ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

1
Lesson 1

COMMUTATION AND ARMATURE CONSTRUCTION

What is this Lesson about?

In this lesson you will be introduced to the basic parts of a simple DC machine, its construction
and basic operation. This lesson specifically deals with the concept of commutation as vital part of DC
machine operation. Armature construction is discussed with emphasis on the types of windings. It is
expected that you will be able to interpret and draw different types of armature winding for different
application at the end of this lesson.

What Will You Learn? What Do You Already Know?

At the end of the lesson, you should be (PRE-TEST)
able to do the following: To determine what you already know about
✓ discuss the characteristic of a DC the topics under this lesson, please answer the
Machine following questions:

✓ discuss the commutation process

1. In a 6-pole DC machine, 90 mechanical degrees
✓ describe the basic parts of a DC machine correspond to ______ electrical degrees:
✓ differentiate the types of windings a. 30 c. 45
✓ draw winding diagrams b. 180 d. 270

2. The commutation process in a DC generator

To achieve the said outcomes, this basically involves:
lesson is divided into the following sub-topics: a. passage of current from moving armature
● Introduction to a stationary load
● Rotor Coils b. reversal of current in an armature coil as it
crosses MNA
● Connections to the Commutator Segments
c. conversion of AC to DC
o Lap Winding
d. suppression of reactance voltage
o Wave Winding
o Frog-leg Winding 3. The basic requirement of a DC armature
winding is that it must be a:
What You Should Already Know? a. closed one c. wave winding
b. lap winding d. any of these
Before taking this lesson, you are expected
to be knowledgeable in the following topics: 4. A wave winding must go at least _______ around
✓ Faraday’s Law the armature before it closes back where it
✓ Fundamentals of Electromagnetism started.
✓ Simple Electrical Circuits a. once c. thrice
b. twice d. four times
✓ Conductors and Insulators

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

5. The DC armature winding in which coil sides are

a pole pitch apart is called ............ winding.
a. multiplex c. full pitch
b. fractional-pitch d. pole-pitch

6. For making coil span equal to a pole pitch in the

armature winding of a DC generator, the back
pitch of the winding must equal the number of:
a. commutator bars per pole
b. winding elements
c. armature conductors per path
d. armature parallel paths

7. The primary reason for making the coil span of

a DC armature winding equal to a pole pitch is
to:
a. obtain a coil span of 180º (electrical)
b. ensure the addition of emfs of consecutive
turns
c. distribute the winding uniformly under
different poles
d. obtain a full-pitch winding

8. The sole purpose of a commutator in a DC

Generator is to:
a. increase output voltage
b. reduce sparking at brushes
c. provide smoother output
d. convert the induced AC into DC

9. If in the case of a certain DC armature, the

number of commutator segments is found
either one less or more than the number of
slots, the armature must be having a simplex
______ winding.
a. wave c. lap
b. frog leg d. multielement

10. Lap winding is suitable for ______ current, ______

voltage DC generators.
a. High, low c. Low, low
b. Low, high d. High, high

Answer Key:
1. d; 2. b; 3. a; 4. b; 5. c; 6. a; 7. b; 8. d; 9. a; 10. a.

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

Let us READ! ROTOR COILS

Most of the rotor’s windings are consist
Introduction
of diamond-shaped preformed coils which are
DC machines can be classified into two:
inserted into the armature slots as a unit (see
DC Motors and DC Generators. DC generators
Figure 1-1). Each coil consists of several turns
convert mechanical energy to DC electrical
(loops) of wire, each turn taped and insulated
energy and motors convert DC electrical energy
from the other turns and from the rotor slot.
to mechanical energy. Most dc machines, like
Each side of a turn is called a conductor.
AC machines, have AC voltages and currents
within them but DC machines have a DC output Note: each turn has two sides, hence to
because it has a mechanism that converts the conductors
internal AC voltages to DC voltages at their The number of conductors on a machine's
terminals. This mechanism is called a armature is given by the formula:
commutator (employs commutation).
Commutation is the process of 𝑍 = 2𝐶𝑁𝐶
converting the AC voltages and currents in the
rotor of a DC machine to DC voltages and where: Z = number of conductors on rotor
currents at its terminals. This is done by C = number of coils on rotor
switching the loop connections on the rotor of NC = number of turns per coil
a DC machine just as the voltage in the loop
switches polarity, to maintain an essentially
constant DC output voltage. Since DC
machinery uses commutator, it is also known as
commutating machinery.
In real DC machines, there are several
ways in which the loops on the rotor (also called
the armature) can be connected to its
commutator segments. These different
connections affect the following:
1. number of parallel current paths within the
rotor;
2. output voltage of the rotor; and
3. number and position of the brushes riding
on the commutator segments.

In the following sections, we will examine

the construction of the coils on a real DC rotor
Figure 1-1: (a) The shape of a typical preformed rotor coil.
and its connection to the commutator to
(b) A typical coil insulation system showing the insulation
produce a DC voltage. between turns within a coil.
Winding [Diagram]. (2019, December 18). Retrieved from
https://www.theengineeringknowledge.com/commutation-and-
armature-construction-in-real-dc-machines/

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

Let us WATCH! Let us WATCH!

Click the video icon to watch the video: Click the video icon to watch the video:
DC Motor, How it works? Full Pitch and Short Pitch Winding
https://www.youtube.com/watch?v=LAtPHANEfQo https://www.youtube.com/watch?v=pfj4w2Jz3xA

Normally, a coil has a span of 180 Pitch Factor (p)

electrical degrees. This means that when one It is the amount of chording in a
side of the coil is under the center of a certain winding. Pitch Factor is defined by the equation:
magnetic pole (e.g. North), the other side is
under the center of the pole of opposite polarity
𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑖𝑙
(e.g. South) (see Figure 1-2a). 𝑝=
180°
× 100%

Take note that the physical poles may

not be located 180 mechanical degrees apart.
Two-Layer Windings
This can happen when two poles of opposite
Two-layer windings rotor is constructed
polarity are not directly (physically) opposite to
such that sides from two different coils are
each other (see Figure 1-2b). The relationship
inserted into each slot. One side of each coil will
between the electrical angle and mechanical
be at the bottom of its slot, and the other side
angle in a given machine is given by:
will be at the top of its slot (see Figure 1-3). Such
a construction requires the individual coils to be
𝑃
𝜃𝑒 = 𝜃 placed in the rotor slots by a very elaborate
2 𝑚
procedure.
where θe = electrical angle, in degrees 180 mechanical degrees
θm = mechanical angle, in degrees (Physical location)

P = number of magnetic poles on the 180 electrical degrees

machine (North to South)

Full-Pitch Coil
(a)
Full-pitch coil are coils where the span
is 180 electrical degrees. In this set-up the
voltages in the conductors on either side of the
90 mechanical degrees
coil will be exactly the same in magnitude and (Physical location)
opposite in direction at all times.
180 electrical degrees
(North to South)
Fractional-Pitch Coil
Fractional-pitch coil are coils that are (b)
built that spans less than 180 electrical degrees. Figure 1-2: (a) Two-pole motor with θe = θm = 180 degrees;
The rotor winding wound with fractional pitch (b) Four-pole motor with θe ≠ θm.
Source: Retrieved from https://www.electronics-tutorials.ws/wp-
coils is called a chorded winding. content/uploads/2013/08/io31.gif?fit=508%2C296

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

CONNECTIONS TO THE COMMUTATOR

SEGMENTS
After the windings are installed in the
rotor (inserted in slots), they are to be
connected to the commutator segments (See
Figure 1-4). There are different ways to
accomplish this, and each winding
arrangements have different advantages and
Figure 1-3: Two-layer windings
disadvantages. Two-layer winding [Diagram]. (n.d.). Retrieved from
http://www.pengky.cn/zz-generator-principle-and-structure/06-ac-
motor-winding/07-ac-motor-winding.jpg
Commutator Pitch (yC)
It is the distance (in number of
segments) between the commutator segments
to which the two ends of a coil are connected.

Progressive Winding
A connection where the end of a coil (or
a set number of coils, for wave construction) is
connected to a commutator segment ahead of
the one its beginning is connected to (see
Figure 1-5a). Figure 1-4: Commutator segments in a DC machine
Commutator Segmet [Photograph]. (n.d.). Retrieved from
https://www.engineeringbookspdf.com/wpcontent/uploads
/2017/11/Commutator.jpg
Retrogressive Winding
A connection where the end of a coil is
connected to a commutator segment behind
the one its beginning is connected to (see
Figure 1-5b).

Simplex and Multiplex Winding

Rotor (armature) windings are further (a) (b)
classified according to the plex of their Figure 1-5: (a) Progressive Winding;
windings. A simplex rotor winding is a single, (b) Retrogressive Winding
Winding [Diagram]. (2019, December 18). Retrieved from
complete, closed winding wound on a rotor. A https://www.theengineeringknowledge.com/commutation-and-
duplex rotor winding is a rotor with two armature-construction-in-real-dc-machines/

complete and independent sets of rotor

windings. All armatures with more than one set Note: For multiplex windings, each of the
of windings (duplex, triplex, etc.) are said to windings will be associated with every other
have multiplex windings. commutator segment depending on the
multiple: Say for duplex, one winding will be
connected to segments 1, 3, 5, etc., (odd

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

numbered segments) and the other winding will The implications of this unique
be connected to segments 2, 4, 6, etc. (even characteristic of a Lap Winding are:
numbered segments).
1. The number of coils per path is equal to
Armature windings are also classified total number of coils divided by number
according to the sequence/order of their of poles;
connections to the commutator. There are 2. The number of brushes in the
three sequences of armature winding commutator is equal to the number of
connections: the lap windings, wave windings poles
and the frog-leg winding (combination of the 3. The machine is best suited for fairly low-
lap and wave winding). voltage, high current applications

LAP WINDING

Lap winding is the simpler compared to

the other classifications. A simplex (single coil)
lap winding is consists of coils (with one or more
turns of wire) with two ends coming out at
adjacent commutator segments (see Figure 1-6).

Figure 1-6: Simplex Lap Winding

Progressive Lap & Retrogressive Lap Winding Lap Winding [Diagram]. (2017, August 27). Retrieved from
If the end of the coil is connected to the http://3.bp.blogspot.com/-
9NXSR1gKOVM/Vo5TY7uB9eI/AAAAAAAAAfY/-VFZDb2wj50/s1600/lap-
segment after the segment that the beginning winding.png

of the coil is connected to, the winding is a

progressive lap winding; but if the end of the
coil is connected to the segment before the
segment of which the beginning of the coil is
connected, the winding is a retrogressive lap
winding. A simple two pole machine with lap
windings is shown in Figure 1-7.

Parallel Current Path (a) for Lap Winding

For lap windings, the parallel current
Figure 1-7: A simple two-pole lap-wound dc machine
path (a) through the machine is equal to the Chapman, S. J. (2012). Electric machinery fundamentals. McGraw-Hill
number of poles (P) on the machine multiplied Medical Publishing.

to multiplier (m) which corresponds to the plex.

Let us WATCH!

𝑎 = 𝑚𝑃 Click the video icon to watch the video:

Armature Lap & Wave Winding
https://www.youtube.com/watch?v=wex3ZenASl0

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

WAVE WINDING
2(𝐶 ± 1)
Wave winding is an armature winding in 𝑦𝐶 =
𝑃
which two coils is connected in series and
follows each other on the surface of the Where C is the number of coils on the
armature like waves such that there are only two rotor and P is the number of poles on the
paths for the current flow irrespective of the machine. The plus sign is associated with
number of poles in the circuit. Therefore, there progressive windings, and the minus sign is
are two coils in series between the adjacent associated with retrogressive windings.
commutator segments. Furthermore, since
each pair of coils between adjacent segments The following are the characteristics of wave
has a side under each pole face, all output winding:
voltages are the sum of the effects of every
pole, and there can be no voltage imbalances 1. Only two brushes are needed per set of
(see Figure 1-8). winding; and
2. It is best suited for high-voltage
Progressive Wave & Retrogressive Wave applications
Winding

The lead from the second coil may be

connected to the segment either ahead of or
behind the segment at which the first coil
begins. If the second coil is connected to the
segment ahead of the first coil, the winding is
progressive; if it is connected to the segment
behind the first coil, it is retrogressive.

Parallel Current Path (a) for Wave Winding

For wave windings, the parallel current
path (a) through the machine is equal to two (2) (a)
multiplied to multiplier (m) which corresponds to
the plex. Therefore for a simplex wave DC
machine, there are two (2) current paths.

𝑎 = 2𝑚
(b)
Figure 1-8: (a) A simple four-pole wave-wound dc
Commutator Pitch (yC) for Wave Winding machine;
(b) Simplex wave wound
The general expression for commutator
pitch in any simplex wave winding is: Wave Winding [Diagram]. (2019, December 25). Retrieved
from https://www.theengineeringknowledge.com/wave-
winding-in-dc-machines/

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

FROG-LEG WINDING
POST-TEST

The frog-leg winding or self-equalizing Take time to take the Post-Test for this
winding gets its name from the shape of its coils lesson to check your learning. Please refer to the
(see Figure 1-9). It consists of a lap winding and lesson if you score less than 80%. The Post-Test can
be accessed in the course site.
a wave winding combined. The equalizers in an
ordinary lap winding are connected at points of
equal voltage on the windings. Wave windings
reach between points of essentially equal
voltage under successive pole faces of the same Let us TRY this!
polarity, which are the same locations that
equalizers tie together. A frog- leg or self- ACTIVITY 1-1
equalizing winding combines a lap winding with
Instruction: In a letter-sized paper, answer the
a wave winding, so that the wave windings can following questions. Upload your answer in pdf
function as equalizers for the lap winding. format to this link.
The number of current paths present in
a frog- leg winding is
1. What is commutation? How can a commutator
convert ac voltages on a machine's armature to
dc voltages at its terminals?
𝑎 = 2𝑃𝑚𝑙𝑎𝑝 2. Why does curving the pole faces in a dc
machine contribute to a smoother dc output
voltage from it?
where P is the number of poles on the
3. What is the pitch factor of a coil?
machine and mlap is the plex of the lap winding. . 4. Explain the concept of electrical degrees. How
is the electrical angle of the voltage in a rotor
conductor related to the mechanical angle of
the machine's shaft?
5. What is commutator pitch?
6. What is the plex of an armature winding?
7. How do lap windings differ from wave
windings?
8. What are equalizers? Why are they needed on
a lap-wound machine but not on a wave-
wound machine?

ASSESSMENT

Figure 1-9: A frog-leg or self-equalizing winding coi

Chapman, S. J. (2012). Electric machinery fundamentals. McGraw-Hill
Medical Publishing.
l

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ELECTRICAL MACHINE 1 Lesson 1: Commutation and Armature Reaction

ASSESSMENT TASK

Choose a mode of presentation (video,

power point, etc.); identify all classifications of
windings; prepare a report/discussion about
each classification; prepare diagrams; and
submit it in the given link.

REFERENCES

Chapman, S. J. (2012). Electric machinery

fundamentals. McGraw-Hill Medical Publishing.

Gross, C. A. (2006). Electric machines. CRC Press.

Fitzgerald, A., Fitzgerald, A. E., Kingsley, C., &

Umans, S. (2003). Electric machinery. McGraw-Hill
Professional.

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