DESIGN OF POLES, YOKE, AND WINDINGS

Item 7: Leakage Factor. Refer to Art. 46. This may be estimated at 1.16. This
value may later be checked by drawing a flux-leakage map, like that previously
explained (Art. 42), after the preliminary pole dimensions are determined.
Items 8 and 9: Cross Section of Pole Core. Refer to Art. 40 for calculation of the
full-load flux per pole. This flux, as estimated in Art 18, is maxwells. The
maximum flux density in the pole core will occur in the cross section near the yoke
ring, and, being determined by the total flux, i.e., useful and leakage flux, may be
fairly high. From the B-H curve of Fig. 61, it appears that 102,500 lines per sq in. will
not require an excessive number of ampere-turns. The pole-core cross section must,
therefore, be

sq in.
The dimension of the pole shoe measured parallel to the shaft will be about

(see Art. 47), the numerical values of

and being given in items 4 and 6. Thus

( ) in.
The width of the pole core should, therefore, be

in.
Item 10: Length of Winding Space on Pole. Refer to Art. 47, and the Illustrative
Example of Art. 48. This dimension will tentatively be made

in. and is subject to

change if later temperature-rise calculations indicate that it should be modified. It
should be noted that the radial dimension of the pole must correspond approximately
with that of the commutating pole, which was not designed for this machine.
However, the dimensions for the main and commutating poles are not particularly
critical at this stage and may be altered one way for another when the final design is
which the permeance is that of the air gap and tooth combined, in the neighborhood
of the pole tip; this, however, involves a considerable amount of calculation, not
particularly justified. An assumption that yields reasonably good accuracy is that the
maximum air-gap density at a point near the pole tip is 20 per cent greater than the
average under the pole face. This The corresponding tooth density read, Bg(max) =
x 1.2 = 58,026 lines per sq in., or 58,026/6.45 = 9,000 gauss. The
corresponding tooth density read from Fig. 49 is Bt = 19,000 gauss. This is the
density where the tooth thickness is t
mid
= 0.324 in. (Fig. 68). For the cross section of
tooth one-third of the distance from the bottom of the slot.
B
t
= 19,000 x .(0.324/0.310) = 19,860 gauss, or 122,600 lines per sq in. (approx)
Referring again to Fig. 67, the loss per pound per cycle at this density is 0.232 watt.
The total loss in the teeth is, therefore,
0.232 x 48.5 x 190 = 2,137.9 watts
Combining the core and teeth losses, the total loss in the armature stampings is
3,382.7 + 2,137.9 = 5,520.6 watts.

m 40 Diameter of Commutator = 17.5 in.
Item 52 Axial length of commutator = 13.2 in.
Total width of 10 brush holders per set, each one 1 in wide (measured
parallel to shaft) = 12 in.
Number of brush sets = 6
Radial depth of exposed ends of copper bars (assumed to be about 2/3 of
radial depth of bar, item 46) = 2.1 in.
D
e
(see fig. 69) = 17.5 3 = 20.5in.
D
r
(see fig. 69) = 17.5 + 4 = 21.5 in. In the formula given above it is
assumed that the risers add up to a limiting distance of 2 in. (in this design the actual
over-all riser diameter is about 27 in. the core diameter)
Velocity of commutator = x 17.5 x (970 / 12) = 1,775 fpm.
Combining the three portions of the commutator surface and brush holder
surface, the total cooling surface is

[( )

()

()

[()

()

] ( )


The cooling coefficient by formula (49) is
(

)
= 0.043 watt per sq. in per degree centigrade rise in temperature

The total watts dissipated as calculated in illustrative example of art. 55 are
897 watts. Whence

It should be pointed out that soft graphitic carbon was used in this design in
order to keep the brush-contract and friction losses down to acceptable values; with

63. Illustrative Example. Efficiency of Generator. Calculate the efficiencies
of 500-kw 460/480-volt 970-rpm generator designed in Art. 18 and Art. 50, for outputs
ranging from 25 to 150 per cent of rated load. The following data, taken from
previously calculated results, will be needed:
Item 33, Art. 18. I
2
R loss in armature winding at full load = 5.04 kilowatts.
Item 22, Art. 50. Shunt-field current at full load = 13.3 amp.
Item 26, Art. 50. I
2
R loss in series-field winding at full load = 0.24 kw.
From Art. 53. Core losses = 5.520 kw.
From Art. 55. Brush I
2
R loss at full load = 1.562 kw.
From Art. 55. Brush-friction losses = 0.585 kw.

In preparing the accompanying table, listing the various quantities required for
these calculations, several assumptions were made. These are: (1) the machine is
connected long-shunt , which means that the armature, series field, and interpole field
carry the total armature current; (2) the terminal emf rises linearly from 460 at no load to
480 at full load, then rises to 484.8 and 489.6 at overloads of 125 and 150 per cent,
respectively; (3) the commutating-field loss is estimated as 1.75 times the series-field
loss at full load, because this field was not designed for the specifications given (in the
actual machine design this loss would, of course, be known); (4) the iron loss is
constant at all loads, although flux-density changes with load changes would affect this
quantity somewhat; (5) the brush I
2
R loss is determined by using Fig. 38 for the various
current densities at the brushes, and adding about 10 per cent, as explained in Art. 55;
(6) the stray-load loss was computed as 1 per cent of the various output values, as
indicated in the table on page 138; (7) referring to the table on page 153, the bearing
friction and windage losses were estimated as 1.39 kw, for peripheral velocity 6,391.2
fpm and I
a
D
2
of 11,190 (see table, Art. 18).