Term Paper On DC Motor :-

Name :- Deepshikha Verma

Roll No :- RK6003B56

Section :- RK6003

Reg No :- 11011921

SUBMITTED TO:

Mrs.Cherry Bhargava
ACKNOWLEDGEMENT 3) Review Of DC Motor

This is to acknowledge that I Inside A DC Motor.

Deepshikha Verma of B.tech-
History And Background.
MBA (ece) is thankful to my
electrical and electronics Articles By Scientist.
teacher “Mrs. Cheery
Bhargava” who inculcated the
prestigious qualities in me,
which helped me in completing 4) Sugesstion And Clussion.
this term paper.

Only due to her keen presence it

was easier for me to complete 5) References.
this term paper on time.

Contents :-

1) Intorduction

Intoduction About DC Motors

How Does DC Motor Works

2) Types

Brushed DC Motors.

Coreless DC Motors.

Coreless Or Ironless DC Motors.

Introduction:

Industrial applications use dc motors

because the speed-torque relationship can be
varied to almost any useful form -- for both
dc motor and regeneration applications in
either direction of rotation. Continuous
operation of dc motors is commonly
available over a speed range of 8:1. Infinite
range (smooth control down to zero speed)
for short durations or reduced load is also
common.

Dc motors are often applied where they

momentarily deliver three or more times
their rated torque. In emergency situations,
dc motors can supply over five times rated
torque without stalling (power supply
permitting).

Dynamic braking (dc motor-generated

energy is fed to a resistor grid) or
regenerative braking (dc motor-generated
energy is fed back into the dc motor supply)
can be obtained with dc motors on
applications requiring quick stops, thus
eliminating the need for, or reducing the size DC Motors
of, a mechanical brake.
A DC motor is designed to run on DC
Dc motors feature a speed, which can be electric power. Two examples of pure DC
controlled smoothly down to zero, designs are Michael Faraday's homopolar
immediately followed by acceleration in the motor (which is uncommon), and the ball
opposite direction -- without power circuit bearing motor, which is (so far) a novelty.
switching. And dc motors respond quickly By far the most common DC motor types
to changes in control signals due to the dc are the brushed and brushless types, which
motor's high ratio of torque use internal and external commutation
respectively to create an oscillating AC
current from the DC source -- so they are not
purely DC machines in a strict sense.

How Does DC Motor Works

 assembly of many parts. There are three
types of DC motor:

1. DC series motor
2. DC shunt motor
3. DC compound motor - there are also
two types:
1. cumulative compound
2. differentially compounded

Some of the problems of the brushed DC

motor are eliminated in the brushless design.
In this motor, the mechanical "rotating
switch" or commutator/brushgear assembly
is replaced by an external electronic switch
synchronised to the rotor's position.
Brushless motors are typically 85-90%
efficient, whereas DC motors with brushgear
Brushed DC electric motor are typically 75-80% efficient.

The classic DC motor design generates an Midway between ordinary DC motors and
oscillating current in a wound rotor with a stepper motors lies the realm of the
split ring commutator, and either a wound or brushless DC motor. Built in a fashion very
permanent magnet stator. A rotor consists of similar to stepper motors, these often use a
a coil wound around a rotor which is then permanent magnet external rotor, three
powered by any type of battery. phases of driving coils, one or more Hall
effect sensors to sense the position of the
Many of the limitations of the classic rotor, and the associated drive electronics.
commutator DC motor are due to the need
for brushes to press against the commutator. The coils are activated, one phase after the
This creates friction. At higher speeds, other, by the drive electronics as cued by the
brushes have increasing difficulty in signals from the Hall effect sensors. In
maintaining contact. Brushes may bounce effect, they act as three-phase synchronous
off the irregularities in the commutator motors containing their own variable-
surface, creating sparks. This limits the frequency drive electronics. A specialized
maximum speed of the machine. The current class of brushless DC motor controllers
density per unit area of the brushes limits the utilize EMF feedback through the main
output of the motor. The imperfect electric phase connections instead of Hall effect
contact also causes electrical noise. Brushes sensors to determine position and velocity.
eventually wear out and require
replacement, and the commutator itself is These motors are used extensively in electric
subject to wear and maintenance. The radio-controlled vehicles. When configured
commutator assembly on a large machine is with the magnets on the outside, these are
a costly element, requiring precision
referred to by modelists as outrunner poorly ventilated buildings risking
motors. harm to occupants' health.
• Brushless motors are usually used in
Brushless DC motors are commonly used small equipment such as computers
where precise speed control is necessary, as and are generally used to get rid of
in computer disk drives or in video cassette unwanted heat.
recorders, the spindles within CD, CD-ROM • They are also very quiet motors
(etc.) drives, and mechanisms within office which is an advantage if being used
products such as fans, laser printers and in equipment that is affected by
photocopiers. They have several advantages vibrations.
over conventional motors:
Modern DC brushless motors range in
• Compared to AC fans using shaded- power from a fraction of a watt to many
pole motors, they are very efficient, kilowatts. Larger brushless motors up to
running much cooler than the about 100 kW rating are used in electric
equivalent AC motors. This cool vehicles. They also find significant use in
operation leads to much-improved high-performance electric model aircraft.
life of the fan's bearings.
• Without a commutator to wear out,
the life of a DC brushless motor can
be significantly longer compared to a Coreless or Ironless DC motors
DC motor using brushes and a
commutator. Commutation also Nothing in the design of any of the motors
tends to cause a great deal of described above requires that the iron (steel)
electrical and RF noise; without a portions of the rotor actually rotate; torque is
commutator or brushes, a brushless exerted only on the windings of the
motor may be used in electrically electromagnets. Taking advantage of this
sensitive devices like audio fact is the coreless or ironless DC motor, a
equipment or computers. specialized form of a brush or brushless DC
• The same Hall effect sensors that motor. Optimized for rapid acceleration,
provide the commutation can also these motors have a rotor that is constructed
provide a convenient tachometer without any iron core.
signal for closed-loop control (servo-
controlled) applications. In fans, the The rotor can take the form of a winding-
tachometer signal can be used to filled cylinder inside the stator magnets, a
derive a "fan OK" signal. basket surrounding the stator magnets, or a
• The motor can be easily flat pancake (possibly formed on a printed
synchronized to an internal or wiring board) running between upper and
external clock, leading to precise lower stator magnets.
speed control.
• Brushless motors have no chance of The windings are typically stabilized by
sparking, unlike brushed motors, being impregnated with Electrical epoxy
making them better suited to potting systems. Filled epoxies that have
environments with volatile chemicals moderate mixed viscosity and a long gel
and fuels. Also, sparking generates time.
ozone which can accumulate in
These systems are highlighted by low very low frequency AC supplies, with 25
shrinkage and low exotherm. and 16.7 hertz (Hz) operation being
common. Because they are universal motors,
Because the rotor is much lighter in weight locomotives using this design were also
(mass) than a conventional rotor formed commonly capable of operating from a third
from copper windings on steel laminations, rail powered by DC.
These motors were commonly used to drive
the capstan(s) of magnetic tape drives and The advantage of the universal motor is that
are still widely used in high-performance AC supplies may be used on motors which
servo-controlled systems, like radio- have the typical characteristics of DC
controlled vehicles/aircraft, humanoid motors, specifically high starting torque and
robotic systems, industrial automation, very compact design if high running speeds
medical devices, etc. are used.

Universal motors Universal motors generally run at high

speeds, making them useful for appliances
A variant of the wound field DC motor is the such as blenders, vacuum cleaners, and hair
universal motor. The name derives from the dryers where high RPM operation is
fact that it may use AC or DC supply desirable. They are also commonly used in
current, although in practice they are nearly portable power tools, such as drills, circular
always used with AC supplies. and jig saws, where the motor's
characteristics work well. Many vacuum
The principle is that in a wound field DC cleaner and weed trimmer motors exceed
motor the current in both the field and the 10,000 RPM, while Dremel and other
armature (and hence the resultant magnetic similar miniature grinders will often exceed
fields) will alternate (reverse polarity) at the 30,000 RPM.
same time, and hence the mechanical force
generated is always in the same direction. Motor damage may occur due to
overspeeding (running at an RPM in excess
In practice, the motor must be specially of design limits) if the unit is operated with
designed to cope with the AC (impedance no significant load. On larger motors,
must be taken into account, as must the sudden loss of load is to be avoided, and the
pulsating force), and the resultant motor is possibility of such an occurrence is
generally less efficient than an equivalent incorporated into the motor's protection and
pure DC motor. control schemes. In smaller applications, a
fan blade attached to the shaft often acts as
Operating at normal power line frequencies, an artificial load to limit the motor speed to
the maximum output of universal motors is a safe value, as well as a means to circulate
limited and motors exceeding one kilowatt cooling airflow over the armature and field
(about 1.3 horsepower) are rare. But windings.
universal motors also form the basis of the
traditional railway traction motor in electric With the very low cost of semiconductor
railways. rectifiers, some applications that would have
previously used a universal motor now use a
In this application, to keep their electrical pure DC motor, sometimes with a permanent
efficiency high, they were operated from magnet field
Inside an Electric Motor

Let's start by looking at the overall plan of a

simple two-pole DC electric motor. A
simple motor has six parts, as shown in the
diagram below:
• Armature or rotor
• Commutator
• Brushes
• Axle
• Field magnet
• DC power supply of some sort
Parts of an electric motor..

In the above diagram, you can see two

magnets in the motor: The armature (or
An electric motor is all about magnets and rotor) is an electromagnet, while the field
magnetism: A motor uses magnets to create magnet is a permanent magnet (the field
motion. If you have ever played with magnet could be an electromagnet as well,
magnets you know about the fundamental but in most small motors it isn't in order to
law of all magnets: Opposites attract and save power).
likes repel. So if you have two bar magnets
Toy Motor
with their ends marked "north" and "south,"
then the north end of one magnet will attract The motor being dissected here is a simple
the south end of the other. On the other electric motor that you would typically find
hand, the north end of one magnet will repel in a toy:
the north end of the other (and similarly,
south will repel south). Inside an electric
motor, these attracting and repelling forces
create rotational motion.

Motor Image Gallery

You can see that this is a small motor, about

as big around as a dime. From the outside
you can see the steel can that forms the body More Motor Parts
of the motor, an axle, a nylon end cap and
two battery leads. If you hook the battery The axle holds the armature and the
leads of the motor up to a flashlight battery, commutator. The armature is a set of
the axle will spin. If you reverse the leads, it electromagnets, in this case three. The
will spin in the opposite direction. Here are armature in this motor is a set of thin metal
two other views of the same motor. (Note plates stacked together, with thin copper
the two slots in the side of the steel can in wire coiled around each of the three poles of
the second shot -- their purpose will become the armature. The two ends of each wire
more evident in a moment.) (one wire for each pole) are soldered onto a
terminal, and then each of the three
terminals is wired to one plate of the
commutator. The figures below make it easy
to see the armature, terminals and
commutator:

The nylon end cap is held in place by two

tabs that are part of the steel can. By bendin-
g the tabs back, you can free the end cap and
remove it. Inside the end cap are the motor's
brushes. These brushes transfer power from
the battery to the commutator as the motor
spins:
The final piece of any DC electric motor is
the field magnet. The field magnet in this
motor is formed by the can itself plus two
curved permanent magnets:
 wire around a nail and connecting it to a
battery. The nail would become a magnet
and have a north and south pole while the
battery is connected.
electromagnet would be repelled from the
north end of the horseshoe magnet and
attracted to the south end of the horseshoe
magnet. The south end of the electromagnet
would be repelled in a similar way. The nail
would move about half a turn and then stop
in the position shown.

One end of each magnet rests against a slot Electromagnet in a horseshoe magnet
cut into the can, and then the retaining clip
presses against the other ends of both
You can see that this half-turn of motion is
magnets.
simply due to the way magnets naturally
attract and repel one another. The key to an
electric motor is to then go one step further
Electromagnets and Motors so that, at the moment that this half-turn of
To understand how an electric motor works, motion completes, the field of the
the key is to understand how the electromagnet flips. The flip causes the
electromagnet works. (See How electromagnet to complete another half-turn
Electromagnets Work for complete details.) of motion. You flip the magnetic field just
by changing the direction of the electrons
An electromagnet is the basis of an electric flowing in the wire.
motor. You can understand how things work
in the motor by imagining the following
scenario. Say that you created a simple
electromagnet by wrapping 100 loops of
Armature, The diagram at the right shows how the
commutator and brushes work together to let
current flow to the electromagnet, and also
to flip the direction that the electrons are
flowing at just the right moment. The
contacts of the commutator are attached to
the axle of the electromagnet, so they spin
with the magnet. The brushes are just two
pieces of springy metal or carbon that make
contact with the contacts of the commutator.

Armature
Commutator and Brushes
Consider the image on the previous page.
The armature takes the place of the nail in
an electric motor. The armature is an
electromagnet made by coiling thin wire
around two or more poles of a metal core.
The armature has an axle, and the
commutator is attached to the axle. In the
diagram to the right, you can see three
different views of the same armature: front,
side and end-on. In the end-on view, the
Armature
winding is eliminated to make the
commutator Motors Everywhere!
more
obvious. Look around your house and you will find
You can see that it is filled with electric motors. Here's
that the an interesting experiment for you to try:
commutator Walk through your house and count all the
is simply a motors you find. Starting in the kitchen,
pair of plates there are motors in:
attached to • The fan over the stove and in the
the axle. microwave oven
These plates • The dispose-all under the sink
provide the • The blender
two • The can opener
connections Brushes and commutator • The refrigerator - Two or three in
for the coil of the electromagnet. fact: one for the compressor, one
The "flipping the electric field" part of an for the fan inside the refrigerator,
electric motor is accomplished by two parts: as well as one in the icemaker
the commutator and the brushes. • The mixer
• The tape player in the answering
machine
 • Probably even the clock on the
oven
In the utility room, there is an electric motor
in:
• The washer
• The dryer
• The electric screwdriver
• The vacuum cleaner and the
Dustbuster mini-vac
• The electric saw
• The electric drill
• The furnace blower
Even in the bathroom, there's a motor in:
• The fan
• The electric toothbrush
• The hair dryer
• The electric razor
Your car is loaded with electric motors:
• Power windows (a motor in each
window)
• Power seats (up to seven motors
per seat)
• Fans for the heater and the
radiator
• Windshield wipers
• The starter motor
• Electric radio antennas
Plus, there are motors in all sorts of other
places:
• Several in the VCR
• Several in a CD player or tape
deck
• Many in a computer (each disk
drive has two or three, plus there's
a fan or two)
• Most toys that move have at least
one motor (including Tickle-me-
Elmo for its vibrations)
• Electric clocks
• The garage door opener
• Aquarium pumps

In walking around my house, I counted over

50 electric motors hidden in all sorts of
devices. Everything that moves uses an
electric motor to accomplish its movement
PRINCIPLE OF OPERATIONS

In any electric motor, operation is based on simple

electromagnetism. A current-carrying conductor generates a
magnetic field; when this is then placed in an external
magnetic field, it will experience a force proportional to the
current in the conductor, and to the strength of the external
magnetic field. As you are well aware of from playing with
magnets as a kid, opposite (North and South) polarities
attract, while like polarities (North and North, South and
South) repel. The internal configuration of a DC motorYou'll
is notice a few things from this -- namely, one pole is
designed to harness the magnetic interaction betweenfully
a energized at a time (but two others are "partially"
energized).
current-carrying conductor and an external magnetic field to As each brush transitions from one commutator
generate rotational motion. contact to the next, one coil's field will rapidly collapse, as
the next coil's field will rapidly charge up (this occurs within
a few microsecond). We'll see more about the effects of this
Let's start by looking at a simple 2-pole DC electric motor
later, but in the meantime you can see that this is a direct
(here red represents a magnet or winding with a "North"
result of the coil windings' series wiring:
polarization, while green represents a magnet or winding
with a "South" polarization).

Every DC motor has six basic parts -- axle, rotor (a.k.a.,

armature), stator, commutator, field magnet(s), and brushes.
In most common DC motors (and all that BEAMers will
see), the external magnetic field is produced by high-strength
permanent magnets1. The stator is the stationary part of the There's probably no better
motor -- this includes the motor casing, as well as two or way to see how an average
more permanent magnet pole pieces. The rotor (together DC motor is put together,
with the axle and attached commutator) rotate with respect to than by just opening one up.
the stator. The rotor consists of windings (generally on a Unfortunately this is tedious
core), the windings being electrically connected to the work, as well as requiring the
commutator. The above diagram shows a common motor destruction of a perfectly
layout -- with the rotor inside the stator (field) magnets. good motor.

Luckily for you, I've gone

ahead and done this in your
stead. The guts of a
disassembled Mabuchi FF-
 In 1997-1998 I designed a new type of
simple inexpensive brushless motor . It is
a reed switch based motor. This motor is
very simple but at the same time fast,
reliable and efficient. It is also easy to
030-PN motor (the same understand its principles of operation. This
model that Solarbotics sells) is how my original project looked:
are available for you to see
here (on 10 lines / cm graph
paper). This is a basic 3-pole
DC motor, with 2 brushes and
three commutator contacts.

The use of an iron core armature (as in the Mabuchi, above)

is quite common, and has a number of advantages2. First off,
the iron core provides a strong, rigid support for the
windings -- a particularly important consideration for high-
torque motors. The core also conducts heat away from the
rotor windings, allowing the motor to be driven harder than
might otherwise be the case. Iron core construction is also
relatively inexpensive compared with other construction
types.

But iron core construction also has several disadvantages.

The iron armature has a relatively high inertia which limits
motor acceleration. This construction also results in high
winding inductances which limit brush and commutator life.
My second year research was devoted to
the further development of this motor. At
In small motors, an alternative design is often used which this time I improved and simplified its
features a 'coreless' armature winding. This design depends design.
upon the coil wire itself for structural integrity. As a result,
the armature is hollow, and the permanent magnet can be For my 1999-2000 project I designed and
mounted inside the rotor coil. Coreless DC motors have built 7 more different brushless motors.
much lower armature inductance than iron-core motors of All of these motors shared a common
design, and thus I could easily compare
comparable size, extending brush and commutator life.
them together. Several of the motors that
I used in my project were modified and
are now available as kits on this site. They
include the transistor controlled reed
switch motor, the optointerrupter motor,
and the motor based on the Hall effect.
These motors were simplified to have the
minimum number of parts and to operate
as efficiently as possible.
Stan Pozmantir ( Location :-
Texas)
Theodore Gray

Theodore Gray make a world’s simplest

motor

Attach the magnet to one end of the battery. The weak, singl
that you are making serves as an low-friction bearing. I like t
button end, but the other end will work as well. (If you do so
spin the opposite direction. You can also reverse the directio
The ingredients (L-R): One ferromagnetic screw, one battery cell, a few
magnet up side down.)
inches of copper wire, and a neodymium disk magnet.
(Note to physics geeks: The heavier your magnet plus screw
I used a drywall screw both because it has a flat head and because it's easy to
lower the friction will be, right up to the point that magnet is
tell when it's turning. You can use a nail instead. The battery needn't be any
enough to hold them any more. This is because the friction fo
particular type; an alkaline C-cell works fine and is easy to hold. Just about
proportional to the normal force. In other words, a bigger ma
any copper wire will work fine for this application. I used some wire with
better.)
partially stripped (and partially striped) red insulation that is easy to see in
the photos. Bare copper will work just as well.

The magnet came from an LED throwie with a dead battery. The best
magnets for this job are neodymium disc magnets with a conductive plating.

Press and hold the top end of the wire to the top end of the ba
electrical connection from the top battery end to the wire.

Set the screw on the magnet, bend the wire.

Here we go: Lightly touch the free end of the wire toany
the new major problems. Dedicated
The magnet and screw start to spin immediately. Wecomponents
can get ourshelp
up tothe microcontroller
10,000 RPM in about fifteen seconds. to handle the more complex control
algorithms. The use of the
Watch out: The screw and magnet can easily fly out ofbrushless
control,motor
and youresults in a slightly slower
not want that screw ending up in your eye. Also notesystem thanoffor
that some thea normal
DC motor.
components, like the wire, can get very warm while you're However,
doing this. Wear since it has more
safety glasses and use common sense! torque, a good idea would be
to change gear reduction to speed up the
system. That of course depending
Conclusion :- on the speed and torque requirements. The
results show that the motor runs at around
1) Motors = Generators when expected speed and handles the
operated in reverse shifting of the driving positions well. The
A rotor, which is a large coil control algorithm performs
of wire, is spun in a magnetic satisfactorily and is well adjusted to the
field by an electric charge system.
that is delivered to the rotor
by the armatures that touch 3) Future Work :-The next
natural step will be to build
the shaft. The rotors are the actuator into the
connected to the shaft and the transmission.Then the real
armature skips a little bit so system can be tested. After
that it won’t short out another that it is time to build
rotor. Because of this one the transmission into a car and evaluate it.
Finally a decision has to
rotor, of an opposite polarity be made, if this is something we want in
of the permanent magnetic, is our future cars. Interesting
energized at a time; this would also be to try a brushless motor
action caused the rotors to without hall sensors. That would
move which rotates the shaft, probably be required if the system is to go
into serial production.
which means the motor spins.

2) The nature of this thesis is

one that leaves little to be
analyzed and
concluded. The motor runs satisfactorily and
that is the thesis objective.
Due to time limitations the motor was not
tested in oil inside
the transmission. That has to be done to be
able to come to any _nal
conclusions. Some things can however be
said about the performance
of the system.
The switch from a normal to a brushless DC
motor does not create
References http://www.howstuffworks.com/motor.ht
m
http://www.members.home.net/r
doctors/ http://fly.hiwaay.net/~pa
lmer/motor.html
http://www.exploratorium.edu/sn
acks/stripped_down_motor.html
http://www.hb.quik.com/~norm/
motor/
http://members.tripod.com/simpl
emotor/
http://www.qkits.com/serv/qkits/
diy/pages/QK77.asp
http://store.jalts.com/elmogekit.h
tml