PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

MODULE 6: DC GENERATORS

DC Generators 1
PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

LEARNING OUTCOMES

1. Explain the concepts involving the fundamentals laws

and theories of aircraft electricity
2. Demonstrate tests and analytical skills on electrical
CLO components, circuits, generators, and other aircraft
electrical equipment.
3. Demonstrate mastery of the principle of aircraft-related
electricity.

1. Explain the electrical principle by which electricity is

TLO produced in a generator/alternator
2. Discuss the basic electrical theory of AC and DC
generation

1. Explain how the mechanical energy changes to

electrical energy.
MLO 2. Identify the different types of a DC generators and
its functions.
3. Evaluate the voltage output of a DC Generators

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

CONTENTS
DC Generators…………………………………………………………………………………..4
1.0 Theory of operation of a DC Generator……………………………………….4
1.1 Generation of a DC Voltage……………………………………………………5
2.0 Construction features of a DC Generators…………………………………...7
2.1 Field Frame………………………………………………………………………7
2.2 Armature………………………………………………………………………….8
2.3 Commutators…………………………………………………………………….9
3.0 Types of DC Generators………………………………………………………..9
3.1 Series Wound……………………………………………………………………9
3.2 Parallel (Shunt) wound DC Generators……………………………………..10
3.3 Compound Wound DC Generators………………………………………….10
4.0 Generator Ratings……………………………………………………………..11
4.1 Aircraft Generators…………………………………………………………….12
4.2 DC Generators Maintenance…………………………………………………13

Summary………………………………………………………………………………………..14
Key Points………………………………………………………………………………………14
Activity 6………………………………………………………………………………………...14
Honesty Clause………………………………………………………………………………..15
Rubrics………………………………………………………………………………………….16
References……………………………………………………………………………………..16

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

DC Generators strength of the induced voltage is dependent

upon the speed of the conductor and the
strength of the magnetic field.
If the ends of the conductor are
connected to form a complete circuit, a
current is induced in the conductor. The
conductor and the magnetic field make up an
elementary generator.
This simple generator as shown in Figure 1,
together with the components of an external
generator circuit which collect and use the
energy produced by the simple generator.
24-volt aircraft generator

DC generators transform mechanical

energy into electrical energy. As the name
implies, DC generators produce direct
current and are typically found on light
aircraft. In many cases, DC generators have
been replaced with DC alternators. Both
devices produce electrical energy to power
the aircraft’s electrical loads and charge the
aircraft’s battery. Even though they share the
same purpose, the DC alternator and DC
generator are very different.
Fig. 1

DC generators require a control

circuit in order to ensure the generator • The loop of wire (A and B) is arranged
maintains the correct voltage and current for to rotate in a magnetic field. When the
the current electrical conditions of the plane of the loop of wire is parallel to
aircraft. Typically, aircraft generators the magnetic lines of force, the
maintain a nominal output voltage of voltage induced in the loop causes a
approximately 14 volts or 28 volts. current to flow in the direction
indicated by the arrows in the
illustration.
1.0 Theory of operation of a DC
Generator • The voltage induced at this position is
The principles of electromagnetic maximum, since the wires are cutting
induction are key to understanding generator the lines of force at right angles and
operation. When lines of magnetic force are are thus cutting more lines of force
cut by a conductor passing through them, per second than in any other position
voltage is induced in the conductor. The relative to the magnetic field.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

As the loop approaches the vertical position

shown in the Figure 2, the induced voltage The direction of cutting, however, is in the
decreases because both sides of the loop (A opposite direction to that occurring in Figures
and B) are approximately parallel to the lines 1 and 2, so the direction (polarity) of the
of force and the rate of cutting is reduced. induced voltage is reversed.
• When the loop is vertical, no lines of As rotation of the loop continues, the number
force are cut since the wires are of lines of force having been cut again
momentarily traveling parallel to the decreases, and the induced voltage
magnetic lines of force, and there is becomes zero at the position shown in Figure
no induced voltage. 4, since the wires A and B are again parallel
to the magnetic lines of force.

Fig. 2

As the rotation of the loop continues, the Fig. 4

number of lines of force cut increases until
the loop has rotated an additional 90° to a
horizontal plane. 1.1 Generation of a DC Voltage

As shown in Figure 3, the number of lines of These principles show that voltage is
force cut and the induced voltage once again induced in the armature of a generator
are maximum. throughout the entire 360° rotation of the
conductor. The armature is the rotating
portion of a DC generator. As shown, the
voltage being induced is AC. (Figure 5)

Fig. 3
Fig. 5

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

Since the conductor loop is constantly

rotating, some means must be provided to
connect this loop of wire to the electrical
loads. As shown in Figure 6, slip rings and
brushes can be used to transfer the electrical
energy from the rotating loop to the
stationary aircraft loads.
Fig. 7
The slip rings are connected to the loop and
rotate; the brushes are stationary and allow In Figure 7, the red side of the coil is
a current path to the electrical loads. The slip connected to the red segment and the amber
rings are typically a copper material and the side of the coil to the amber segment. The
brushes are a soft carbon substance. segments are insulated from each other. The
two stationary brushes are placed on
opposite sides of the commutator and are so
mounted that each brush contacts each
segment of the commutator as the
commutator revolves simultaneously with the
loop. The rotating parts of a DC generator
(coil and commutator) are called an
armature.
As seen in the very simple generator of
Figure 7, as the loop rotates the brushes
make contact with different segments of the
commutator.
In positions A, C, and E, the brushes touch
Fig. 6
the insulation between the brushes; when
the loop is in these positions, no voltage is
being produced. In position B, the positive
It is important to remember that the
brush touches the red side of the conductor
voltage being produced by this basic
loop.
generator is AC, and AC voltage is supplied
to the slip rings. Since the goal is to supply In position D, the positive brush touches the
DC loads, some means must be provided to amber side of the armature conductor. This
change the AC voltage to a DC voltage. type of connection reversal changes the AC
Generators use a modified slip ring produced in the conductor coil into DC to
arrangement, known as a commutator, to power the aircraft. An actual DC generator is
change the AC produced in the generator more complex, having several loops of wire
loop into a DC voltage. and commutator segments.
The action of the commutator allows Because of this switching of
the generator to produce a DC output. By commutator elements, the red brush is
replacing the slip rings of the basic AC always in contact with the coil side moving
generator with two half cylinders (the downward, and the amber brush is always in
commutator), a basic DC generator is contact with the coil side moving upward.
obtained.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

Though the current actually reverses

its direction in the loop in exactly the same
way as in the AC generator, commutator
action causes the current to flow always in
the same direction through the external
circuit or meter. The voltage generated by
the basic DC generator in Figure 7 varies
from zero to its maximum value twice for
each revolution of the loop

Fig. 9 DC Generator Commutator

2.0 Construction features of a DC

Generators
The major parts, or assemblies, of a DC
generator are a field frame, a rotating
armature, and a brush assembly.

2.1 FIELD FRAME

The frame has two functions:
Fig. 8 1. to hold the windings needed to
produce a magnetic field,
2. and to act as a mechanical support
This variation of DC voltage is called ripple for the other parts of the generator.
and may be reduced by using more loops, or
coils, as shown in Figure 8.

As the number of loops is increased, the

variation between maximum and minimum
values of voltage is reduced in Figure 8, and
the output voltage of the generator
approaches a steady DC value. For each
additional loop in the rotor, another two
commutator segments is required. A photo of
a typical DC generator commutator is shown
in Figure 9.
The actual electromagnet conductor is
wrapped around pieces of laminated metal
called field poles. The poles are typically
bolted to the inside of the frame and

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

laminated to reduce eddy current losses and a. GRAMME-RING ARMATURE

serve the same purpose as the iron core of
There are two general kinds of armatures:
an electromagnet; they concentrate the lines
of force produced by the field coils. The field i. ring
coils are made up of many turns of insulated ii. drum.
wire and are usually wound on a form that fits
over the iron core of the pole to which it is Made up of an iron core, an eight-section
securely fastened. winding, and an eight-segment commutator.

A DC current is fed to the field coils to The disadvantage of this arrangement is that
produce an electromagnetic field. This the windings, located on the inner side of the
current is typically obtained from an external iron ring, cut few lines of flux. As a result,
source that provides voltage and current they have very little voltage induced in them.
regulation for the generator system. For this reason, the Gramme-ring armature
is not widely used.
b. DRUM-TYPE ARMATURE
2.2 ARMATURE
The armature core is in the shape of a drum
The armature assembly of a generator and has slots cut into it where the armature
consists of two primary elements: the wire windings are placed. The advantage is that
coils (called windings) wound around an iron each winding completely surrounds the core
core and the commutator assembly. so that the entire length of the conductor cuts
through the magnetic flux. The total induced
voltage in this arrangement is far greater
than that of the Gramme ring type armature.
Drum-type armatures are usually
constructed in one of two methods, each
method having its own advantage.

The armature windings are evenly spaced

around the armature and mounted on a steel
shaft. The armature rotates inside the
magnetic field produced by the field coils.
The core of the armature acts as an iron
The two types of winding methods are the
conductor in the magnetic field and, for this
reason, is laminated to prevent the 1. lap winding
circulation of eddy currents. 2. wave winding.
Lap windings are used in generators that
are designed for high current. The windings
are connected in parallel paths and for this
reason require several brushes.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

Wave winding is used in generators that are Since the contact resistance of carbon is
designed for high voltage outputs. The two fairly high, the brush must be quite large to
ends of each coil are connected to provide a current path for the armature
commutator segments separated by the windings. The commutator surface is highly
distance between poles. This results in a polished to reduce friction as much as
series arrangement of the coils and is possible. Oil or grease must never be used
additive of all the induced voltages. on a commutator, and extreme care must
be used when cleaning it to avoid marring or
scratching the surface.
2.3 COMMUTATORS
3.0 TYPES OF DC GENERATORS
The commutator is located at the end of an
armature and consists of copper segments There are three types of DC generator:
divided by a thin insulator. The insulator is
often made from the mineral mica. 1. series wound
2. parallel (shunt) wound
The brushes ride on the surface of the 3. series-parallel (or compound wound).
commutator forming the electrical contact
The appropriate generator is determined by
between the armature coils and the external
the connections to the armature and field
circuit. A flexible, braided copper conductor,
circuits with respect to the external circuit.
commonly called a pigtail, connects each
The external circuit is the electrical load
brush to the external circuit. The brushes are
powered by the generator. In general, the
free to slide up and down in their holders in
external circuit is used for charging the
order to follow any irregularities in the
aircraft battery and supplying power to all
surface of the commutator.
electrical equipment being used by the
aircraft. As their names imply, windings in
series have characteristics different from
windings in parallel.
3.1 Series Wound
The series generator contains a field
winding connected in series with the external
circuit.

The constant making and breaking of

electrical connections between the brushes
and the commutator segments, along with
the friction between the commutator and the
brush, causes brushes to wear out and need
regular attention or replacement.
For these reasons, the material commonly
used for brushes is high-grade carbon. The
carbon must be soft enough to prevent
undue wear of the commutator and yet hard
enough to provide reasonable brush life.

DC Generators 9
PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

Series generators have very poor In a shunt generator, any increase in

voltage regulation under changing load, load causes a decrease in the output
since the greater the current is through the voltage, and any decrease in load causes an
field coils to the external circuit, the greater increase output voltage. This occurs since
the induced EMF’s and the greater the output the field winding is connected in parallel to
voltage is. When the aircraft electrical load is the load and armature, and all the current
increased, the voltage increases; when the flowing in the external circuit passes only
load is decreased, the voltage decreases. through the armature winding (not the field).
Since the series wound generator has such
In Figure A, the output voltage of a shunt
poor voltage and current regulation, it is
generator can be controlled by means of a
never employed as an airplane generator.
rheostat inserted in series with the field
Generators in airplanes have field windings,
windings. As the resistance of the field circuit
that are connected either in shunt or in
compound formats. is increased, the field current is reduced;
consequently, the generated voltage is also
reduced. As the field resistance is
decreased, the field current increases and
3.2 PARALLEL (SHUNT) WOUND DC
the generator output increases. In the actual
GENERATORS
aircraft, the field rheostat would be replaced
A generator having a field winding with an automatic control device, such as a
connected in parallel with the external circuit voltage regulator.
is called a shunt generator. 3.3 COMPOUND WOUND DC
GENERATORS
A compound wound generator employs two
field windings one in series and another in
parallel with the load.

It should be noted that, in electrical

terms, shunt means parallel. Therefore, this
type of generator could be called either a
shunt generator or a parallel generator.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

This arrangement takes advantage of both 4.1 Aircraft Generator

the series and parallel characteristics
There are two basic types of driving
described earlier. The output of a compound
mechanisms used on aircraft generators,
wound generator is relatively constant, even
direct gear or belt driven. To install a gear-
with changes in the load.
driven generator, remove the mounting-pad
4.0 GENERATOR RATINGS cover and install the proper gasket over the
studs. Fit the generator spline or gear into
A DC generator is typically rated for its
place, being careful not to damage them.
voltage and power output. Each generator is
Tighten the nuts on the hold down studs,
designed to operate at a specified voltage,
applying torque as recommended for the size
approximately 14 or 28 volts. It should be
of the nuts used. Connect the generator
noted that aircraft electrical systems are
cables to the proper terminals, and see that
designed to operate at one of these two
all connections are clean and tight. If the
voltage values. The aircraft’s voltage
generator employs an air duct for cooling,
depends on which battery is selected for that
make sure that is connected properly to
aircraft. Batteries are either 12 or 24 volts
avoid the possibility of its coming loose
when fully charged.
during operation.
The generator selected must have a voltage
To install a belt-driven generator, mount the
output slightly higher than the battery
unit in the appropriate location and install all
voltage. Hence, the 14-or 28-volt rating is
hardware. The drive belt should then be
required for aircraft DC generators. The
around the aircraft and generator drive
power output of any generator is given as the
pulleys. Once the belt is in the proper
maximum number of amperes the generator
location, position the generator to tighten the
can safely supply. Generator rating and
drive belt and secure all hardware and safety
performance data are stamped on the equipment as necessary.
nameplate attached to the generator. When
replacing a generator, it is important to After generator installation has been
choose one of the proper ratings. completed, the entire charging system
should be tested. Both a static and dynamic
The rotation of generators is termed either
check should be performed to ensure that
clockwise or counterclockwise, as viewed
the generator functions properly under
from the driven end. The direction of rotation
various loads and rpm conditions. If all
may also be stamped on the data plate. It is
voltage and amperage readings are within
important that a generator with the correct
specifications, the aircraft can be returned to
rotation be used; otherwise, the polarity of service.
the output voltage is reversed. The speed of
an aircraft engine varies from idle rpm to 4.2 DC Generators Maintenance
takeoff rpm; however, during the major
The inspection of the generator installed in
portion of a flight, it is at a constant cruising
the aircraft should include the following
speed. The generator drive is usually geared
items:
to turn the generator between 11/8 and 11/2
times the engine crankshaft speed. Most 1. Security of generator mounting.
aircraft generators have a speed at which 2. Condition of electrical connections.
they begin to produce their normal voltage. 3. Dirt and oil in the generator. If oil is
Called the “coming in” speed, it is usually present, check engine oil seals. Blow
about 1, 500 rpm. out any dirt with compressed air.

DC Generators 11
PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

4. Condition of generator brushes. Pull the sandpaper in the direction of

5. Generator operation. armature rotation, being careful to keep the
6. Voltage regulator operation. ends of the sandpaper as close to the slip
ring or commutator surface as possible in
order to avoid rounding the edges of the
Sparking of brushes quickly reduces the brush. When pulling the sandpaper back to
effective brush area in contact with the the starting point, raise the brush so it does
commutator bars. The degree of such not ride on the sandpaper.
sparking should be determined. Excessive
wear warrants a detailed inspection and
possible replacement of various
components.

Sand the brush only in the direction of

rotation. Carbon dust resulting from brush
sanding should be thoroughly cleaned from
all parts of the generators after a sanding
operation. After the generator has run for a
short period, brushes should be inspected to
make sure that pieces of sand have not
become embedded in the brush.

Wear areas of commutator and brushes.

Manufacturers usually recommend the

following procedures to seat brushes that do
not make good contact with slip rings or
commutators. Lift the brush sufficiently to
permit the insertion of a strip of extra fine 000 brush sanding should be thoroughly cleaned
(triple aught) grit, or finer, sandpaper under from all parts of the generators after a
the brush, rough side towards the carbon sanding operation. After the generator has
brush. run for a short period, brushes should be
inspected to make sure that pieces of sand
have not become embedded in the brush.
Under no circumstances should emery cloth
or similar abrasives be used for seating
brushes (or smoothing commutators), since
they contain conductive materials that cause
arcing between brushes and commutator
bars. It is important that the brush spring
pressure be correct. Excessive pressure
causes rapid wear of brushes. Too little

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PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

pressure, however, allows bouncing of the permitted to alter or restrict the free motion of
brushes, resulting in burned and pitted the brush. The purpose of the pigtail is to
surfaces. The pressure recommended by the conduct the current from the armature,
manufacturer should be checked by the use through the brushes, to the external circuit of
of a spring scale graduated in ounces. Brush the generator.
spring tension on some generators can be
adjusted. A spring scale is used to measure
the pressure that a brush exerts on the
commutator. Flexible low-resistance pigtails
are provided on most heavy current carrying
brushes, and their connections should be
securely made and checked at frequent
intervals. The pigtails should never be

DC Generators 13
PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

SUMMARY
Generators were the first means of supplying electrical power for aircraft aircraft. Generators or
generator derivatives called alternators are found in a wide variety of sizes and output capacities.
On aircraft the mechanical energy is usually provided by the aircraft’s engine. Light aircraft use
14 or 28-V dc generators. Large aircraft typically employ generators which produce an alternating
current of 208 or 117 V at 400 Hz, Compared to a 28-V dc system, a higher-voltage ac system
will develop several times as much power for the same weight.

Key Points
The direction of the current flow is determined by the direction of the magnetic flux and the
direction in which the conductor is moved through the flux.

Activity 6
1. Compare the shunt field windings in an aircraft generator with series windings.
2. What determines the voltage value in a generator?
3. Describe the steps for the installation of a typical aircraft generator.
4. Name the essential parts of a dc generator.
5. Explain the electrical principle by which electricity is produced in a generator.

• DEADLINE OF SUBMISSION OF THESE ACTIVITIES WILL BE EVERY SATURDAY 11:59 AM

• SUBMISSION PLATFORM WILL BE AT GOOGLE CLASSROOM

DC Generators 14
PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

Honesty Clause

This honesty clause establishes a fundamental social contract within which the College
community agrees to live. This contract relies on the conviction that the personal and academic
integrity of each individual member strengthens and improves the quality of life for the entire
community. It recognizes the importance of honesty, trust, fairness, respect, and responsibility
and wishes these principles to be a defining part of Philippine State College of Aeronautics

The Institute of Engineering and Technology values and fosters an environment of academic and
personal integrity, supporting the ethical standards of the engineering profession, where we
design and build for the benefit and safety of society and our environment.

I agree that the submission of any academic work shall constitute a representation on my part
both that such work has been done, and its submission is being made, in compliance with honesty
and integrity. Furthermore, my responsibility includes taking action when I have witnessed or am
aware of another’s act of academic dishonesty.

_________________________
Students Name over Signature

DC Generators 15
 PHILIPPINE STATE COLLEGE OF AERONAUTICS Associate in Aviation Electronics Technology

Criteria Excellent Very Good Good Fair Poor

Content The content is The content is Content is not Content is an Incomplete content is
Development comprehensive, precise comprehensive, precise comprehensive and incomplete the topic is not clearly pointed
and encouraging, clearly and encouraging, clearly encouraging, even not clearly indicated out and not
stated and well stated and well though the topic is not and is not encouraging encouraging (1 out of
supported by the subject. supported by the well supported but (2 of the 5 questions 5 questions had been
(50 pts) The writing and its subject. The scripture addressed.) To have the addressed) addressed with)
purpose are very clear and its purpose are subject matter
(Exceptionally, all clear. (4 of the 5 inconsistent with its
questions were questions were content and to clarify
addressed) addressed in an thoughts. (It addressed 3
exceptional way) out of 5 questions

(40-31 pts) (30-21 pts) (20-11 pts) (10-10 pts)

(50-41 pts)
Organization & Paper structure and The paper structure and The paper's organization Paper structure and Organization and
Structure organization are excellent organization is very clear and structure are clearly organization is not easy structure are not
easy to follow. The and easy to follow. easy to follow. to follow. The suitable for the topic.
transitions of paragraphs Paragraph transitions Paragraph transitions transitions to Paragraph is confused
(20 pts) are present and very throughout the paper throughout the paper paragraphs need and thought is lacking
logical and maintain the are present and logical are present and logical improvement transition.
thought flow throughout and maintain the flow of and maintain the flow of
the paper. thought. thought.

(20-17 pts) (16-13 pts) (12-9 pts) (04 -01 pts)

(08 -05 pts)
Format and Paper follows the exact The paper follows most Most of the guidelines Paper complies with Paper disorder made
References designated guidelines guidelines and includes go through paper. some guidelines. of lacks of elements
and correctly includes incorrect spacing Borderlines, size of Included are incorrect formatting
complete references. between text lines, using paper, inappropriate ink borderlines, paper size, this include as such:
different font sizes with used and 3 references inappropriate ink used borderlines, paper
4 references. are included. and 2 references. size, improper ink
(20 pts) used, overlap text,
copied plagiarized or
prepared by another
person with 1
reference are
included.

(16-13 pts) (12-09 pts) (08 -05 pts) (04 -01 pts)
(20-17 pts)
Grammar Grammar rules, usage are Grammar rules, usage is Grammar rules, usage is Paper made few Language utilizes
Punctuation and fully followed, spelling is followed and spelling is followed and spelling is mistakes in grammar misleading
Spelling correct. Language is very correct. The language is correct. and spelling, language conversional tone,
clear and precise; very clear and precise; Language is clear and lacks clarification or made of numerous
(10 pts) sentences consistently the structure of phrases precise; sentences includes some grammatical and
display strong, varied is consistently strong display varied structure misleading spelling errors.
structure. and varied. consistently strong. conversional tone. The activity was
The activity was The activity was The activity was The activity was submitted two weeks
submitted on time. submitted two days late. submitted four days submitted one week late.
late. late.
(08-07 pts)
(06-05 pts) (04-03 pts)
(10-09 pts) (02-01 pts)

REFERENCES

• Aircraft Electricity and Electronics Eismin/Bent/McKinley 4TH Edition

• Aviation Maintenance Handbook - General FAA-H-8083-30A

DC Generators 16