UNIT-1

DC MACHINCES
Lecture-1 & 2
By
Prof.(Dr.) Amit Shrivastava
B.E., M.E., Ph.D., LMIE, LMISTE
1
Introduction & Application
 Three electrical Machines (dc, induction & synchronous) are used extensively
for electromechanical energy conversion.
 In these machines, conversion of energy results from the
following two electromagnetic phenomena:
1. When a conductor moves in a magnetic field voltage is induced in the conductor
(generator action)
2. When a current –carrying conductor is placed in a magnetic field, the conductor
experiences a mechanical force (Motor action)

Electrical Mechanical

System System
Electrical

E, I T, n
Machines Motor
Generator
 Note that the two systems in fig. 1, electrical and mechanical, are different in
nature.
 In electrical system the primary quantities involved are voltage & current
 While in mechanical system, the analogous quantities are torque &
speed.

 The coupling medium between these different systems is the magnetic field
2
 The dc machines are versatile and extensively used
in industry.
 A wide variety of volt-ampere or torque-speed characteristics
can be obtained from various connections of the field winding.
 Dc machines can work as generators, motors & brakes.
 In the generator mode the machine is driven by a prime mover
(such as a steam turbine or a diesel engine) with the mechanical
power converted into electrical power.
 While in the motor mode, the machine drives a mechanical load
with the electrical power supplied converted into mechanical
power.
 In the brake mode, the machine decelerates on account of the
power supplied or dissipated by it and, therefore, produces a
mechanical braking action.

3
 There is almost no modern use of dc machines as generators
although in the earlier stages of electrical power generator and
distribution, dc generators were the principle means of supplying
electrical power to industrial and domestic consumers.
 Presently, all the land based electrical power networks are a.c
systems of generation, transmission and distribution.
 The almost universal use of ac systems is on account of their
 lower generation and transmission costs,
 higher efficiency (large bulk of ac power can be transmitted and
distributed over wide areas and long distance at much higher
voltages that are impossible in dc system),
 greater reliability on account of interconnection and control.
 No doubt, application like aircrafts, ships and road mounted
vehicles which are isolated from land based ac networks employ dc
sources including dc generators and secondary batteries for power
supply but the modern trend is to use ac generators with the dc
supply being obtained by rectification with the help of static power
rectifiers.
 DC generators are still being used to produce power in small back
up and stand-by generating plants driven by windmill and mountain
streams (minihydro-electric plants) to provide uninterrupted pow4er
supply.
 As apart from dc generators, the dc motors are finding
increasing applications, especially where large
magnitude and precisely controlled torque is required.
 Such motors are used in rolling mills, in overhead
cranes and for traction purpose like in forklift trucks,
electric vehicles, and electric trains.
 They are also used in portable machine tools supplied
from batteries, in automotive vehicles as starter
motors, blowermotors and in many
applications
controlas actuators and as speed and position
sensing device (tachogenerators for speed sensing
and servomotors for positioning and tracing).

5
 CONSTRUCTION
 The dc machines used for industrial applications have essentially
three major parts:
a) Field system (Stator)
b) Armature (Rotor) and
c) commutator

6
Cut-away view of DC Machines
Fie
ld- Fr
wi am
Ma nd
Ar in- ing e End-shield
m po
atu le
co re
mm Bru
uta she
t ors

End-bearings
Shaft

Ventilator

Bearings
Basement 7
 Field System
 The field system is located
on the stationary part of the
machine called stator.
 The field system is
Yoke
designated for producing
magnetic flux and, therefore,
provides the
Main
excitation necessary for
operation of Pole
 machine.
The stator of dc
machines comprises of
1. Main Poles
2. Inter-poles Field
3. Frame (Yoke) Winding

8
 STATOR
 The stator of a dc machines consists of a frame or yoke,
and poles, which support the field windings.
 The frame or yoke in addition to being a part of a magnetic circuit
serves as mechanical support for entire assembly.
YOKE
 Earlier, cast iron was used for the construction of
yoke but it has been replaced by cast steel.
 This is because cast iron has saturation density of 0.8 Wb/m2
while saturation occurs in cast steel at density of approximately
1.5 Wb/m2.
 Thus, the cross section of the cast steel frame or yoke is half that
of iron cast and hence cast steel is used in case it is desired to
reduce the weight of machine.
 Fabricated steel yokes are commonly
economical and used, as they are have
properties. consistent magnetic &
mechanical
 For very small sized machines it may still be advantageous to
use cast iron frames but for medium and large sizes rolled steel
is used.
9
MAIN POLES
 Poles are made of sheet steel laminations of 1.0 to 1.2mm thickness
(nowadays the thickness becomes 0.4-0.5mm)
 The pole shoes support the field coils placed on the pole body and
also spread the total flux over a greater area, thereby reduce the air
gap reluctance and giving the desired flux distribution to limit
saturation in the teeth of the armature.

 The poles are secured to the yoke by means of bolts.

 In small machines the pole are built of steel forgings, bolted directly to
the yoke.
 In case of machines having compensating windings, the pole face is
slotted to accommodate the windings.

INTERLOPES
 In addition to the main poles, modern direct current machines are also
provided with interlopes with windings on them in order to improve
commutation under loaded conditions.
 They are arranged midway between the mains poles and are bolted to
the yolk.
 Laminated interlopes are used in machine with sever commutation
problems. 10
 For small and medium size machines they could be solid.
 Armature
 The armature is the rotating
part (rotor) of the dc
machine where the process
of electromechanical energy
conversion takes pace.
 The armature is a cylindrical
body, which rotates
between the magnetic
poles.
 The armature and the field
system are separated from
each other by an air gap.
 The armature consists of:
 Armature core with slots and
 Armature winding accommodated 11
in slots
 The armature of the dc machines is a cylindrical shape, consists of
slots, teeth, winding and the core.
 The purpose of the armature is to rotate the conductors in the
uniform magnetic field and to induce an alternating emf in its
winding.
 The armature core is normally made from high permeability silicon-
steel laminations of 0.4-0.5mm thickness, which are insulated from
one another by varnish or ceramic insulation.
 The use of high grade steel is made:
 To keep hysteresis loss low, which is due to cyclic change of
magnetization caused by rotation of the core in the magnetic
field and
 To reduce the eddy current in the core which are induced by the
rotation of the core in the magnetic field
 In order to dissipate the heat produced by hysteresis and eddy
current losses etc, ventilating ducts are provided.
 By the fanning action of the armature, air is drawn in through these
ducts, thus producing efficient ventilation.
 In the armature core of small diameters, circular holes are
punched in the center of the laminations for the shaft. 12
 The Commutator
Commutator
 The commutator is Riser segment
V-groove
mounted on the rotor
of a dc machine and it Thread
Bolt
performs with help of Insulator

brushes a mechanical
rectification of power
from
 ac to dc in case
of generators and
 dc to ac in case
of motors.

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 The ends of armature coils are connected to the commutator,
which together with the brushes rectifies the alternating emf
induced in the armature coils and helps in the collection of current.
 It is cylindrically shaped and is placed at one end of the armature.
 The construction of the commutator is quite complicated because it
involves the combination of copper, iron and insulating materials.
 The connection of armature conductors to the commutator is made
with the help of risers.
 The commutator bars are built of a small wedge shaped segments
of high conductivity hard drawn copper insulated from each other
by mice or micanite of about 0.8mm thickness.
 V-shaped grove is provided at each end of the segments to prevent
them from flying away under the action of centrifugal force.
 The commutator assembly is force and press fitted on the shaft.
 Satisfactory performance of dc machines is dependent under good
mechanically stability of the commutator under all conditions of
speed and temperature within the operating range.
 A mechanically unstable commutator manifests itself in a poor
commutation performance and results in unsatisfactory bush life.14
 BRUSHES AND BRUSH HOLDER
 Brushes are needed to collect
the current from the rotating
commutator
or to lead the current to it. Pigtail Pressure
 Normally brushes are made up of adjusting
carbon and graphite, so that while in lever
contact with the commutator, the
commutator surface is not spoiled.
 The brush is accommodated in the
brush holder where a spring presses
it a gains the commutator with
pressure of 1,5 to 2,0 Ncm2
 A twisted flexible
copper conductor called
fixed
pigtailin securely
to the brush is used to brush
make the connection between Spring
the brush and its brush holder. holder
 Normally brush holders used in Brush
dc machines are of box type.
 The numbers of brush holders
usually equal to the number of
main poles in dc machines.
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PRINCIPLE OPERATION OF
DC GENERATOR

16
 PRINCIPLE OPERATION OF DC GENERATOR
 An electrical generator is a machine, which
converts mechanical energy into electrical
energy. B C
 The energy conversion is based on principle
of dynamically induced emf, whenever a
conductor cuts magnetic flux, dynamically N S
induced emf is produced in it (Faraday’s law).
 This emf cause a current to flow if
conductor
the is closed. D
 The basic essential parts of an electrical A
generator are: B1
 A magnetic Field and R1
 A conductor or conductors, which can so
move as to cut the flux. B2
 Fig. 1 shows the schematic diagram of a R2
simple machine consists of a coil ABCD
rotating in the magnetic field of a strong
permanent or powerful electromagnet.
 The magnetic lines in the space between N
and S poles are directed from the North Pole Load Fig.1
N to the South Pole S as shown in fig 1.
 The ends of the coil ABCD are connected to
two copper rings R1 and R2, fixed on the
shaft.
 Two brushes B1 and B2 connected to the
external load circuit make contact with the
copper rings R1 and R2 respectively. 17
 Let the coil be rotated in an ACW
direction, with constant surface speed
v in relation to the magnetic field.
 According to Faraday’s laws of
electromagnetic induction, an emf will
be induced in the rotating coil and is
given by
e  Blv volts
 As l and v are constant for particular
case,
e  constant  B volts
 Hence under the given conditions, the
change in the magnitude of induced
emf with time depends upon the
magnetic flux density distribution under
the poles.
 Though the flux density distribution
under the poles is of a complex nature,
it may be assumed that neglecting
harmonics, it is a sine wave
distribution.
 Thus the emf induced in the coil varies
with time as a sine function.
 The direction of the induced emf in this
case can be determined by Fleming’s 18
right hand rule.
 Right-hand Rule

ν


S N

Motion

Flux
e
EMF
19
 Hence the conductor AB of the coil
ABCD moves downward and CD
moves upward, the direction of the
induced emf in the coil is along
DCBA as shown in Fig1. (a).
 The current in the external remains
the same half a revolution of the
coil starting from its vertical
position.
 Similarly, in the next half of the Fig.1 (a) In the 1st half revolution
revolution, the direction of the
induced emf is reversed and hence
the current flows from brush B2 to
B1 as shown in Fig 1 (b).
 The magnitude of current in the
external circuit also varies with time
as per sine law; i.e. its magnitude
is not constant with time.

20
Fig.1 (b) In the 2nd half revolution
 If the machine has P poles and the
armature rotates at N revolutions per
minute, then the frequency of the
induced emf in the armature is,
PN
f 
120
 The above discussion clearly
indicates that the emf induced in the

Current
armature of a dc generator is of
alternating nature, alternating with
frequency of f hertz depending upon
the number of poles in the machine
θ
and the speed of the armature.
 However the output voltage or the
current of dc generator must be
unidirectional and that too of a
constant value.
 Thus to compel the above
load circuit, the dc machine
withis a special
furnished
device called
the commutator 21
 Fig.2 show that the coil ABCD
connected to a ring commutator split in
two halves R1 and R2 well insulated
from each other.
 The rings of the commutator are so
arranged that during half the revolution
of the coil, each half ring remain in
contact with a particular brush.
 Fig 2 (a) while during the next half
revolution, when the current is
reversed, the same half ring is in Fig.2 (a) In the 1st half revolution
contact with other brush as shown
in fig.2 (b).
 As a result, current in the external load
circuit remains in the same direction.
current

Fig.2 (b) In the 2nd half revo2l2ution

time
 To overcome the above difficulty of the nature of a wave shape, consider two
coils whose planes are inclined to each other at an angle of 900 and divided the
commutator ring mounted on the same shaft into four parts.
 The leads of each coil are connected to the two diametrically opposite parts of
the ring. In such case, the emf or current wave shape due to either coil will be
of the same type but 900 out of phase, i.e. when the current in one reaches
maximum value, the current in the other coil has zero value as shown in fig.4.
 The resultant current in the external circuit due to the rotation of the two coils
simultaneously at the same speed can be obtained by superimposing the two
current waves.
 Hence, the resultant current wave shape is less fluctuating.
 Similarly, if a large number of coils are provided on the rotating armature of the
machine with double the number of commutator segments, the wave shape of
the resultant current or the emf will practically be parallel to the time axis and
hence constant with respect to time.
Resultant
Coil 1 current wave Coil 2
current

23
time Fig.4
TYPES OF DC MACHINES

24
 TYPES OF DC MACHINES
 The field winding and the armature winding can be
interconnected in various ways to provide a wide variety
of performance characteristics.
 This can be taken as outstanding advantages of a dc
machines.
 A dc machine can work as an electromechanical energy
converter only when its field winding is excited with
direct current, except for small dc machines employing
permanent magnets.
 According to the method of their field excitation dc
machines are classified into the following group:
a) separatelyexcited and
b) self excited
 DC machines may have one or more field windings and
their method of excitation, determines the performance
characteristics of the dc machine.
25
 IL
a) Separately Excited
 Its field winding consists of
several hundreds turns of fine
wire and is connected to a
Ish Eg VL
separate or external dc source Vdc Ia
i.e. field winding are energized
from an independent external
sources of dc current.
 The voltage of the external dc Fig. separately excited dc machines
source has no relation with the
armature voltage, i.e. the field
winding energized from i) Ia  L
separate supply, a ii) EI g  VL  I a Ra
can
for any convenient Pdev  Eg  I a
designed be
voltage. iii) Pdel  VL  L
iv)
I 26