What is a DC Machine?

A DC machine is an electromechanical energy alteration device. The working principle of a DC machine is when electric current
flows through a coil within a magnetic field, and then the magnetic force generates a torque that rotates the dc motor. The DC
machines are classified into two types such as DC generator as well as DC motor.

The main function of the DC generator is to convert mechanical power to DC electrical power, whereas a DC motor converts DC
power to mechanical power. The AC motor is frequently used in industrial applications for altering electrical energy to
mechanical energy. However, a DC motor is applicable where good speed regulation & an ample range of speeds are necessary
like in electric-transaction systems.
 Construction of DC Machine

The construction of the DC machine can be done using some of the essential parts like Yoke, Pole core & pole shoes, Pole coil &
field coil, Armature core, Armature winding otherwise conductor, commutator, brushes & bearings. Some of the parts of the DC
machine is discussed below.

Yoke of DC Machine:

Yoke is also called as frame of the machine. It provides protection to the rotating and other parts of the machine from moisture,
dust and mechanical damage etc. Also it provides the mechanical support for the poles.
It is an iron body which provides the low reluctance path for the flux. This is essential to complete the magnetic circuit.
Materials used for the yoke are basically the low reluctance materials such as cast iron, silicon steel, rolled steel, cast steel.
It’s provides the mechanical support for the poles.
For small dc machines the Yoke are made of cast iron. But for larger machines, cast steel or rolled steel is used.

Poles, Pole Shoe and Pole Core:

A pole of a dc machine is a supporting structure to electromagnet. The field winding is

wound over the poles.
Poles produce the magnetic flux when the field winding is excited by DC supply voltage.
Pole shoe is an extended part or shower like structure of a pole. Due to its typical shape,
it enlarges the area of the pole. Due to this enlarged area, more flux can spread and pass
through the air gap to armature core and armature winding.
For the construction of a pole or pole shoe low reluctance magnetic material such as cast steel or cast iron is used .
Field Winding of DC machine:

The coils wound around the pole cores are called as field coils.
Series combination of field coils with each other to form the field winding of dc machine.
Field winding is also called as Exciting winding, Because it produces the flux.
Materials used for the field conductor is enameled copper.

Armature Core of Dc Machine:

Armature core is a cylindrical drum like structure which is mounted on the shaft.

It is provided with a large number of slots all over its periphery, all these slots are parallel to the shaft axis, Armature conductors
are placed in these slots.
Armature core provides a low reluctance path to the flux produced by the field
winding and this flux is cut by the armature conductor.

The air holes are also provided in the armature core for the air circulation, which
helps in cooling the armature core.

Core constructed using laminations so as to minimize the eddy current loss.

Que. State functions of the armature core in DC machine and name material used for armature core.
Functions of armature core:

Rotate as a rotor with armature winding.

Increase the permeance (ease of magnetization) of the magnetic path to increase the magnitude of induced EMF for a certain
MMF created by the field

Material used for armature core:

High permeability, low reluctance materials such as cast steel or cast iron are used for the armature core.

Armature Winding of dc machine

Que. State the function of armature winding and name the material used for its construction.

The armature conductor is placed on the armature core slot to form an armature winding. And its conductors made of copper or
aluminum wire.

Armature winding is connected to the external circuit (to load in case of generator) through the commutator and brushes.
Commutator of DC Machine:

A commutator is a cylindrical drum mounted on the shaft along with the armature core.
It is made of a large number of wedge-shaped segments of hard-drawn copper.
The segments are insulated from each other by thin layers of mica.
Armature winding is tapped at various points and these tapping’s are successively
connected to various segments of the commutator.
For a dc generator it converts the alternating EMF generated internally into a DC
voltage. So it basically works like a rectifier.
It collects the current from the armature conductors and passes it to the external load via brushes.

Que. State the function of commutator in DC generator and name the material used for commutator.

Function of Commutator:
Commutator converts AC induced current in the armature winding into DC for external load.

Material:
Commutator segments are made up of Copper.
Commutator segments are insulated from each other by Mica.
Brushes:

Current is collected from the armature to the external load by the carbon brushes which
are placed against the surface of commutator by small pressure using springs.

It wear with time, hence they should be inspected regularly and replaced periodically.
Brushes are made of carbon or graphite and shape like rectangular.

Shaft:

Shaft is a solid long rod like structure, which place by support of bearing in alignment for proper rotation. And it help to support
and rotate rotor .
 Working Principle of a DC Generator

An electromagnetic field (emf) is induced in a current-carrying conductor when it is put in a changing magnetic field
according to Faraday’s law of electromagnetic induction and Fleming’s right-hand rule states that as the conductor’s
direction of motion alters, so does the direction of the induced current.

The induced current will flow along the closed path of the conductor when the situation is provided. The armature
conductors are spun into the electromagnetic field created by the field coils in a DC generator. As a result, the
conductors in the armature produce an electromagnetically induced emf.

Consider an armature revolving in a clockwise

direction while a conductor is travelling upward from
the left. The direction of that specific conductor’s
motion will change to downward after the armature
completes a half rotation. As a result, the current will
flow through each armature conductor in an alternating
fashion. However, a split ring commutator also
reverses the connections of the armature conductors
when the current is reversed. As a result, the terminals
experience unidirectional current.
 e=ΦP N/60×Z/A volts
Consider an armature revolving in a clockwise direction while a conductor is travelling upward from the left. The
direction
Where, of that specific conductor’s motion will change to downward after the armature completes a half rotation. As a
result, the current will flow through each armature conductor in an alternating fashion. However, a split ring
commutator
Z representsalso reverses
the total the of
number connections
conductorsof the armature conductors when the current is reversed. As a result, the
terminals experience unidirectional current.
A stands for the number of parallel paths

P is the number of poles in the generator

Z/A = number of serially connected conductors

N represents the rotation of armature in r.p.m

N/60 = number of turns per second

e= induced emf of the DC generator

 DC Motor Working Principle

When a current carrying conductor is placed in a magnetic field, a mechanical force acts on it, which can be
determined by Fleming's left hand rule. Due to this force the conductor becomes mobile in the direction of the force.

DC Motor Working

Imagine that a current-free conductor (which is not connected to the supply) is placed in the main magnetic field the and without the
magnetic field flowing through the conductor. Assume, there is an air gap from N pole to S pole.
Current is flowing in the conductor but the magnetic effect of N pole and S pole has been removed. In this situation the conductor will
maintain its own magnetic field. The magnetic field lines of force of the conductor will be clockwise according to the cork screw rule.
Current is flowing in the conductor and main magnetic field is also present. The magnetic field produced due to the current in the
conductor acts along with the main field above the conductor but opposes the main field below the conductor. The result is that flux
accumulates in the region above the conductor and flux density reduces in the region below.
From this it is clear that when the force is acting on the conductor, it works to push the conductor downwards. If the direction of
current in the conductor is changed, the flux will accumulate downwards and will try to move the conductor upwards.
DC Motor Characteristics
If length of conductor = L meter, field intensity = B weber per square meter (Bwb/m2) and current flowing in the
conductor = i ampere, then the force experienced by the conductor will be F = iBL Newton.

DC Motor Torque Formula

Torque, also known as moment or moment of force, is the force that tends to rotate or move an object around a
central axis. A force is a push or pull, similarly, torque creates twisting to an object. Mathematically, torque is given
as T = F × r. For DC Motor, the torque is given as
T = (0.159PΦNZ/A)Ia
where,

T is Torque of Armature Ф is Flux per pole A is Number of parallel paths

Ia is the armature current N is Speed of motor in (RPM)
P is Number of Poles Z is Number of conductors
 EMF or the electromotive force is responsible for flow of current in the electrical appliances. EMF is not an force but the
electric potential. In case of DC Motor, a back EMF is produced which counters the armature current.
The direction of this back EMF is given by Lenz Law. The formula of back emf is given as

DC Motor Speed
The formula for DC Motor speed is given as:
N = KEb/Φ
where,
•N is speed in RPM
•K is constant proportionality which is equal to 60A/ZP (P = number of field poles, Z = total no. of armature conductors,
A = no. of parallel paths in armature)
Types of DC Motors

DC Motors can be classified into various categories based on the application and winding connections. Based on the
winding of armature DC Motor is of two types
•Self Excited DC Motors
•Separately Excited DC Motors

Self Excited DC Motor

DC motors that excite themselves have a part and coil of field connected in series or partly so, same for parallel connection. They can
also have combination of series and Parallel connections. They also get power from only one place. Three types of self-excited DC
motors exist:
•Series DC motor
•Shunt DC motor
•Compound DC Motor

Series DC Motor

It is a motor in which the field is in series with the armature and its starting torque is very high. This means that the same flow of
current goes through both the coil and armature. Series motors always go in one direction and their speed is affected by the physical
load.

Shunt DC Motor

Shunt motor is a DC motor in which the field is jointed in parallel to the armature and its starting torque is less than that of series
motor. Inside the shunt motor the field winding is connected parallel to the armature winding. The field winding is made of more turns
Compound DC Motor

Compound Motor is a Motor in which both series and parallel fields are added. Compound DC motors use both parallel
and connected field windings. In the armature winding, everything is in series. However, field coils can be shunt or
series types.

Separately Excited DC Motor

In DC motors with a separate excite, field coil to make permanent magnets. But, the armature and field coils are not
connected electrically to each other. They work separately and do not bother the other. But, the result of the engine is
added up with both.

More Types of DC Motor

Some more types of DC Motor on the various parameters are discussed below:

1. Based on Commutation:

•Brushed Motors: Use brushes and a commutator for current reversal.

•Brushless Motors: Switch currents in the windings by electronic commutation.

2. Based on Application:

DC Servo Motors: Exact control of position and speed. Applied in robotics, CNC machine tools and automation.
•Stepper Motors: Take small steps, accurate position control. Widely employed in printers and CNC machines.

•Hysteresis Motors: The materials 'motion makes use of their magnetic hysteresis. Used in devices such as record
players, rather simple.

•Brushed DC Gear Motors: Have a gearbox for high torque at low speeds. Applied in robotics, electric vehicles and
automation.

•DC Traction Motors: Intended for use in traction devices, including electric vehicles and trains.

3. Based on Speed-Torque Characteristics:

•High-Speed DC Motors: Designed for uses involving high rotational speeds. Examples include tools and appliances.

•Low-Speed DC Motors: Offer high torque at low speeds. Commonly used in industrial machinery.

4. Based on Size and Shape:

Micro DC Motors: Applications such as consumer electronics call for very small motors.

Large DC Motors: As used in industrial purposes such as steel mills, paper industries and ship propulsion.
5. Based on Control System:

•Closed-Loop DC Motors: Feedback mechanisms can be employed for more precise control. Applications where
precision control is important.

•Open-Loop DC Motors: Control without feedback, simpler design. In applications where control is not so critical.