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Tech Note No. 4 Frog-Leg Windings for DC Machines

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TECH NOTE NO. 4 Reliable Solutions Today! EA SA

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FROG-LEG WINDINGS FOR DC MACHINES

By Preben Christensen
EASA Staff Engineer (retired)

The frog-leg winding is a combination of a lap and a wave coil sides per slot, a frog-leg winding has four, as is also
winding, principally used on medium and large size direct- illustrated in Figure 3.
current machines. Developed by the Allis-Chalmers Instead of the customary two leads, in a frog-leg winding
Manufacturing Company around 1925, its primary advan- four leads are connected to each commutator bar, two from
tage is that it eliminates the separate equalizer winding the lap section and two from the wave section. The charac-
normally required in a lap-wound armature. This departure teristic manner in which the coil ends are bent gives the coil
from conventional winding design made the manufacture of the frog-like appearance from which it gets its name (see
self-equalizing armatures possible. photograph below).
The lap and wave sections of frog-leg coils are wound in
the same slots of the armature and connected to the same
commutator. Figure 1 shows a typical one-turn frog-leg coil.
The lap and the wave sections are insulated from each other
and are usually wound on the armature as separate coils.
This makes installation much easier than if the coils are tied
together and placed in the slot as a single unit.

FIGURE 1: ONE-TURN FROG-LEG COIL

WAVE LAP
SECTION SECTION
The lap section of most frog-leg windings is a simplex
winding, wound progressively. For this reason, all calcula-
Figure 2 shows the lap section of the coil sandwiched in tions referred to here are based on this type of lap winding.
between the wave section. The wave section of the frog-leg winding, on the other hand,

FIGURE 2: RELATIVE POSITION OF LAP AND FIGURE 3: POSITION OF LAP AND WAVE
WAVE SECTIONS OF A FROG-LEG COIL SECTIONS
WAVE SECTION
WAVE SECTION

LAP SECTION LAP SECTION

The position of the lap and
wave sections of a one-turn
frog-leg coil in an armature LAP SECTION
slot.
Assuming that the number of slots equals the number of
commutator bars, the position of the sides of a one-turn frog- WAVE SECTION
leg coil in a slot would be as shown in Figure 3. While an
armature wound with either a lap or a wave winding has two

(Update - 10/03)
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Frog-Leg Windings for DC Machines Tech Note No. 4

is wound retrogressively, because the lap and the wave

sections in a frog-leg winding must not both be connected FIGURE 4: FROG-LEG WINDING DIAGRAM
alike. If the lap section is progressive, the wave section must (4 POLES, 44 SLOTS, 132 BARS)
be retrogressive, or vice versa.
The coil of a frog-leg winding is formed by combining a WAVE COIL
LAP COIL
lap and a wave coil into one coil. These combined coils are
wound (and connected to the commutator) in the same
manner as separate lap and wave coils. The same rules that
are used for calculating coil and commutator pitch for
ordinary lap and wave windings, therefore, also apply to the
frog-leg winding:
1. The lap and the wave sections of the frog-leg coil both
span a pole pitch.
2. The commutator pitch of the simplex lap winding is
always equal to one bar. The coil leads, therefore, are
connected to adjacent commutator bars.
3. The commutator pitch of the wave winding is always
in accordance with the following equation:

BARS ± “PLEX”
COMMUTATOR PITCH = COMMUTATOR PITCH = BARS-"PLEX" = 132-2 = 65 BARS
POLES/2 (WAVE SECTION) POLES/2 4/2

(Using the positive value will result in a progressive

winding. Using the negative value will produce a retro- BARS = 132 = 66 BARS
gressive winding.) 2 POLE PITCHES =
POLES/2 4/2

In order to calculate the commutator pitch of the wave SLOTS = 44 = 11

section in a frog-leg winding, the multiplicity or “plex” of this RATIO
POLES 4
section must first be determined. The lap and the wave
sections of the frog-leg winding are connected in parallel. THIS RATIO IS A WHOLE NUMBER. THEREFORE THE
Successful operation requires both winding sections to be COIL PITCH MUST BE THE SAME FOR BOTH WINDINGS.
made with an equal number of parallel paths.
While the simplex lap section has as many parallel paths SUMMARY OF WINDING DETAILS
or circuits as there are poles, the simplex wave section has
only two circuits regardless of the number of poles. For this Lap Wave
reason, the wave section is always a multiplex winding, Type of Winding Simplex, Prog. Duplex, Retrog.
having the “plex” equal to the number of pairs of poles, so Number of Paths 4 4
that the number of circuits of the two winding sections will be
Coil Pitch 11 Slots 11 Slots
equal.
For example, a four-pole frog-leg winding having a Coil Span Slots 1-12 Slots 1-12
simplex lap section will require a duplex wave section in Commutator Pitch 1 Bar 65 Bars
order to make the circuits in both sections equal. Table 1 Succession of
indicates the correct lap-wave “plex” combination for 4-, 6- Bars When Tracing 1-2 1-66-131
and 8-pole machines. Winding

TABLE 1: COMBINATION OF LAP-WAVE “PLEX”

AND PATHS FOR FROG-LEG WINDINGS the same wire size and the same number of turns per coil.
Winding Section Number of Paths Figures 4 and 5 show typical frog-leg winding diagrams
No. of for both 4- and 6-pole armatures. Notice that in these
Lap Wave Poles Lap Wave Frog-Leg commutator pitch of the 6-pole, retrogressive triplex wave
Section Section Section Section Coil
winding (Figure 5) is calculated to be 39 bars. Tracing this
S Duplex 4 4 4 8 winding once around the commutator (1-40-79-118), we
I
M arrive three bars behind the starting point. Notice that the
P Triplex 6 6 6 12 “plex” of the wave section is equal to the number of bars we
L
E arrive at behind the starting point when tracing the wave
Quadruplex 8 8 8 16
X winding once around the armature. The number of paths of
these windings also conforms with those shown in Table 1.
As mentioned above, both winding sections must have In a frog-leg winding commutator bars located exactly
an equal number of parallel paths. In order to share the two pole pitches apart will always have equal electrical
armature current equally, the coils also must be wound with potential (just as in a lap-winding).

(Update - 10/03)
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Tech Note No. 4 Frog-Leg Windings for DC Machines

FIGURE 5: FROG-LEG WINDING DIAGRAM (6 POLES, 60 SLIOTS, 120 BARS)

WAVE COIL
LAP COIL

THIS RATIO IS A WHOLE NUMBER. THEREFORE THE

COMMUTATOR PITCH = BARS-"PLEX" = 120-3 = 39 BARS COIL PITCH MUST BE THE SAME FOR BOTH WINDINGS.
(WAVE SECTION) POLES/2 6/2
SUMMARY OF WINDING DETAILS

BARS = 120 = 40 BARS Lap Wave

2 POLE PITCHES =
POLES/2 6/2
Type of Winding Simplex, Prog. Triplex, Retrog.
SLOTS = 60 = 10 Number of Paths 6 6
RATIO
POLES 6 Coil Pitch 10 Slots 10 Slots
Coil Span Slots 1-11 Slots 1-11
Commutator Pitch 1 Bar 39 Bars
Succession of
Bars When Tracing 1-2 1-40-79-118
Winding

The distance between the commutator bars referred to a cross-connector. Similarly, any other pair of wave/lap coils
above is the same as that spanned by cross-connectors in connected in series between commutator bars spaced
an ordinary lap winding. In the frog-leg winding in Figure 4, exactly two pole pitches apart can also be thought of as a
for example, commutator bars 1 and 67, located exactly two cross-connector in the frog-leg winding. The frog-leg wind-
pole pitches apart, are not connected with a cross-connec- ing, therefore, is self-equalizing and requires no separate
tor as could be the case if the winding had been an ordinary equalizer winding.
lap winding. Instead, wave coil W1 and lap coil L12 (each
having a lead connected to commutator bar 66) are con- SPLIT-PITCH COILS
nected in series between bars 1 and 67. These two When the ratio of slots/poles is a whole number for an
commutator bars have the same electrical potential be- armature with a frog-leg winding, as in Figures 4 and 5, the
cause the voltages induced in wave coil W1 and lap coil L12 coil pitch of both winding sections is made equal. If, however,
are equal and opposite at any position of the armature. the ratio of slots/poles is a mixed number (such as 121/2),
The voltages induced in coils W1 and L12 are equal the coil pitch of the lap and the wave coils must be made
because these two coils are always positioned identically in equal to the nearest whole numbers of the slots/poles ratio.
the magnetic field of the main poles. One side of both W1 With a ratio of 121/2, for instance, the nearest whole
and L12 occupy a common slot (slot 12). The other sides of numbers are 12 and 13. The lap coil is usually made with the
W1 and L12 occupy slots 1 and 23, which are exactly two shorter pitch (e.g., 12, slots 1-13); the wave coil is made with
pole pitches apart. The voltages induced in coils W1 and the longer pitch (e.g., 13, slots 1-14). This type of frog-leg
L12 are not only equal, but also oppose each other because coil is known as a “split-pitch” coil. It is made very much like
these two coils are connected retrogressively and progres- the one previously described, except that only one coil side
sively, respectively. Therefore, the voltage measured of the lap section and one coil side of the wave section are
between commutator bars 1 and 67 is, theoretically, zero. placed in the same slot. The other side of each of the two coil
Figure 4 shows wave coil W1 and lap coil L12 serving as sections are placed in adjacent slots.

(Update - 10/03)
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Frog-Leg Windings for DC Machines Tech Note No. 4

The following example shows how split-pitch coils should

be connected. A four-pole, frog-leg winding in an armature FIGURE 6: FROG-LEG WINDING DIAGRAM
with 62 slots and 124 commutator bars has a slots/poles (4 POLES, 62 SLOTS, 124 BARS)
ratio of 62/4, or 151/2. Since this ratio is not a whole number,
the lap and the wave coils must be made with different slot
spans, as shown in Figure 6.
The lap section of frog-leg coil 1 is placed in slots 1 and
16, while the wave section (W1) spans slots 1-17—one slot
larger. The lap section (L17) of frog-leg coil 17 is placed in
slots 17 and 32, while the wave section of this same coil
spans from slot 17 to slot 33. One side of wave coil W1 and
lap coil L17 occupy a common slot (slot 17). A lead from
each of these coils is connected to commutator bar 62. Both
coils are connected in series between bars 1 and 63, which
are two pole pitches apart.
Wave coil W1 and lap coil L17 are therefore serving as
a cross-connector because the voltages induced in these
two coils neutralize each other at any position of the arma-
ture, as explained earlier. WAVE COIL
LAP COIL

SUMMARY
1. The frog-leg winding, a combination of a lap and a wave
winding, requires no separate equalizers.
2. Frog-leg windings have balanced armature circuits
”
because of the equalizing effect of the combined lap COMMUTATOR PITCH = BARS -“PLEX = 124-2 = 61 BARS
POLES/2 4/2
and wave sections. (WAVE SECTION)

3. In a frog-leg winding any series-connected lap/wave 2 POLE PITCHES = BARS = 124 = 62 BARS
pair of coils are connected to commutator bars which POLES/2 4/2
are spaced exactly two pole pitches apart. SLOTS 62
RATIO = = 151⁄2
4. Both lap and wave coils of a frog-leg winding are wound POLES 4
with the same wire size and with the same number of
turns per coil. The two winding sections also have an
equal number of parallel paths.
THIS RATIO IS A MIXED NUMBER. THEREFORE THE COIL
5. The lap section of a frog-leg winding is usually a
PITCH MUST NOT BE THE SAME FOR BOTH WINDINGS.
simplex winding, wound progressively, while the wave
section is a multi-plex winding, wound retrogressively.
6. Frog-leg windings require the use of split-pitch coils
SUMMARY OF WINDING DETAILS
when slots/poles is a mixed number.
Lap Wave
Type of Winding Simplex, Prog. Duplex, Retrog.
Number of Paths 4 4
Note: This article was first published in July/August 1984. Coil Pitch 15 Slots 16 Slots
Coil Span Slots 1-16 Slots 1-17
Commutator Pitch 1 Bar 61 Bars
Succession of
Bars When Tracing 1-2 1-62-123
Winding

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IA Reliable Solutions Today! Copyright
(Update© 2003
- 10/03)
TN4-4 Version 1003 DP32C-1003