Electrical Machine Design V Rajini Full Chapter PDF
Electrical Machine Design V Rajini Full Chapter PDF
Electrical Machine Design V Rajini Full Chapter PDF
Rajini
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About Pearson
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Electrical Machine
Design
Electrical Machine
Design
V. Rajini
V. S. Nagarajan
Department of Electrical and Electronics Engineering
SSN College of Engineering, Chennai
Copyright © 2018 Pearson India Education Services Pvt. Ltd
Published by Pearson India Education Services Pvt. Ltd, CIN: U72200TN2005PTC057128, for-
merly known as TutorVista Global Pvt. Ltd, licensee of Pearson Education in South Asia.
No part of this eBook may be used or reproduced in any manner whatsoever without the pub-
lisher’s prior written consent.
This eBook may or may not include all assets that were part of the print version. The publisher
reserves the right to remove any material in this eBook at any time.
ISBN 978-93-325-8557-7
eISBN 9789353063689
Head Office: 15th Floor, Tower-B, World Trade Tower, Plot No. 1, Block-C, Sector 16,
Noida 201 301, Uttar Pradesh, India.
Registered Office: 4th Floor, Software Block, Elnet Software City, TS-140, Blocks 2 & 9,
Rajiv Gandhi Salai, Taramani, Chennai 600 113, Tamil Nadu, India.
Fax: 080-30461003, Phone: 080-30461060
Website: in.pearson.com, Email: [email protected]
Dedicated to Our Parents
—V. Rajini and V. S. Nagarajan
Contents
Forewordxv
Preface xvii
About the Authorsxix
7. DC Machine 7.1
7.1 Introduction 7.1
7.2 Construction 7.1
7.2.1 Field or Excitation System 7.1
7.2.2 Rotor 7.3
xiv Contents
IndexI.1
Foreword
It gives me great pleasure to write the foreword to the book entitled, “Electrical Machine
Design”.
Electrical machines play a vital role in domestic and industrial fronts. Hence, it is
essential that students of electrical engineering have a strong grounding in electrical
machines. Conventional courses in electrical machines are not adequate for the purpose
of understanding as they throw light on the construction, principle, characteristics and
testing. A deeper understanding is possible only when they study the design aspects and
their influence on the performance of the machines. It is thus necessary to have a course
on electrical machine design, suitable for study by undergraduate students of electrical
engineering.
This book is designed to meet the needs of a textbook for a course in electrical machine
design. It gives a comprehensive design aspects of DC and AC machines with an appropriate
introduction to basic design considerations and the magnetic circuits involved. Introduction
to the design and analysis of the machines using the finite element analysis is also included
as one chapter, to enable the readers to have a much deeper understanding. A design process
always involves a long iterative process and a designer is required to take decisions in
conflicting situations. The design procedure of all the machines is given as simple flowcharts
for the reader to understand the iterative nature of design process. In addition to the worked
examples, most chapters include number of problems designed to test the grasp of the
subject. The readers will also appreciate the pedagogical practices followed in this book.
This book is the outcome of the long experience of the authors in teaching electrical
machines and allied courses. The authors have made a commendable effort to present the
contents in a clear and lucid form.
I hope this book will be well received by students, teachers and practicing engineers.
Dr V. Kamaraj
Professor and Head
Department of Electrical and Electronics Engineering
SSN College of Engineering
Chennai
Preface
Electric machines have become a part and parcel of our day-to-day lives. They play an
inevitable role, right from a small toy to an electric power plant. Hence, the knowledge
of their operating characteristics and performance is essential to Electrical Engineering
graduates. Also, it is important for them to learn the design of these machines considering
various technical and economical aspects. Hence, this book is intended to serve as a textbook
for those who are interested in learning the design of electrical machines.
The target audience also include academicians, students of B.E./B.Tech. (Electrical and
Electronics Engineering, Electronics and Instrumentation Engineering and Instrumentation
and Control Engineering) and industrial employees.
Flow chart based approach has been employed for problem solving. A large number of
examples with increasing order of difficulty have been incorporated with a step-by-step
procedure for solving. The examples cover university questions of all Indian universities.
Matlab and C programs have been provided for computer-aided design of different
electrical machines. Finite element simulations using MotorSolve software will provide
a new perspective in-depth understanding of concepts. Multiple-choice questions with
answers covering syllabus of GATE and UPSC exams also find a place in this book. Two
mark questions have been provided with answers, which will help the readers enhance the
understanding of the subject.
This book is divided into 8 chapters. Chapter 1 deals with basic design considerations
of electrical machines, which is inclusive of constraints, standards, choice of materials and
cooling requirements. Design of magnetic circuits involving different types of slots and
magnetic pull effects are dealt in Chapter 2. Chapter 3 covers the design of transformer
encompassing core, yoke, window, winding and cooling design requirements. Concepts
related to stator and rotor design of three-phase induction motor are covered in Chapter 4.
Chapter 5 provides an insight into the design of single-phase induction motor. Topics related
to construction, pole design and design of turbo machines under synchronous machines are
discussed in Chapter 6. Chapter 7 discusses about the design of DC machine comprising
the aspects of field winding, commutator and brush arrangement and interpole design.
The computer-aided design of electrical machines using finite element analysis software,
MotorSolve, is detailed in Chapter 8.
Acknowledgements
This book consumed huge amount of work, patience and dedication. Still, implementation
would not have been possible if we did not have the support of many individuals
and organizations. Therefore, we would like to extend our sincere gratitude to all. We
would like to sincerely thank our Principal, Dr S. Salivahanan, and the Management of
SSN College of Engineering, Chennai, for their constant encouragement and providing
necessary facilities for completing this project. We are grateful to our HOD, Dr V. Kamaraj,
for his encouragement in bringing out this book, our colleagues Dr R. Arumugam and
Dr M. Balaji, for obtaining and making the infolytica softwares available for use in
xviii Preface
Chapter 8 of this book and Dr R. Deepalaxmi, for helping us in reviewing certain chapters
of this book. We are also thankful to our students, especially S. Sivaramakrishnan, R. Rahul,
R. Gayathri, C. Ramaseshan, B. Shiva Shankar, M. Lohit, Shreyas Srivatchan, P. Praneeth,
M. Karthik, S. Narendran, R. Bharath Kumar, R. Vedha Vyass, R. Manovenkatesh,
N. Ajithbalaji, S. Krishnamurthy, S. Joselin Jebalamalar, R. Kavitha and M. Premkarthik
who had helped us in matlab and C coding, creation of figures, content enhancement,
proof correction and review.
We are indebted to Sojan Jose, R. Dheepika and M. Balakrishnan of Pearson India
Education Services Pvt. Ltd, Chennai, for bringing out this book successfully in a short span
of time.
We would like to express our sincere gratitude to our family for the continuous support,
patience and motivation. A heartfelt thanks to our family members, R. Harikrishnan,
H. Harshini, H. Karunya, V. Nagalakshmi, L. Santhanakrishnan, Dr L. V. Chandramohan,
V. Sureshkumar, T. S. Sasikaladevi, family friends, S. Premalatha, Secretary & Correspondent,
Mahatma Montessori Schools, Madurai, R. Panneerselvam, President, Mahatma Montessori
Schools, Madurai, for inspiring and encouraging us in writing this book.
We would like to dedicate this book to parents Shri. G. Veeraraghavalu and V. Saroja,
grand parents, L. Venkatesan, T. S. Swaminathan and S. Vardhini without whom none of
our success would have been possible. We would also like to dedicate this book to Professor
C. Palani, Annamalai University for laying the foundation for Electrical Machines and
Prof. Raman Nair, Annamalai University for making us believe anything is possible.
We will appreciate any constructive suggestions and feedbacks from the readers for
further improvement of this book.
V. Rajini
V. S. Nagarajan
About the Authors
V. Rajini has been working as a Professor in the Department of
Electrical and Electronics Engineering, SSN College of Engineering.
She has 22 years of teaching and research experience. She was
graduated from Annamalai University in 1992 and subsequently
obtained her Ph.D. in High Voltage Engineering from Anna
University in 2008. She has published over 90 research publications
in referred journals. She has completed various projects funded by
SSN Trust and AICTE and MNRE. She is currently working on the
fields of Insulating Materials, High Voltage Applications in Process
Technologies, Hybrid Electric Vehicles, Power Electronics for HV
Applications, Solar Photovoltaic and Wind Energy Systems.
She has received Best paper awards in various conferences,
has also received the Best teacher awards. Ms Rajini is the recipient of CTS – SSN Best
Faculty Award – 2011 and distinguished scientist award – 2016 by VIRA foundation for her
contributions in the field of high voltage engineering. She is a senior member of IEEE and
Life member of ISTE.
1.3 Classification
1.3 classification of
of Design
Design Problem
Problem
A
A machine
machine has
has field
field and
and armature
armature winding
winding supported
supported byby stator
stator and
and rotor.
rotor. It
It also
also has
has
dielectric
dielectric materials for insulating the live parts, cooling system and mechanical parts for
materials for insulating the live parts, cooling system and mechanical parts for
support.
support. Hence,
Hence, the
the basic
basic components
components ofof design
design are
are shown
shown in
in Fig.
Fig. 1.1.
1.1.
Magnetic
circuit
Mechanical Electric
system circuit
Basic
components
of design
Thermal Dielectric
system system
fig. 1.1
Fig. 1.1 || Basic
Basic components
components of
of design
design of
of electric
electric machine
machine
1.
1. Magnetic design
Magnetic design or
or magnetic
magnetic circuit
circuit design
design
The design of magnetic circuit must establish
The design of magnetic circuit must establish thethe required
required flux
flux with
with minimal
minimal ampere
ampere
turns. It should also produce less core loss.
turns. It should also produce less core loss.
2. Electric circuit design
Specifications and Standards 1.3
(Continued)
Constraints of Design 1.5
Table | (Continued)
IS No. Part Year Title specification
6600 – 1972 Guidelines for loading of oil immersed transformers
1885 28 1973 Electro technical vocabulary of transformers
2026 1 1977 Power transformers: General specifications
2026 2 1977 Power transformers: Temperature rise specifications
2026 3 1977 Power transformers: Insulation levels and dielectric test
specifications
2026 4 1977 Power transformers: Terminal markings, circuit tapping and
connections
•• Total efficiency of a machine indirectly influences its capital and running costs.
•• When efficiency is high, the power losses are low and hence the running costs will
be less.
•• But, to limit the electric and magnetic losses, the specific electric and magnetic
loadings ought to be as low as possible.
•• This in turn formulates a need for a machine with an excessively large active material
(such as iron for magnetic parts, copper and aluminium for winding conductors),
which results in an increased initial investment (capital) cost.
•• Thus, machines with enhanced efficiency will have substantially low running cost at
the expense of higher capital cost.
1.6
1.6 Basic
BasicDesign
DesignConsiderations
Considerationsof
ofElectrical
ElectricalMachines
Machines
Commutation Efficiency
Electromagnetic Temperature
saturation rise
Shaft Standard
limitations Air gap
specifications
fig.1.2
Fig. 1.2 || Limitations
Limitationsimposed
imposedon
onthe
thedesign
designof
ofelectrical
electricalmachines
machines
Temperaturerise
Temperature rise
••• Temperature
Temperaturerise riseisiscaused
causedin inan
anelectrical
electricalmachine
machinedue duetotothe
theheat
heatgenerated
generatedby bythethe
flowof
flow ofelectric
electriccurrent
currentin inconductors
conductorsand andflux
fluxlinking
linkingthetheiron
ironparts.
parts.
••• Elaborate
Elaborate cooling cooling arrangements
arrangements are are to
to be
be made
made ifif the
the temperature
temperature rise
rise isis excessive.
excessive.
Thisincreases
This increasesthe thecapital
capitalcost
costof
ofthe
themachine.
machine.
••• Also,
Also, the the type
type ofof insulation
insulation provided
provided largely
largely affects
affects the
the machine’s
machine’s operating
operating lifelife as
as
eachof
each ofthe
theinsulating
insulatingmaterials
materialsusedusedhas hasaalimiting
limitingtemperature
temperaturelimit.
limit.
••• IfIfoperated
operatedabove abovethisthislimit,
limit,the
thelongevity
longevityof ofinsulating
insulatingmaterial
materialreduces
reducesconsiderably,
considerably,
therebydeteriorating
thereby deterioratingthe themachine’s
machine’slifetime
lifetimeandandcost-effectiveness.
cost-effectiveness.
••• ItIt isis therefore
therefore required
required to to provide
provide appropriate
appropriate cooling
cooling andand ventilation
ventilation methods,
methods, to to
maintainthe
maintain thetemperature
temperaturerise risewithin
withinthe thepermissible
permissiblelimits.
limits.
Insulation
Insulation
The insulating materials used in a machine must endure the following stresses:
The insulating materials used in a machine must endure the following stresses:
• Electrical stress – Inflicted by the continually varying high operating voltage
•• Electrical stress – Inflicted by the continually varying high operating voltage
• Mechanical stress – Due to the flow of short circuit currents in secondary windings as
•• Mechanical stress – Due to the flow of short circuit currents in secondary windings as
they induce large radial and axial forces as in the case of transformers
they induce large radial and axial forces as in the case of transformers
Constraints of Design 1.7
•• Thermal stress – Caused by the heat developed (due to power losses) in the machine
components
•• The type of insulation to be fitted is determined principally by the maximum operating
temperature of the machine components to avoid any thermal breakdown.
•• Furthermore, the size of insulation is influenced by the maximum voltage stress
(electrical stress) and the size of conductors used (mechanical stress).
Power factor
•• For the same power rating of a machine, a poor factor leads to larger values of current
(as they are inversely proportional).
•• Hence, the conductor size (and cost) increases to accommodate this increased current
flow.
•• Conversely, for the power factor to be kept high (for reduced current levels and stress),
■■ the specific magnetic loading should be less, i.e. the volume of active material has
to be increased
■■ the air gap should be as small as mechanically possible which in turn increases the
fabrication cost of rotors
•• Eventually, the size and capital cost increase anyhow and power factor is used rather
as a limiting factor influencing the air gap length, winding conductor size and flux
density and saturation in the core.
•• The effect of power factor is a key consideration in the design of induction motors.
Electromagnetic saturation
•• Since ferro-magnetic materials are used as stator/rotor cores, their saturation level
determines the maximum allowable flux density.
•• A high value of flux density is achieved by reducing the air gap, but it results in
saturation of the core, thereby depleting the power factor and also causes an increased
excitation resulting in higher cost for the field system.
Mechanical components
The physical dimensions and shape of the mechanical components deeply influence the
limits of parameters of electrical machine such as critical speed, power factor, etc.
The three primarily influential mechanical portions are as follows:
•• Air gap: It must be kept as low as mechanically possible to have a high power factor
and flux density.
•• Central rotor shaft: Longer shaft lengths lead to excessive Unbalanced Magnetic Pull
(UMP) when deflected and disrupt the running mechanism. Thus, rotor shaft must be
short and rigid to downplay any deflection in running conditions and void the effect
of UMP, if any. In large machines, the shaft size is determined by the critical speed
which in turn depends on shaft deflection.
•• Bearings and rotating parts: Typically, they are subjected to external loads, inertial
forces, rotor weights caused by unbalanced rotors and forces due to UMP. Thus, these
factors play a vital part in the selection of bearing types in machines along with the
mounting used (vertical/horizontal).
1.8 Basic Design Considerations of Electrical Machines
Commutation
•• In DC machines where commutation is involved, commutating difficulties (production
of sparks) and drawbacks increase directly with the output power (Po).
•• Thus, commutation acts as a limiting factor and presently the maximum power
output that can be efficiently obtained from a single DC machine is 10 MW.
Specifications
Some restrictions are imposed on the manufacturer to produce electrical machines such as
(i) Consumer specifications: Different applications such as pumps, cranes, fans,
automobiles have different requirements for electric machines (constant torque/
power or constant speed or constant load) which have to be met by the manufacturer,
along with the economic, maintenance and serviceability constraints.
(ii) Standard specifications: These benchmark specifications (duly explained later),
concerning safety measures, voltage ratings and torque requirements are stipulated
by ISO and ought to be fulfilled by the manufacturer before commercializing their
machines.
1.7.1 DC Machine
In general, the output power developed by a DC machine is given by
Po = EI a (1.1)
From machine design point of view, it is required to express the above equation in terms
of main dimensions [diameter, D and length, L], specific electric and magnetic loading and
speed of operation. Hence, the following steps are followed to obtain the output equation in
relation with the above stated parameters.
We know that,
Emf induced in armature of DC machine is given by
φ pZN φ pZn N
E= = ∵ = n (1.2)
60 A A 60
Output Equation 1.9
Ia
Iz = ⇒ I a = I z A (1.3)
A
where Ia – Total armature current.
Substituting Eqs. (1.2) and (1.3) in Eq. (1.1), we get
φ pZn
Po = ×Iz A
A
= φ pZnI z
Rewriting the above equation, we get
Po = pφ × I z Z × n (1.4)
From the above equation, the terms ‘ pφ ’ and ‘ I z Z ’ can be related to specific magnetic,
which is defined as average flux density over the air gap of an electric machine and specific
electric loading, which is defined as total number of armature ampere conductors per metre
of armature periphery at the air gap of an electric machine by
pφ
Specific magnetic loading, Bav =
πDL
And
Iz Z
Specific electric loading, ac =
πD
⇒ I z Z = ac ×πD (1.6)
⇒ Po = Co D2 Ln (1.7)
where Co = π 2 Bav ac and is called the output coefficient. Equation (1.7) is the output
equation of DC machine.
1.7.2 AC Machine
In general, the output power developed by a three-phase AC machine is given by
Q = 3Eph I ph (1.8)
1.10 Basic Design Considerations of Electrical Machines
From machine design point of view, it is required to express the above equation in terms
of main dimensions [diameter, D and length, L], specific electric and magnetic loading and
speed of operation. Hence, the following steps are followed to obtain the output equation in
relation with the above stated parameters.
We know that,
Emf induced per phase of three-phase AC machine is given by
where f – frequency, φ – flux, Tph – total number of turns per phase, Kws – winding factor.
pN
Also, frequency, f=
120
pN p N p N
= = × = × ns ∵ ns = (1.10)
2× 60 2 60 2 60
where ns – Synchronous speed in rps.
Current in each conductor is given by
I ph
Iz = ⇒ I ph = I z A (1.11)
A
Total number of conductors, Z = Number of phases × 2Tph
I ph = I z (1.13)
Q = 3 × 4.44 f φTph K ws × I z
( )
= 1.11pφI z 6Tph K ws ns
From the above equation, the terms ‘ pφ ’ and ‘ I z Z ’ can be related to specific magnetic and
specific electric loading by
pφ
Specific magnetic loading, Bav =
πDL
⇒ Q = Co D2 Lns (1.17)
where Co = π 2 Bav acK ws and is called the output coefficient. Equation (1.17) is the output
equation of AC machine.
✓ High conductivity
✓ Very low temperature coefficient of resistance (or low resistivity)
✓ Malleability and ductility that is essential for windings and stampings
✓ Adequate tensile strength to prevent wear and tear of machine with a certain degree
of flexibility
✓ Ability to withstand bimetallic corrosion, dealloying
Magnetic
Insulator
Conductive
and
resistive
fig. 1.3
Fig. 1.3 || Constituent
Constituent materials
materials of
of an
an electric
electric machine
machine
Of the
Of the existing
existing materials,
materials, aluminium,
aluminium, silver,
silver, copper
copper andand its
its certain
certain alloys
alloys are
are good
good
conductors of
conductors of electricity.
electricity. Silver,
Silver, despite
despite having
having thethe highest
highest conductivity,
conductivity, isis never
never used
used in
in
fabrication due
fabrication due to
to its
its expensive
expensive nature.
nature. Aluminium
Aluminium is is increasingly
increasingly being
being used
used in
in low
low power
power
applications, yet
applications, yet suffers
suffers from
from high
high resistivity
resistivity as
as it
it will
will be
be duly
duly explained.
explained. Hence,
Hence, copper
copper is
is
predominantly used
predominantly used inin making
making electrical
electrical machines
machines along
along with
with its
its alloys
alloys and
and aluminium.
aluminium.
➣
➢ Copper
Copper
The reddish
The reddish looking
looking copper
copper isis extracted
extracted in
in the
the hard-drawn
hard-drawn form,
form, which
which becomes
becomes soft
soft
after annealing process. It involves heating at a temperature of around
after annealing process. It involves heating at a temperature of around 500–600°C 500–600°C
and then
and then cooling
cooling toto obtain
obtain annealed
annealed copper
copper with
with slightly
slightly less
less resistivity.
resistivity.
Copper exhibits:
Copper exhibits:
• Good tensile strength
•• Good tensile strength
• Lowest electrical resistivity among metals (excluding the uneconomical silver)
•• Lowest electrical resistivity among metals (excluding the uneconomical silver)
• Ductility or machinability
•• Ductility or machinability
• On exposure to atmosphere it forms copper oxide which acts as a protective layer and
•• On exposure to atmosphere it forms copper oxide which acts as a protective layer and
hence it is highly immune from oxidation and corrosion
hence it is highly immune from oxidation and corrosion
• Can be easily maneuvered to make coils, windings, soldered joints, castings, bus-
•• Can be easily maneuvered to make coils, windings, soldered joints, castings, bus-
bars, high voltage underground cables and overhead conductors
bars, high voltage underground cables and overhead conductors
• However, when copper is alloyed with silicon, manganese, phosphorus, chromium,
However, when copper
the resulting materialishas
alloyed
betterwith silicon, manganese,
mechanical phosphorus,
properties than copper yetchromium,
suffers from thea
resulting
risematerial has better
in resistivity mechanical
and hence properties
use of copper than
alloys copper yet suffers from a rise in
is limited.
resistivity and hence use of copper alloys is limited.
➣ Alloys of copper
➢ Alloys
Bronze:of This
copperalloy of copper (85–90%) comprising tin, manganese, aluminium
Bronze: among This
otheralloy
metals is prepared
of copper in several
(85–90%) compositions.
comprising Thesealuminium
tin, manganese, ‘bronzes’ possess
among
enhanced
other metalsmechanical
is preparedstrength thancompositions.
in several copper at theThese
price of increased
‘bronzes’ resistivity.
possess It is
enhanced
Materials for Electrical Machines 1.13
mechanical strength than copper at the price of increased resistivity. It is extensively used
as the alloy ‘Phosphor Bronze’ and in Bearings due to its excellent friction properties.
Brass: It is principally an alloy of copper (55–75%) and zinc (30–50%). Like bronze they
exhibit an enhanced mechanical strength as well with an increase in resistivity. Brass
has higher malleability and relatively low melting point than bronze and is hence
easily cast. Aluminium makes brass more corrosion-resistant due to the formation of
Aluminium Oxide (Al2O3) layer on its surface. The Copper–Zinc proportions can be
varied to produce alpha brass, beta brass, gamma brass, white brass, etc. with varied
properties and applications.
Copper–silver alloy: This alloy contains about 99.1% Cu and 0.06% Ag with a
resistivity (1.18 × 10−8 ohm-m) marginally higher than Cu. It is primarily used in
turbo-alternators due to its resistance against distortion under load (creep) and
thermal shortening.
Copper beryllium: A ductile, weldable, high strength alloy is obtained when a
copper alloy is blended with 0.5–3% beryllium. It has superior metal working, non-
magnetic and non-sparking traits. This Copper Beryllium (CuBe) is used in current
carrying springs, brush holders, sliding contacts and knife switch blades.
Copper cadmium: This high copper alloy consisting of 0.1–1.5% cadmium, with
a higher tensile strength than copper, is used to produce stiffer contact wires,
connectors, commutator segments and high strength transmission lines. Cadmium
copper is also used for cage windings as it can be flame brazed without deterioration
due to its heat-resistant property.
Copper chromium: When copper alloys are fused with 0.6–1.2% chromium, they gain
considerable mechanical strength, electrical conductivity and corrosion resistance,
as chromium improves the chemical properties of the protective oxide film. It is
chiefly utilized in making cable connectors, circuit breaker parts, spot welding tips
and electrical conductors, which require improved tensile strength.
➢ Aluminium
Aluminium is the next abundantly available good electrical conductor after copper
on earth. It can also serve as a plausible alternative upon the extinction of copper
resources in the coming years due to the scarcity of existing copper deposits. It is
prepared in hard drawn or annealed form.
Its properties are listed as follows:
•• Being approximately 3.3 times lighter and inexpensive than copper
•• Sufficiently malleable into thin sheets
Despite these aspects, aluminium must be cautiously used in electrical machines as below:
(a) It has a considerably high resistivity (around 1.62 times than that of copper)
(b) Inadequate mechanical strength leading to poor ductility, thereby limiting its
usability
These shortcomings can be downplayed by using alloys of aluminium with cooper
and zinc in small proportions to improve its mechanical strength albeit with an increase in
specific weight. Aluminium finds applications in varied fields such as:
1.14 Basic Design Considerations of Electrical Machines
•• It is principally used in the aviation industry on account of its extremely light weight.
•• Aluminium Conductor Steel-Reinforced (ACSR) cables with pure Aluminium (as
high as 99.5%) are used in overhead transmission lines on account of its excellent
conductivity, low weight and cost.
•• They are used in bus-bar conductors over copper due to their inexpensiveness.
•• Aluminium conductors decrease the overall cost when used in small transformers, but
in large transformers they substantially increase the size (increase in cross-sectional
area of coils to compensate for the amplified resistivity of aluminium over copper)
and hence the overall cost.
➢ Iron and its alloys
Cast iron is used to fabricate the starters of large motors and steel, which predominantly
contains iron along with manganese, nickel, chromium and aluminium, is used for
making starter rheostats where an optimal trade-off between specific weight and
tensile strength, heat dissipation is required.
➢ Carbon materials
In alternators, electric motors and turbo-generators, where current flows between
stationary wires and rotating coils, an electric brush made of graphite/carbon
powder, with a conductivity marginally less than above metals and alloys is utilized
owing to their smooth surface. Carbon brushes are heat treated along with copper
powder to improve their conductivity and reduce their hardness to prevent wearing
down of commutator parts.
➢ Superconducting materials
The resistance of certain positive temperature coefficient materials reduces
concurrently with temperature and virtually attains a zero value at a temperature
(of the order of 0–100 K) known as transition temperature and these materials are
identified as superconductors.
The following inferences from the study of these materials are strange but true:
•• Good conductors of electricity at room temperatures (copper, aluminium, silver, etc.)
do not exhibit superconducting properties.
•• Very poor conductors of electricity at room temperature attain exceptionally good
superconducting properties.
•• Superconductivity disappears on applying a sufficiently strong magnetic field as well
as on increasing the temperature above transition temperature.
These unique futuristic materials evidently have a wide scope in electric machines such as:
•• In transformers and power distribution, where they can be used as windings, coils or
transmission lines with virtually zero I2R losses.
•• In large turbo-generators (above 1000 MW), as cost-effective rotor windings to cut
down on copper losses and attain unprecedented levels of efficiency.
Nevertheless, these pricey superconductors suffer from their own setbacks as the cost of
development and of refrigeration plant is immensely high. They can be practically employed
only in machines with higher power rating as above where the effects of copper losses are
pronounced and cannot serve as a viable alternative to copper unless they can be designed
and produced in an inexpensive or a cost-effective way.
Materials for Electrical Machines 1.15
Manganin, an alloy of copper (86%), manganese (12%) and nickel (2%), developed by
Edward Weston as an alternative to constantan, is predominantly utilized in these devices.
Addition of Nickel serves to reduce the thermal emf to about 1 µV/oC.
Ferro
magnetic
Magnetic
materials based
on permeability
Para Dia
magnetic magnetic
Ferromagnetic materials
Ferromagnetic materials
The relative permeability is largely greater than one (µ >> 1), i.e., very large positive
The relative permeability is largely greater than one (µnn >> 1), i.e., very large positive
susceptibility, e.g., iron, nickel, cobalt, alnico. Magnetization of these materials is easy and
susceptibility, e.g., iron, nickel, cobalt, alnico. Magnetization of these materials is easy and
retain considerable amount of it when removed from magnetic field. They are affected by
retain considerable amount of it when removed from magnetic field. They are affected by high
AQ1 high temperatures. When they are used above ‘Curie temperature’, the critical temperature
temperatures. They lose the magnetic properties when used above ‘Curie Temperature’, which
above which it loses magnetic properties. They have nonlinear B-H curve.
is the critical temperature affecting the magnetic properties. They have nonlinear B-H curve.
Ferromagnetic materials are of great significance in contribution towards manufacturing
Ferromagnetic materials are of great significance in contribution towards manufacturing
of electric machines.
of electric machines.
Diamagnetic materials
Diamagnetic materials
The relative permeability is less than or equal to one (µ ≤ 1), i.e., very small negative
The relative permeability is less than or equal to one (µnn ≤ 1), i.e., very small negative
susceptibility, e.g., copper, silver, gold.
susceptibility, e.g., copper, silver, gold.
Paramagnetic materials
Paramagnetic materials
The relative permeability
The relative permeability is is slightly
slightly greater
greater than
than or
or equal
equal to
to one
one (µ ≥ 1),
(µn ≥ 1), i.e.
i.e. very
very small
small
n
positive susceptibility, e.g., air, platinum, tungsten. Paramagnetic materials are temperature
positive susceptibility, e.g., air, platinum, tungsten. Paramagnetic materials are temperature
dependent.
dependent.
Note: Diamagnetic and
Note: Diamagnetic and paramagnetic
paramagnetic materials
materials have
have linear
linear B-H characteristics and
B-H characteristics and are
are
largely non-magnetic.
largely non-magnetic.
Materials for
Materials for Electrical
Electrical Machines 1.17
Machines 1.17
Apart from
Apart from the
the classification
classification shown
shown in
in Fig.
Fig. 1.4,
1.4, magnetic
magnetic materials
materials are
are classified
classified based
based on
on
the nature of hysteresis loop as shown in Fig. 1.5.
the nature of hysteresis loop as shown in Fig. 1.5.
Magnetic materials
based on hysteresis loop
Non grain
Cast steel Perminvar
oriented
High nickel
Gray cast iron permalloy
Low nickel
Ferro cobalt
permalloy
Soft steel
fig.
Fig. 1.5
1.5 || Classification
Classification of
of magnetic
magnetic materials
materials based
based on
on hysteresis
hysteresis loop
loop
Hard magnetic
material
Soft magnetic
material
–H H
–B
fig.1.6
Fig. 1.6 || Hysteresis
Hysteresisloops
loopsof
ofsoft
softand
andhard
hardmagnetic
magneticmaterial
material
Further,classification
Further, classificationof
ofsoft
softmagnetic
magneticmaterials
materialsasasshown
shownin inFig.
Fig.1.5
1.5isisdetailed
detailedasasfollows.
follows.
Solidcore
Solid corematerials
materials
This type of magneticmaterials
This type of magnetic materialsisismade
madewithwithmaterials
materialslisted
listedin
inTable
Table1.1
1.1ininorder
ordertotoexhibit
exhibit
high permeability with lesser losses than iron in low flux density. These materials
high permeability with lesser losses than iron in low flux density. These materials find its find its
applications in machines such as relays, field portion of DC machines and DC electromagnets.
applications in machines such as relays, field portion of DC machines and DC electromagnets.
Thesematerials
These materialsare
arerequired
requiredto toexhibit
exhibithigh
highpermeability
permeabilityat athigh
highflux
fluxdensities.
densities.
But alloying steel with silicon enhances its tensile strength, while reducing its inherent
ductility, thereby making it brittle. This makes machining silicon-steel a relatively arduous
task.
There are two types of electrical sheet steel, depending upon the orientation of grains or
crystallites, in a polycrystalline material (i.e., electrical sheet steel), namely
•• Cold Rolled Non Grain Oriented (CRNGO or CRNO) Steel
•• Cold Rolled Grain Oriented (CRGO) Steel, which are detailed in Table 1.2
Special-purpose alloys
This type of magnetic materials are made using a mix of iron, nickel, molybdenum, chromium
in order to exhibit high permeability with lesser losses than iron in low flux density. These
materials find its applications in machines such as current and potential transformer
(instrument transformer) which require high flux density in weak magnetic fields. These
alloys are also required to exhibit high initial and maximum permeability. The significant
special-purpose alloys and their key features are listed in Table 1.3.
1.20 Basic Design Considerations of Electrical Machines
(Continued)
Materials for Electrical Machines 1.21
Apart from the classification discussed earlier, magnetic materials can also be classified
based on type of flux passing through it into
•• S teady flux type
•• Pulsating flux type
Steady flux type
These materials need to have high permeability, i.e. the material ought to have high
induction density at low ampere turns. This results in the reduction of cross-sectional
area and eventually weight of the core. They are predominantly used in the yokes and
cores of DC machines, relays and castings. Some commonly used materials are given as
follows:
(a) Castings: The yokes of DC machines, which require inexpensive materials, are made
of Cast-Iron despite their poor magnetic properties and increased weight, while
Cast-Steel is employed in those parts which require superior magnetic qualities and
are not subject to high mechanical stresses.
(b) Steel forgings: They are extensively used in the rotors of high power turbo-
generators, owing to their enhanced mechanical strength and machinability.
Pulsating flux type
For the magnetic materials to allow pulsating flux to pass through, they ought to be laminated
to minimize the large eddy current losses. These materials have to be so designed that the
specific core loss (or loss co-efficient) is less. Sheet steel, already discussed in the previous
section, is used under this category.
•
•• Liquid
L iquid –– no
no evaporation
evaporation or
or volatilization.
volatilization.
•
•• SSolid
olid –– high
high melting or softening point
melting or softening point
•
•• N Noo deterioration
deterioration even
even with
with repeated
repeated heat
heat cycle
cycle
•
•• G ood machinability for mass production
Good machinability for mass production
•
•• G ood thermal
Good thermal conductivity
conductivity
Insulators
Insulators are
are non-metallic
non-metallic materials
materials which
which are
are used
used in in electric
electric machines
machines to
to provide
provide
insulation
insulation (thermal insulation, galvanic separation, etc.) between live parts. They can
(thermal insulation, galvanic separation, etc.) between live parts. They can be
be
organic or inorganic, natural or synthetic, homogeneous or heterogeneous in composition.
organic or inorganic, natural or synthetic, homogeneous or heterogeneous in composition.
These
These materials
materials exhibiting
exhibiting manifold
manifold properties
properties can
can be
be segregated
segregated as as shown
shown in
in Fig.
Fig. 1.7.
1.7.
Insulation
resistance,
dielectric
strength
Electrical
Machinability,
Appearance, mouldability,
color and viscosity,
crsytallinity solubility and
Visual Mechanical porosity
Properties of
insulating
materials
Chemical Thermal
Thermal
conductivity,
Chemical resistance,
resistance and volatility, flash
hygroscopicity point, melting
point
fig. 1.7
Fig. 1.7 || Properties
Properties of
of insulating
insulating materials
materials
These properties
These properties differ
differ depending
depending upon
upon where
where thethe insulating
insulating materials
materials are
are employed
employed in in
the machine. Insulation materials are classified into seven types based on their
the machine. Insulation materials are classified into seven types based on their operating operating
temperature range
temperature range and
and thermal
thermal stability
stability as
as shown
shown in in Table
Table 1.4.
1.4. The
The temperature
temperature upup to
to which
which
these materials can be safely operated upon is listed along with the typically used materials
these materials can be safely operated upon is listed along with the typically used materials
from each
from each class
class in
in Table
Table 1.4.
1.4. These
These specifications
specifications areare standardized
standardized and
and governed
governed by by the
the
Indian Standard (IS) publication, IS 1271 (year 1958).
Indian Standard (IS) publication, IS 1271 (year 1958).
Materials for Electrical Machines 1.23
Table 1.5 | Classification of insulating materials based on their chemical structure, physical properties
and state
Insulating material Key features
Asbestos • M echanically weak, even when combined with cotton fibres
• When combined with synthetic resin, it has good mechanical
strength and thermal resistivity
• Have been manufactured in the form of wires and strip coverings,
providing high resilience and abrasion resistance
Askarels • I t is non-flammable synthetic liquid, gets converted into non-
explosive gas on decomposing with an electric arc
• Typical type used is hexachlorodiphenyl trichlorovenzine (60/40
mixture), having good viscosity, thermal stability and low pour
point
Black tape (friction • I t is formed when cotton tape is applied in either one or both sides
tape) with bituminous compound, which is adhesive and insulating
• Typical usage is in replacement of protective braid of cables and as
finishing tape over rubber
(Continued)
1.24 Basic Design Considerations of Electrical Machines
(Continued)
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observer might have perceived that she was slightly marked with the
small-pox. Her skin was delicately fair, and her beautiful flaxen hair
clustered in heavy ringlets, less showery than generally worn
according to the fashion of the time, over her forehead and neck. Her
eyes were blue, swimming in softened light, and her countenance
was overspread by a regard so tender yet so full of modesty, that
she gained at the same moment the love and esteem of all who
gazed upon her; and yet, when the occasional lighting up of her
features as the King addressed her, died away, they became pale
and sad. Her smile was followed by a pensive expression, which
accorded but ill with the festivity around her.
‘Ah, times are changing!’ said the abbe, as he gazed at her; ‘and
that fair lady’s reign is nearly over. I question whether La Montespan,
with all her witcheries, will love him half so well though.’
‘Who is it?’ asked Jean.
The abbe appeared slightly astonished at the ignorance of his new
acquaintance, as he replied—
‘Who could it be but Louise de la Vallière? Ah! hers was a curious
destiny. Picked out by Louis to cover his attention to his sister-in-law
Henriette, she has supplanted her. But it does not seem likely that
the liaison will last much longer. Montespan has his heart.’
As he spoke, Mademoiselle de la Vallière rose from her seat and
crossed over to speak to Madame de Maintenon, who was sitting on
the parapet of the basin that received the water from the fountain.
She limped as she walked along, and Jean saw that she was lame.
‘She seldom dances,’ continued the garrulous abbe, ‘on account of
her defect; and so she does not care always to be present at the
balls. I can conceive the reason of her not being at the play.’
‘How was that?’ inquired the Gascon.
‘Because the King’s sentiments appear to be somewhat changed
since our Molière was commanded to write the Princesse d’Elide. He
was then madly in love with La Vallière, although at the time she
resisted all his entreaties. What else could these lines mean?’
And Jean flinched as the abbe again commenced a piece of
declamation, quoting from the piece in question in a monotonous
tone of dulness suited to the subject—
The homage which is offer’d to a countenance refined
Is an honest indication of the beauty of the mind;
And scarcely possible it is, if love be not innate,
That a young prince should come to be or generous or great:
And this above all other regal qualities I love,
This sign alone the tenderness of royal hearts can prove!
To one like you, a bright and good career we may presage,
When once the soul is capable of loving, at your age.
Yes, this immortal passion, the most noble one of all,
An hundred goodly virtues training after it can call;
The most illustrious actions are engender’d by its fires,
And all the greatest heroes have experienced its desires.’13
Gaudin made no reply, but his bosom heaved rapidly, betraying his
internal emotion. Once he turned towards Louise Gauthier as if to
speak: the words died on his tongue.
‘This is idle talk,’ said the Marchioness, as she drew Sainte-Croix
to her side. ‘If you would not be taken for our accomplice, girl, you
will keep silent as to what you have heard. Sainte-Croix, you are
stupefied by this person’s raving. Will you not come with me,
Gaudin?’
She seized his hand, and rapidly changing the tone of anger she
had adopted to one of softness and affection, gazed tenderly at her
lover, as her fair countenance resumed its tranquillity, and her eyes,
beaming with gentleness and light, looked into Sainte-Croix’s, with
an expression that thrilled his very soul.
‘Marie!’ cried Gaudin faintly, ‘take me where you list. In life or after
it,—on earth or in hell, I am yours—yours only.’
A flush of triumph passed over her face as she led Sainte-Croix
from the grotto, leaving Louise Gauthier clinging to one of the
statues for support—so pale, that she might have been taken for
another figure of the group, but for the violent emotion that agitated
her slight and trembling frame.
CHAPTER XVII.
THE GASCON GOES THROUGH FIRE AND WATER TO ATTRACT ATTENTION
—THE BROTHER AND SISTER