Lesson 6.

DC Machines

At the end of the lesson, the students will be able to:

1. Explain the principle of operation of DC Machines

1. Differentiate DC generators and DC Motors

2. Identify the main parts of a DC machine

DC machines are generators that convert mechanical energy to dc electric energy, and motors that
convert dc electric energy to mechanical energy. Therefore, a dc machine can operate both as a dc
motor and a dc generator depending on the energy input.

Forcing the dc machine rotate (i.e. applying mechanical power) will result to an electrical output on the
other, thus it operates as a generator.

On the other hand, applying voltage on the the terminals of the dc machine will cause it to rotate, thus it
operates as a motor.

The figure below summarizes the electromechanical energy conversion of a dc machine

1. Armature

The armature is a cylinder of laminated iron mounted on an axle. The axle is carried in bearings
mounted in the external structure of the generator.

The armature (rotor) is made up of cylindrical steel structure. However, it cannot be fabricated from
solid steel, since eddy and hysteresis losses may reach prohibitive values and damage the armature
windings insulation.
Losses in the Armature

a) Eddy Currents

Eddy currents (also called Foucault currents) are loops of electrical current induced within conductors by
a changing magnetic field in the conductor, due to Faraday's law of induction. Eddy currents flow in
closed loops within conductors, in planes perpendicular to the magnetic field.

Reduction of eddy current losses can be achieved by fabricating armature core of insulated laminated
silicon steel. Dividing the iron core into thin insulated laminations minimizes eddy current loss

b) Hysteresis Loop

It is also known as Iron Loss or Core Loss and it is always constant. Hysteresis loss is due to the reversal
of magnetization of transformer core whenever it is subjected to alternating nature of magnetizing force
Hysteresis loss can be reduced by adjusting the amount of silicon in the steel such that the hysteresis
loop area of the alloy is kept as low as possible.

2. The Commutator

The commutator is made up from a number of hard drawn copper segments forming a cylinder rotating
with the shaft.

The Commutator is a mechanical rectifier, which converts the alternating voltage generated in the
armature winding into direct voltage across the brush. It is made of copper segments insulated from
each other by mica and mounted on the shaft of the machine. The armature windings are connected to
the commutator segments.

3. Brushes

The purpose of the brush is to ensure electrical connections between the rotating commutator and
stationary external load circuit. It is made of carbon and rest on the commutator.

Brushes are fitted to collect or conduct current from or into the armature. They are made of graphite
with high hardness to ensure long life time during service. Brushes are usually fitted in brush box
(holder) are pressed on commutator segments by virtue of spring. The brush holder is fixed in the
machine frame and insulated from it.

4. Field System

The magnetic flux in a DC machine is established by electromagnets shaped in the form of salient poles
attached to a cylindrical yoke. Field windings are made by concentric number of turns of insulated
copper wire wound on a former, much like an electromagnet.
In a few designs, permanent magnets are used.

5. Armature Windings

Armature windings are made of the shape of pre-wound coils as shown in figure. To obtain a reasonable
value of collected voltage, the coils are connected in series maintaining that their voltages are in the
same sense. This is achieved in two alternative methods of windings; namely, Lap and Wave types of
windings

The turn, coil, and the winding are shown schematically as:
a) A turn consists of two conductors connected to one end by an end connector.

b) A coil is formed by connecting several turns in series.

c) A winding is formed by connecting several coils in series

5.1 Lap Winding

Lap winding is the winding in which successive coils overlap each other. It is named "Lap" winding
because it doubles or laps back with its succeeding coils.

In this winding the finishing end of one coil is connected to one commutator segment and the starting
end of the next coil situated under the same pole and connected with same commutator segment.

In lap winding, the finishing end of coil - 1 and starting end of coil - 2 are both connected to the
commutator segment - 2 and both coils are under the same magnetic pole that is N pole here.

Lap winding are of two types –

1. Simplex Lap Winding

A winding in which the number of parallel path between the brushes is equal to the number of poles is
called simplex lap winding.
2. Duplex Lap Winding

A winding in which the number of parallel path between the brushes is twice the number of poles is
called duplex lap winding.

Advantages of Lap Winding

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

1. It gives less emf compared to wave winding. This winding requires 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.

5.2 Wave Winding

Wave winding is one type of armature winding. In this winding the end of one coil is connected to the
starting of another coil of the same polarity as that of the first coil.
In this type of winding the coil side(A-B) progress forward around the armature to another coil side and
goes on successively passing through N and S pole till it returns to a conductor (A1-B1) lying under the
starting pole. This winding forms a wave with its coil, that’s why it is named as wave winding. It is also
called series winding because its coils are connected in series.

Progressive Wave Winding

If after one round of the armature the coil falls in a slot right to its starting slot the winging is called
Progressive wave winding.

Retrogressive Wave Winding

If after one round of the armature the coil falls in a slot left to its starting slot the winging is called
Retrogressive wave winding.

In the figure above we can see that 2nd conductor CD is in the left of the 1st conductor.

Characteristics and Advantage of Simplex Wave Winding

2. This winding gives sparkles commutation. The reason behind that it has two parallel paths irrespective
of no of poles of the machine. The conductors in each of the two parallel path distributed around the
armature in the entire circumference.

𝑍
3. No. of conductors in each 𝑝𝑎𝑡ℎ = , Z is the total no. of conductors.
2

4. Generated emf = average emf induced in each path times Z/2

5. For a given no. of poles and armature conductors it gives more emf than that of lap winding. Hence
wave winding is used in high voltage and low current machines. This winding is suitable for small
generators circuit with voltage rating 500-600V.

6. Current flowing through each conductor

𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑝𝑎𝑡ℎ (𝐼𝑎 )

Ia is the armature current. Current per path for this kind of winding must not be exceeded 250A.

7. Resultant emf around the entire circuit is zero.

Disadvantage of simplex wave winding

1. Wave winding cannot be used in the machines having higher current rating because it has only two
parallel paths.

Principle of Operation

If a conductor of length l moves at a linear speed v in a magnetic field the induced voltage in the
conductor is, 𝑒 = 𝐵𝑙𝑣

For the current carrying conductor of length l, the force known as Lorentz force produced is 𝐹 = 𝐵𝑖𝑙
With the left hand rule and the right hand rule, the system will induce motion and voltage respectively.

Some important points in the study of DC Machines:

- DC currents are required for both its field winding (stator) and armature winding (Rotor)

- DC machine is mainly used as DC motors

- DC motors are characterized by superior torque and a wide range of speed

- DC machine is costlier than comparable AC machine and their maintenance cost is higher.