Module 1

Direct Current Generator

Generator Principle
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Introduction: This module is design for students of Electrical Engineering enrolled Electrical machines may be associated to an electrical energy of an alternating
in the subject EE 302 (Electrical machines) to give knowledge about direct current type called a.c. machine or may be associated to an electrical energy of direct
generator. It makes learning easier but challenging for the students to become type called d.c. machines
independent and resourceful. Every topic contains sample problem and activity
DC generators and Dc motors are the classifications of DC machines. Their
for them to think and analyzed.
construction are identical whether it is a generator or a motor.
It covers the principles of a generator, the different parts and functions of a
generator, the types and advantages of armature winding.

To fully understand this module, set aside other task that may disturb you while
doing this module. Read and understand the lesson carefully. Analyzed the
sample problems and answer all the activities including the self-evaluation test to
gauge how well you understand the lesson. For problem solving, read the
problem carefully, write down what are the given and the unknown, draw the
circuit and analyze, formulate the equation that fits with the unknown so that you
can check what is missing based on the given, solve the problem step by step
until you reach the final answer.
Fig. 1.1 Conversion of mechanical energy to electrical energy and vice versa.
Objectives:
After thoroughly studying this module the student should be able to:
II. Generator Principle
 Understand the principle of generator
 Know the function of various parts of dc generator. An electrical generator is a machine which converts mechanical energy
 Know the types and importance of armature winding (or power) into electrical energy.
 Know how to compute the pitch of the winding as well as the number of
equalizer ring The principle of energy transformation is based on the production of
dynamically (or motionally) induced emf. According to Faradays’s law of
Lesson Proper: electromagnetic induction, each time a conductor cuts magnetic flux,
dynamically induced emf is produced. This emf will push the current to flow if
I. Overview the conductor circuit is closed.

The electrical engineering study mainly includes the analysis of the Faraday’s Law states that:
energy transfer from one form to another. An electrical machine, deals with the The magnitude of the generated voltage is directly proportional to the
transfer of energy either from mechanical energy to electrical energy or vice rate which a conductor cuts magnetic lines of force.
versa. This process is called electro mechanical energy conversion.

A machine that converts mechanical energy to an electrical energy is called an

electric generator. While a machine that converts electrical energy to
mechanical energy is called an electric motor.

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 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'.

Fig. 1.2

In short the principle of generator action involves:

1. the existence of magnetic lines of force

2. the motion of conductor cutting the flux 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
3. then voltage is generated
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.
Fig. 1.3 Generation of voltage 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.
III. Construction Of A DC Machine:

Note: Theoretically, 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

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 Armature core (rotor) IV. Armature Windings

4. Armature core: Armature core is the rotor of a dc machine. It is cylindrical in What is Pole Pitch?
shape with slots to carry armature winding. The armature is built up of thin
Pole pitch is defined as the peripheral distance between the center of two
laminated circular steel disks for reducing eddy current losses. It may be
adjacent poles in a DC machine. This distance is measured in terms of
provided with air ducts for the axial air flow for cooling purposes. Armature is armature slots or armature conductors that come between two adjacent pole
keyed to the shaft. centers.
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 Pole Pitch is equal to the total number of armature slots divided by the total
also from the armature core. Armature winding can be wound by one of the number of poles in the machine.
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 For example, if there are 96 slots on the armature periphery and 4 poles, the
will carry two different coils. number of armature slots that come between two adjacent pole centers would
6. Commutator and brushes: Physical connection to the armature winding is be 96/4 = 24. Hence, the pole pitch of that DC machine would be 24.
made through a commutator-brush arrangement. The function of a
Hence pole pitch is equal to total numbers of armature slots divided by total
commutator, in a dc generator, is to collect the current generated in armature
numbers of poles, we alternatively refer to it as armature slots per pole.
conductors. Whereas, in case of a dc motor, commutator helps in providing
𝑆
current to the armature conductors. A commutator consists of a set of copper 𝑃𝑜𝑙𝑒 𝑃𝑖𝑡𝑐ℎ =
𝑃
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 What is a Coil?
armature coil and the commutator is keyed to the shaft. Brushes are usually The coil of the DC machine is made up of one turn or multi turns of the conductor.
made from carbon or graphite. They rest on commutator segments and slide If the coil is made up of a single turn or a single loop of the conductor, it is called
on the segments when the commutator rotates keeping the physical contact a single turn coil. If the coil is made up of more than one turn of a conductor, we
to collect or supply the current. refer to it as a multi-turn coil.
A single turn coil will have one conductor per side of the coil whereas, in multi
turns coil, there will be multiple conductors per side of the coil. Whatever may be
the number of conductors per side of the coil, each coil side is placed inside one
armature slot only.

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That means all conductors of one side of a particular coil must be placed in one
single slot only. Similarly, we place all conductors on the opposite side of the coil
in another single armature slot.

Coil Span or Coil Pitch (Ys) - It is the distance between the two sides of a
coil measured in terms of armature slots between them.
That means, after placing one side of the coil in a particular slot, after how many
conjugative slots, the other side of the same coil is placed on the armature.
This number is known as coil span.

𝑆
𝑌𝑠 = −𝐾
𝑃
Where:
Ys = coil pitch in slots
S = total number of armature slots
P = number of poles
K = any number of S / P, that is subtracted to make Ys an integer
Problem 1.1]

Calculate the coil pitches and indicate the slots into which the first coil should
If the coil span is equal to the pole pitch, then the armature winding is said to be placed for the following armature windings.
be full – pitched. In this situation, two opposite sides of the coil lie under
two opposite poles.
Full Pitched a) 20 slots, 4 poles
The pole span or coil pitch is equal to the pole pitch. It means that the coil span
is 180 electrical degrees. In this case, the coil sides lie under opposite poles, 𝑌𝑆 = =5 slot 1 to a slot 6
hence the induced emf in them are additive. Therefore, maximum emf is induced b) 58 slots, 4 poles
in the coil as a whole, it is being the sum of the emfs induced in the two coil sides.
𝑌𝑆 = − = 14 slot 1 to slot 15
Fractional Pitched
The coil span is less than the pole pitch. In this case there is phase difference
between the emfs in the two sides of the coil. Therefore, the total emf around the
coil which is vector sum of emfs in the two sides is less in this case as compared
to that in the first case. If the number of slots is 35, then𝑌𝑆 = 354 − 34 = 8, because
it is customary to subtract fractions.

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V. Pitch of Armature Winding after one trip around the commutator, a segment is reach that is m behind or m
ahead of the starting segment.
Solution:

21±1
a. 𝑌𝐶 = 4⁄ = 11/10
2

Tracing 𝑌𝐶 = 10
1+10=11+10=21 therefore:
1---------11-----------21 (see Figure 1.15)
1 segment behind segment 1

Tracing 𝑌𝐶 = 11
Commutator Pitch (Yc)
The distance between the two segments to which the two ends of the coil are 1+11=12+11=23 Since there is no segment 23 therefore;
connected. For lap winding, Yc is equal to the number of plex. For wave winding 1----------12------------2
Yc is equal to; 1 segment ahead segment 1
𝐶±𝑚
𝑌𝑐 =
𝑃⁄
2 34±1
(b). 𝑌𝐶 = 6⁄ = 11 𝑜𝑟 11.66
2
Where: Tracing YC 11
Yc – Commutator pitch
C – No. of Commutator segments 1---------12--------23---------34
m – number of plex
1 segment behind segment 1
P – number of poles
For𝑌𝐶 = 11.66, wave winding is impossible
Note: If 𝑌𝑐 is not an integer, then wave winding is not possible.

Problem 1.2.
VI. Types of Armature Winding
Calculate the commutator pitches for the following pole and commutator segment There are two methods used in armature winding of a Dc
combination. machine
a.) 4 poles, 21 segments, simplex wave
1. lap winding
b.) 6 poles, 34 segments simplex wave
In each case trace the winding around the commutator once; start at segment 1 2. wave winding.
and show that

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 In lap winding, the successive coils overlap each other. In a simplex lap In wave winding, the coil ends are connected to the commutator
winding, the two ends of a coil are connected to adjacent commutator segments very nearly, but never exactly equal to the distance between poles of
segments. the same polarity, that is, alternate poles. Since one cycle always occurs in
distance covered by a pair of poles, this distance is arbitrarily called 360 electrical
degrees

Fig. 1.15 Complete winding diagram of a 21 slots, 4 pole simplex wave winding

Fig.1.13 Complete winding diagram of a 20 slots, 4 pole simplex lap winding

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 is used when the number of segments is one minus 2 times the number of slots,
The difference between these two is simply due to the end connections and or even 3,4 5, etc. times the number of slots
commutator connections of the conductor. To know how armature winding is
done, it is essential to know the following terminologies –
Multiplex Winding
Multiplex winding is use to limit the current per path, because as the number of
plex increases the number of parallel paths in lap winding also increases.

Number of parallel path:

Lap winding= 𝑝𝑙𝑒𝑥 × 𝑝𝑜𝑙𝑒

Wave winding= 2 × 𝑝𝑙𝑒𝑥

Multiplex lap winding are mostly limited to low voltage, high current
machines because practically speaking, it is desirable to limit the current
per path to values no greater than 250 to 300 amperes. When the current
per path is in excess of these general practical limits, commutation
becomes difficult.

For example, a machine with 100 Kw, 50 V, 4 pole would have an armature
current of :

100 × 103
= 2000 𝐴𝑚𝑝.
50

Fig. 1.16 Winding diagram for four pole simplex wave armature with dummy element.
2000
If we are going to use simplex lap winding, the current per path = = Equalizer Ring
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It is used to avoid unequal distribution of current at the brushes, in so doing,
500 𝐴𝑚𝑝.Almost double the limit; if we used duplex lap winding the current / path
aiding to become sparkless commutation. It is a copper conductor in the form of
2000
= = 250 𝐴𝑚𝑝. This describes the persistence of multiplex lap winding. ring that is connected to the armature conductor so that the circulating current
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due to slight difference in the emfs of several parallel paths, passes over these
Dummy or Idle Coils equalizer rings instead of passing through the brushes.
Dummy element is used to provide mechanical balance for the armature. It is a
wire that is similar to the other coils but it is not connected to the commutator so In lap winding all conductors in any parallel path lie under one pair of poles.
that it does not affect the electrical characteristics of the winding. If fluxes from all poles are exactly similar, then emf induced in each parallel
path is the same and each carries the same current. However, some
It is used when the combination of slots and segments is like this, 15 slots and 29 inequalities in flux unavoidably occur due either to minor variations in air –
segments. The usual is 15 slots and 30 segments for a double element wave gap length or in the magnetic properties of steel. Hence, there is continually
winding. If we use 15 slots and 29 segments, one element on the fifteenth slot slight imbalance of emf in various parallel paths. The effect is that
will be open, so the armature will become unbalance. Therefore, dummy element conductors under stronger poles generate greater emf and hence carry
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 larger current. The current circulation at the brushes becomes unequal.
Some brushes are overloaded, or carry more than their normal current
whereas others carry less. Overloaded brushes spark badly whatever their Problem. 1.3]
position may be. This results in poor commutation and may even limit the Determine the number of equalizer connections at the commutator of 36
output of the machine. segments, six pole armature for 100% equalization and make a table showing
By joining together, a number of symmetrical points on armature those that are joined together at each one.
winding which would be at the same potential if the pole fluxes were equal,
the difference in brush currents is reduced. This requires that should be a
whole number of slots per pair of poles so that for example, if there is a slot
under the center of N-pole, at some instant, then there would be one slot
under the center of every other N pole, at some instant, then there would Solution:
be one slot under the center of every other N-pole. The equalizing
conductors. 36
Number of Equalizer = = 12
3

1-----13-----25 7-----19-----31
2-----14-----26 8-----20-----32
3-----15-----27 9-----21-----33

4-----16-----28 10----22-----34

5-----17-----29 11----23-----35

6-----18-----30 12----24-----36

Advantages of Lap and Wave Windings

Fig. 1.17 Sketch showing two equalizer connections in a six pole lap type armature
winding. For wave winding:

Maximum number of equalizer rings is equal to the number of conductors under • It gives more emf, so that wave winding is used for high voltage
one pair of poles. Hence: low current machine.
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 • It is not required to use equalizer ring because each path
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑖𝑛𝑔𝑠 = contains conductor which lie under all poles.
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑎𝑖𝑟 𝑜𝑓 𝑃𝑜𝑙𝑒𝑠

To achieve 100% equalization, all coils must be properly connected.

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For lap winding:

• It gives more parallel paths so that it is suitable for high current 1.3 A commutator has 456 segments. Indicate whether or not the following
low voltage machine windings are possible:
a. simplex-wave for six poles
b. triplex-wave for six poles
Exercises No. 1
c. duplex-wave for eight poles
1.1 Calculate the coil pitches and indicate the slots into which the first coil should d. simplex wave for ten poles
be placed for the following armature windings.
If possible, trace the winding around the commutator once starting at segment 1
a) 62 slots, 6 poles and show that after one trip around the commutator, a segment is reached that
𝑏) 140 slots, 8 poles is m segments behind or ahead of the starting segment.
𝑐) 290 slots, 10 poles
𝑑) 240 slots, 12 poles
1.2. Calculate the commutator pitches for the following pole and commutator
segment combination.
a. 4 poles, 120 segments duplex wave
b. 6 pole, 126 segments triplex wave
In each case trace the winding around the commutator once; start at segment 1
and show that after one trip around the commutator, a segment is reach that is m
behind or m ahead of the starting segment.

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1.4 What type of lap winding is used for a 90 KW, 30 volt, four pole machine 1.6 . A 500 kW, 600V, 8 pole generator has an armature with 108 slots, 216
to avoid difficulty in commutation process, show your solution to support commutator segments and a triplex lap winding with a total of 648
your answer conductors. Calculate (a) the number of conductors per slot, (b) the coil
pitch and indicate the slots into which the first coil should be placed, (c)
the commutator pitch (d) the current per path, (e) the number of turns per
slot.

1.5 How many equalizers are there in a six pole 25% equalized armature in
which there are 72 segments? Make a table showing those that are joined
together at each one.

1.7. An 8 pole triplex wave wound armature carries a total of 660

amperes. If there are 8 brush arms, Calculate the current in each
armature winding path..

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References:

Fundamentals of Electrical Machines, (2012, January 30) M.A. Salam, Alpha

Science International Ltd. Oxford U.K.,
https://www.amazon.com/FundamentalsElectrical-Machines-Second-
Salam/dp/1842657046
Electrical Machines and Automatic Controller . , Technical Publications., 2014

Electrical Machines., S.K. Bhattacharya, Tata McGraw-Hill Publishing Company

Limited

Electric Machinery., P. F. Ryff., Prentice Hall, Englewood Cliffs, New Jersey

07632

Electric Machinery; S.D. Umans., McGraw-Hill Inc.,

2014 Electrical Technology ;BL Theraja : Vol.
Introduction to Electrical Engineering; M.S. Naidu S.
Kamakshaiah Electrical Machines, Siskind. McGrawhill, 1979

https://www.electricaleasy.com/2012/12/basic-construction-
and-working-of-dc.html
https://www.electrical4u.com/armature-winding-pole-pitch-coil-
span-commutator-pitch/

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