MODULE 3
MODULE 3
Module-3
DC Machine
Any electrical machine that converts mechanical energy to electrical energy is called as Generators. The
electrical machine that converts electrical energy to mechanical energy is called as motor. They work
on the principle of electromechanical energy conversion. However, the construction of both
motors and generators are same, they differ by the principle of operation.
The first DC electrical machine was invented in 1839 in Edinburgh but took 4 decades to be
commercialized.
The working principle of a generator can be better understood by simple concept of faradays
laws. Consider two conductors AB and CD which are tied together in the back end and to the
separate slip rings S1 and S2 in the front end as shown in the Fig 3.1(a). the conductors ABCD
as a whole forms one coil. Let the coil be rotated in the counterclockwise direction such that
AB rotates under the influence of north pole and CD under south pole and the current flows
from M to N through the resistor as shown. Similarly, after rotation of 1800 the conductor CD
will be under the influence of north pole and AB under the influence of south pole thus from
1800 to 3600 rotation the emf induced in the conductor gets reversed and the current flows from
N to M through resistor R as shown in Fig 3.1(b). The type of emf generated will be alternating.
In view of obtaining DC voltage, split ring can be replaced with slip rings as depicted in Fig
3.1(c). In the split rings there are two segments a and b which are separated by an insulting
medium and the brushes are placed on these segments. When AB is under the influence of south
pole and CD under north pole the brushes just slide through the split rings to maintain the
direction of current flow from M to N only.
Fleming's right-hand rule (for generators): - shows the direction of induced emf
(current) when a conductor moves in a magnetic field.
The right hand is held with the thumb, first finger and second finger
mutually perpendicular to each other (at right angles)
The construction of the motor parts can be broadly classified into two: stator and rotor. Stator
is the stationary part and rotor is rotating. The stator parts include: Base Plate, yoke,
field system, lifting eye and terminal box. The rotor parts include: armature. Commutator
and brushes is shown in Fig 3.3.
Pole Cores and Pole Shoes: The field system consists of pole shoe and pole field. The
poles are made up of alloy steel that has high permeability and less hysteresis loss. The
coil is wound on the pole which is excited to provide the magnetic field. The poles are
tightly reverted to the yoke using nuts and bolts. The pole shoes serve two purposes: (i)
They spread out the flux in the air gap and also, being of larger cross-section, reduce the
reluctance of the magnetic path. (ii) They support the exciting coils (or field coils) as
shown below. There will be small ducts provided along the pole shoe that keeps the air
circulation intact.
Pole Coils: The field coils or pole coils, which consist of copper wire or strip, are former-
wound for the correct dimension. Then, the former is removed and wound coil is put into
place over the core. When current is passed through these coils, they electro magnetize
the poles which produce the necessary flux that is cut by revolving armature conductors.
Armature Core: It houses the armature conductors or coils and causes them to rotate and
hence cut the magnetic flux of the field magnets. In addition to this, its most important
function is to provide a path of very low reluctance to the flux through the armature from
a N-pole to a S-pole. It is cylindrical or drum-shaped and is built up of usually circular
sheet steel discs or laminations approximately 0.5 mm thick. The slots are either die-cut
or punched on the outer periphery of the disc and the keyway is located on the inner
diameter as shown. In small machines, the armature stampings are keyed directly to the
shaft. Usually, these laminations are perforated for air ducts which permit axial flow of
air through the armature for cooling purposes. The purpose of using laminations is to
reduce the loss due to eddy currents. Thinner the laminations, greater is the resistance
offered to the induced emf, smaller the current and hence lesser the I2 R loss in the core.
Armature Windings: The armature windings are usually former-wound. These are first
wound in the form of flat rectangular coils and are then pulled into their proper shape in
a coil puller. Various conductors of the coils are insulated from each other. The
conductors are placed in the armature slots which are lined with tough
insulatingmaterial. This slot insulation is folded over above the armature conductors
placed in the slot and issecured in place by special hard wooden or fiber wedges.
Commutator: The functions of the commutator are to facilitate collection of current from
the armature conductors, and to convert the alternating current induced in the armature
conductors into unidirectional current in the external load circuit. It is of cylindrical
structure and is built up of wedge-shaped segments of high-conductivity hard-drawn or
drop forged copper. These segments are insulated from each other by thin layers of mica.
The number of segments is equal to the number of armature coils. Each commutator
segment is connected to the armature conductor by means of a copper lug or riser. To
prevent them from flying out under the action of centrifugal forces, the segments have V-
grooves, these grooves being insulated by conical micanite rings.
Brushes and Bearings: The brushes, whose function is to collect current from
commutator, are usually made of carbon or graphite and are in the shape of a rectangular
block. These brushes are housed in brush-holders, the brush-holder is mounted on
a spindle and the brushes can slide in the rectangular box open at both ends. The brushes
are made to bear down on the commutator by a spring. A flexible copper pigtail mounted
at the top of the brush conveys current from the brushes to the holder. The number of
brushes per spindle depends on the magnitude of the current to be collected from the
commutator.
Because of their reliability, ball-bearings are frequently employed, though for heavy
duties, roller bearings are preferable. The ball and rollers are generally packed in hard oil
for quieter operation and for reduced bearing wear, sleeve bearings are used which are
lubricated by ring oilers fed from oil reservoir in the bearing bracket.
(a) Permanent Magnet Generators: These do not find application in the industry because of
their low efficiency. However, low-power, low-cost, small size machines use permanent
magnet.
(b) Separately Excited Generators As shown in Fig 3.4, the field coils are excited from a
storage battery or from a separate de source.
(c) Self-Excited Generators The field coils are excited by the de voltage generated by
the generator itself. Such generators are further subdivided into following three
categories
(i) Series-Wound Generators: The field coils are connected in series with the armature
circuit (Fig. 3.5).
(iii) Compound-Wound Generators: There are two windings on each pole, one
connected in series and the other in parallel with the armature circuit. The
compound-wound generators may again be of two types:
• Short-Shunt in which the shunt field winding is connected in parallel with the
armature (Fig 3.7).
• Long-Shunt in which the shunt field winding is connected in parallel with both the
armature and series winding (Fig 3.8).
The field windings provide the excitation necessary to set up the magnetic fields in the
machine. There are various types of field windings that can be used in the
generator or motor circuit.
In addition to the following field winding types, permanent magnet fields are used on
some smaller DC products. Generators may be divided in to
(a) Separately-excited generators are those whose field magnets are energized
from an independent external source of DC current
(b) Self-excited generators are those whose field magnets are energized by the
current produced by the generators themselves. Due to residual magnetism, there is
always present some flux in the poles. When the armature is rotated, some emf and
hence some induced current is produced which is partly or fully passed through the
field coils thereby strengthening the residual pole flux.
Self-excited generators are classed according to the type of field connection they use.
Series-wound generator: - In the series-wound generator, shown in Fig 4.6, the field
windings are connected in series with the armature. Current that flows in the armature
flows through the external circuit and through the field windings. The external circuit
connected to the generator is called load circuit.
A series-wound generator uses very low resistance field coils, which consist of a few
turns of large diameter wire.
The voltage output increases as the load circuit starts drawing more current. Under
low-load current conditions, the current that flows in the load and through the
generator is small. Since small current means that a small magnetic field is set up by
the field poles, only a small voltage is induced in the armature. If the resistance of the
load decreases, the load current increases. Under this condition, more current flows
through the field. This increases the magnetic field and increases the output voltage.
A series-wound dc generator has the characteristic that the output voltage varies with
load current. This is undesirable in most applications. For this reason, this type of
generator is rarely used in everyday practice.
Armature current
Ia=Ise=IL=I Terminal
voltage V=Eg-
I(Ra+Rse) Power
developed P=EgIa
Shunt wound: - In this field winding is connected in parallel with the armature
conductors and have the full voltage of the generator applied across them. The field
coils consist of many turns of small wire. They are connected in parallel with the load.
In other words, they are connected across the output voltage of the armature.
In actual use, the output voltage in a dc shunt-wound generator varies inversely as load
current varies. The output voltage decreases as load current increases because the
voltage drop across the armature resistance increases (E = IR).
In a series-wound generator, output voltage varies directly with load current. In the
shunt-wound generator, output voltage varies inversely with load current.
A combination of the two types can overcome the disadvantages of both. This
combination of windings is called the compound- wound dc generator.
Compound-wound generator: -
In the compound-wound generator when load current increases, the armature voltage
decreases just as in the shunt-wound generator. This causes the voltage applied to the
shunt-field winding to decrease, which results in a decrease in the magnetic field. This
same increase in load current, since it flows through the series winding, causes an
increase in the magnetic field produced by that winding.
Module 3B
DC MOTOR
Principle of operation:
Whenever a current carrying conductor is placed in a magnetic field it experiences a force and
the force is given by:
F = 퐵I푙
Where F: Force experienced in Newtons
B: Flux Density of magnetic field in Wb/m2
I: current flowing through the conductor in amperes
l: length of the conductors in meters
By Fleming’s left-hand rule: -It states that “when the thumb, fore finger and middle
finger are held mutually perpendicular to each other, with the fore finger in the
direction of magnetic field, middle finger in the direction of the current, then
the direction of thumb indicates the direction of force experienced by the conductor”.
The principle of operation of a d.c. motor can be stated in a single statement as ‘when a current
carrying conductor is placed in a magnetic field; it experiences a mechanical force’. In a
practical d.c. motor, field winding produces a required magnetic field while armature
conductors play a role of a current carrying conductors and hence armature conductors
experience a force. As conductors are placed in the slots which are on the periphery, the
individual force experienced by the conductors acts as a twisting or turning force on the
armature which is called a torque. The torque is the product of force and the radius at which
this force acts. So overall armature experiences a torque and starts rotating. Let us study this
motoring action in detail.
Consider a single conductor placed in a magnetic field as shown in the Fig. 3.1(a). The
magnetic field is produced by a permanent magnet but in a practical d.c. motor it is produced
by the field winding when it carries a current.
Figure 3.1: (a) conductors in a magnetic field, (b) flux produced by current carrying conductor.
Now this conductor is excited by a separate supply so that it carries a current in a particular
direction. Consider that it carries a current away from an observer as shown in the fig. 3.1(b).
Any current carrying conductor produces its own magnetic field around it, hence this conductor
also produces its own flux, around. The direction of this flux can be determined by right hand
thumb rule. For direction of current considered, the direction of flux around a conductor is
clockwise. For simplicity of understanding, the main flux produced by the permanent magnet is
not shown in the Fig. 3.1(b).
These are shown in the fig.3.2(a). From this, it is clear that on one side of the conductor, both
the fluxes are in the same direction. In this case, on the left of the conductor there is gathering
of the flux lines as two fluxes help each other. As against this, on the right of the conductor, the
two fluxes are in opposite direction and hence try to cancel each other. Due to this, the density
of the flux lines in this area gets weakened. So on the left, there exists high flux density area
while on the right of the conductor there exists low flux density area as shown in the Fig. 3.2(b).
This flux distribution around the conductor acts like a stretched rubber band under tension. This
exerts a mechanical force on the conductor which acts from high flux density area towards low
flux density area, i.e, from left to right or the case considered as shown in the fig.3.2(b)
Figure 3.2: (a) Interaction of two fluxes, (b) force experienced by the conductor.
The magnetic of the force experienced by the conductor in a motor is given by,
The direction of such force i.e., the direction of rotation of a motor can be determined by
Fleming’s left hand rule. So Fleming’s right hand rule is to determine direction of induced
e.m.f. i.e., for generating action while Fleming’s left hand rule is to determine direction of
force experienced i.e. for motoring action.
Back EMF (Eb):When the voltage V is applied to the motor, current Ia will flow through the
armature and Ish will flow through the field of the motor which will set the flux causing EMF. The
EMF developed in the armature opposes the applied voltage and hence it is called the back e.m.f
(Eb).The applied voltage V has to drivecurrent through the armature conductors against the opposition of
the back E.M.F andhence work has to be done. It is in the form of mechanical power developed by the
armature. The armature current Ia is given by eq (1)
Significance of Back EMF: Back EMF is a must in a motor which helps to regulate the armature
current and also the real cause for the production of torque.
Torque Equation:
Torque is the turning moment about its axis. It is also equal to Force x Distance
Consider the armature of the DC Motor of radius r and let F be the force acting
tangential to its surface as shown in Fig .
Therefore, Torque = Ta = F x r in Newton meter ------------------------- (1)
Ta = armature torque
TL = lost torque due to iron losses and mechanical
Types of DC Motors
DC Shunt Motor: -In this type of motor, the field winding is connected in parallel
with armature as shown in Fig 3.7. There are as many number of field coils as there
are poles. When connected to supply, constant voltage appears across the field
windings (as they are connected in parallel with armature). The field current is
therefore constant and is independent of the load current.Shunt field winding usually
are designed to have large number of turns of fine wire. Its resistance, therefore, is
high enough to limit the shunt field current to about 1 to 4 percent of the rated motor
current
Eb = V – Ia Ra – B.C.D – A.R.D
where B.C.D is brush contact drop (1 V/brush, A.R.D is the armature reaction drop
DC Series Motor: -A series motor receives its excitation from a winding which is connected
in series with the armature and carries load current Fig 3.8 dc series motor. As the series field
has to carry high load current, it is made of a thick wire and a few turns. As the resistance is
low, the voltage drop across the series winding is small.This motor has excellent starting and
over-load torque characteristics. The disadvantages are that the motor attains dangerously high
speed at no-load. Speed adjustment of the motor is somewhat difficult.
Ia = I = Ise
view of starting and overload torque; and has definite stable no-load speed like a shunt
motor. Speed of this motor is adjustable as easily as that of a shunt motor. It’s speed,
however, tends to change as much as 25 percent between full-load and no-load due to
the effect of series winding.
TaαIa
This implies that the characteristic is a straight line. Larger armature current is
required to start a heavy load. Therefore, a shunt motor should not be started on
heavy load.
The characteristic does not have a point of zero armature current, because a small current
is necessary to maintain the rotation of motor at no-load.
As there is no change in the speed of shunt motor, during the transition from no load to
full load, it may be connected to loads which can be suddenly disconnected withoutfear of
excessive speeding.
(c) N/Ta characteristics or mechanical characteristics:-
The values of N and Ta for various armature currents Ia is shown. The speed falls as
the load torque increases.The N/Ta characteristic is of great importance
in determining which type of motor is best suited to drive a given load.
Since T α Ia 2 in the linear zone and Tα Ia in the saturation zone, the T vs.
Ia characteristic is as shown in Fig. At light loads, Ia and hence ϕ is small, but as Ia
increases, Ta increases as the square of the current in a parabolic manner till the point
of saturation A is reached. After saturation ϕ is practically independent of Ia, hence Ta α
Ia and so that the characteristic becomes straight line.
The speed vs torque characteristic of a series motor is shown. From the curve, it is
apparent that the series motor develops a high torque at low speed and vice versa. This
is because an increase in torque requires an increase in armature current, which is also
the field current. The result is that the flux is strengthened and hence speed drops.
Similarly, at low torque, the motor speed is high.
Applications of DC Motors:
(1) DC Shunt Motor: When constant speed is required DC shunt motors are used.
(2) DC Series Motor: For high starting torque we prefer DC series motor. Example:
Electric traction, electric locomotive, cranes, hoists, conveyors etc.
(3) DC Compound Motor: When we require constant speed and high starting torque
Cumulative compound motors are preferred. Example: shears, punches, coal cutting
machine, elevators, conveyors, printing presses etc. Differential compound motors
have no practical applications (being unstable).
Problems
1) A 6 pole lap wound dc generator has 51 slots, each slot has 18 conductors. The
useful flux per pole is 35 mwb. Find the generated emf in the armature, if it is
driven at a speed of 750 rpm.
= 401.6 volts.
2) An 8 pole d.c. generator has 650 armature conductors. The flux per pole is 20
mWb. Find the value of emf generated when the armature is wave wound and
is rotating at a speed of 1200 rpm. What must be speed at which the armature
is to be driven to generate the same emf, if the armature is lap wound.
generate the same emf, if the armature is
lap wound. Given: P = 8;
A = 2 (wave wound)
No. of conductors = 650
ϕ = 20 mWb; N = 1200 rpm,emf
generated
To find the speed of armature, when it is lap wound,
3) A d.c series motor is running with a speed 800 rpm while taking a current of
20 A from the supply. If the load is changed such that the current drawn by the
motor is increased to 50A, calculate the speed of the motor on new load. The
armature and series field winding resistances are 0.2 ohm and 0.3 ohm
respectively. Assume that the flux produced is proportional to the current.
Assume the supply voltage as 250 V.
N2 = 300 rpm
4) The armature current of a series motor is 60 A when on full load. If the load
is adjusted so that this current decreases to 40 A, find the new torque
expressed as a percentage of full load torque. The flux for a current of 40 A is
70% of thatwhen the current is 60 A.
TϕIa,
i) Full load torque = Tfl = ϕ x 60
ii) T40 = 0.7 ϕ x 40
Tfl/ T40 = 60 ϕ/
(0.7 ϕx 40) T40 =
0.4667 Tfl
Torque at 40 A is 46.67% of full load torque
5) A 4 pole 250 V d.c. shunt motor has a back emf of 240.8 V and takes a
current of 20 A. Calculate the power developed. Take the resistance of the
field winding as 250 ohms.
P=4
V = 250 V
Eb= 240.8 V
IL=20A
Rsh= 250 ohms
Rsh= 250 ohms
Power developed = EbIa
Ia = IL – Ish and
Ish = V/Rsh
Ish = 250/250 =1 A
Ia = 20 – 1 = 19 A
Power developed =240.8 x 19 = 4572.8 W.
6) A 230 V dc series motor takes 12 A and runs at 800 rpm. At what speed will
it run, when 10 ohm resistance is connected in series with the armature the
motor taking the same current at the same supply voltage. Take Ra and Rse
of the motor as 0.5 ohm each.
V = 230 V
IL = Ia = Ise = 12 A
Ra = Rse = 0.5 ohms
Eb1 = V – IseRse- IaRa.
= 230 - 12 x 0.5 - 12 x 0.5 = 218.
When 10-ohm resistance is connected in series with the armature, thenEb2
= V – Ise (Rse + Ra + 10)
= 230 - 12(0.5 + 10 + 0.5) = 98 V.
Let N2 be the corresponding speed then
Eb2/Eb1=(N2/N1) x (f1/f2)
Since f1 = f2
N2 = (Eb2/Eb1) xN1
N2 = 98 x 800/218 =359.6 rpm.