Herbert Morrison Technical High School

David Wheatle
13 Industrial Technology
September 16, 2018
Industrial Technology Department
Electrical and Electronic Technology
D.C. Power Machines
Mr. Branford

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 Table of Contents
Introduction…………………………………………………………………………..3

DC Generator…………………………………………………………………………...4
Construction of A DC Machine……………………………………………………..4

Working Principle of A DC Generator……………………………………………..6

Types of DC Generator……………………………………………………………...7
What is a DC Motor………………………………………………………………………...9
Construction of a DC Motor………………………………………………………...9

Working Principle of a DC Motor…………………………………………………10

Types of DC Motor………………………………………………………………………..10

Safety Precautions When Using DC Machines…………………………………...12

Bibliography……………………………………………………………………….. 15

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 Introduction

D.C. machines are the electro mechanical energy converters which work from a D.C. source and
generate mechanical power or convert mechanical power into a D.C. power. These machines can
be broadly classified into two types, on the basis of their magnetic structure. They are generators
and motors. This booklet will expound on the different types of D.C. machines, their
construction and an explanation.

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 DC Generator
A dc generator is an electrical machine which converts mechanical energy into direct current
electricity. This energy conversion is based on the principle of production of dynamically
induced emf. This outlines basic construction and working of a DC generator.

Construction of A DC Machine:

Note: A DC generator can be used as a DC motor without any constructional changes and vice
versa is also possible. Thus, a DC generator or a DC motor can be broadly termed as a DC
machine. These basic constructional details are also valid for the construction of a DC motor.
Hence, let's call this point as construction of a DC machine instead of just 'construction of a dc
generator'.

The above figure shows constructional details of a simple 4-pole DC machine. A DC machine
consists of two basic parts; stator and rotor. Basic constructional parts of a DC machine are
described below.

1. Yoke: The outer frame of a dc machine is called as yoke. It is made up of cast iron or
steel. It not only provides mechanical strength to the whole assembly but also carries the
magnetic flux produced by the field winding.

2. Poles and pole shoes: Poles are joined to the yoke with the help of bolts or welding. They
carry field winding and pole shoes are fastened to them. Pole shoes serve two purposes; (i)
they support field coils and (ii) spread out the flux in air gap uniformly.

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 Figure Showing a Pole Shoe

3. Field winding: They are usually made of copper. Field coils are former wound and placed
on each pole and are connected in series. They are wound in such a way that, when
energized, they form alternate North and South poles.

Figure Showing Field Windings

4. Armature core: Armature core is the rotor of a dc machine. It is cylindrical in shape with
slots to carry armature winding. The armature is built up of thin laminated circular steel
disks for reducing eddy current losses. It may be provided with air ducts for the axial air
flow for cooling purposes. Armature is keyed to the shaft.

Figure Showing Armature Core

5. Armature winding: It is usually a former wound copper coil which rests in armature slots.
The armature conductors are insulated from each other and also from the armature core.

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 Armature winding can be wound by one of the two methods; lap winding or wave winding.
Double layer lap or wave windings are generally used. A double layer winding means that
each armature slot will carry two different coils.

6. Commutator and brushes: Physical connection to the armature winding is made through a
commutator-brush arrangement. The function of a commutator, in a dc generator, is to
collect the current generated in armature conductors. Whereas, in case of a dc motor,
commutator helps in providing current to the armature conductors. A commutator consists of
a set of copper segments which are insulated from each other. The number of segments is
equal to the number of armature coils. Each segment is connected to an armature coil and
the commutator is keyed to the shaft. Brushes are usually made from carbon or graphite.
They rest on commutator segments and slide on the segments when the commutator rotates
keeping the physical contact to collect or supply the current.

7. Bearings: The ball or roller bearings are fitted in the end housings. The function of the
bearings is to reduce friction between the rotating and stationary parts of the machine.
Mostly high carbon steel is used for the construction of bearings as it is very hard material.

8. Shaft: The shaft is made of mild steel with a maximum breaking strength. The shaft is
used to transfer mechanical power from or to the macine. The rotating parts like armature
core , commutator ccoling fans etc. are keyed to the shaft.

Commutator

Working Principle of A DC Generator

According to Faraday’s laws of electromagnetic induction, whenever a conductor is placed in a

varying magnetic field (OR a conductor is moved in a magnetic field), an emf (electromotive
force) gets induced in the conductor. The magnitude of induced emf can be calculated from
the emf equation of dc generator. If the conductor is provided with a closed path, the induced
current will circulate within the path. In a DC generator, field coils produce an electromagnetic
field and the armature conductors are rotated into the field. Thus, an electromagnetically induced
emf is generated in the armature conductors. The direction of induced current is given

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by Fleming’s right hand rule.

Need of a Split ring commutator:

According to Fleming’s right hand rule, the direction of induced current changes whenever the
direction of motion of the conductor changes. Let’s consider an armature rotating clockwise and
a conductor at the left is moving upward. When the armature completes a half rotation, the
direction of motion of that particular conductor will be reversed to downward. Hence, the
direction of current in every armature conductor will be alternating. If you look at the above
figure, you will know how the direction of the induced current is alternating in an armature
conductor. But with a split ring commutator, connections of the armature conductors also get
reversed when the current reversal occurs. And therefore, we get unidirectional current at the
terminals.

Types of DC Generator:
DC generators can be classified in two main categories separately excited and Self-excited.
Separately excited: In this type, field coils are energized from an independent external DC
source.

Self excited: In this type, field coils are energized from the current produced by the generator
itself. Initial emf generation is due to residual magnetism in field poles. The generated emf
causes a part of current to flow in the field coils, thus strengthening the field flux and thereby
increasing emf generation. Self excited dc generators can further be divided into three types -
(a) Series wound - field winding in series with armature winding
(b) Shunt wound - field winding in parallel with armature winding
(c) Compound wound - combination of series and shunt winding

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 Self Excited DC Generator

These are generators in which the field winding is excited by the output of the generator itself.
As described before – there are three types of self-excited dc generators – they are 1) Series
2) Shunt and 3) Compound.

a. Series DC Generator

A series DC generator is shown below in fig (a) – in which the armature winding is connected in
series with the field winding so that the field current flows through the load as well as the field
winding. The field winding is a low resistance, thick wire of few turns. Series generators are also
rarely used!

b. Shunt DC Generator

A shunt DC generator is shown in figure (b), in which the field winding is wired parallel to
armature winding so that the voltage across both are same. The field winding has high resistance
and more number of turns so that only a part of armature current passes through field winding
and the rest passes through load.

c. Compound Generator

A compound generator is shown in figure below. It has two field findings namely Rsh and Rse.
They are basically shunt winding (Rsh) and series winding (Rse). Compound generator is of two
types: 1) Short shunt and 2) Long shunt

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a) Short shunt: Here the shunt field winding is wired parallel to armature and series field winding
is connected in series to the load. It is shown in fig (1).

b) Long shunt: Here the shunt field winding is parallel to both armature and series field winding.
It is shown in figure (2).

What is a DC Motor
A Motor is a machine that converts electrical energy into mechanical energy. There is no
difference between a DC motor and DC generator from a construction point of view. The only
difference is that the generators are usually operated in more protected locations and, therefore,
their construction is generally of the open type.

Construction of a DC Motor

There is no basic difference in the construction of a DC generator and a DC motor. In fact,

the same DC machine can be used interchangeably as a generator or as a motor. Like
generators DC motors are also classified in to shunt-wound, series-wound and compound-
wound.

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 Working Principle of a DC Motor

Its operation is based on the principle that when a current carrying conductor is placed in a
magnetic field, the conductor experiences a mechanical force. The direction of this force is
given by Fleming’s left hand rule and magnitude is given by F = BIL Newtons

Consider a part of a multipolar d.c. motor as shown in Figure below. When the terminals of
the motor are connected to an external source of d.c. supply:

1. The field magnets are excited developing alternate N and S poles

2. The armature conductors carry currents.
All conductors under N-pole carry currents in one direction while all the conductors under
S-pole carry currents in the opposite direction.

Suppose the conductors under N-pole carry currents into the plane of the paper and those
under S-pole carry currents out of the plane of the paper as shown in Figure.

Since each armature conductor is carrying current and is placed in the magnetic field,
mechanical force acts on it.

On applying Fleming’s left hand rule, it is clear that force on each conductor is tending to
rotate the armature in anticlockwise direction. All these forces add together to produce a
driving torque which sets the armature rotating.

When the conductor moves from one side of a brush to the other, the current in that
conductor is reversed and at the same time it comes under the influence of next pole which
is of opposite polarity. Consequently, the direction of force on the conductor remains the
same.

It should be noted that the function of a commutator in the motor is the same as in a
generator. By reversing current in each conductor as it passes from one pole to another, it
helps to develop a continuous and unidirectional torque.

Types of DC Motor
A Direct Current Motor, DC is named according to the connection of the field winding with the
armature. Mainly there are two types of DC Motors. First, one is Separately Excited DC Motor

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and Self-excited DC Motor. The self-excited motors are further classified as Shunt wound or
shunt motor, Series wound or series motor and Compound wound or compound motor.

Series Motors

Series DC motor

In a series DC motor the field is connected in series with the armature. The field is wound with
a few turns of large wire because it must carry the full armature current.

A characteristic of series motors is the motor develops a large amount of starting torque.
However, speed varies widely between no load and full load. Series motors cannot be used
where a constant speed is required under varying loads.

Shunt Motors

DC

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 Shunt Motor

In a shunt motor the field is connected in parallel (shunt) with the armature windings. The
shunt-connected motor offers good speed regulation. The field winding can be separately
excited or connected to the same source as the armature.

Compound Motors

Compound DC motor

Compound motors have a field connected in series with the armature and a separately excited
shunt field. The series field provides better starting torque and the shunt field provides better
speed regulation.

Safety Precautions When Using DC Machines

WARNING
General Do not use the product in potentially explosive, flammable,
corrosive or wet environments to prevent fire or personal injury.
Assign qualified personnel to perform all tasks of installing,
wiring, operating/controlling, inspecting and troubleshooting related to
this product. Failure to do so may result in fire or injury.

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 Whenever a problem triggers the driver's protection function,
correct the problem. Continuing to operate the driver without
correcting the problem may result in motor malfunction, leading to
personal injury or equipment damage.
To avoid injury, do not disassemble or alter the motor or driver.

Installation Install the motor and driver inside the equipment housing.

The driver is designed for a DC power supply. To prevent fire,

be sure to connect the driver using correct polarity.
To prevent fire, use the driver within the rated input voltage
range.
To prevent fire, follow the wiring diagram when connecting the
Connection motor and driver.
To prevent fire, do not forcefully bend, pull or pinch the cables.
To prevent electric shock, when connecting the driver use a
direct current power supply with reinforced insulation between the
primary and secondary circuits.

In the event of a power failure, cut off the driver's power

supply. Failure to turn off the power may result in the motor suddenly
starting up when the power comes back on, possibly causing personal
Operation injury or damage to equipment.
Do not use the product for lifting and lowering
devices. Movable components may fall, resulting in personal injury or
damage to equipment.

CAUTION
To avoid injury or damage to equipment, do not use the motor
and driver beyond their specification values.
General Do not touch the motor and driver while in operation or
immediately after operation has ceased. The surface of the motor and
driver is hot and may cause burn injuries.

The motor could drop if carried by the output shaft or cable. To

Transport avoid injury, do not carry the motor by the output shaft or cable.

Installation Do not place any flammable material near the motor and driver
to avoid fire or burn injuries.
Do not place any material around the motor and driver that
might block ventilation to avoid causing damage to your equipment.

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 Cover the output shaft while the motor is in operation to avoid
injury.

To prevent injury, install an external emergency stop device or

circuit breaker that will ensure safe operation of your equipment in the
event of equipment failure or malfunction.
In the event of malfunction, stop operation immediately and
turn off the driver's power supply to prevent fire, electric shock, or
injury.
To avoid injury, do not touch the spinning component (output
shaft) while the motor is in operation.
Shut off all driver input signals before turning on the driver's
power supply to prevent injury or damage to equipment due to sudden
start of motor operations.
Operation To prevent injury, turn off the driver's power supply before
manually operating the motor output shaft.
To prevent injury or damage to equipment, do not use the
power supply's on/off switch to start or stop operation of the motor.
Use the START/STOP and RUN/BRAKE switches.
The motor's surface temperature may exceed 80℃ even under
normal operating conditions. If there is a chance that anyone can come
into contact with the motor during operation, attach a warning label, as
shown below, to the motor so that it is clearly visible in order to
prevent the risk of burn injuries.

Warning label

To dispose of the motor and driver, disassemble them into parts

Disposal and components as best as possible and dispose of the individual
parts/components as industrial waste.

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 Bibliography

https://circuitglobe.com/types-of-dc-motor.html

https://circuitglobe.com/construction-of-dc-generator.html

https://www.electricaleasy.com/2012/12/basic-construction-and-working-of-dc.html

http://www.studyelectrical.com/2014/12/working-principle-of-dc-motor.html

https://www.eminebea.com/en/engineering_info/rotary/brushless/brushless_industrial/cat-
3/004.shtml

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