DC Machine: Construction and their Applications

The DC machine can be classified into two types namely DC

motors as well as DC generators. Most of the DC machines
are equivalent to AC machines because they include AC
currents as well as AC voltages in them. The output of the DC
machine is DC output because they convert AC voltage to DC
voltage. The conversion of this mechanism is known as the
commutator, thus these machines are also named as
commutating machines. DC machine is most frequently used
for a motor. The main benefits of this machine include torque
regulation as well as easy speed. The applications of the
DC machine are limited to trains, mills, and mines. As
examples, underground subway cars, as well as trolleys, may
utilize DC motors. In the past, automobiles were designed
with DC dynamos for charging their batteries.

DC Machine
A DC machine is an electromechanical energy alteration
device. The working principle of a DC machine is when
electric current flows through a coil within a magnetic field,
and then the magnetic force generates a torque which rotates
the dc motor. The DC machines are classified into two types
such as DC generator as well as DC motor. The main function
of the DC generator is to convert mechanical power to DC
electrical power, whereas a DC motor converts DC power to
mechanical power. The AC motor is frequently used in the
industrial applications for altering electrical energy to
mechanical energy. However, a DC motor is applicable where
the good speed regulation & ample range of speeds are
necessary like in electric-transaction systems.

Construction of DC Machine
The construction of DC machine can be done using some of
the essential parts like Yoke, Pole core & pole shoes, Pole
coil & field coil, Armature core, Armature winding otherwise
conductor, commutator, brushes & bearings. Some of
the parts of the DC machine is discussed below.
Yoke
Another name of a yoke is the frame. The main function of the
yoke in the machine is to offer mechanical support intended
for poles and protects the entire machine from the moisture,
dust, etc. The materials used in the yoke are designed with
cast iron, cast steel otherwise rolled steel.

Pole and Pole Core

The pole of the DC machine is an electromagnet and the field
winding is winding among pole. Whenever field winding is
energized then the pole gives magnetic flux. The materials
used for this are cast steel, cast iron otherwise pole core. It
can be built with the annealed steel laminations for reducing
the power drop because of the eddy currents.

Pole Shoe
Pole shoe in DC machine is an extensive part as well as
enlarge the region of the pole. Because of this region, flux can
be spread out within the air-gap as well as extra flux can be
passed through the air space toward armature. The materials
used to build pole shoe is cast iron otherwise cast steed, and
also used annealed steel lamination to reduce the loss of
power because of eddy currents.

Field Windings
In this, the windings are wounded in the region of pole core &
named as field coil. Whenever current is supplied through
field winding then it electromagnetics the poles which
generate required flux. The material used for field windings is
copper.

Armature Core
Armature core includes the huge number of slots within its
edge. Armature conductor is located in these slots. It provides
the low-reluctance path toward the flux generated with field
winding. The materials used in this core are permeability low-
reluctance materials like iron otherwise cast. The lamination is
used to decrease the loss because of the eddy current.

Armature Winding
The armature winding can be formed by interconnecting the
armature conductor. Whenever an armature winding is turned
with the help of prime mover then the voltage, as well as
magnetic flux, gets induced within it. This winding is allied to
an exterior circuit. The materials used for this winding are
conducting material like copper.
Commutator
The main function of the commutator in the DC machine is to
collect the current from the armature conductor as well as
supplies the current to the load using brushes. And also
provides uni-directional torque for DC-motor. The commutator
can be built with a huge number of segments in the edge form
of hard drawn copper. The Segments in the commutator are
protected from thin mica layer.

Brushes
Brushes in the DC machine gather the current from
commutator and supplies it to exterior load. Brushes wear
with time to inspect frequently. The materials used in brushes
are graphite otherwise carbon which is in rectangular form.

Types of DC Machines
The excitation of the DC machine is classified into two types
namely separate excitation, as well as self-excitation. In
separate excitation type of dc machine, the field coils are
activated with a separate DC source. In self-excitation type of
dc machine, the flow of current throughout the field-winding is
supplied with the machine. The principal kinds of DC machine
are classified into four types which include the following.
 Separately excited DC machine
 Shunt wound/shunt machine.
 Series wound/series machine.
 Compound wound / compound machine.
Separately Excited DC Machine
In Separately Excited DC Machine, a separate DC source is
utilized for activating the field coils.

Shunt Wound DC Machine

In Shunt wound DC Machines, the field coils are allied in
parallel through the armature. As the shunt field gets the
complete o/p voltage of a generator otherwise a motor supply
voltage, it is normally made of a huge number of twists of fine
wire with a small field current carrying.
In series wound D.C. Machines, the field coils are allied in
series through the armature. As series field winding gets the
armature current, as well as the armature current is huge, due
to this the series field winding includes few twists of wire of
big cross-sectional region.

Compound Wound DC Machine

A compound machine includes both the series as well as
shunt fields. The two windings are carried-out with every
machine pole. The series winding of the machine includes few
twists of a huge cross-sectional region, as well as the shunt
windings, include several fine wire twists.

The connection of the compound machine can be done in two

ways. If the shunt-field is allied in parallel by the armature
only, then the machine can be named as the ‘short shunt
compound machine’ & if the shunt-field is allied in parallel by
both the armature as well as series field, then the machine is
named as the ‘long shunt compound machine’.

Series Wound DC Machine

In series wound D.C. Machines, the field coils are allied in

series through the armature. As series field winding gets the
armature current, as well as the armature current is huge, due
to this the series field winding includes few twists of wire of
big cross-sectional region.

Compound Wound DC Machine

A compound machine includes both the series as well as
shunt fields. The two windings are carried-out with every
machine pole. The series winding of the machine includes few
twists of a huge cross-sectional region, as well as the shunt
windings, include several fine wire twists.

The connection of the compound machine can be done in two

ways. If the shunt-field is allied in parallel by the armature
only, then the machine can be named as the ‘short shunt
compound machine’ & if the shunt-field is allied in parallel by
both the armature as well as series field, then the machine is
named as the ‘long shunt compound machine’.

Characteristics of DC motors
Generally, three characteristic curves are considered important for DC
motors which are, (i) Torque vs. armature current, (ii) Speed vs.
armature current and (iii) Speed vs. torque. These are explained
below for each type of DC motor. These characteristics are
determined by keeping the following two relations in mind.
Ta ∝ ɸ.Ia and N ∝ Eb/ɸ

For a DC motor, magnitude of the back emf is given by the same emf
equation of a dc generator i.e. Eb = PɸNZ / 60A. For a machine, P, Z
and A are constant, therefore, N ∝ Eb/ɸ
Characteristics of DC series motors
Torque vs. armature current (Ta-Ia)
This characteristic is also known as electrical characteristic. We
know that torque is directly proportional to the product of armature
current and field flux, Ta ∝ ɸ.Ia. In DC series motors, field winding is
connected in series with the armature, i.e. I a = If. Therefore, before
magnetic saturation of the field, flux ɸ is directly proportional to Ia.
Hence, before magnetic saturation Ta α Ia2. Therefore, the Ta-Ia curve
is parabola for smaller values of Ia.
After magnetic saturation of the field poles, flux ɸ is independent of
armature current Ia. Therefore, the torque varies proportionally to Ia
only, T ∝ Ia.Therefore, after magnetic saturation, Ta-Ia curve
becomes a straight line.
The shaft torque (Tsh) is less than armature torque (Ta) due to stray
losses. Hence, the curve Tsh vs Ia lies slightly lower.
In DC series motors, (prior to magnetic saturation) torque increases as
the square of armature current, these motors are used where high
starting torque is required.

Speed vs. armature current (N-Ia)

We know the relation, N ∝ Eb/ɸ
For small load current (and hence for small armature current) change
in back emf Eb is small and it may be neglected. Hence, for small
currents speed is inversely proportional to ɸ. As we know, flux is
directly proportional to Ia, speed is inversely proportional to Ia.
Therefore, when armature current is very small the speed becomes
dangerously high. That is why a series motor should never be
started without some mechanical load.
But, at heavy loads, armature current Ia is large. And hence, speed is
low which results in decreased back emf Eb. Due to decreased Eb,
more armature current is allowed.

Speed vs. torque (N-Ta)

This characteristic is also called as mechanical characteristic. From
the above two characteristics of DC series motor, it can be found
that when speed is high, torque is low and vice versa.

Characteristics of DC shunt motors

Torque vs. armature current (Ta-Ia)
In case of DC shunt motors, we can assume the field flux ɸ to be
constant. Though at heavy loads, ɸ decreases in a small amount due
to increased armature reaction. As we are neglecting the change in
the flux ɸ, we can say that torque is proportional to armature current.
Hence, the Ta-Ia characteristic for a dc shunt motor will be a straight
line through the origin.
Since heavy starting load needs heavy starting current, shunt motor
should never be started on a heavy load.

Speed vs. armature current (N-Ia)

As flux ɸ is assumed to be constant, we can say N ∝ Eb. But, as back
emf is also almost constant, the speed should remain constant. But
practically, ɸ as well as Eb decreases with increase in load. Back emf
Eb decreases slightly more than ɸ, therefore, the speed decreases
slightly. Generally, the speed decreases only by 5 to 15% of full load
speed. Therefore, a shunt motor can be assumed as a constant
speed motor. In speed vs. armature current characteristic in the
following figure, the straight horizontal line represents the ideal
characteristic and the actual characteristic is shown by the dotted line.

Characteristics of DC compound motor

DC compound motors have both series as well as shunt winding. In a
compound motor, if series and shunt windings are connected such
that series flux is in direction as that of the shunt flux then the motor is
said to be cumulatively compounded. And if the series flux is opposite
to the direction of the shunt flux, then the motor is said to be
differentially compounded. Characteristics of both these compound
motors are explained below.
(a) Cumulative compound motor
Cumulative compound motors are used where series characteristics
are required but the load is likely to be removed completely. Series
winding takes care of the heavy load, whereas the shunt winding
prevents the motor from running at dangerously high speed when the
load is suddenly removed. These motors have generally employed a
flywheel, where sudden and temporary loads are applied like in rolling
mills.
(b) Differential compound motor
Since in differential field motors, series flux opposes shunt flux, the
total flux decreases with increase in load. Due to this, the speed
remains almost constant or even it may increase slightly with increase
in load (N ∝ Eb/ɸ). Differential compound motors are not commonly
used, but they find limited applications in experimental and research
work.
What is AC Motor – Definition, Operation
and Applications
The machine that turns the class of input electrical form to an output
mechanical form. Here, in this type of machine, the input given to the
field winding is alternating. Hence, the name AC motor. The supply
given to the field winding classifies its type whether it is AC or DC
type machine

Construction of AC Motor

It consists of a Frame or Yoke, stator, rotor, bearings, fan, shaft, and

slip rings. The parts of an AC machine is explained below.
The frame is used as an outer protecting cover that is used to protect
against environmental conditions. The frame also acts as an outer
periphery such that the inner parts can be easily housed. The stable
state section of the equipment is stator on which the stator winding is
enclosed.
The rotor is the moving part that either move in clockwise or anti-
clockwise depending upon thrust impelled on it. The bearings provide
proper friction for the rotor to run smoothly. A fan is employed to
remove the unwanted heat that gained during the running of the rotor.
It is expelled out through the ventilation that is provided behind the
machine. A shaft is provided to deliver the mechanical output as the
rotor rotates. The slips rings are employed for a normal Ac machine
where rotating armature stationary field winding is employed. In this
situation, the slip rings allow the input alternating current to change
continuously in the coils

Working Principle of AC Motor

It works on the principle of Lorentz force equation I,e whenever a

current-carrying conductor is placed in the magnetic field it exhibits
some force in it. The working of a normal AC machine with the rotating
armature and stationary field winding is shown in the figure below.

When alternating current supply is fed to the coil of the rotor, it

experiences some force due to the law of the Lorentz force equation.
Due to this force, torque will be developed in the clockwise direction
that enables the rotor to rotate.
A normal AC machine has its field winding on the stator and armature
winding rotor. But due to this the size of the motor increases and also
due to commutator and brushes, the efficiency of the machine
decreases. So, to avoid these problems, the proper arrangement is
made for the housing of stator and rotor windings on the armature.
This placement has great advantages compared to the rotating
armature type. Almost all the industrial machines used are of
stationary armature type. Let us discuss in detail these machines by
studying the different types of motors.

Types

There are several varieties of AC machines based on the speed they

are classified as a synchronous and asynchronous motor. The
asynchronous motor is also known as an induction motor. It is a
machine that runs at a constant speed I,e synchronous speed. But an
asynchronous motor runs at a speed less than that of synchronous
speed. The induction motor is further classified into single-phase, and
three-phase induction motors.

The classification of the alternating type of motors is illustrated below.

Working of Synchronous Motor

The stator winding is given a three-phase power supply such that a

rotating magnetic field (RMF) is developed. This RMFrotates in the air
gap and tries to interact with the field winding. The field winding is
given a DC supply in the synchronous machine. The field winding
develops a stationary magnetic field. The rotating magnetic field and
the stationary magnetic field interact with each other. Due to the
inertia of the rotor, the rotor is unable to achieve unidirectional torque.
So, the synchronous motor is not a self-starting machine. To avoid
this, an initial rotation is provided. When an initial rotation is given, the
stator and rotor poles get interlocked with each other. Further,
the machine develops unidirectional torque that allows the rotor to
rotate continuously.

Working of a Single-phase Induction Machine

When a three-phase power supply is given to the stator winding of the

machine, RMF will be developed. The RMF interacts with the short-
circuited rotor conductors. Due to this, an emf is induced in the rotor
bars according to the principle of mutual induction just like a
transformer. But the rotor cannot develop the unidirectional torque
because the main winding produces a two-directional torque. The flux
produced by the main winding develops two fluxes which oppose each
other. To produce a unidirectional torque, an auxiliary winding with a
capacitor is arranged at a phase displacement of 90 degrees with the
main winding. Due to this arrangement, the opposition force is
canceled out and an additional force greater the existing force is
developed. This makes possible for the rotor to develop unidirectional
torque and the rotor runs smoothly. The working of a single-phase
induction machine is displayed below.