Electrical Machine Design -21EE643

Field winding Design

2.9 Pole Design :
The design of pole involves the determination of area of cross-section of the poles, their height
and the design of field windings.

2.9.1 Area of poles

Flux in pole body 𝜙𝑝 = Leakage co-efficient X Useful flux per pole = 𝐶𝑙 × 𝜙 -------1
Where, 𝐶𝑙 is the leakage coefficient it values vary from 1.12 to 1.16
Flux density in the pole body can be assumed to lie between 1.2 to 1.7 Wb/m2 for laminated
poles
𝜙𝑝 𝐶𝑙 ×𝜙
∴ 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑜𝑙𝑒 𝑏𝑜𝑑𝑦 𝐴𝑝 = = --------2
𝐵𝑝 𝐵𝑝
Length of pole is taken less than that of armature in order to permit end play and avoid magnetic
centring. The difference in the length is about 10 to 15mm.
Length of pole 𝐿𝑝 = 𝐿 − (0.001 𝑡𝑜 0.015)
𝐴𝑝 𝜙𝑝
∴ 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑝𝑜𝑙𝑒 𝑏𝑜𝑑𝑦 𝑏𝑝 = =
𝐿𝑝𝑖 𝐵𝑝 𝐿𝑝𝑖
Where 𝐿𝑝𝑖 =net iron length of pole core =0.9𝐿𝑖
For machines using laminated core for poles, the axial length of poles is equal to that of armature
∴ 𝐿𝑝𝑖 = 𝐿𝑖
2.9.2 Height of poles:
• Height of the pole should be selected in such a way, that it conveniently accommodate the total
ampere turns to be provided on the pole in the form of exciting coil.
• Height of pole is calculated using field mmf at full load value.
• The field mmf required at full load by using output characteristics of the machine. Assume
suitable value of filed mmf at full load in order to prevent the effects of armature reaction
becoming too excessive, the field system is so designed that the mmf developed by the field
coil is sufficiently powerful in comparison with the mmf developed by the armature at full load
• The relationship between field mmf at full load
𝐴𝑇𝑓𝑙 𝑓𝑖𝑒𝑙𝑑 𝑚𝑚𝑓 𝑎𝑡 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑
= = 1.1 𝑡𝑜 1.25
𝐴𝑇𝑎 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑚𝑚𝑓 𝑎𝑡 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑

2.9.3 Height of the filed coil :

The relationship between field mmf at full load
𝐴𝑇𝑓𝑙 𝑓𝑖𝑒𝑙𝑑 𝑚𝑚𝑓 𝑎𝑡 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑
= = 1.1 𝑡𝑜 1.25 -------1
𝐴𝑇𝑎 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑚𝑚𝑓 𝑎𝑡 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑
𝑍 1𝑎 𝐼 𝑍
Armature full load ampere turns per pole, 𝐴𝑇𝑎 =(𝐼𝑎 × 2) 𝑃 = ( 2𝑃 ) -------2
Substituting the equation 1 in 2
𝐼𝑎 𝑍
∴ 𝐴𝑇𝑓𝑙 = 1.1 𝑡𝑜 1.25 ( 2𝑃 )
More over 𝐴𝑇𝑓𝑙 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑙𝑒𝑑 𝑐𝑜𝑖𝑙 × 𝑎𝑚𝑝𝑒𝑟𝑒 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡
𝐴𝑇𝑓𝑙 = ℎ𝑓 × 𝑎𝑚𝑝𝑒𝑟𝑒 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 --------3
Using equation 3 approximate height of the field coil can be calculated.
𝐴𝑇𝑓𝑙 = 𝐼𝑓 × 𝑇𝑓

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Electrical Machine Design -21EE643

Since𝐼𝑓 = 𝛿𝑓 𝑎𝑓
𝐴𝑇𝑓𝑙 = 𝛿𝑓 𝑎𝑓 𝑇𝑓 ------- 4
Where copper in each coil = 𝑎𝑓 𝑇𝑓 = 𝑠𝑓 𝑑𝑓 ℎ𝑓 --------5
2 𝜌𝑙𝑚𝑡𝑓 𝑇𝑓
Copper losses in each filed coil = 𝐼𝑓2 𝑅𝑓 = (𝛿𝑓 𝑎𝑓 ) ( ) = 𝛿𝑓2 𝜌 𝑙𝑚𝑡𝑓 𝑎𝑓 𝑇𝑓 -------6
𝑎𝑓
𝜌𝑙𝑚𝑡𝑓 𝑇𝑓
𝑅𝑓 = 𝑎𝑓
Substituting equation 6 in 5
Copper losses in each filed coil = 𝛿𝑓2 𝜌𝑙𝑚𝑡 𝑆𝑓 𝑑𝑓 ℎ𝑓 ---------7
Permissible copper loss in the field coil = 𝑝𝑓 × 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑠𝑢𝑟𝑔𝑎𝑐𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑖𝑙 ---------8
Heat dissipated by the top and bottom surface of the field coil is quite negligible. Thus
cooling surface of the field coil is given by = 2𝑙𝑚𝑡𝑓 ℎ𝑓 --------9
Substituting equation 9 in 8
Hence Permissible copper loss in the field coil = 𝑝𝑓 × 2𝑙𝑚𝑡𝑓 ℎ𝑓 = 2𝑝𝑓 𝑙𝑚𝑡𝑓 ℎ𝑓 -------10
For temperature rise with in the specified limit , the copper losses in the field coil should be
equal to the permissible losses. There fore equating equation 7 and 10
𝛿𝑓2 𝜌𝑙𝑚𝑡 𝑠𝑓 𝑑𝑓 ℎ𝑓 = 2𝑝𝑓 𝑙𝑚𝑡𝑓 ℎ𝑓
2𝑝𝑓
Current density in the coil 𝛿𝑓 = √ ----------11
𝜌𝑠 𝑓 𝑑𝑓

Substituting 𝛿𝑓 from equation 11 and 𝑎𝑓 𝑇𝑓 from equation 5, in Equation 4

2𝑝𝑓
𝐴𝑇𝑓𝑙 = √𝜌 𝑠 × 𝑆𝑓 𝑑𝑓 ℎ𝑓 --------12
𝑓 𝑑𝑓

Substituting 𝜌 = 2 × 10−8 Ω-m/mm2 in equation 12

2𝑝𝑓 2𝑝𝑓 𝑠𝑓 𝑑𝑓
𝐴𝑇𝑓𝑙 = √𝜌 𝑠 × 𝑠𝑓 𝑑𝑓 ℎ𝑓 √= × ℎ𝑓 = 104 ℎ𝑓 √𝑝𝑓 𝑠𝑓 𝑑𝑓 ---------13
𝑓 𝑑𝑓 2 × 10−8
From Equation 3
𝐴𝑇
𝑎𝑚𝑝𝑒𝑟𝑒 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 = ℎ 𝑓𝑙 -------14
𝑓
Substituting equation 13 in 14
104 ℎ𝑓 √𝑝𝑓 𝑠𝑓 𝑑𝑓
𝑎𝑚𝑝𝑒𝑟𝑒 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 = = 104 √𝑝𝑓 𝑠𝑓 𝑑𝑓 -------15
ℎ𝑓
𝐴𝑇𝑓𝑙
∴ 𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑙𝑒𝑑 𝑐𝑜𝑖𝑙 ℎ𝑓 = --------16
𝑎𝑚𝑝𝑒𝑟𝑒 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡
Substituting equation 15 in 16
𝐴𝑇𝑓𝑙 104 𝐴𝑇𝑓𝑙
ℎ𝑓 = =
104 √𝑝𝑓 𝑠𝑓 𝑑𝑓 √𝑝𝑓 𝑠𝑓 𝑑𝑓
Where,
𝛿𝑓 – Current density in the filed coil , A/ mm2
𝑎𝑓 – Sectional area of the conductor of field winding , mm2
𝑇𝑓 – Total number of turns in each field coil
ℎ𝑓 – Height of the filed coil, m , 𝑑𝑓 – Depth of the field coil, m , 𝑠𝑓 – Copper space factor
𝐼𝑓 – Current in the field coil in the field winding, A
𝑅𝑓 – Resistance of the field winding
𝜌 - Specific resistance of the copper, 2 × 10−8 Ω-m/mm2
𝑙𝑚𝑡𝑓 – mean length of turns of field winding, m
𝑝𝑓 – Permissible loss per m2 of cooling surface, w/m2

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Electrical Machine Design -21EE643

2.10 Dimension of the yoke: The dimension of yokr are determined by the value of flux in the yoke
𝜙𝑦 . The leakage coefficient for yoke carries half of the total flux.
1 𝐶𝑙 𝜙
Flux in the yoke 𝜙𝑦 = 𝐿𝑒𝑎𝑘𝑎𝑔𝑒 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑋 2
𝑢𝑠𝑒𝑓𝑢𝑙 𝑓𝑙𝑢𝑥 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒 = 2
Flux density in cast steel yoke is normally equal to 1.2 wb/m2 while in laminated yoke it is about
1.5 𝑤𝑏/m2.
𝜙𝑦
Area of the yoke 𝐴𝑦 = 𝐵𝑦
𝜙𝑦
Depth of the yoke 𝑑𝑦 = 𝐵
𝑦 𝐿𝑦𝑖

Where 𝐵𝑦 = Flux density in the yoke and 𝐿𝑦𝑖 = net axial length of yoke.
(Derive an Expression for total ampere turns of magnetic path)
2.11 Magnetic Circuit: Magnetic circuit of dc machine consist of the following parts
• Yoke
• Pole &Air gap
• Armature teeth
• Armature core
Calculation of ampere tuns in the yoke:
a) Find out the ampere per meter of flux path length , Hy corresponding to yoke flux density
By, using the magnetisation curve of the material of yoke.
b) Calculate the mean diameter of he yoke 𝐷𝑚𝑦 = 𝐷 + 2𝑙𝑔 + 2ℎ𝑝 + 𝑑𝑦 = 𝐷 + 2ℎ𝑝 + 𝑑𝑦
1 𝜋𝐷𝑚𝑦
c) Calculate the length of the mean flux path, ly in the yoke i.e 𝑙𝑦 = 2 [ ]
𝑃
d) Find out the total ampere turns, 𝐴𝑇𝑦 = 𝐻𝑦 × 𝑙𝑦
Calculation of ampere turns for the pole
a) Find out ampere turns per meter of flux path length 𝐻𝑝
b) Length of magnetic flux path in the pole 𝑙𝑝 = ℎ𝑝
c) Total ampere turns 𝐴𝑇𝑝 = 𝐻𝑝 × ℎ𝑝
Calculation of ampere turns for armature tooth
Total ampere turns 𝐴𝑇𝑖 = 𝐻𝑡 × ℎ𝑠
Where, 𝐻𝑡 – Flux path in the total teeth
ℎ𝑠 – Height of slots
Calculation of ampere turns for armature core
a) Fin out ampere turns per meter in the core 𝐻𝑐
b) Calculate the mean diameter 𝐷𝑚𝑐 = 𝐷 − 2ℎ𝑠 − 𝑑𝑐
1 𝜋𝐷𝑚𝑐
c) Calculate the length of magnetic path in the core 𝑙𝑐 = [ ]
2 𝑃
d) Determine the total ampere turns, 𝐴𝑇𝑐 = 𝐻𝑐 × ℎ𝑐
Total ampere turns per pole, for all the iron parts of the magnetic circuit is given by
𝐴𝑇𝑖 = 𝐴𝑇𝑦 + 𝐴𝑇𝑝 + 𝐴𝑇𝑖 + 𝐴𝑇𝑐
Normally all the iron parts of the magnetic circuit, of d.c machine require nearly 30 to 35% of the total no
load mmf.

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Electrical Machine Design -21EE643

2.12 Design of the field winding: Shunt winding must be designed to develop continuously
the ampere turn necessary to generate rated e.m.f at no load. The series winding should be designed
to develop the additional ampere turns needed to maintain constant output voltage under loaded
conditions.
2.12.1 Design of Shunt field winding: The aim in the design of shunt field winding is to
achieve the following information regarding this winding, based on the design information of the
pole and the voltage rating of the machine.
1. Cross sectional area of the conductor for the winding.
2. Current in the filed winding
3. Number of turns in the winding
4. Proper arrangement of winding
5. Resistance of the winding
6. Copper losses in the winding

Shunt field windings for small machines employ coild of a few hundred turns of small section
varnished covered wire. In compound machines , 80% of the winding space is taken up by shunt
field and the rest 20% by series field winding.

A. Design Procedure of shunt field winding :

( Discuss the design procedure of shunt field winding of d.c machine)
To design the shunt field winding following steps.
1. Assume a suitable depth 𝑑𝑓 , for given area of conductor
2. Calculate the length of mean turn 𝐿𝑚𝑡 = 2(𝐿𝑝 + 𝑏𝑝 ) + 2𝑑𝑓
3. Calculate the voltage across the shunt filed winding = (0.8 to 0.85)V and voltage across each
shunt filed coil is :
(0.8 to 0.85)V (0.8 to 0.85)V
𝐸𝑓 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠ℎ𝑢𝑛𝑡 𝑐𝑜𝑖𝑙𝑠 = 𝑃
Number of shunt coils will be as many as number of poles
𝜌 𝐿𝑚𝑡 𝑇𝑓
4. Area of each field coil 𝑎𝑓 = 𝑅𝑓
𝐸𝑓
𝐵𝑢𝑡 𝑅𝑓 = substituting this value in the above equation
𝐼𝑓
𝜌 𝐿𝑚𝑡 𝐼𝑓 𝑇𝑓 𝐴𝑇𝑓 𝜌 𝐿𝑚𝑡
Or area of filed conductor 𝑎𝑓 = =
𝐸𝑓 𝐸𝑓
5. Choose a suitable cross-section for the conductor. For small cross-section standard round wire
size should be used. For smaller cross section square or rectangular conductors should be used.
6. Calculate the winding height
The space for winding along the radial height is
ℎ𝑓 = ℎ𝑝𝑙 – height of shoe insulation and clearance
= ℎ𝑝𝑙 − (0.1 𝑡𝑜 0.2)ℎ𝑝𝑙 − (0.1 𝑡𝑜 0.15)𝜏
ℎ𝑓 ×𝑑𝑓
7. Number of turns of field winding 𝑇𝑓 = . Where, 𝑠𝑓 – space factor for the winding
𝑠𝑓
𝜌 𝐿𝑚𝑡 𝑇𝑓
8. Find the resistance of each field coil 𝑅𝑓 = 𝑎𝑓

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Electrical Machine Design -21EE643

𝐸
9. Find the value of shunt field current 𝐼𝑓 = 𝑅𝑓 .
𝑓
𝐼
10. Check for current density of the above value of shunt field current 𝛿𝑓 = 𝑎𝑓 , the value of
𝑓
2
current density should be between 1.2 to 2.5 A/mm .
11. Determine the field mmf 𝐴𝑇𝑓 = 𝐼𝑓 𝑇𝑓 , Check whether the mmf provided on the shunt field
is nearly equal to the value required.
12. Calculate the copper loss in each field coil 𝑄𝑓 = 𝐼𝑓2 𝑅𝑓 .
13. Calculate the cooling surface of the coil .
Cooling surface of each coil 𝑆 = 2𝐿𝑚𝑡 (𝑎𝑓 + 𝑑𝑓 )
14. Assume a suitable value of cooling co efficient
0.14 𝑡𝑜 0.16
Cooling co-efficient 𝑐 = 1+0.1𝑉𝑎
𝑄𝑓 × 𝑐
15. Calculate the temperature rise of the coil 𝜃𝑚 = . The value of temperature rise should
𝑆
be in the limit.
(Discuss the design procedure of series D.C. Motor)
2.12.2 Design of Series filed winding :Series field winding must be designed to develop about
15 to 20% of the full load ampere turns, in order to compensate the armature reaction at
full load and thus maintaining nearly constant output voltage across load. Series field
winding design is given below.
𝑎 𝐼 𝑍
1) Find out ampere turns 𝐴𝑇𝑠𝑒 = 0.15 𝑡𝑜 0.2 ( 2𝑃 )
2) Current in the series field winding 𝐼𝑠𝑒 = 𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑐𝑢𝑟𝑟𝑛𝑡 𝐼𝑎
𝐴𝑇𝑠𝑒
3) Calculate the number of turns per pole i.e 𝑇𝑠𝑒 = .
𝐼𝑠𝑒
4) Find out modified amp, turns per pole 𝐴𝑇𝑠𝑒 = 𝑇𝑠𝑒 × 𝐼𝑠𝑒 .
5) Assume suitable value of current density 𝛿𝑠𝑒 in this winding. Normally, current density
current can be assumed varying from 2 to 2.3 A/mm2.
𝐼
6) Find out sectional area of conductor i.e. 𝑎𝑠𝑒 = 𝛿𝑠𝑒 .
𝑠𝑒
7) Make proper arrangement of the turns in the space available for this winding i.e
winding depth and 20% of the exciting coil height, hf and finalise the size of the
rectangular conductor.
8) Calculate the modified area of conductor with size chosen. Find out the resistance of
𝜌 𝑙𝑚𝑡𝑠𝑒 𝑇𝑠𝑒
the winding 𝑅𝑠𝑒 = 𝑎𝑠𝑒
Mean length of the turn of this winding will be the same as for the shunt winding.
2
9) Calculate the copper losses in the series field winding i.e = 𝐼𝑠𝑒 𝑅𝑠𝑒
1400 𝑡𝑜 1600 ×𝑝𝑓 o
10) Temperature rise 𝜃 = C
1+0.07 𝑣
Where, 𝑝𝑓 – losses of the field system per unit cooling surface , W/cm2
𝑣 – peripheral speed of armature in m/sec.
Based on the design values of the field system, the temperature rise should be
calculated and confirmed that it is with in the limit.

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