DC Motors and Generators

EXPERIMENT DC Machine

DC Motors and Generators 1800RPM

OBJECTIVE

This experiment explores all the possible design connections of a DC machine. Also studied are
the performance and control characteristics of these configurations. The method of testing to derive the
equivalent circuit of a given design is demonstrated.

REFERENCES
1.

Electric Machinery, Fourth Edition, Fitzgerald, Kingsley, and Umans, McGraw-Hill Book
Company, 1983, Chapters 2, 3 and 5.

2.

Electromechanical Energy Conversion, Brown and Hamilton, MacMillan Publishing Company,

1984, Chapters 2 and 5.

3.

Electric Machines, Steady-State Theory and Dynamic Performance, Sarma, M. S., Wm. C.
Brown Publishers, 1985, Chapters 5 and 9.

BACKGROUND INFORMATION

DC machines are one of the three basic multiply-excited rotational electromechanical energy
converters. Figure 1 shows an elementary doubly-excited magnetic system.

Figure 1: Elementary doubly-excited magnetic system.

The electromagnetic torque produced by a machine can be described by the following equation:

Revised: April 14, 2015

1 of 20

DC Motors and Generators

dev

1
2

i dL
d
2

SS

iS iR

dL
d

sR

1
2

2
R

dL

RR

Nm
(4.1)

If the machine is to produce a continuous torque, one of the windings must provide for current switching.
This current switching establishes a moving flux field which the machine rotor essentially chases. The
typical DC machine has a stator-mounted field winding which produces a flux that is stationary in space.
The armature winding is located on the machine rotor, and the armature coils are terminated with copper
bars that form segment of a commutator. The commutator is supplied armature current through a set of
graphite brushes that ride on the commutator surface. As the rotor turns, successive commutator segments
enter and leave the brush contact zone, thereby switching the current from one armature coil to the next.
Figures 2 through 5 illustrate the general construction of DC machines and the commutator.

Figure 2: Schematic diagram of a DC machine.

Revised: April 14, 2015

2 of 20

DC Motors and Generators

Figure 3: Cross-section of a DC machine showing the commutator.

Figure 4: A single-coil elementary commutator system.

From Figure 2, it is evident that keeping the fields 90 electrical degrees displaced causes each of
the fields to see an essentially constant air gap. Therefore, Eq. 4.1 reduces to

Revised: April 14, 2015

3 of 20

DC Motors and Generators

dev

i S i R dL SR N m
d
(4.2)

dev

iS iR sin N m
(4.3)

It should now be evident that the 90 electrical degree displacement causes the machine to produce the
maximum possible torque.

When both the field and armature circuits are excited, the rotor will begin to turn. As the rotor turns,
the armature windings are moving through the flux created by the field windings. This action causes a
voltage to be induced in the armature windings as described by Faradays Law. The induced voltage acts
to counteract the voltage that is producing the armature current and is, therefore, called the back EMF of
the motor.

The magnitude of the back EMF is proportional to the number of turns in the armature winding and the timerate-of-change of the field flux as seen by the armature winding. If steady-state operation is assumed, the
time-rate-of-change of the flux is just the product of the rotor velocity and the flux magnitude. An additional
simplification is made by recognizing that the magnitude of the field flux is essentially proportional to the
field current. Thus, the back EMF can be described as

K I
m

volts
(4.4)

Where:

back EMF, volts

a constant representing armature winding geometry, H

rotor velocity, Rad/sec.

field current, amperes

The armature circuit contains windings which have resistance. Therefore, the steady-state armature circuit
is normally modeled as a voltage source in series with a resistance as shown in Figure 7. Since the model
is for the steady-state, the inductances are not included.

Revised: April 14, 2015

4 of 20

DC Motors and Generators

Figure 7: Model of armature circuit.

DC motors are described by the method used to excite the field. The four most common methods
are:

separately-excited, shunt-connected, series-connected, and compound.

The separately-excited

machine has no physical connection between the field and armature windings. Each circuit is excited from
its own power supply. A shunt-connected machine has the field circuit connected in parallel with the
armature circuit. Both circuits have the same total voltage drop across them. The series-connected
machine has the field circuit in electrical series with the armature circuit. Both circuits share the same
current. A compound machine contains two independent field circuits. One field circuit is connected in
series with the armature circuit, and the other field circuit is connected to shunt either the armature circuit
or the series combination of series field and armature circuits. The former is called a short shunt, and the
latter is called a long shunt. Figure 8 shows the various connections.

Revised: April 14, 2015

5 of 20

DC Motors and Generators

Figure 4-8: DC motor connections.

The symbols used in Figure 8 are:

fld

R
R

fld

EXC

motor terminal voltage

field current

armature current

field resistance

armature resistance

motor back EMF

excitation voltage

The torque produced by a DC motor is described as the ratio of output power to mechanical rotor
speed. The output power is

Revised: April 14, 2015

6 of 20

DC Motors and Generators

EI

OUT

(4.5)

hence, the output torque is

OUT

EI

(4.6)

Combining Eq. 4.6 with Eq. 4.4 yields

K I I
f

KI f

(4.7)

Eq. 4.7 compares to Eq. 4.2 when we realize that the current
current

is analogous to the rotor current

is analogous to the stator current

, and the constant K is analogous to the derivative of

inductance with respect to position.

The different winding connections shown in Figure 8 produce different speed vs. torque
characteristics. Figure 9 shows typical curves for three of the connections.

Revised: April 14, 2015

7 of 20

DC Motors and Generators

Figure 9: Typical speed vs. load characteristics for DC motors.

The fourth connection, separately-excited, can be made to respond like any of the other three by
proper control of the excitation voltage. For the cumulative compound machine shown in the figure, both
the series and shunt field produce flux in the same orientation. The differential compound machine is
connected so the series and shunt fields are in magnetic opposition. Eq. 4.6 shows that the armature
current is a good measure of the torque load on the motor.

A question that often arises is how the torque forces produced by the motor are neutralized, or
equally opposed. The basic concept, from Newtonian mechanics, is that for every force there is an equal
and opposite force that brings the entire system into equilibrium. A primary force (torque) is created by the
magnetic field interaction in the air gap of the motor and transmitted to the load. The balancing force is
caused by the motor stator (frame) interacting with its mountings, perhaps the floor of a room. Thus, the
system is neutralized by an object of great mass.

The DC motor creates torque from electrical excitation of two magnetic circuits, the field and the
armature. If the process is partially reversed by electrically exciting the stator mounted field and providing
torque from an external prime-mover, the machine becomes a generator. As the prime-mover spins the
armature circuit through the magnetic field, a voltage is created in the armature circuit. The generated

Revised: April 14, 2015

8 of 20

DC Motors and Generators

voltage is described by Eq. 4.4. A schematic diagram of a separately excited DC generator looks identical
to Figure 8 (a), but the armature current

is reversed.

As with the DC motor, the shaft torque of the DC generator is countered by a force created at the
stator mounting point. If the stator mounting is through a measurement device such as a strain gauge, the
force that counteracts the shaft torque can be measured. A DC generator mounted in this fashion is called
a dynamometer. A dynamometer equipped with a speed measuring device (tachometer) can be used to
determine the power output of any type of rotating prime-mover.

To this point, we have assumed that the DC machine is a linear device; such is not the case. The
influence of magnetic saturation can be seen by observing the no-load terminal voltage of the separately
excited DC generator at different excitation levels. At high levels of excitation (large

), the field magnetic

circuit becomes saturated and the voltage generated per ampere of exciting current tends to decrease.
Figure 10 shows a typical curve.

Figure 10: No-load terminal voltage versus field current for a separately-excited generator at rated
speed.

Revised: April 14, 2015

9 of 20

DC Motors and Generators

THE TEST SET-UP

The DC machine to be tested and the dynamometer have already been placed on the bench and
mechanically coupled. On the right-hand end of the dynamometer is a clamp which locks the rotor and
stator. This lock is used when measuring the locked-rotor torque of the test machine. Observe how the
lock is installed so it may be properly replaced when the time arrives.

The force required to counteract the shaft torque is measured by the strain gauge that connects
the overhanging arm to the dynamometer stator. The strain gauge is connected through a cable (follow it)
to a gray box on top of the bench. This box contains A/D converter, digital display, and assorted drivers.
The display indicates torque in Newton-meters. Be sure to set the torque meter to zero before each
measurement.

The dynamometer acts as a generator when it is being used to load a motor. The dynamometer
armature is loaded by the resistor bank. All switches should be in the center off position for no-load tests.
To load the dynamometer, move all the switches to up position.
Speed measurements are made with a tachometer. On the bench is a portable digital tachometer.
Its the little blue box that has RPM on the front. Attached to the box is a cable with an optical head at the
remote end. This head contains a light source and an optical receiver. On the large pulley connected to
the dynamometer youll find a piece of reflective tape. When the light source is aimed at the pulley, a small
amount of light is reflected back each time the tape crosses the beam. The reflected light causes an
electrical pulse from the receiver. The blue box times the pulses, converts them to RPM, and displays the
speed.
CAUTION Do not look into the light source. It is very intense and will hurt your Eyes!!!!
The efficiency of the coupling system is, in very good approximation, 96 percent.
Figure 12 illustrates the faceplates of the Dynamometer and figure 11 shows the connections of the DC
motor, there are two shunt fields wired internally in series.

Revised: April 14, 2015

10 of 20

DC Motors and Generators

Motor
Current
F1
Yellow

Ifld
Field
Current

Ia
Armature
Current

A1
Red
Ra

DC Supply
Vt

DC

Terminal
voltage

Rfld1
DC

F2

E
Back EMF

F3
Rfld2
F4
Blue

A2
Black

Shunt Field

Armature

Figure 11 DC motor connections

Note: To reverse the direction of the motor you must reverse the ether the Field or the Armature
connection but not both.

Revised: April 14, 2015

11 of 20

DC Motors and Generators

Figure 12 Dynamometer face plate

Revised: April 14, 2015

12 of 20

DC Motors and Generators

SUGGESTED PROCEDURE
Be sure to make all connections as shown in the figures. Variations might cause erroneous data.
Before proceeding, make sure you have read the Test-Setup-Section.
Open the Metering instruments in the software LVDAC-EMS. Change the current range for I1 to 40A on the
right-hand menu, and set up 2 displays to measure E1 and I1. Change the operating modes for the voltage
meter E1 and the current meter I1 accordingly.

Iarm

40A

I1
A1

F1

DC supply
#2
DC

Ra
Rfld

Vt

Vt
E1

F4

DC

A2
Figure 13 Shunt Configuration DC Motor
Part 1a: Connect the dc motor in the shunt configuration (figure 13). Make sure that the torque
meter is set to 0 Newton-meters before energizing the DC motor and that it only reads positive torques
as the motor starts running. Note: To reverse the direction of the motor, you must reverse either
the Field or the Armature connection but not both. With the dynamometer locked, adjust the
motor terminal voltage (Vt) power supply (#2) until the motor armature current is 3.4 amperes: Caution
the terminal voltage will be less than 15Vdc. This is the rated armature current for the machine.
Record the torque, armature current and terminal voltage in table 1. The terminal voltage and armature
current values obtained during the locked-rotor test are used to determine the armature resistance
of the machine.
Table 1: Locked Rotor armature resistance Vt<15Vdc (figure 13)
Iarm

Vt (Varm)

Torque

3.4A

Ra = Varm/Iarm = _________________________

Revised: April 14, 2015

13 of 20

DC Motors and Generators

Make sure power is turned off before removing the lock.
1b: Remove the dynamometer lock. Maintain the shunt configuration DC motor connections and wire the
dynamometer circuit below (figure 14). Adjust the motor (Figure 13) power supply (#2) until the terminal
voltage (Vt) is 90Vdc, no load dynamometer (dynamometer field voltage = 0Vdc). Record in table 2 the
armature current (Iarm), motor speed (RPM), torque reading (windage and friction of the dynamometer).

Table 2: No load (figure 13)

Vt (Varm)

Iarm

Torque

RPM

90Vdc

Armature 1

Shunt 1

Ra

Dynamometer
shunt field
DC

DC

DC supply
#3

E
Generated
Voltage

Resistor
load bank

Shunt 2

Armature 2
Figure 14 Dynamometer

Revised: April 14, 2015

14 of 20

DC Motors and Generators

1c: Place all the dynamometer load switches in the up position. Increase the voltage to the dynamometer
field and adjust the motor terminal voltage to 90Vdc and the motor armature current is 3.4 amperes. This
is the rated load point for the motor. Record in table 3 the torque, speed, motor terminal voltage, motor
armature current, dynamometer output voltage, and dynamometer output current.

Table 3: Rated Load Point Shunt Motor circuit in (figure 13).

Vt (Varm)

Iarm

90Vdc

3.4A

Torque

RPM

1d: You are now going to record a few points for the speed vs. torque curve. Place all the dynamometer
load switches in the up position. The motor terminal voltage must be adjusted so it remains constant during
this test. Set the Rated Load Point of the motor from part 1c. Then adjust the dynamometer until the
motor is 20% overloaded; 3.4 amperes armature current. Record in table 4 the torque and speed. Now,
check a few points below the rated load. (Ranging from 4.0 to 2.5 in 0.3 A increments).

Table 4: Speed vs. torque shunt configuration of (Figure 13).

Vt const

Iarm

90Vdc

3.4A

90Vdc

4.0A

90Vdc

3.7A

90Vdc

3.4A

90Vdc

3.1A

90Vdc

2.8A

90Vdc

2.5A

Revised: April 14, 2015

Torque

RPM

15 of 20

DC Motors and Generators

Part 2a:

Connect the separately-excited configuration shown in Figure 15. Keeping the

previously used Metering instruments in the software LVDAC-EMS, change the current range
for I2 to 40A on the right-hand menu, and set up 2 additional displays to measure E2 and I2.
Change the operating modes for the voltage meter E2 and the current meter I2 accordingly.

Adjust the motor field supply (#3) to 90 volts and record in table 5 the field voltage and field
current. These two values are needed to determine the shunt field resistance seen in the
equivalent circuit of the shunt DC configuration. Vt = 0V

40A
A

I1

Iarm

40A

Ifld

I2

Varm

A1

E1

DC supply
#2 DC
Armature
Supply

DC Supply
#3
DC
Field
supply

F1
Vfld
V

Ra
Rfld

E2
F4
DC
A2
Shunt field
Armature

Figure 15 Separately excited Motor configuration

Table 5: Shunt Field Resistance circuit of figure 15.

Vt or Varm

Vfld

0V

90V

Ifld

RPM Dyno
0 RPM

Rshunt = Vfld/Ifld = ________________

Revised: April 14, 2015

16 of 20

DC Motors and Generators

2b: In the circuit of figure 15, adjust the motor field supply (#3) until the field current is 0.3
amperes. Make sure that the torque meter is set to 0 Newton-meters before energizing the DC
motor and that it only reads positive torques as the motor starts running. Adjust the motor terminal
voltage (DC supply #2) to obtain rated speed (2000RPM) Investigate the effect of the motor field
current with a constant motor armature voltage (Vt) on the motor performance at no load by
filling-up the table 6 below. Note: torque will be small.
Table 6: Circuit of (figure 15). Vt 90Vdc
No Load, Separately excited
Vt

Ifld

Torque

0.30A
Const Vt

RPM Dyno

Iarm

2000 rpm

0.275A

Var Ifld

0.25A

2c. Lock the dynamometer and investigate the effect of the motor field current with a constant
motor armature voltage on the starting torque. Recalibrate the torque meter to 0 Newtonmeters if need be. The motor armature voltage will be small less than 15Vdc. Adjust the
armature voltage (#2) to obtain an armature current of 3.4A. Maintain the armature voltage
constant. Do not exceed amperes armature current of 4.0A. Fill-up the table 7 below.
Table 7: Field Current VS Starting Torque
Locked Rotor Circuit of (figure 15). Vt <15Vdc
Vt

Ifld

Torque

Iarm

0.30A
Const Vt

0.25A

Var Ifld

0.20A

3.4A

2d. Make sure power is turned off before removing the lock.
Unlock the dynamometer. Recalibrate the torque meter to 0 Newton-meters if need be. In the
circuit, adjust the motor field supply (#3) until the field current is 0.3 amperes. Adjust the motor
armature voltage Vt (#2) to 90Vdc. Investigate the effect of the motor terminal voltage with a
constant motor field current on the motor performance by filling-up the table 8 below.
Table 8: Circuit of (figure 15.)
No Load
Ifld
Torque
RPM Dyno

Vt
Const Ifld
Var Vt

Revised: April 14, 2015

90 V

0.30A

80 V

0.30A

70 V

0.30A

Iarm

17 of 20

DC Motors and Generators

2e: Lock the dynamometer and investigate the effect of the motor armature voltage with a constant motor
field current on the starting torque. Recalibrate the torque meter to 0 Newton-meters if need be. Do not
exceed 3.5 amperes armature current. Fill-up the table 9 below. Use Vt*0.67 for row 2, use Vt*0.33 for row
3.
Table 9: Armature Voltage VS Starting Torque
Locked Rotor circuit of (figure 15). Vt < 20Vdc
Vt

Ifld

Torque

0.30A
Const Ifld

Iarm
3.4A

0.30A

Var Vt
0.30A

Part 3a. Make sure power is turned off before removing the lock.
Unlock the dynamometer and connect the separately-excited generator configuration shown in Figure
16. Set the dynamometer field rheostat to the mid-point and make sure that the torque meter is set to 0
Newton-meters before energizing the dynamometer and that it only reads positive torques as the motor
starts running. Adjust the dynamometer supply so the dynamometer runs at 2000 RPM and maintain this
speed. With no load on the generator, increase the generator field supply in 20-volt steps until it reaches
120 volts. Record the generator field current, the generator terminal voltage and the torque, also calculate
K at each step in table 10. The terminal voltage and field current data points will yield the curve shown in
Figure 10 plot this table for your report.

Note that from the previously used Metering instruments in the software LVDAC-EMS, the displays to
measure E1, E2, and I2 will be used again with the same settings as before.

Open the Oscilloscope and select E1 as the input signal for channel 1. Run the oscilloscope and observe
the waveform of the voltage generated by the DC generator as its field supply is increased in 20-volt steps.
Make observations as you complete Table 10.

Revised: April 14, 2015

18 of 20

DC Motors and Generators

Ifld
A

40A
I2

A1
Varm
V

F1

DC Supply
#3
DC
Field
supply

Vfld
V

E1

Ra

E2

DC supply
#2
DC
Dyno
Supply

1
Field
Rheostat

Rfld
DC

1
Ra

2
E

DC

Shunt
Field

F4

A2

Armature

Shunt field
motor

Armature
motor

Dynamometer
wired as a motor

Figure 16 Separately excited generator configuration

Table 10: Field Current Vs Generated Voltage at rated speed

No Load Magnetization Curve circuit (figure16)
Vfld

Ifld

Vt

Torque

RPM

20

2000 rpm

40

2000 rpm

60

2000 rpm

80

2000 rpm

100

2000 rpm

120

2000 rpm

K = E/(m Ifld) =___________________

3b: Adjust the dynamometer speed (DC supply #2) to 2000 RPM with no load on the generator.
Set the generator field voltage to 90V (DC supply #3).

3c: By adjusting the dynamometer voltage, investigate the effect of speed changes on the
generator output voltage by recording data in table 11 below and by observing in the oscilloscope
the waveform of the voltage generated as the speed is varied in steps. Plot this table 11 for your

Revised: April 14, 2015

19 of 20

DC Motors and Generators

review. After completing this section, reinstall the lock on the dynamometer and clean up the
bench for the next lab class.

Table 11: Speed VS Generated Voltage

No Load circuit (figure 16)
Vfld

Ifld

Vt

RPM Dyno

90V

2000

90V

1800

90V

1600

90V

1400

90V

1200

90V

1000

Review Things to keep in mind as you complete the experiment.

1. Use the data from the locked-rotor tests in Parts 1a find the armature resistance of the machine.
From the field test in Part 2a find the shunt field resistance. From the no-load test in Part 3a table
10 to find average value of k for the machine.
Ra=_______________ Rshunt=______________ k=________________
Explain the procedure used to find the values in terms of the model of each machine setup.
2. Draw speed vs. torque curves for the shunt motor. Relate these performance curves to the general
theory of multiply-excited rotating energy converters. Should magnetic saturation be considered for
the performance and why?
3. Explain the generator performance observed in Part 3 in terms of general energy conversion theory.
Is magnetic saturation a factor in the performance, how does it affect the performance? Plot table
5 and table 6 and explain the plots.

Revised: April 14, 2015

20 of 20