DC Machines

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 Losses & Efficiency in a DC Machine
 In a DC machine, mechanical energy is
converted into the electrical energy or vice
versa
 During this process, the total input power is not
transformed into output power
 Some amount from the input power gets wasted
in various forms which are nothing but power
losses in the machine
 These losses the rise in temperature of the
machine and reduce the efficiency of the
machine. 2
 Losses & Efficiency in a DC Machine
 It is more accurate to determine the efficiency of a
rotating machine by determination of its losses
rather than by the direct load test in which the
input and output are required to be measured
 In large and even in medium-size machines, it is
not practically possible to arrange for the actual
loading of the machine

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 Losses & Efficiency in a DC Machine
 Once the losses have been determined, the
machine efficiency (η) can be computed from the
relationships

 The process of energy conversion in rotating

machines involves currents, fluxes and rotation
which cause losses in conductors and ferromagnetic
materials, and mechanical losses of rotation
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Losses in a DC Machine

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 Losses in a DC Machine
Constant Losses:
 A machine is normally designed to run at constant
voltage mains and at a substantially constant
speed in most of the applications.
 As a result, some of the losses remain nearly
constant in the working range of the machine and
are, therefore, named constant losses.
 The constant losses can be further classified as no-
load core-loss and mechanical-loss.

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 Core Losses or Iron Losses
 The iron losses or core losses are caused by
changing flux densities in the iron core of the
machine when the main winding is excited.
 The core-loss is largely confined to the armature of
a dc machine
 As core of the armature is rotating in magnetic
field, these losses occurs in the armature core
 These losses are almost constant
 These losses are categorized in two forms;
1. Hysteresis loss and
2. Eddy current loss. 7
 Hysteresis loss
 Hysteresis losses occur in the armature winding
due to reversal of magnetization of the core.
 In a DC Machine, the core of the armature
undergoes magnetic reversal while it rotates.
 The portion of the armature which is under S-pole,
will be under the N-pole after completing half
(electrical) revolution.

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 Hysteresis loss
 The constant process of magnetic reversal in the
armature, consume some amount of energy which
is called hysteresis loss.
 This loss depends upon the quality and volume of
the iron in addition to the frequency of magnetic
reversal.
 The Frequency of Magnetic Reversal is
=
120
Where, P = Number of poles
N = Speed in rpm
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 Hysteresis loss
Steinmetz Formula
.
=
The Steinmetz formula is for the calculation
of hysteresis loss.
Where,
= Steinmetz hysteresis co-efficient
= Maximum flux Density in armature core
= Frequency of magnetic reversals
V= Volume of armature in m3.

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 Eddy Current Loss
 When armature rotates in the magnetic field, a
small amount of emf is induced in the core.
 The emf sets up some circulating current in the
core and is called eddy current.
 The power loss due to the flow of this current is
known as eddy current loss.
 Eddy Current loss: Pe=KeBmax2f2t2V Watts
ke = constant
Bmax = Maximum flux density in wb/m2
t = Thickness of lamination in m
V = Volume of core in m3 11
 Eddy Current Loss
 Constant (Ke) depend upon the resistance of core
and system of unit used.
 This loss is almost constant for the DC machines.
 To minimize eddy current losses the armature core
is made of thin laminated stampings. The thickness
of lamination used for armature core is 0.35 to 0.5
mm.

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 Mechanical Losses
 The losses associated with mechanical friction of
the machine are called mechanical losses.
 These losses occur due to

1. friction in the moving parts of the machine like

bearing, brushes etc, and
2. windage losses occur due to the air near the
rotating part of the machine and also due to
ventilation system.

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 Variable Losses
Variable Losses
 These losses vary with the load supplied by

the machine and are hence called “variable

losses”.
 These can be split into

1. copper loss (I2R) and

2. stray-load loss.

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 Copper Losses
 The copper losses are the winding losses that takes
place when current flows through the windings.
 These losses occur due to the resistance of the
winding.
 In a DC machine, there are only two windings:
armature and field winding. (Interpoles and
compensating windings will also be there in some
DC machines)
 Thus copper losses categories in three parts;
armature loss, the field winding loss, and brush
contact loss.
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 Copper Losses
 Armature Copper Loss in DC Machine
Armature copper loss = Ia2Ra
Where, Ia is armature current and Ra is armature
resistance.

Field Winding Copper Loss in DC Machine

 Field winding copper loss = If2Rf
Where, If is field current and Rf is field resistance.

 The loss due to interpole windings and

compensating winding are also computed in the
similar manner 16
 Brush Contact Loss
 The conduction of current between the brushes
(made of carbon) and the commutator of a dc
machine is via short arcs in the air-gaps which are
bound to exist in such a contact.
 As a consequence, the voltage drop at the brush
contact remains practically constant with load.
 Its value for positive and negative brushes put
together is of the order of 1 to 2 V.
 The brush-contact loss in a dc machine is therefore
directly proportional to current.
 It is given by the equation PBD=VBDIa
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 Stray Load Losses
 There are certain types of losses which can not be
easily determined.
 They appear when the machine is loaded. This

indeterminable losses are called stray load losses

and are due to the following reasons:
1. Distortion of flux because of armature reaction.
2. Due to eddy current in conductors there will be
additional I²R loss.
3. Short circuit current in the armature coils
undergoing commutation.
 Stray load losses may be assumed 0.5 to 1% of the

power output of the machine. 18

 Power flow in a DC Generator

=Windage and Frictional Loss

=Total core loss (including stray core loss, if any)
=shunt field loss in shunt and compound machine
=armature copper losses including loss in series
winding
=brush contact losses 19
 Power flow in a DC Generator
 In the case of a generator, we apply mechanical
power to the shaft of the machine and deliver
electrical power to a load
 Rotational losses are then subtracted from the
mechanical power. This includes friction and
windage loss and total core loss.
 The remaining power is transformed into electrical
power, and this quantity is called the developed
power.
 In the case of a DC generator, the developed
power is
= 20
 Power flow in a DC Generator
 From the developed power the copper losses in the
machine windings, as well as the loss due to the
brushes are subtracted to get Electrical power as
the output of the generator

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 Power Flow in a DC Motor

=Windage and Frictional Loss

=Total core loss (including stray core loss, if any)
=shunt field loss in shunt and compound machine
=armature copper losses including loss in series
winding
=brush contact losses 22
 Power Flow in a DC Motor
 Motors receive electrical power as their input and
deliver mechanical power at the shaft of the
machine.
 In this case, the electrical power is the input at the
left.
 The copper and brush losses are subtracted,
leaving the developed power in the middle.
 From the developed power, we subtract the friction
and windage, core, and stray losses to find the
output mechanical power.

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 Losses & Efficiency in a DC Machine
The losses can be combined as follows
 Constant Loss: = + +
 Variable Loss: = + +
where =total stray load loss
∝ square of the armature current
=
The brush contact loss will be treated
separately as it proportional to .
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 Losses & Efficiency in a DC Machine
 The expression for the efficiency of DC Machine are
derived below
Machine Efficiency η =
 For a Generator,
= = 1−

 In the form of symbols,

+ +
=1−
+ + +

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 Losses & Efficiency in a DC Machine
 For a Motor,

= = 1−
 In the form of symbols,
+ +
=1−

 Maximum Efficiency occurs when

Variable Loss= Constant Loss
=

=
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