R1 73.1885

mmfP =N1 11 =1100(5.6703)=6237.3187 A-t

Where:
V, Rated Terminal Voltage
R1 Field resistance of a series connection
mmfp Magnetomotive per pole

It is concluded that this field winding can adequately excite the motor for the rated point
of operation.

4.7 Performance Analysis

The design stages continued by performing MATLAB program to analyze the
performance of this motor design. The program clearly indicate how the performance of
design towards the specification given by the customer.

The program <Shunt.m> is formulated with use of OCC that has been saved by
<Magnetcurve.m> to plots the speed-torque, speed-armature current, speed-output
power and speed-efficiency curves for the motor design to allow assessment with regard
to performance specifications. If the motor does not meet the desired performance, thus
the design must be iterated as indicated in Figure 3.1. <Shunt.m> is the final program in
this design project. This program is collaboration with the previous source codes and
merely depends on each successful execution of all above programs. The program is
attached in Appendix H.

47
4.7.1 MATLAB Outcomes for Performance Analysis
<Shunt.m> develop torque-speed, speed-line current, speed-output power and speed-
efficiency analysis curves for shunt excited de motor with rated voltage applied.
Armature reaction is neglected in this program. The complete MATLAB program for
the analysis is attached in Appendix H. Figure 4.14, Figure 4.15, Figure 4.16 and Figure
4.17 illustrate the analysis of de motor based upon the performance specification.

------------~--------------~---{7----
' '
'
'
------------i--------------~-------------i--------------~------------
0 ' '
' '
------------~--------------~-------------~--------------~------------
' ' '
' '
' '
1·2000!-- --- -- -- -- -- -., -- - -- - -- -- -- -- ~ - -- -- -- -- -- -- i--------- -- ---~- -- ---------
' '
'
I I ' I I
------------,--------------~-------------,--------------r------------
' I I I
I I I I

I 'I '
I 'I
••••••••••·-~--------------L-••••••••••••J·-------------L-----··•••••
I I I I

'' ' ''

------------~--------------~-------------~--------------~------------
' I I I

'' ''
f 4UO;f-- --- -- -- -- -- - ~ - -- - -- -- -- -- -- ~ -- --- -- -- -- -- i----- -- --- -- --~ ------------
' ' '
'
I I I '
I

------------~--------------~-------------~--------------~------------
' ' '
' ' '
' ' '

Figure 4.12: MATLAB Speed versus Torque Curve

48
 I I I I I

----------~-----------:-----------i-----------:-----------f----------

----------L-----------L-----------~-----------~-----------~----------
1 I : : I

0 0
I I I I I

----------r-----------r-----------T-----------T-----------y----------
1
0
I I I
0

----------r-----------r-----------r-----------r-----------r----------
I

1
I

I
I

I
1

I
t

I I I I I

----------L-----------L-----------l-----------l-----------l----------
1 I
0
I
0
I I
0

I I I I

----------~-----------~-----------·-----------·-----------·----------
: I I I I

I I I I I

----------;-----------~-----------~-----------~-----------T----------

I I I I I

----------L-----------L-----------l-----------l-----------l----------
1 I
0
I I I
0

Figure 4.13: MATLAB Speed versus Armature Current Curve

--------L-----------L-----------~-----------~-----------~----------
1 I I I I
0 0 0

I I I I

---------~-----------t-----------t-----------l----------

----------~----------- -------i-----------f----------- ----------

0 0

----------r-----------r-----------
0

0
0
---------T·----------T·---------

----------r-----------r-----------T---------
0
0
0 0

----------~-----------~-----------·-----------·----------
0 0 0
0

Figure 4.14: MATLAB Speed versus Output Power Curve

49
 I I I I 'I I
---l------J·------~------L
1 I I I
...... lI ...... JI • • • • • • ~-----
I
------L-----
I
I I I I I I I I

' '

I I I I I I

----- i--- -- -~------ -,-------:------- +-- ---- -i -------:-------:----

I I I I I I I

' ' '

' '
I I I 1 I I I 'I
----- T----- -,-------,------ -r---- -- T - - - - - - , - - - - - - "1------ -r-----
'

I I I I I I
••••-T·-----~----·--r------~------T·-----,------,-------~-----
1 I I I I I I
I I I I

I I I I I
----- +--- - - - - 1 - - - - - - _,_ - - - - - _,_ - - - - - - +-- - - - ._... - - - - - _,_--- -- _,_------
I I I I I I I
I I I I I I I
I I I I

Figure 4.15: MATLAB Speed versus Efficiency Curve

4.8 Discussion
The main purpose of designing de motor studies is to provide an accurate shunt excited
de motor design with regard to performance specification given by the user. In this
project, the designing stages started with volume and bore sizing and ended with design
refinement or performance analysis. All the required parameters in every design stages
are calculated and the values are being used in MATLAB as data input of the
programming. The analysis part where the plot-curves become the main element is
accomplished using an interactive computer software, MATLAB programming. The
MATLAB programs are mainly comprise of specifications given by the customer, set of
commands and relevant functions, the equations for performing data input and also
added in small portion of C++ coding.

50
All de motors must receive their excitation from an outside source or independent
source; therefore, they are separately excited. Their field and armature windings are
connected, however, in one of three different ways employed for self excited de
generators. Thus, according to the field arrangement, there are three types of de motors
namely:
1. Series Wound.
2. Shunt Wound.
3. Compound Wound.

For this design, the field arrangement selected is shunt excited de motor. The shunt de
motor arrangement is illustrated in Figure 4.16. A shunt wound motor is one in which
field winding consisting large number of turns of comparatively fine wire connected in
parallel with armature circuit. The field current of the motor gets its power directly
across the armature terminals of the motor.

Figure 4.16: Shunt DC Motor Equivalent Circuit

51
4.8.1 Motor Characteristic
The important characteristic curves of de motor are:
1. Speed-Torque Characteristic: This curve gives relationship between speed at
rated load nmR and developed rated torque rdR .

2. Speed-Armature Current Characteristic: The characteristic curve gives

relationship between speed at rated load nmR and armature current Ia.
3. Speed-Output Power Characteristic: This curve gives relationship between
speed at rated load nmR and output power P aut·
4. Speed-Efficiency Characteristic: The curve gives relationship the efficiency IJR
of the design with respect to the speed nmR·

4.8.2 DC Shunt Motor Performance

For this study, the motor performance is based on a constant value of impressed
terminal voltage. In such a case, the field voltage remains constant for the shunt de
motor so that its field current remains constant, rendering its performance nature
identical to the separately excited de motor.

Applying Kirchoffs Voltage Law (KVL) to the equivalent circuit of Figure 4.13 and
solving for speed Wm gives:

wm = Va- laRa ............................................... (4.41)

K(fJP

The expression of (4.41) yields the motor shaft speed regardless of the field connection.
For the case of a shunt motor, Va = V1• The motor shaft torque r, is given by:

T, = TdR -TFw =K(fJpfa _PFw/ ........................... (4.42)

/ {j}m

Where:
<Fw Friction and windage torque
TdR Developed rated torque
K Constant depend on the construction of a particular DC machine

52
Ia Armature Current
<Pp Flux per pole
Wrn Motor Speed
PFw Mechanical rotational losses

In many power conditioned drives, the field winding may be excited from an
independent source as mentioned earlier. This is where the field current is controlled to
allow versatility in performance such as shaping torque or power profiles as functions
of motor speed. Figure 4.14 presents the general power flow diagram for a de motor.
For the case of shunt motor, P;n = V,Ja + Vff· Any core losses are lumped with the
mechanical rotational losses, PFw.

4.8.3 Speed-Torque Characteristic Curve

Figure 4.14 results a straight line with negative slope for this analysis. When the rated
speed nrnR is 1800 rpm, the developed torque 'fdR is 1228.07 ft-lb. This result meets the
design specification due to the fact that the indicated value is the same compared to the
calculated using equation (4.1). For a shunt de motor to respond with the load, the load
on the shaft of a motor is supposedly increased. Then the rated developed torque, 'fdR

will exceed the induced torque r;nd in the machine, and the motor will start to slow
down. When the motor slows down, its internal generated voltage drops (Ea=K<Ppwrn)
decreases, thus the armature current in the motor Ia increases. As the armature current
rises, the induced torque in the motor increases (<;nrK<Ppla), and finally the induced
torque will equal to the rated developed torque at a mechanical speed of rotation Wrn.

The output characteristic of a shunt de motor can be derived from the induced voltage
and torque equations of the motor plus Kirchhoffs voltage law. The KVL equation for
a shunt motor is indicated in (4.43):

V, =£a+ laRa························· ....... ····· (4.43)

The induced voltage Ea = K<Ppwrn, so (4.43) is expressed as:

53
 V, = KciJ P111m + I.R• .................................... (4.44)

Since 7:;ntFKcf>pla, armature current Ia can be expressed as:

rind
fa = KciJ P · ······ ···· ·· ···· ·· ···· ··· ·· ................... (4.45)

Combining equation (4.44) and (4.45) produces:

rr. l"ind
Vt = K "-' OJm + --Ra ·· ········· ......................... ( 4.46)
p KciJ p

Finally, solving for the motor's speed yields:

{i}m =l- Ra
KciJP (KciJP)
2 l",d ••·••••·••••·•·•·••·•••·•·••••·•·••
'
(4.47)

Where:
V1 Terminal Voltage
Ea Internal generated voltage
Ra Armature Resistance
r:;nd Induced Torque
7:dR Developed Rated Torque

This equation indicates that the result is a straight line with a negative slope. In order to
the speed of the motor to vary linearly with torque, the other terms in this expression
must be constant as the load changes. The terminal voltage supplied by the de power
source is assumed to be constant. If it is not constant, then the voltage variations will
affect the shape of the torque-speed curve. Consequently, in shunt de motor case the
flux is considered to be constant and thus will increase torque as the load current keep
increasing which leads to reduction in C/>p. Owing to the relative sizes of the two terms of
(4.43), their difference will increase in value, or the motor speed increases for a
particular value of "idR·

Accordingly, the torque-speed curve of Figure 4.14 would display less speed droop if
armature reaction were considered. Stated in term of speed regulation, armature reaction

54
can reduce the speed regulation of a de shunt motor. If a shunt motor is operating with a
weak shunt field, armature reaction can reduce <Pp sufficiently so that the loaded
exceeds the unloaded speed, giving a negative value of speed regulation. On the other
hand, the current is remains constant as well as speed of the motor.

4.8.4 Speed-Current Characteristic Curve

The shunt de motor speed-current curve which is illustrated Figure 4.15 exhibits the
nearest value to a constant speed characteristic of all de motor configurations when no
control of field current is exercised. When the speed is at 1800 rpm, the armature
current is 756.88 A. By rearrange the equation (4.43), the armature current Ia become
independent variable as indicate below:

I
a
= V, R-Ea ............................................... (4.48)
a

Armature resistance Ra and terminal voltage V, are considered constant in this analysis,
thus the curves only affected with the changes of internal generated voltage Ea with the
respect to armature current Ia. When the motor slows down, its internal generated
voltage drops (Ea=K<Ppwm) decreases, therefore the armature current in the motor Ia
increases drastically in wide range as illustrate in Figure 4.15.

The applied voltage V, is kept constant, so that the field current is remain constant.
Hence, flux per pole <Pp will have maximum value on no load and will decrease slightly
due to armature reaction as the load increases. However, in this study the flux is
considered to be constant and the armature reaction's effect is neglected. From the
expression of speed, nmR is directly proportional to back e.m.f. Eb or (V, -laRa) and
inversely proportional to the flux <Pp. Since the flux is considered to be constant as
mentioned above, therefore with increasing in armature current, the speed slightly falls
due to increase in voltage drop in armature circuit.

55
In view of the fact that there is a slight variation in speed of the shunt motor from no
load to full load and this slightly variation in speed can be made up by inserting
resistance in the shunt field and thus reducing the flux. As a result, shunt motor can be
used for loads which are totally and suddenly thrown off without ensuing in excessive
speed. Shunt motor being constant speed motor is best suited for driving of line shaft,
machine lathe, milling machine, conveyor, fan and for all purposes where constant
speed is required. It is not suitable for use with flywheel or with fluctuating loads or for
parallel operation due to its constant speed characteristic.

4.8.5 Speed-Output Power Performance Curve

From speed-rated output power curve illustrated in Figure 4.16, the design motor
produces an output power of 400 hp when the rated speed of 1800 rpm. The equation
(4.49) defines the relationship between speed and output power.

Po"'= l"dROJm •• •• •••••• · ••• ·• · •· ·••• •• •••••·· •• ••· •••• •• (4.49)

For this analysis, the output power Pout is increased when developed rated torque TdR

increases and the motor speed Wrn decreases. The analysis is true based on rearranging
equation (4.49) which results:

"[dR = Po"' . •......... ••............................... (4.50)

OJm

Hence, the design meet the specification given as the motor produce the rated output
power of 400 hp when the motor's speed is 1800 rpm. DC motor is used where a
substantially constant speed is required as the machine shop drives.

56
4.8.6 Speed-Efficiency Performance Curve
MATLAB program also produced the efficiency curve of Figure 4.17 for 400-hp de
shunt motor over the load torque range from a small value to approximately 150 percent
of rated torque. From Figure 4.17, it is noted that the efficiency of shunt motor at rated
speed of 1800 rpm successfully meet the specified design goal of 95 percent. This
relationship is best described by equation (4.51 ):

1JR = p'"' ····•• •••••·········· ··• ••••····· ............ (4.51)

~n

Input power P 1n is assumed to be constant, thus the efficiency of the motor is increases
as the output power Pout also increases. As mention earlier, with increasing of Pout the
speed will drop respectively. So, when the speed decreases in small variation, the
efficiency is rapidly increases in wide range of values.

The efficiency remams above 90 percent for the developed rated torque that
approximately above 50 percent of the rated value. However, it drops off
characteristically for light loads as the near constant rotational and field winding
become comparable to the output power in value. The armature copper loss varies as the
square of the current, so this loss termed as variable loss. The efficiency of the shunt
motor becomes high when variable loss is equal to the constant loss. For this shunt
motor case of near-constant speed and voltage operation, any core losses of the
armature have been absorbed in the Ppwvalue.

57
 CHAPTERS

CONCLUSION AND RECOMMENDATION

In the late 1800s, several inventors built the first working motors, which used direct
current (DC) power. After the invention of the induction motor, alternating current (AC)
machines largely replaced DC machines in most applications. However, DC motors still
have many uses and demands from customer. Due to its outstanding capability, a good
and significant design of de motor is essential in order to meet customer's requirement.
The design phases definitely require several stages from calculating the developed
torque until formulating MATLAB program to produce the required analysis. The
analysis from MATLAB with regard to performance specifications given by the
customer will reflect the accuracy of overall design procedures.

Shunt motors use high resistance field windings connected in parallel with the armature.
By varying the field resistance, it changes the motor speed. Shunt motors are prone to
armature reaction, a distortion and weakening of the flux generated by the poles that
result in commutation problems evidenced by sparking at the brushes. Installing
additional poles, called interpoles, on the stator between the main poles wired in series
with the armature reduces armature reaction. DC motors are classified or identified
according to the field winding connection.

Significantly different torque-speed characteristics are exhibited by de motors

depending on the field winding connection configuration chosen. The characteristic
curve displays a less speed drop when increasing the torque if armature reaction were
considered. Speed-current characteristic curve exhibits the nearest value to a constant
speed characteristic when no control of field current is exercised. For speed-output
power, the design is accurately meet the requirement where for speed of 1800 rpm, the
output power is 400 hp. The assessment of speed-efficiency curve is correct as it meet
the performance requirement. As the conclusion, the objectives of this project have been
successfully achieved and the use of MATLAB in magnet circuit and performance
analysis was found to be very applicable, imperative and beneficial.

58
As a recommendation, the project on designing shunt de motor can be improved by
adding graphical user interface or GUI as the main interface to the customer to insert
any specifications desired and will automatically generate the correct performance
analysis for the design machine. A graphical user interface (GUI) is a user interface
built with graphical objects, such as buttons, text fields, sliders, and menus. In general,
these objects already have meanings to most computer users. Applications that provide
GUis are generally easier to learn and use since the person using the application does
not need to know what commands are available or how they work. The action that
results from a particular user action can be made clear by the design of the interface.
Thus, by implementing GUI, the user can make any changes or modification to the
specification which in tum will result different plot-curves analysis. This will ease the
user to do comparison on dissimilar machine design and choosing the appropriate
design based upon their application's requirement.

The project can be improved by implement the actual prototype of the de motor design.
This only can be done if all the necessary equipments are provided. The mechanical
design of the motor can be tested whether it meet the requirement based on MATLAB
analysis. By implementing both hardware and software, the accuracy of the design is
increased and can fully satisfy the user's requirement.

59
 REFERENCES

[1] G.R. Siemon and A. Straughen, Electric Machines, Addison-Wesley

Publishing Company, New York, 1982.
[2] David R. Carpenter, Electrician's Technical Reference (Motors), Delmar
Publishers, New York, 1998.
[3] R.K. Rajput, Direct Current Machines, Laxmi Publications (P) Ltd, New Delhi,
1993.
[4] Stephen J. Chapman, Electric Machinery and Power System, McGraw-Hill
Publishing Company Limited, New York, 2002.
[5] I J Nagrath and D P Kothari, Electrical Machines Second Edition, Tata
McGraw-Hill Publishing Company Limited, New Delhi, 1997.
[6] Chee-Mun Ong, Dynamic simulation of Electric Machinery Using MATLABI
Simulink, Prentice Hall Ptr, New Jersey, 1998.
[7] Kenneth R. Demarest, Engineering Electromagnetics, Prentice Hall Ptr, New
Jersey, 1998.
[8] Steven J. Marrano and Craig DiLouie, Electrical System Design & Specification
Handbook For Industrial Facilities, The Fairmont Press Inc, GA,1998.
[9] L.O. Dallin, BTSJ Septum Magnets, CLS Design Note-2.1.41 Rev.O, University
of Saskatchewan Saskatoon, Canada, 2000.
[10] J.B. Gupta, Theory & Performance of Electrical Machines, SSMB Publishing
Division, India, 1997.
[11] The MathWorks. MATLAB Student Version Learning MATLAB 6 (Release 12),
2nd printing, New York, 2001.
[12] http://www.electricmotorwarehouse.com/NEMA frame info.htm
[13] http://www.google.com/dc machine/design consideration.htm
[14] http://www .mathworks.com/access/helpdesklhelp/techdoc/leam MATLAB/ch
1intro.shtrnl#12671
[15] http://www.mathworks.com/access/helpdesklhelp/pdf doc/ MATLAB/
using ml.pdf

60
 APPENDIX A

c p

I Tu
,i~ I
I
I !l: II
2F BA

Basic NEMA Frame Dimension

168AT 15.88 1.75 0.875 8.00 3.25 7.88 4.00 3.25

188AT 19.25 2.25 1.125 9.00 2.75 9.50 4.50 3.75
219AT 22.75 2.75 1.375 11.00 3.50 11.00 5.25 4.25
258AT 26.62 3.25 1.625 12.50 4.25 13.00 6.25 5.00
288AT 30.75 3.75 1.875 14.00 4.75 14.00 7.00 5.50
323AT 27.62 4.25 2.125 9.00 5.25 16.00 8.00
365AT 33.12 4.75 2.375 12.25 5.88 18.00 9.00
405AT 36.00 5.25 2.625 13.75 6.62 20.00 10.00
505AT 50.12 6.50 3.250 18.00 8.50 25.00 12.50 10.00
583AT 53.62 7.50 3.750 16.00 10.00 29.00 14.50 11.50
687AT 68.38 9.50 4.500 32.00 10.00 29.50 14.50 11.50
688AT 72.88 9.50 4.500 36.00 11.50 35.00 17.00 13.50
NEMA Frame Designation (nnit in inch)

61
 APPENDIXB

DC Machine Sizing Value

DC machine sizing value

3.5

"~
,
.5 2.5
u.
~
~
a 2
c
B
•
..E
~

-~ 1.5

0.5

7 10 50 100 500 1000

power,hp

62
 APPENDIXC

Specification

Armature diameter and No

length sizing

Select no. armature slots

Yes

Size armature slot and

conductor

No

No

Acceptable

Commutator design

Field pole design

Logic flowchart for armature design

63
 APPENDIXD

MATLAB Source Codes for Data Input of DC Motor

%Specification of de motor
VtR=415; %Rated terminal voltage(V)
PsR=400; %Rated power(hp)
nmR=l800; %Rated speed(rpm)
eTaR=0.95; %Efficiency
f=SO; %Frequency(Hz)
nmax=3000; %Maximum speed(rpm)
p=4; %Number of pole

%1st stage:Volume and bore sizing

%Set armature diameter( d)
Df=29; %Outside frame diameter. From NEMA dimension,P=Df=29 inch.
d=0.6*Df; %din range of 0.55Df<d<0.65Df. Choose midrange(0.6Df)
%Rated developed torque(ft.Lb). Assumption of 5% rotational losses.
TdR=5250*PsR/0.95/nmR;
%Armature stack length( Ia)
vT=1.91; %Normalized sizing value; taken from de sizing value
la=vT*TdR/d"2; %Unit in inch

%2nd:Armature Design
%Number of armature slots(N)
lambdal=l;
Nl=pi*d/lambdal;
N=54; %N must be an even number,thus choose N=54
lambda=pi*d/N; %Armature slot pitch(inch)
%Voltage and torque constant(kE and kT)
nc=3; %Number of coils per slot
Z=2*nc*N; %Total conductor of armature winding
a=4; %Number of lap winding( consider simplex,a=p)
kE=p*Z/(a*60*10"8); %Unit in V/lines.rpm
kT=p*Z/(a*8.525*10"8); %Unit in ft.Ib/lines.A

64
%Rated current and flux per pole(IaR & phiR)
IaR=746*PsR/eTaR/VtR %Unit in Ampere
phiR=TdR/kT/IaR; %Unit in Megalines

%Slot design
bs=0.45; %Armature slot width for irregularity material
ds=1.15; %Slot depth for irregularity material
triA=4200; %Self-ventilated machine fall in midrange of 3200<triA,5200
A/in"2
sa=IaR/a/triA; %Armature conductor area (in"2)
wc=O.llO; %To have bs in midrange(0.4<bs<0.5), select armature
conductor with bare copper width(wc)=O.ll
dc=sa/wc; %Conductor height(inch)

%Coil characterization
%Complete end-turn overhang(OH)
se=0.125; %Slot wedge
be=0.5;
ge=ds;
de=se+bs;
lambdaC=pi*( d-ds)/N;
alpha=asin( de/lambdaC);
tC=(N/p)*lambdaC;
fe=(tC/2)*tan(alpha);
OH=be+fe+ge;
%Mean-length turn of armature coii(MLTa)
x=tC/cos(alpha);
y=2*be;
z=2*ge;
MLTa=2*(x+y+z+la);
%Armature resistance(Ra)
T=150; %Average conductor temperature(degC)
rho=( (234.5+ T)/254.5)*0.69* lOe-7;
Ra=(rho*MLTa*Z/2)/a" 2/sa

65
%Flux density check(Btra)
wtr= (pi*( d-2*ds )/N)-bs;
tp=9.S*Iambda;
chi=p*tp/pi/d; %Field pole arc-to-pole pitch ratio
SF=0.96;
q=chi*N*wtr*la*SF;
Btra=phiR*p/q;

%Commutator design
%Number of commutator bars(Kc)
Kc=nc*N;
%Average volts per bar( ecav)
ecav=VtR*p/Kc;
%Commutation dimension
dc=34000/nmax;
%Brush dimension(tb)
tb= (pi*dc/Kc)*( nc+O. 5);
%Total width of nb brushes per set(nbwb)
triB=SO; %Eiectrograhitic brushes current density(A/inA2)
nbwb= ( 2 *IaR)/p/tri B/tb;

%3rd stage: Field pole design

%Air gap length
delta=0.0335*sqrt( d);
%Cross-sectional area of fame perpendicular to flux flow
LF=l.2; %Leakage factor(1.1<LF<1.2)
Af=LF*phiR/200000;
wf=la+OH;
tf=Af/wf; %Frame thickness
hp=O.S*(Df-2*delta-2*tf-d); %Height of field pole
lsk=0.9*hp; %Pole shank
lsh=hp-lsk; %Pole shoe length
%Field pole width
wsk= ( LF*phiR)/110000/Ia/SF;

66
>> info
d=
17.4000
TdR =
1.2281e+003
Ia =
7.7474
N1 =
54.6637
lambda=
1.0123
Z=
324
kE =
5.4000e-008
kT =
3. 8006e-007
IaR =
756.8802
phiR =
4.2692e+006
sa =
0.0451
we=
0.1100
de=
0.4096
ge =
1.1500
de=
0.5750
lambdaC =
0.9454
alpha =
0.6538

67
tC =
12.7627
fe =
4.8896

OH =
6.5396
X=
16.0786
y=
1
Z=
2.3000
MLTa =
54.2521
rho=
1.0425e-006
Ra =
0.0127
wtr =
0.4285
tp =
9.6168
chi=
0.7037
q =
121.1005
Btra =
1.4101e+005
Kc =
162
ecav =
10.2469
de=
11.3333

68
tb =
0.7692
triB =
80

nbwb =
6.1496
delta =
0.1397
Af =
25.6151
wf=
14.2871
tf =
1.7929
hp =
3.8674
lsk =
3.4806
Ish=
0.3867
wsk =
6.2619

69
 APPENDIXE

MATLAB Source Codes ofMaguetization Curve for M-22 ESS, 26-gage

<Hm22.m> B-H interpolation routine
function y=Hm22(Bx)
%Hm22 is field pole and armature ferromagnetic materiai(M-22, 26-gage ESS)
% B-H values that follow are valid for M-22, 26 ga. ESS
B=[O 0.4 0.8 2 8 9.2 1112.5 13.8 15.2 16.5 18 19 19.6 19.8 20 20.4 20.6 21.7
28]*6.45e3 %Lines/sq.in
H=[O 0.18 0.26 0.38 1.4 1.8 3 5 9.5 28 70 160 260 370 420 520 825 1000 2000
8000]*2.021 %A-t/in
%Activate to plot B-H curve
%m=15; plot(H(1:m),B(1:m)); grid; pause; %Linear plot
%xlabel ('Magnetizing Intensity (H), A-t/inch');
%ylabel ('Flux Density (B), kilolines/sq-in');
%title ('Magnetization Curve for M-22 ESS, 26 gage');
n=length(B); k=O;
if Bx==O; k=-1; y=O; end
if Bx<O; k=-1; y=O; disp('WARNING- Bx<O, Hm22=0 returned'); end
if Bx>B(n); y=H(n); k=-1; disp('CAUTION- Beyond B-H curve'); end
for i=1:n
if k==O & (Bx-B(i))<=O; k=I; break; end
end
if k>O;
y= H( k-1) +( Bx-B( k-1) )/ ( B( k)- B( k-1) )*(H (k)-H (k-1));
else;
end

70
 APPENDIXF

MATLAB Source Codes of Magnetization Curve for AISI 1010 Steel Frame

<HIOIO.m> B-H interpolation routine

function y=y1010(Bx);
%Hx is AISI 1010 steel frame
%B-H values that follow are valid for 1010 steel plate
B=[O 2.6 5.2 7.7 10.3 12.9 18.1 24.5 31 38.7 51.6 64.5 71 77 83.8 90.3 97 103
110 116 122 129 135 142 150 260]*1000;
H=[O 0.6 1.3 2 2.5 2.8 3.4 4 4.7 5.5 6.9 8.5 9.9 11.9 14.3 19.2 28.3 46.5 86.9
155.6 242.5 444.6 647 950 2021 4e4];
%Activate values to plot B-H curve
%m=26; plot(H(1:m),B(1:m)); grid; pause; %Linear plot
%xlabel ('Magnetic Field Intensity (H), A-t/inch');
%ylabel ('Flux Density (B), kilolines/sq-in');
%title ('Magnetization Curve for AISI 1010 Steel Frame');
n=length(B); k=O;
if Bx==O; k=-1; y=O; end
if Bx<O; k=-1; y=O; disp('WARNING -Bx<O, Hx=O returned'); end
if Bx>B(n); y=H(n); k=-1; disp('CAUTION -Beyond B-H curve'); end
for i=1:n
if k==O & (Bx-B(i))<=O; k=i; break; end
end
if k>O;
y=H(k-1)+(Bx- B(k-1))/(B(k)- B(k-1))*(H(k)- H(k-1));
else;
end

71
 APPENDIXG

MATLAB Source Codes of Magnetization Curve for DC Motor

<Magnetcurve.m>

clear;
info,
kE= 1.666667e-10*p* N*2*nc/a;
kT= 1.173e-9*p*N*2*nc/a;
phiR=TdR/kT/IaR;
%Plot magnetization curve for de motor
%Build apparent tooth flux density array
Bt=linspace(O,lOOOOO,SOO); %generate N points(100) between 0 and 100000
for i= 1: length(Bt); Ht(i)=hm22(Bt(i)); end
lam3=pi*(d-4/3*ds)/N; %slot pitch calculated at one-third tooth depth from the
bottom
kt=3.2* (SF*Iam3/ (lam3-bs)-1); %permeability of parallel air path
for i=1:1ength(Ht)
Ba(i)=Bt(i)+kt*interpi(Bt,Ht, Bt(i)); end
taut=fix(chi*N/p)+O.S; %Teeth per pole span
At3=SF*Ia*(lam3-bs)*taut; %Total tooth area @ 1/3 depth
dshft=4.0; %Armature dimension
rc=( d-2*ds-dshft)/2;
Ac=2*SF*Ia*rc; %Rotor core area
Af=wf*tf; %Frame area
taup=taut*p/ N*pi/ 4*(d+2*delta); %Pole arc
Ask=SF* (la+0.125)* wsk; %Pole shank area
Ash3=SF* (la+0.125)* (2*wsk+taup)/3; %Shoe area@ 1/3 depth
qty=lambda* (S*delta+bs);
ks=qty/ (qty-bs"2); %Carter coefficient
phip=linspace(0,1.2*phiR,500); %generate flux per pole point within range 0 to
200
phip=[phip phiR]; m=length(phip);
for i=1:m
ATt=interpl (Ba,Ht,phip(i)/ At3)*ds;
ATc=hm22(phip(i)/ Ac)* pi/2/p* (d-ds-rc/2);

72
ATf=hx(LF* phip(i)/ Af/ 2)* pi/2/4*(Df-tf);
ATsh=hm22(LF* phip(i)/ Ash3)* Ish;
ATsk=hm22(LF* phip(i)/ Ask)*(Df-d-2*delta-2*1sh-2*tf)/2;
ATg=p*ks*delta*phip(i)/ pi/ 0.665/ d/ Ia/ 3.2;
ATp(i)=ATg+ATsk+ATsh+ATf+ATc+ATt;
end
plot(ATp(1:m-1), phip(1:m-1)/1000, ATp(m), phip(m)/1000, 'o');
title('Magnetization curve for de machine'); grid;
xlabei('MMF per pole,A-t');
ylabei('Fiux per pole, Kilolines');

73
 APPENDIXH

MATLAB Source Codes of Performance Analysis for DC Shunt Motor

%Plot developed torque-speed curve for shunt excited de motor with rated voltage
applied.
%Armature reaction neglected
clear; elf;
VtR=415; %Rated terminal voltage(V)
PsR=400; %Rated output horsepower(hp)
nmR=1800; %Rated speed(rpm)
Ra=0.01271; %Armature resistance( Ohm)
eTaR=0.95; %Efficiency
a=0.4; b=1.2e-5; %F&W loss equation coefficients
%Rated developed torque( unit in ft.Lb). Assumption of 5% rotational losses.
TdR=5250*PsR/0.95/nmR
%Rated armature current (unit in Ampere)
IaR= 746*PsR/eTaR/VtR;

load ('C:\MATLAB6\fyp\eif.txt'); %Load eif data

m=length(eif); npts=200;
KphiR=eif(l: m,l)/(nmR*pi/30); If=eif(l: m,2);
%Develop rated field current (If)
IfR= interp 1( Kphi R,If,(VtR- IaR *Ra )/ ( nmR *pi/30));
Rfeq=VtR/IfR; %Total shunt field circuit resistance
npts=25; Ia=linspace(1.5*PsR*746/VtR, 0, npts);

%Plot torque versus speed (Td-nm)

for i=l:npts
Kphi=interpl(If, KphiR, IfR);
Td(i)=Kphi*Ia(i);
wm(i) =VtR/Kphi-Td( i)*Ra/Kphi,.., 2;
nm(i)=wm(i)*30/pi;
Pfw=a*nm(i)+b*nm(i),..,2. 7;
eff(i)=(l-(Pfw+Ia(i)A2*Ra+VtR+IfR)/ (IfR+Ia(i))/VtR)*lOO;
Ps(i)=(Td(i)*wm(i)-Pfw) I 746;

74
 if eff(i)<O; m=i-1; break; end %F&W over driving
end

subplot(2,2,1); plot(0,0,0.96*Td(l:m), nm(l:m), 0.96*TdR, nmR, 'r:o'); grid

title ('Shunt de motor');
ylabei('Speed, rpm'); xlabei('Torque, ft-Lb');
subplot(2,2,2); plot(O,O,Ia(l:m)+lfR, nm(l:m), IaR+lfR, nmR, 'g:*'); grid
title ('Shunt de motor');
ylabei('Speed, rpm'); xlabei('Line current, A');
subplot(2,2,3); plot(Ps(l:m), nm(l:m), PsR, nmR, 'b:o'); grid
title ('Shunt de motor');
ylabei('Speed, rpm'); xlabei('Output power, hp');
subplot (2,2,4); plot(eff(l:m), nm(l:m), 95, nmR, 'c:*'); grid
title ('Shunt de motor');
ylabel ('Speed, rpm'); xlabei('Efficiency, %')

75
 APPENDIX I

Eif.txt- data input to be loaded into <Shunt.m>

5.OOOOOOOOOOOOOOOOe+OOO O.OOOOOOOOOOOOOOOOe+OOO
3.37 54945320409560e+OO I 5 .OOOOOOOOOOOOOOOOe-002
6.25 OOOOOOOOOOOOOOe+OO I I. OOOOOOOOOOOOOOOOe-00 I
9.1148160780059280e+OO I 1.5000000000000000e-OO I
1.1961242440187520e+002 2.0000000000000000e-001
1.4780578760673 590e+002 2.5000000000000000e-OO I
I. 7564124 713592920e+002 3 .OOOOOOOOOOOOOOOOe-00 I
2.0303179973074300e+002 3.5000000000000000e-001
2.2989044213246520e+002 4.0000000000000000e-OO 1
2.5613017108238380e+002 4.5000000000000000e-001
2.8166398332178680e+002 5.0000000000000000e-OOI
3.06404875 59196200e+002 5.5000000000000000e-00 I
3.3026584463419720e+002 6.00000000000000 I Oe-00 I
3.5315988718978060e+002 6.5000000000000000e-OOI
3. 7500000000000000e+002 7.00000000000000 I Oe-00 I
3.9572523670681530e+002 7 .SOOOOOOOOOOOOOOOe-00 I
4.1537887855487400e+002 8.0000000000000000e-001
4.3403026368949550e+002 8.5000000000000010e-OOI
4.5174873025599940e+002 9.0000000000000000e-001
4.686036163997051 Oe+002 9 .5000000000000000e-OOI
4.8466426026593220e+002 I.OOOOOOOOOOOOOOOOe+OOO
5.0000000000000000e+002 1.0500000000000000e+OOO
5.1466839300048620e+002 1.1 OOOOOOOOOOOOOOOe+OOO
5.2867987367899990e+002 1.1500000000000000e+OOO
5.4 203 309 57 0040890e+002 1.2 OOOOOOOOOOOOOOOe+OOO
5.54 72671272958040e+002 1.2500000000000000e+OOO
5.667593 784313821 Oe+002 1.3000000000000000e+OOO
5. 781297 464 7068120e+002 1.3500000000000000e+OOO
5.8883647051234530e+002 1.4000000000000000e+OOO

76
5.9887820422124170e+002 1.4500000000000000e+OOO
6.0825360126223 800e+002 1.5000000000000000e+OOO
6.1696131530020160e+002 1.5500000000000000e+OOO
6.2500000000000000e+002 1.6000000000000000e+OOO
6.323 74094 77997800e+002 1.6500000000000000e+OOO
6.39111182072391 00e+002 I. 7000000000000000e+OOO
6.4524463006297140e+002 I. 7500000000000000e+OOO
6.5080780693 7 4521 Oe+002 1.8000000000000000e+OOO
6.5583408088156570e+002 1.8500000000000000e+OOO
6.60356820081 04470e+002 1.9000000000000000e+OOO
6.644093927216221 Oe+002 1.9500000000000000e+OOO
6.6802516698903030e+002 2.0000000000000000e+OOO
6. 71237511 06900200e+002 2.0500000000000000e+OOO
6.7407979314727020e+002 2.1000000000000000e+OOO
6.7658538140956700e+002 2.1500000000000000e+OOO
6.7878764404162560e+002 2.2000000000000000e+OOO
6.8071994922917840e+002 2.2500000000000000e+OOO
6.8241566515795820e+002 2.3000000000000000e+OOO
6.83908160013697 50e+002 2.3 500000000000000e+OOO
6.8523080198212920e+002 2.4000000000000000e+OOO
6.8641695924898580e+002 2.4500000000000000e+OOO
6.8750000000000000e+002 2.5000000000000000e+OOO
6.8851329242090460e+002 2.5 500000000000000e+OOO
6.89490204697 4321 Oe+002 2.6000000000000000e+OOO
6.9046410501531520e+002 2.6500000000000000e+OOO
6.9146836156028670e+002 2. 7000000000000000e+OOO
6.9253634251807910e+002 2.7500000000000000e+OOO
6.93 70 141607442530e+002 2.8000000000000000e+OOO
6.9499695041505780e+002 2.8500000000000000e+OOO
6.9645631372570930e+002 2.9000000000000000e+OOO
6.9811287419211250e+002 2.9500000000000000e+OOO

77