DC Machine

BETM 3513
Instructor : Firdaus
DC Motor

1. The very basic construction of a dc motor contains a current carrying

armature which is connected to the supply end through commutator segments
and brushes and placed within the north south poles of a permanent or an
electro-magnet as shown in the diagram below.
2. Unlike AC motor, both stator and rotor
3. Is supplied by DC power
Construction of DC Motor
Yoke
The magnetic frame or the yoke of dc motor made up of cast
iron or steel and forms an integral part of the stator or the
static part of the motor. Its main function is to form a
protective covering over the inner sophisticated parts of the
motor and provide support to the armature. It also supports the
field system by housing the magnetic poles and field winding of
the dc motor.

Poles of DC Motor
The magnetic poles of DC motor are structures fitted onto the
inner wall of the yoke with screws. The construction of
magnetic poles basically comprises of two parts namely, the
pole core and the pole shoe stacked together under hydraulic
pressure and then attached to the yoke.
Construction of DC Motor
 The field winding of dc motor are made with field coils (copper wire) wound over the
slots of the pole shoes in such a manner that when field current flows through it, then
adjacent poles have opposite polarity are produced. The field winding basically form an
electromagnet, that produces field flux within which the rotor armature of the
dc motor rotates, and results in the effective flux cutting.
 The armature winding of dc motor is attached to the rotor, or the rotating part of the
machine, and as a result is subjected to altering magnetic field in the path of its
rotation which directly results in magnetic losses. For this reason the rotor is made of
armature core, that’s made with several low-hysteresis silicon steel lamination, to
reduce the magnetic losses like hysteresis and eddy current loss respectively. These
laminated steel sheets are stacked together to form the cylindrical structure of the
armature core.
 The commutator of dc motor is a cylindrical structure made up of copper segments
stacked together, but insulated from each other by mica. Its main function as far as the
dc motor is concerned is to commute or relay the supply current from the mains to the
armature winding housed over a rotating structure through the brushes of dc motor.
Types of winding

 Lap winding
In this case the number of parallel paths between conductors A is equal to the
number of poles P.
i.e A = P
 Advantages of Lap Winding
1. 1. This winding is necessarily required for large current application because it
has more parallel paths. 2. It is suitable for low voltage and high current
generators.
Disadvantages of Lap Winding
2. 1. It gives less emf compared to wave winding. This winding is required more no.
of conductors for giving the same emf, it results high winding cost. 2. It has less
efficient utilization of space in the armature slots.
Lap winding method

A company is building a new two pole motor for their new

electrical vehicle project.
As an engineer, you are required to design the winding
configuration so that the total slot of this motor is kept
under 15 slots
The winding also need to follow the lap winding method.
Lap winding method

 Figure below is 2 poles

 The slot should be equally distributed among the segment
 Max slot = 15
 Each segment = 15/4 = 3.75 -----------we need to round down to 3

1
12 2
S N
11 3

10 4

9 5
N S
8 6
7
Shunt DC Motor

 The shunt wound dc motor falls under the category of self excited dc
motors, where the field windings are shunted to, or are connected in parallel
to the armature winding of the motor, as its name is suggestive of. And for
this reason both the armature winding and the field winding are exposed to
the same supply voltage, though there are separate branches for the flow of
armature current and the field current as shown in the figure of dc shunt
motor below.
Torque and Speed of Shunt DC Motor
Shunt DC Motor Load Profile
This increase in the amount of torque increases
the speed and thus compensating for the speed
loss on loading. Thus the final speed
characteristic of a dc shunt motor, looks like.

From there we can well understand this special

ability of the shunt wound dc motor to regulate
its speed by itself on loading and thus its rightly
called the constant flux or constant speed
motor. Because of which it finds wide spread
industrial application where ever constant
speed operation is required.

Cousin of Synchronous Motor

DC Motor Starter Problem

 For the motor to function properly, it has to be protected against physical

damage during starting.
 At starting condition, the motor is not moving, thus, Ea = 0V. Since the internal
resistance of the normal dc motor is low, a very high current will flow at starting.

 Example: 50HP, 250V motor has armature resistance of 0.06 ohm and the full load
current is 190 A. Calculate the starting current of this motor.
 I= V/R= 250/0.06 = 4167A ----------------- dangerous current value – 20x rated
current.
 There is a possibility the motor get damage severely by this current.
Reducing the inrush current at starting

Adding resistor in series with

armature can reduce the
inrush current

Inrush current, input surge current or switch-on surge is

the maximum, instantaneous input current drawn by an
electrical device when first turned on.
DC Shunt Motor

 Armature current of the motor can be calculated when the rated power and
voltage is given.
 Find the Rated Armature Current from the
 Name plate given

 Answer: 25A
DC Motor – Separately excited
DC Motor – Shunt Wound Example
DC Motor – Shunt Wound Example
DC Motor – Shunt Wound Example
DC shunt generator

 A shunt Generator consists of armature winding and the field winding in

parallel. The magnetic field of the generator are exited by coils around the
field poles. the construction of these coils and their connections to other
electrical circuits determine the operating characteristics of the machine

where:
 V- terminal voltage, voltage at
the load,V
 IL- is the Load current
 E- Generated emf, V
 Ia- Armature current,A
 If-  Shunt field current,A
Exercise

A shunt generator supplies a 40kW load at 400V. Resistance 0.2 ohm is in series
with the armature resistance. If the field winding is 50 ohm and the armature
resistance is 0.05 ohm, determine :

 Terminal Voltage
 EMF generated
Solution
Given
• Load power and voltage
• Armature Resistance
EA • Resistance series to the
armature
• Field resistance

Vterminal= Vload = 400V

IL = 40kW/400 = 100A

IF = 400V/50 = 8 A
IA = 100-8=92A
EA = VT – IA (RA1+RA2)
= 400 – 92 (0.25)
= 377 V
Mechanical Power and Torque of DC
motor
 The power and torque of a dc motor are two of its most important properties. Two
simple equation is required to calculate them
 The induced voltage EA is proportional to the speed of rotation n of the motor and to
the flux F per pole, as in equation below

 EA = ZnF/60, Z is the number of conductors

 The output power of the motor in the form of electrical power is converted to
mechanical power.
 Total Power (non electrical) = Mechanical Power + Losses -
 Theory of conservation energy,
 Total Power (electrical) = (Induced V X Armature Current) + Electrical Losses
 Hence, Mechanical Power = (Induced V X Armature Current) = EAIA
Mechanical Power and Torque of DC
motor
 The mechanical power is expressed by the following equation
 P = nT/9.55 – where n is the speed, T is the torque

 Inserting both mechanical and electrical power output, we get

nT/9.55 = EAI= ZnFI/60

Exercise

 6 pole wound dc motor has 200V supply. The armature has 800 conductors
and resistance of 0.8 ohm. If useful flux per pole is 40mWb and the armature
current is 30A, calculate
 The speed of the motor
 Torque developed from the motor
Solution

 Terminal Voltage = Induced Voltage + Voltage drop

 200 = EA - IARA ; IARA = 0.8 x 30
 EA = 200 – 24 = 176V
 EA = ZnF/60 ; Z = 800, n = speed, F = 40mWb
 n = 176 x 60 / (800 x 0.04) = 330 rpm

 Torque =  ZFI/6.28 = 800x0.04x30/6.28 = 152.866 Nm

Industrial Based Problem (Rewinding the
motor)
a. Armature of Fig above in the
process of being wound, coil-
forming machine gives the coils
the desired shape.
b One of the 81 coils ready to be
placed in the slots
c Connecting the coil ends to the
commutator bars.
d. Commutator connections ready
for brazing (H Roberge)
Figure shows bare armature and commutator of
a dc motor rated 225 kW, 250 V, 1200 r/min. It
is composed of 400 stacked laminations 0.56 mm
thick.(H. Roberge)
The following details are given on a 225 kW (»
300 hp),
• armature coils 243
• turns per coil 1
• type of winding lap
• armature slots 81
• commutator segments 243
• field poles 6
• diameter of armature 559 mm
• axial length of armature 235 mm
• The effective flux is given by F = 60 Eo/Zn
Industrial Based Problem
Calculate
a. The rated armature current
b. The number of conductors per slot
c. The flux per pole
 a. We can assume that the induced voltage Eo is nearly equal to the applied voltage (250 V).
The rated armature current is
 / = P/EA = 225 000/250
=900A
 b. Each coil is made up of 2 conductors, so altogether there are 243 X 2 = 486 conductors on the
armature.

Conductors per slot = 486/81 = 6

c. The motor torque is

 T = 9.55 P/n = 9.55 X 225 000/1200 = 1791N×m
 The flux per pole is F = 6.28 T/ZI
= (6.28 X 1790)/(486 X 900)
= 25.7 mWb
DC Motor Efficiency

The calculation of efficiency requires the following losses to be determine

 Copper Losses
 Brush Drop Losses
 Mechanical Losses
 Core Losses
 Stray Losses
Example

 A 50 HP, 250V, 1200 rpm shunt dc motor has a rated armature current of 170A
and rated field current of 5A. When the rotor is blocked, the armature
voltage of 10.2V of rated current while field voltage of 250V of rated current.
The brush voltage drop is 2V. Core losses and Mechanical losses were
determined to be 3168W. Assume stray loss to be 1% of input power
 Calculate the Output Power at rated condition.
 Calculate the efficiency
Solution

 Copper losses in the motor are the losses in the armature and field circuit. The
loss is identified as the power loss of at resistance
 P=I2R both for armature and field respectively
 Cu losses = Cu losses at armature + Cu losses at field
 Cu losses at armature = IA2RA
 Cu losses at field = IF2RF
 (1734;1250) - answer

 Brush losses is the losses occur at brush resistance area

 Brush losses at armature = I A2RB (brush current is the same as armature) current
 (340) - answer
Solution

 Input power = VTIL = 250 x (170+5) =

 Stray Losses = Input Power x 0.01 =
 Pout = Pin – losses = ?
 Efficiency = Pin/Pout = ?
DC motor control

One of the important features of dc motor is that its speed can be controlled
with relative ease. We know that the expression of speed control dc motor is
given as
 EA = ZnF EA 60
 n, speed = 60EA / ZF
Therefore speed (N ) of 3 types of dc motor – SERIES, SHUNT AND COMPOUND can
be controlled by changing the quantities on RHS of the expression. So speed can
be varied by changing
(i) terminal voltage of the armature V ,
(ii) external resistance in armature circuit R and
(iii) flux per pole F . ;
Control of DC Series Motor

1. Flux Control Method

2. Variable Resistance In Series With Armature
3. Series-Parallel Control – resistor network

MR FIRDAUS ADVICE :
I. As long as you understand the relationship between the speed and its
component, you can always have a different idea to control your motor…
II. It can start from designing stage.
III. If you have the end product of the motor; and you have no access to the
internal structure, you can always control the motor via its input power.
AC vs DC Motor

Motor DC
+ Excellent Speed Control
for acceleration and
deceleration
+ Cheap
- High Maintenance
- Vulnerable to Dust
AC
High Power Factor
Reliable Operation
Operates at minimum 1/3
of base speed
Accuracy for positioning
control is low