Solved Problems · Set 3

Series and Parallel Magnetic Circuits

Part 1 · Principles of Energy Conversion — how to reduce a branched iron path to one reluctance, divide the flux between competing limbs, and reach an answer by trial when the material saturates.

Prof. Mithun Mondal 6 solved problems GATE · ESE · University

Set 3 — Series and Parallel Magnetic Circuits

Real cores are not single uniform rings. They are built of two materials joined end to end, they change section from limb to yoke, and they offer the flux more than one way home. This set applies ordinary network reduction to those structures: mmf drops added along a series path, reluctances combined in parallel, and flux divided between competing limbs by the magnetic equivalent of the current divider.

Two things separate the magnetic version from the electrical one. A change of cross-section changes the flux density and therefore the permeability, so every section must be treated at its own working point; and when a material is worked near saturation the relation between mmf and flux cannot be inverted, so the answer has to be reached by trial. Problem 5 does exactly that, and Problem 6 adds the flux that leaks away before it ever reaches the gap.

Part 1 · Magnetic Circuits · 6 solved problems

i Method Recap
  • Series paths carry the same flux and add their mmf drops. Whatever the section is made of and whatever its area, the flux entering a section equals the flux leaving it, so the ampere-turns are found by adding one drop per section:

    \[ NI = \sum_k H_k l_k = \sum_k \frac{B_k l_k}{\mu_0\mu_{r,k}} \]
  • Parallel paths share the same mmf and add their fluxes. Reluctances combine as resistances do, and the flux divides in inverse proportion — the magnetic current divider, with the opposite branch on top:

    \[ \mathcal{R}_{eq} = \frac{\mathcal{R}_1\mathcal{R}_2}{\mathcal{R}_1+\mathcal{R}_2}, \qquad \Phi_1 = \Phi\,\frac{\mathcal{R}_2}{\mathcal{R}_1+\mathcal{R}_2} \]
  • A change of area changes \(B\), not \(\Phi\). This is the one thing that has no electrical analogue: a series magnetic circuit of varying section has a different flux density, a different \(H\) and a different effective permeability in every section — Problem 2.

  • Which direction the problem runs decides the method. Given the flux and asked for the ampere-turns, work forward: \(B \to H \to Hl\), one section at a time. Given the ampere-turns and asked for the flux, the nonlinear \(H(B)\) cannot be inverted, so guess \(B\), compute the mmf it needs, and correct — Problem 5.

  • Reluctance is only defined where \(\mu_r\) is. Use \(\mathcal{R} = l/\mu_0\mu_r A\) for a material quoted with a permeability and for the air gap; switch to mmf drops read off a \(B\)\(H\) table the moment the material is quoted by a curve — Sets 1 and 2 established both routes.

  • Leakage is handled by a coefficient, not by a new circuit. Not all the flux the coil produces reaches the gap; the ratio of the two is the leakage coefficient, and it multiplies the flux used in the iron:

    \[ \lambda_L = \frac{\Phi_{\text{total}}}{\Phi_{\text{useful}}} \;>\; 1 \]

    Fringing enlarges the gap area and lowers \(\mathcal{R}_g\); leakage bypasses the gap altogether and raises the iron density. They are different effects — Problem 6.

Problem 1Exam levelComposite Series Core

A closed magnetic circuit of uniform cross-section 20 cm2 is built from two materials in series and carries one air gap. The mean path is made up as follows.

SectionMaterialMean lengthArea
1Silicon sheet steel0.600 m20 cm2
2Cast steel0.200 m20 cm2
3Air gap1.0 mm20 cm2

The exciting winding has 600 turns. The two materials are described by the magnetisation data below, which is used throughout this set.

\(B\) (T)0.60.81.01.11.21.31.41.51.6
Silicon sheet steel, \(H\) (A/m)120170250400600100018003500
Cast steel, \(H\) (A/m)350500720900110015002500

Fringing and leakage are neglected. For a flux of 2.4 mWb round the circuit, determine:

  1. the flux density in each section;
  2. the mmf absorbed by each section;
  3. the exciting current, and the share of the total taken by the 1 mm gap;
  4. the effective relative permeability of each material at this working point.
Solution

One flux, one flux density. The three sections are in series, so each carries the whole 2.4 mWb; and because the area happens to be the same in all three, the density is the same as well:

\[ B = \frac{\Phi}{A} = \frac{2.4\times10^{-3}}{20\times10^{-4}} = 1.2\ \text{T} \]

The equality of the three densities is a consequence of the equal areas, not of the series connection. Problem 2 removes it.

Read \(H\) for each material at 1.2 T. Two materials at the same density need very different field strengths, which is the whole point of a composite core:

\[ H_1 = 400\ \text{A/m}, \qquad H_2 = 1100\ \text{A/m} \]
\[ \mathcal{F}_1 = H_1 l_1 = (400)(0.600) = 240\ \text{A}\cdot\text{turns} \]
\[ \mathcal{F}_2 = H_2 l_2 = (1100)(0.200) = 220\ \text{A}\cdot\text{turns} \]

The cast-steel section is three times shorter and still absorbs almost as much mmf, because it is nearly three times harder to magnetise.

The gap takes no curve. Air is linear and, with fringing neglected, carries the same density as the iron:

\[ H_g = \frac{B}{\mu_0} = \frac{1.2}{4\pi\times10^{-7}} = 9.549\times10^{5}\ \text{A/m} \]
\[ \mathcal{F}_g = H_g\,g = \left(9.549\times10^{5}\right)\left(1.0\times10^{-3}\right) = 955\ \text{A}\cdot\text{turns} \]

Add the drops and divide by the turns. Series sections add their mmf, exactly as series resistors add their voltage drops:

Section\(B\) (T)\(H\) (A/m)\(l\) (m)\(\mathcal{F} = Hl\) (AT)Share
Sheet steel1.24000.60024017.0%
Cast steel1.211000.20022015.5%
Air gap1.2\(9.549\times10^{5}\)0.00195567.5%
Total0.8011415100%
\[ I = \frac{\mathcal{F}_{\text{total}}}{N} = \frac{1415}{600} = 2.36\ \text{A} \]

Effective permeabilities, for comparison only. Each material has an apparent \(\mu_r\) at this density:

\[ \mu_{r1} = \frac{B}{\mu_0 H_1} = \frac{1.2}{\left(4\pi\times10^{-7}\right)(400)} = 2390, \qquad \mu_{r2} = \frac{1.2}{\left(4\pi\times10^{-7}\right)(1100)} = 868 \]

Both are numbers valid at 1.2 T and nowhere else. Quoting them as if they were material constants is the error Problem 5 punishes.

A millimetre of air outweighs eight hundred millimetres of iron. The gap is 0.12% of the path length and takes 67.5% of the ampere-turns. But notice what is not true here: the iron is not negligible. Together the two irons need 460 AT, a third of the total, so the perfect-iron shortcut of Set 2 would have understated the current by 33%.
Answer\(B = 1.2\ \text{T}\); \(\mathcal{F} = 240 + 220 + 955 = 1415\ \text{AT}\); \(I = 2.36\ \text{A}\); gap share 67.5%
Problem 2CoreSections Of Unequal Area

A closed core of silicon sheet steel — the material of Problem 1 — is machined so that its cross-section changes twice round the loop. There is no air gap.

SectionMean lengthCross-section
A0.40 m16 cm2
B0.25 m20 cm2
C0.35 m25 cm2

A coil of 400 turns is wound on section B. A flux of 2.0 mWb is required. Find:

  1. the flux density and field strength in each section;
  2. the exciting current;
  3. the reluctance of each section and of the whole circuit;
  4. the inductance of the coil at this working point.
Solution

The flux is common, the density is not. Nothing leaves the core, so all three sections carry 2.0 mWb; the density follows the area:

\[ B_A = \frac{2.0\times10^{-3}}{16\times10^{-4}} = 1.25\ \text{T}, \qquad B_B = \frac{2.0\times10^{-3}}{20\times10^{-4}} = 1.00\ \text{T}, \qquad B_C = \frac{2.0\times10^{-3}}{25\times10^{-4}} = 0.80\ \text{T} \]

This is the step with no electrical counterpart. A current is the same in every series resistor; a current density is not, and it is flux density, not flux, that the magnetisation curve is drawn against.

Field strengths from the table of Problem 1. The value at 1.25 T lies between the 1.2 T and 1.3 T entries and is interpolated linearly:

\[ H_A = 400 + \tfrac{1}{2}(600-400) = 500\ \text{A/m}, \qquad H_B = 250\ \text{A/m}, \qquad H_C = 170\ \text{A/m} \]

One mmf drop per section, then add:

Section\(A\) (cm2)\(B\) (T)\(H\) (A/m)\(l\) (m)\(Hl\) (AT)
A161.255000.40200.0
B201.002500.2562.5
C250.801700.3559.5
Total1.00322.0
\[ I = \frac{322}{400} = 0.805\ \text{A} \]

Section A is 40% of the path and takes 62% of the mmf, purely because it was made narrow.

Reluctances follow by division, since every section carries the same flux and \(\mathcal{R}_k = \mathcal{F}_k/\Phi\):

\[ \mathcal{R}_A = \frac{200}{2.0\times10^{-3}} = 1.000\times10^{5}, \quad \mathcal{R}_B = \frac{62.5}{2.0\times10^{-3}} = 3.125\times10^{4}, \quad \mathcal{R}_C = \frac{59.5}{2.0\times10^{-3}} = 2.975\times10^{4}\ \text{A/Wb} \]
\[ \mathcal{R} = \mathcal{R}_A+\mathcal{R}_B+\mathcal{R}_C = 1.610\times10^{5}\ \text{A/Wb} \]

Inductance at this point only:

\[ L = \frac{N^2}{\mathcal{R}} = \frac{400^2}{1.610\times10^{5}} = 0.994\ \text{H} \]

Equivalently \(L = N\Phi/I = (400)(2.0\times10^{-3})/0.805 = 0.994\) H. Push the flux to 2.5 mWb and section A reaches 1.56 T, where \(H\) is about five times larger; the reluctance climbs and \(L\) falls. An iron-cored inductance is a number attached to an operating point.

Narrow the core anywhere and you have narrowed it everywhere. Because the flux cannot redistribute in a series path, the smallest section sets the highest density and therefore decides when the whole circuit saturates. Machine designers keep the tooth, the yoke and the pole body at comparable densities for exactly this reason.
Answer\(B = 1.25,\ 1.00,\ 0.80\ \text{T}\); \(\mathcal{F} = 322\ \text{AT}\); \(I = 0.805\ \text{A}\); \(\mathcal{R} = 1.61\times10^{5}\ \text{A/Wb}\); \(L = 0.994\ \text{H}\)
Problem 3CoreSymmetric Three-Limb Core

A three-limb core carries a single exciting coil of 500 turns on the central limb. The two outer limbs, together with the yoke sections that connect them to the centre, form two identical return paths. There is no air gap and the material has a constant relative permeability of 1200 over the range used.

PathMean lengthCross-sectionNote
Central limb0.20 m24 cm2carries the coil
Left return path0.50 m12 cm2outer limb + yokes
Right return path0.50 m12 cm2identical to the left

The coil carries 0.8 A. Find the reluctance of each path, the flux in the central limb and in each outer limb, the flux density everywhere, the way the mmf divides, and the inductance of the coil.

Solution

Recognise the topology. The coil drives flux up the central limb; at the top yoke the flux has two identical routes back to the bottom of the central limb. So the circuit is one reluctance in series with two equal reluctances in parallel — the magnetic copy of a resistor feeding two equal resistors.

Compute the three reluctances. With \(\mu_0\mu_r = (4\pi\times10^{-7})(1200) = 1.508\times10^{-3}\):

\[ \mathcal{R}_c = \frac{l_c}{\mu_0\mu_r A_c} = \frac{0.20}{\left(1.508\times10^{-3}\right)\left(24\times10^{-4}\right)} = 5.526\times10^{4}\ \text{A/Wb} \]
\[ \mathcal{R}_o = \frac{0.50}{\left(1.508\times10^{-3}\right)\left(12\times10^{-4}\right)} = 2.763\times10^{5}\ \text{A/Wb} \quad\text{(each outer path)} \]

Combine, remembering which rule applies where. The two outer paths sit across the same pair of yoke nodes, so they are in parallel; being identical, their combination is simply half of one:

\[ \mathcal{R}_{oo} = \frac{\mathcal{R}_o}{2} = 1.382\times10^{5}\ \text{A/Wb} \]
\[ \mathcal{R}_{total} = \mathcal{R}_c + \mathcal{R}_{oo} = 5.526\times10^{4} + 1.382\times10^{5} = 1.934\times10^{5}\ \text{A/Wb} \]

Flux from the magnetic Ohm's law:

\[ \mathcal{F} = NI = (500)(0.8) = 400\ \text{A}\cdot\text{turns} \]
\[ \Phi_c = \frac{\mathcal{F}}{\mathcal{R}_{total}} = \frac{400}{1.934\times10^{5}} = 2.068\times10^{-3}\ \text{Wb} = 2.068\ \text{mWb} \]

Symmetry does the division: each outer limb takes exactly half, \(\Phi_o = 1.034\) mWb. No divider formula is needed when the two branches are identical.

Flux densities — and a deliberate piece of design. The outer limbs have half the area and half the flux:

\[ B_c = \frac{2.068\times10^{-3}}{24\times10^{-4}} = 0.862\ \text{T}, \qquad B_o = \frac{1.034\times10^{-3}}{12\times10^{-4}} = 0.862\ \text{T} \]

Equal densities throughout. Halving the area of a limb that carries half the flux is how a real three-limb core is proportioned, so that no part saturates before the rest.

How the 400 AT divides, and the check that it must sum:

\[ \mathcal{F}_c = \Phi_c\mathcal{R}_c = \left(2.068\times10^{-3}\right)\left(5.526\times10^{4}\right) = 114.3\ \text{AT} \]
\[ \mathcal{F}_o = \Phi_o\mathcal{R}_o = \left(1.034\times10^{-3}\right)\left(2.763\times10^{5}\right) = 285.7\ \text{AT} \]

\(114.3 + 285.7 = 400\) AT. The same drop of 285.7 AT appears across both outer paths, which is what "in parallel" means magnetically.

Inductance:

\[ L = \frac{N^2}{\mathcal{R}_{total}} = \frac{500^2}{1.934\times10^{5}} = 1.293\ \text{H} \]
Series–parallel reduction is the whole technique. Reduce the network to one number, get the total flux, then walk back out through the divisions to recover each branch. The only magnetic subtlety is that the second step needs an area as well as a flux, because it is density, not flux, that tells you whether the iron is comfortable.
Answer\(\mathcal{R}_{total} = 1.934\times10^{5}\ \text{A/Wb}\), \(\Phi_c = 2.068\ \text{mWb}\), \(\Phi_o = 1.034\ \text{mWb}\), \(B = 0.862\ \text{T}\) throughout, \(L = 1.293\ \text{H}\)
Problem 4Exam levelThe Flux Divider

A three-limb core is excited by a coil of 300 turns on the left-hand limb, carrying 1.0 A. The flux it produces returns through two parallel paths: the centre limb, which is solid iron, and the right-hand limb, which contains a 0.5 mm air gap. All three paths have the same cross-section, and the iron has a constant relative permeability of 1500. Fringing and leakage are neglected.

PathIron lengthGapCross-section
A — left limb (wound)0.300 m40 cm2
B — centre limb0.400 m40 cm2
C — right limb0.3995 m0.5 mm40 cm2

Find the flux and flux density in every limb, and state the rule by which the flux divides.

Solution

Set up the analogy explicitly, because the whole problem is a current divider in disguise:

Electric circuitMagnetic circuit
emf \(V\) (V)mmf \(\mathcal{F} = NI\) (AT)
current \(I\) (A)flux \(\Phi\) (Wb)
resistance \(R = \rho l/A\)reluctance \(\mathcal{R} = l/\mu_0\mu_r A\)
conductance \(G = 1/R\)permeance \(\Lambda = 1/\mathcal{R}\)
\(I_1 = I\,\dfrac{G_1}{G_1+G_2}\)\(\Phi_1 = \Phi\,\dfrac{\Lambda_1}{\Lambda_1+\Lambda_2}\)

Reluctance of each path. With \(\mu_0\mu_r = 1.885\times10^{-3}\) and \(A = 40\times10^{-4}\ \text{m}^2\), the iron denominator is \(\mu_0\mu_r A = 7.540\times10^{-6}\):

\[ \mathcal{R}_A = \frac{0.300}{7.540\times10^{-6}} = 3.979\times10^{4}, \qquad \mathcal{R}_B = \frac{0.400}{7.540\times10^{-6}} = 5.305\times10^{4}\ \text{A/Wb} \]

Path C is iron in series with air:

\[ \mathcal{R}_{C,\text{iron}} = \frac{0.3995}{7.540\times10^{-6}} = 5.299\times10^{4}, \qquad \mathcal{R}_{g} = \frac{g}{\mu_0 A} = \frac{5\times10^{-4}}{\left(4\pi\times10^{-7}\right)\left(40\times10^{-4}\right)} = 9.947\times10^{4} \]
\[ \mathcal{R}_C = 5.299\times10^{4}+9.947\times10^{4} = 1.525\times10^{5}\ \text{A/Wb} \]

Half a millimetre of air is worth \(\mu_r g = 1500 \times 0.5\) mm, that is 0.75 metres, of this iron. That single line is why the flux will not divide equally.

Reduce and find the total flux:

\[ \mathcal{R}_{BC} = \frac{\mathcal{R}_B\mathcal{R}_C}{\mathcal{R}_B+\mathcal{R}_C} = \frac{\left(5.305\times10^{4}\right)\left(1.525\times10^{5}\right)}{2.055\times10^{5}} = 3.936\times10^{4}\ \text{A/Wb} \]
\[ \mathcal{R}_{total} = 3.979\times10^{4}+3.936\times10^{4} = 7.915\times10^{4}\ \text{A/Wb} \]
\[ \Phi_A = \frac{NI}{\mathcal{R}_{total}} = \frac{300}{7.915\times10^{4}} = 3.791\times10^{-3}\ \text{Wb} \]

Divide it — with the opposite branch on top:

\[ \Phi_B = \Phi_A\,\frac{\mathcal{R}_C}{\mathcal{R}_B+\mathcal{R}_C} = \left(3.791\times10^{-3}\right)\frac{1.525\times10^{5}}{2.055\times10^{5}} = 2.812\times10^{-3}\ \text{Wb} \]
\[ \Phi_C = \Phi_A\,\frac{\mathcal{R}_B}{\mathcal{R}_B+\mathcal{R}_C} = \left(3.791\times10^{-3}\right)\frac{5.305\times10^{4}}{2.055\times10^{5}} = 0.979\times10^{-3}\ \text{Wb} \]

Check: \(2.812+0.979 = 3.791\) mWb, and the ratio \(\Phi_B/\Phi_C = \mathcal{R}_C/\mathcal{R}_B = 2.87\). The gapped limb takes the smaller share, as the higher-resistance branch of a current divider does.

Densities and the mmf check. All three limbs have the same area, so the densities are in the same ratio as the fluxes:

Limb\(\mathcal{R}\) (A/Wb)\(\Phi\) (mWb)Share\(B\) (T)
A (wound)\(3.979\times10^{4}\)3.791100%0.948
B (solid)\(5.305\times10^{4}\)2.81274.2%0.703
C (gapped)\(1.525\times10^{5}\)0.97925.8%0.245

The mmf drops confirm the reduction:

\[ \mathcal{F}_A = \Phi_A\mathcal{R}_A = 150.8\ \text{AT}, \qquad \mathcal{F}_{BC} = \Phi_A\mathcal{R}_{BC} = 149.2\ \text{AT}, \qquad \text{sum} = 300\ \text{AT} \]

And the same 149.2 AT drives both branches: \(149.2/5.305\times10^{4} = 2.81\) mWb and \(149.2/1.525\times10^{5} = 0.979\) mWb. Either route — divider formula or common mmf — gives the same answer, and computing both is the cheapest available check.

Flux is lazy in exactly the way current is. It takes the easier path in proportion to permeance, so cutting a gap in one limb does not stop the flux — it diverts most of it into the other limb. That is the operating principle of every magnetic shunt, every saturable reactor, and every leakage path in a real machine.
Answer\(\Phi_A = 3.79\ \text{mWb}\), \(\Phi_B = 2.81\ \text{mWb}\ (74.2\%)\), \(\Phi_C = 0.979\ \text{mWb}\ (25.8\%)\); \(B = 0.948,\ 0.703,\ 0.245\ \text{T}\)
Problem 5ChallengeSolution By Iteration

A core of silicon sheet steel — the material tabulated in Problem 1 — has a mean iron path of 0.75 m and a uniform cross-section of 15 cm2. An air gap of 0.8 mm is cut in it. A coil of 800 turns carries 2.0 A. Fringing and leakage are neglected.

Find the flux density in the gap and the flux in the core. Explain why this problem cannot be solved in the same direction as Problems 1 and 2.

Solution

Why the direction matters. Problems 1 and 2 gave the flux and asked for the ampere-turns, so every step ran forward: \(\Phi \to B \to H \to Hl\). Here the ampere-turns are given and the flux is wanted, which needs \(H\) inverted — and \(H(B)\) is a table, not a formula. So the equation to be satisfied is written first and then solved numerically:

\[ NI = H_c(B)\,l_c + \frac{B\,g}{\mu_0} \;\Longrightarrow\; 1600 = 0.75\,H_c(B) + 636.6\,B \]

The gap coefficient is \(g/\mu_0 = 0.8\times10^{-3}/4\pi\times10^{-7} = 636.6\) AT per tesla — a straight line. Only the first term bends.

Test the perfect-iron shortcut first, because when it works there is no need to iterate at all. Setting \(H_c = 0\):

\[ B = \frac{1600}{636.6} = 2.51\ \text{T} \]

No electrical steel reaches 2.51 T. The shortcut has failed, and it has failed in the informative way: the answer it returns is above saturation, which is precisely the condition under which the iron cannot be ignored.

First trial — guess a density near the knee. Take \(B = 1.40\) T, for which the table gives \(H_c = 1000\) A/m:

\[ \mathcal{F} = (1000)(0.75) + (636.6)(1.40) = 750 + 891 = 1641\ \text{AT} \]

More than the 1600 AT available, so 1.40 T is too high.

Second trial — drop to \(B = 1.35\) T. Interpolating the table between 1.3 T (600 A/m) and 1.4 T (1000 A/m) gives \(H_c = 800\) A/m:

\[ \mathcal{F} = (800)(0.75) + (636.6)(1.35) = 600 + 859 = 1459\ \text{AT} \]

Too low. The answer is bracketed between 1.35 T and 1.40 T.

Interpolate between the two trials, treating \(\mathcal{F}(B)\) as locally straight:

\[ B \approx 1.35 + (1.40-1.35)\frac{1600-1459}{1641-1459} = 1.35 + 0.05\,(0.774) = 1.389\ \text{T} \]

Verify — never skip this step. At \(B = 1.389\) T the table interpolation gives \(H_c = 600 + 0.89(400) = 956\) A/m:

Trial\(B\) (T)\(H_c\) (A/m)\(H_c l_c\) (AT)\(Bg/\mu_0\) (AT)Total (AT)
Shortcut2.5130 (assumed)016001600
11.40010007508911641
21.3508006008591459
31.3899567178841601

The trial reproduces 1601 AT against the 1600 AT available — an error of 0.06%, far inside the accuracy with which the curve itself is known. The flux follows:

\[ \Phi = B A = (1.389)\left(15\times10^{-4}\right) = 2.08\times10^{-3}\ \text{Wb} = 2.08\ \text{mWb} \]

Read the split, and see how the balance has shifted. The iron now takes \(717/1600 = 44.8\%\) of the ampere-turns, against 32.5% in Problem 1 and under 1% in the lightly worked cores of Set 2. The reason is the shape of the curve: from 1.2 T to 1.39 T the gap requirement rises by 16% while the iron requirement rises by 139%.

Beyond the knee the iron stops being a detail and starts being the limit. Raising the current by another 25% here would gain under 5% more flux.

Two trials and one interpolation is enough — if the trials bracket the answer. The function \(\mathcal{F}(B)\) is monotonic, so a high guess and a low guess trap the root, and one linear interpolation between them lands within a percent. What is not permissible is to stop at the interpolation: it is an estimate on a curve, and the verification line is what turns it into an answer.
Answer\(B = 1.389\ \text{T}\), \(\Phi = 2.08\ \text{mWb}\); iron 717 AT (45%), gap 884 AT (55%)
Problem 6Exam levelLeakage Coefficient

A cast-steel electromagnet is built as a U-shaped yoke-and-limb assembly closed by a flat keeper. The flux crosses two air gaps, one under each pole face. The magnetisation data of Problem 1 applies.

Part of the pathMean lengthCross-sectionFlux carried
Yoke and two limbs (cast steel)0.50 m30 cm2total flux
Two air gaps, 1.0 mm each2 × 1.0 mm30 cm2useful flux
Keeper (cast steel)0.20 m30 cm2useful flux

A useful flux of 3.0 mWb is required across each gap. Some of the flux produced by the coil leaks from limb to limb without crossing the gaps, and the leakage coefficient of the yoke and limbs is 1.20. Fringing is neglected and the winding has 1400 turns. Find:

  1. the flux density in the gaps and in the keeper, and in the yoke and limbs;
  2. the mmf absorbed by each part and the exciting current;
  3. the leakage flux, and the error made by an engineer who ignores leakage altogether.
Solution

Separate the two fluxes before doing anything else. The leakage coefficient is defined at the coil, and it multiplies the useful flux to give the flux the iron under the winding must actually carry:

\[ \lambda_L = \frac{\Phi_{\text{total}}}{\Phi_{\text{useful}}} = 1.20 \;\Longrightarrow\; \Phi_{\text{total}} = (1.20)\left(3.0\times10^{-3}\right) = 3.6\ \text{mWb} \]
\[ \Phi_{\text{leak}} = 3.6 - 3.0 = 0.6\ \text{mWb} \]

The leakage flux takes a short cut through the air between the two limbs. It never reaches the gaps, so it does no useful work — but it does magnetise the iron it passes through.

Flux density part by part. Same area everywhere, two different fluxes:

\[ B_g = B_{\text{keeper}} = \frac{3.0\times10^{-3}}{30\times10^{-4}} = 1.0\ \text{T}, \qquad B_{\text{yoke}} = \frac{3.6\times10^{-3}}{30\times10^{-4}} = 1.2\ \text{T} \]

Twenty per cent more flux in the yoke, and the cast-steel curve turns that into 53% more field strength — the effect of leakage is amplified by the nonlinearity.

The two gaps. Air is linear, and there are two of them in series on the path:

\[ \mathcal{F}_g = 2\,\frac{B_g\,g}{\mu_0} = 2\,\frac{(1.0)\left(1.0\times10^{-3}\right)}{4\pi\times10^{-7}} = 2\,(795.8) = 1592\ \text{A}\cdot\text{turns} \]

The two iron parts, each at its own density. From the cast-steel row of the Problem 1 table, \(H = 720\) A/m at 1.0 T and 1100 A/m at 1.2 T:

\[ \mathcal{F}_{\text{keeper}} = (720)(0.20) = 144\ \text{AT}, \qquad \mathcal{F}_{\text{yoke}} = (1100)(0.50) = 550\ \text{AT} \]

Total and current:

Part\(\Phi\) (mWb)\(B\) (T)\(H\) (A/m)\(\mathcal{F}\) (AT)
Yoke and limbs3.61.21100550
Two gaps3.01.0\(7.958\times10^{5}\)1592
Keeper3.01.0720144
Total2286
\[ I = \frac{2286}{1400} = 1.63\ \text{A} \]

What ignoring leakage would have cost. Setting \(\lambda_L = 1\) puts the yoke at 1.0 T, where \(H = 720\) A/m:

\[ \mathcal{F}' = 1592 + 144 + (720)(0.50) = 2096\ \text{AT} \;\Longrightarrow\; I' = 1.50\ \text{A} \]

An 8.3% underestimate of the current, and therefore of the copper loss and the temperature rise. Built to that figure, the magnet would not develop its rated pull.

A note on what the model assumes. Applying a single coefficient of 1.20 to the whole yoke-and-limb path treats the leakage as though it all left at the pole tips. In reality it leaves progressively along the limbs, so the flux — and the mmf drop — is largest near the coil and smallest near the poles. The lumped coefficient therefore slightly overstates the iron drop, which is the safe direction to err. Values between 1.15 and 1.25 are usual for lifting magnets and dc-machine poles; the figure comes from measurement or from a field solution, never from this calculation.

Leakage and fringing are different faults with different signs. Fringing spreads the flux at the gap, enlarging \(A_g\) and making the gap slightly easier than calculated. Leakage diverts flux before the gap, so more flux must be produced than is used. Neglecting fringing overestimates the required mmf; neglecting leakage underestimates it. Only the second is dangerous.
Answer\(B_g = 1.0\ \text{T}\), \(B_{\text{yoke}} = 1.2\ \text{T}\); \(\mathcal{F} = 550+1592+144 = 2286\ \text{AT}\); \(I = 1.63\ \text{A}\); \(\Phi_{\text{leak}} = 0.6\ \text{mWb}\); ignoring leakage errs by 8.3%
Formulas

Key Formulas

QuantityRelationNotes
Series mmf\(NI = \sum H_k l_k\)One drop per section — Problems 1, 2, 6
Flux density in a section\(B_k = \Phi/A_k\)Changes when the area does — Problem 2
Reluctance\(\mathcal{R} = \dfrac{l}{\mu_0\mu_r A}\)Only where \(\mu_r\) is constant — Problems 3, 4
Air-gap reluctance\(\mathcal{R}_g = \dfrac{g}{\mu_0 A_g}\)Always linear — Problems 1, 4, 5, 6
Series combination\(\mathcal{R} = \mathcal{R}_1+\mathcal{R}_2+\cdots\)Common flux — Problems 1, 2, 4
Parallel combination\(\mathcal{R}_{eq} = \dfrac{\mathcal{R}_1\mathcal{R}_2}{\mathcal{R}_1+\mathcal{R}_2}\)Common mmf — Problems 3, 4
Flux divider\(\Phi_1 = \Phi\dfrac{\mathcal{R}_2}{\mathcal{R}_1+\mathcal{R}_2}\)Opposite branch on top — Problem 4
Permeance form\(\Phi_1 = \Phi\dfrac{\Lambda_1}{\Lambda_1+\Lambda_2},\ \Lambda = 1/\mathcal{R}\)Direct copy of the current divider — Problem 4
Effective permeability\(\mu_r = \dfrac{B}{\mu_0 H}\)Valid at one density only — Problems 1, 2
Iteration equation\(NI = H_c(B)l_c + \dfrac{Bg}{\mu_0}\)Solve numerically for \(B\) — Problem 5
Linear interpolation\(B \approx B_1 + (B_2-B_1)\dfrac{\mathcal{F}-\mathcal{F}_1}{\mathcal{F}_2-\mathcal{F}_1}\)Between two bracketing trials — Problem 5
Leakage coefficient\(\lambda_L = \dfrac{\Phi_{\text{total}}}{\Phi_{\text{useful}}}\)Multiplies the iron flux — Problem 6
Inductance\(L = \dfrac{N^2}{\mathcal{R}_{total}}\)Operating-point value — Problems 2, 3
mmf check\(\sum \mathcal{F}_{\text{series}} = NI\)The cheapest verification available — Problems 3, 4
Pitfalls

Common Mistakes

  1. Using one flux density for a core of varying section. The flux is common in a series path, the density is not. Sections of 16, 20 and 25 cm2 carrying 2.0 mWb run at 1.25, 1.00 and 0.80 T and need three different field strengths — Problem 2.

  2. Adding reluctances of parallel limbs. Branches across a common pair of yoke nodes combine as \(\mathcal{R}_1\mathcal{R}_2/(\mathcal{R}_1+\mathcal{R}_2)\); adding them gives four times the true value for two equal limbs — Problems 3 and 4.

  3. Putting the same branch on top in the flux divider. The flux in branch B is proportional to the reluctance of branch C. Getting this backwards sends 74% of the flux down the gapped limb instead of 26% — Problem 4.

  4. Averaging permeabilities of two materials. There is no such quantity. Each material gets its own \(H\) read at its own density and its own \(Hl\) term — Problem 1.

  5. Treating an effective \(\mu_r\) as a constant. The 2390 found for sheet steel at 1.2 T becomes about 1110 at 1.4 T. Carrying the first figure into a saturated calculation is what makes Problem 5 look easy and gives the wrong answer.

  6. Applying the perfect-iron shortcut past the knee. It returns 2.51 T in Problem 5 — a physically impossible value, and the signal that the iron must be carried.

  7. Stopping at the interpolated value without verifying. Interpolation on a curved characteristic is an estimate; substituting it back and recovering 1600 AT is what makes it an answer — Problem 5.

  8. Applying the leakage coefficient to the gap. It multiplies the flux in the iron under the winding, never the useful flux across the gap. Using 3.6 mWb in the gap would overstate \(B_g\) by 20% and the gap mmf by 318 AT — Problem 6.

  9. Confusing leakage with fringing. Fringing enlarges the gap area and slightly reduces the required mmf; leakage adds flux to the iron and increases it. Neglecting the second is the unsafe one — Problem 6.

  10. Counting one gap where the flux crosses two. A U-magnet with a keeper has a gap under each pole face; 1592 AT becomes 796 AT if one is forgotten — Problem 6.

Looking Ahead

Sets 1 and 2 built the magnetic circuit; this set finished the network theory that goes with it. Series sections add mmf, parallel limbs divide flux, a change of area changes the density without changing the flux, and a leakage coefficient carries the flux that never reaches the gap. Problem 5 marked the boundary of the whole method: where the material saturates, no closed formula survives and the answer has to be found by trial, bracketing and verification.

Every calculation so far has been static. A flux was required, ampere-turns were supplied, and nothing in the arithmetic depended on time. But the flux in a machine reverses fifty or sixty times a second, and the iron does not follow it back along the same curve it came up. The area trapped between those two paths is energy, and it is dissipated as heat once per cycle.

Next: Set 4 — Hysteresis and Eddy-Current Losses, where the loop area becomes joules per cubic metre, the Steinmetz law scales it with flux density, and two measurements at two frequencies separate the loss that is proportional to \(f\) from the loss that is proportional to \(f^2\).