Unit :2-

DC Drive
By
Amruta Pattnaik
Syllabus
DC Motor Drives:
1. DC motor speed control,
2. Methods of armature control,
3. field weakening,
4. Semiconductor controlled drives,
5. starting, braking, transient analysis,
6. controlled rectifier fed dc drives,
7. chopper controlled dc drives
 Introduction: DC Motor Drives
• Direct current (dc) motors have variable characteristics and are used
extensively in variable-speed drives.
• DC motors can provide a high starting torque and it is also possible to obtain
speed control over a wide range.
• The methods of speed control are normally simpler and less expensive than
those of AC drives.
• DC motors play a significant role in modern industrial drives.
• Both series and separately excited DC motors are normally used in variable-
speed drives, but series motors are traditionally employed for traction
applications.
• Due to commutators, DC motors are not suitable for very high speed
applications and require more maintenance than do AC motors.
• With the recent advancements in power conversions, control techniques, and
microcomputers, the ac motor drives are becoming increasingly competitive
with DC motor drives.
• Although the future trend is toward AC drives, DC drives are currently
used in many industries. It might be a few decades before the DC drives are
completely replaced by AC drives.
 Introduction: DC Motor Drives
• Controlled rectifiers provide a variable dc output voltage from a fixed ac
voltage, whereas a dc-dc converter can provide a variable dc voltage from
a fixed dc voltage.
• Due to their ability to supply a continuously variable dc voltage,
controlled rectifiers and dc-dc converters made a revolution in modern
industrial control equipment and variable-speed drives, with power levels
ranging from fractional horsepower to several megawatts.
• Controlled rectifiers are generally used for the speed control of dc motors.
• The alternative form would be a diode rectifier followed by dc-dc
converter.
• DC drives can be classified, in general, into three types:
– 1. Single-phase drives
– 2. Three-phase drives
– 3. DC-DC converter drives
Basic and modified
characteristics of dc motor
In a separately excited motor, the field and armature
voltages can be controlled independent of each other.
In a shunt motor, field and armature are connected to a
common source.
In case of a series motor, field current is same as
armature current, and therefore, field flux is a function of
armature current.
In a cumulatively compound motor, the magneto-motive
force of the series field is a function of armature current
and is in the same direction as mmf of the shunt field.
 Steady State Speed Torque Relations

E  K em V  E  I a Ra T  K e I a

V  K em  I a Ra
V Ra T
m   Ia Ia 
K e K e K e

V Ra
m   T
K e K e 2
 V Ra
m   T
K e K e 2

• where
• Φ – is the flux per pole, Webers;
• Ia – the armature current, A;
• V – the armature voltage V;
• Ra – the resistance of the armature circuit, ohms;
• ωm – the speed of armature, rad/sec;
• T – the torque developed by the motor, N-m; and
• Ke – the motor constant.
Shunt and Separately Excited Motors:
 K  K e
E  Km V  E  I a Ra T  K Ia

V  Km  I a Ra
V Ra T
m   I a Ia 
K K K

V Ra
m   2 T
K K
Series Motors:
 Series DC Motor
  K f Ia
E  K e K f I am V  E  I a Ra T  K e I a
2
T Ke K f I a
V  K e K f I am  I a Ra
V Ra T
m   I a 
Ke K f I a Ke K f K e K f

V 1 Ra
m  
Ke K f T Ke K f
speed-torque curve
1. The speed-torque curve is a straight line.
2. The no load speed ωm0 is determined by the values of armature voltage and
field excitation.
3. Speed decreases as torque increases and speed regulation depends on the
armature circuit resistance .
4. The usual drop in speed from no load to full load, in case of a medium size
motor, is of the order of 5%.
5. Separately excited motors are employed in applications requiring
good speed regulation and adjustable speed.
Series Motor
 Series motors are suitable for applications requiring high starting
torque and heavy torque overloads.
 Since torque is proportional to the armature current squared, for
the same increase in torque, increase in motor current is less
compared to that in a separately excited motor where torque is
proportional to armature current. Thus, during heavy torque
overloads and starting, power overload on the source and thermal
overloading of the motor are kept limited to reasonable values.
 According to speed equation, as speed varies inversely as the
square root of torque, machine runs at a large speed at light load.
 Generally, mechanical strength of a Types of DC Motor permit it to
operate upto about twice rated speed. Hence, the series motor
should not be used in those drives where there is a possibility of
the load torque being dropped to the extent that the speed may
exceed twice rated value.
 Compound Motor
The no load speed depends on the strength of shunt field and
slope of the characteristic on the strength of series field.
Cumulative compound motors are used in those applications
where a drooping characteristic similar to that of a series motor
is required and at the same time the no load speed must be
limited to a safe value; typical examples are lifts and winches.
 It is also used in intermittent load applications, where the load
varies from almost no load to very heavy loads. In these
applications a fly-wheel may be mounted on the motor shaft
for load equalisation. This apart from equalising load on the
supply, permits the use of a smaller size motor. Pressing
machine is a typical example of this type of application. •
 Universal Motor:
 The universal motor can run both on dc and ac supply.
 It is essentially a dc series motor, with some differences in construction;
which are mainly introduced to get satisfactory performance on ac. In series
motor, torque depends on the product of armature current and field flux.
 Most universal motors are manufactured for use at speeds in excess of 3000
rpm.
 Many universal motors operate at speeds upto 12,000 rpm and can go upto
20,000 rpm. Because of high operating speeds, universal motor is much
smaller in size compared to an induction or a low speed dc motor of
identical rating. Because of brushes and commutator, it requires frequent
maintenance and has a relatively short operating life.
 Until recently, universal motor was the cheapest motor capable of running
at high speeds and having relatively very small weight and size.
 The brushless Types of DC Motor or a single phase induction motor fed
from variable frequency inverter may become its competitor in near future.
 Some applications of universal motor are fans, electric drills, home
appliances etc.
PERMANENT MAGNET DC
MOTORS
• In permanent magnet dc motors, field excitation is obtained by suitably mounting
permanent magnets on the stator.
• Ferrites or rare earth (cobalt samarium) magnets are employed. Ferrites are commonly
used because of lower cost, but the machine becomes bulky due to low retentivity.
• Rare earths because of their high retentivity allow a large reduction in weight and size,
but they are very expensive.
• The permanent magnet motors are mainly employed in fractional horsepower range,
but they are available upto 5 kW rating.
• Use of permanent magnets for excitation eliminates field copper loss and need for field
supply.
• Compared to the field wound motors, they are more efficient, reliable, sturdy and
compact.
• The field flux remains constant for all loads giving a more linear speed torque
characteristic.
• In a separately excited motor, failure of field supply can lead to runaway condition.
• This does not happen in permanent magnet motors. As the flux is constant in these
motors, speed cannot be controlled above base speed. Such motors have applications
in electric vehicles like mopeds, forklift trucks, wheel chairs etc.
 DC Shunt Motor Starter Design
1. For normally designed machines, twice the rated current can be
allowed to flow and for specially designed machines it can be 3.5
times.
2. At standstill, back emf is zero and the only resistance opposing flow of
current is the armature circuit resistance, which is quite small for all
types of dc motors.
3. If a dc motor is started with full supply voltage across its terminals, a
very high current will flow, which may damage the motor due to heavy
sparking at commutator and heating of the winding.
4. Therefore, it is necessary to limit the current to a safe value during
starting.
5. When motor speed is controlled by armature voltage control, the
controller which controls the speed can also be used for limiting motor
current during starting to a safe value
6. As motor accelerates and back emf rises, one section of the resistor is
cut out at a time, either manually or automatically with the help of
contactors, such that the current is kept within specified maximum and
minimum values
 Operating Modes
• In variable-speed applications, a dc motor may be operating in one or
more modes:
– motoring,
– regenerative braking,
– dynamic braking,
– plugging, and
– four quadrants.
Motoring: The arrangements for motoring are shown in Figure a. Back emf
Eg is less than supply voltage Va. Both armature and field currents are
positive. The motor develops torque to meet the load demand.
DC Motor Braking Methods:

• In case of braking , the motor works as a generator developing

a negative torque which opposes the motion.
1. Regenerative braking;
2. Dynamic or Rheostatic braking; and
3. Plugging or reverse voltage braking.
Regenerative Braking:
1. The regenerative braking is possible only when there are loads
connected to the line and they are in need of power more are
equal to the regenerated power.
2. When the capacity of the loads is less than the regenerated
power, all the regenerated power will not be absorbed by the
loads. The remaining power will be supplied to capacitors
(including stray capacitances) in line and the line voltage will
rise to dangerous values leading to insulation breakdown.
Hence, regenerative braking should only be used when there
are enough loads to absorb the regenerated power.
3. Alternatively an arrangement is made to divert the excess
power to a resistance bank where it is dissipated as heat. Such
a braking is known as Composite Braking because it is a
combination of regenerative braking and dynamic braking.
4. When the source is a battery, the regenerated energy can be
stored in the battery
E  K em

Field flux cannot be increased substantially beyond rated because of saturation.

Therefore, according to above Eqs. for a source of fixed voltage of rated value
regenerative braking is possible only for speeds higher than rated and with a
variable voltage source it is also possible below rated speeds.
The speed-torque characteristics can be calculated are shown in Fig for a
separately excited motor.
In series motor as speed increases, armature current, and therefore, flux
decreases. Consequently, condition of second cannot be achieved. Thus
regenerative braking is not possible.
Dynamic Braking

• in dynamic braking, motor armature is disconnected from the

source and connected across a resistance R B. The generated energy
is dissipated in RB and Ra.
• Since series machine works as a self-excited generator, the field
connection is reversed so that field assists the residual magnetism.
• Figures a and b show speed-torque curves and transition from motoring to
braking. These characteristics are obtained for V = 0.
• When fast braking is desired, RB consists of a few sections. As the speed falls,
sections are cut-out to maintain a high average torque, as shown in Fig.(c) for a
separately excited motor.
• During braking, separately excited motor can be converted as a self-excited
generator.
• This permits braking even when supply fails
 Plugging
• For plugging, the supply voltage of a separately excited motor is
reversed so that it assists the back emf in forcing armature current
in reverse direction .
• A resistance RB is also connected in series with armature to limit the
current. For plugging of a series motor armature alone is reversed.

Plugging gives fast braking due to high average torque, even with one section of braking
resistance RB. Since torque is not zero at zero speed, when used for stopping a load, the
supply must be disconnected when close to zero speed. Centrifugal switches are
employed to disconnect the supply. Plugging is highly inefficient because in addition to
the generated power, the power supplied by the source is also wasted in resistances.
 • Speed Torque curves can be calculated by replacing V by -V and are shown in Fig.

A particular case of plugging for motor rotation in

reverse direction arises, when a motor connected
for forward motoring, is driven by an active load
in the reverse direction. Here again back emf and
applied voltage act in the same direction.
However, the direction of torque remains positive
as in below fig. This type of situation arises in
crane and hoist applications and the braking is
then called Counter Torque Braking.
Methods of Speed Control
Armature Voltage Control
V Ra
m   T
K e K e 2
Field Flux Control

Armature Resistance Control

 Armature Voltage Control
Armature voltage control is preferred because of high efficiency, good transient
response and good speed regulation.
It can provide Speed Control of DC Motor Drives only below base (rated) speed
because the armature voltage cannot be allowed to exceed rated value.
For speed control above base(rated ) speed, field flux control is employed.
In a normally designed motor, the maximum speed can be allowed up to twice rated
speed and in specially designed machines it can be six times rated speed.
 V Ra V 1 R
m   T m   a   K f Ia
K e K e 2 Ke K f T Ke K f
m
m
Decreasing flux
D eacreasing  at constant V
at constant V

Decreasing V Torque
at Full flux

D eacreasing V T
at constant 
Separately Series
Torque & Power Limitations in Combined armature Voltage and Field Control
1. The maximum torque and power limitations of dc drives operating with
armature voltage control and full field below rated speed and flux control at rated
armature voltage above rated speed are shown in Fig. .
2. In armature voltage control at full field, T ∞ Ia consequently, the maximum
torque that the machine can deliver has a constant value.
3. In the field control at rated armature voltage, Pm ∞ Ia (because E ≈ V = constant).
Therefore, maximum power developed by the motor has a constant value.

T o rq u e
Pm

Pm

A r m a tu r e V o lta g e
m
F ie ld C o n tr o l
C o n tr o l r a te d
Speed
• In a separately excited motor, flux is controlled by varying
voltage across field winding and in a series motor it is
controlled either by varying number of turns in the field
winding or connecting a diverter resistance across the field
winding.
• In armature resistance control, speed is varied by wasting
power in external resistors that are connected in series with
the armature.
• Since it is an inefficient method of Speed Control of DC
Motor Drives, it was used in intermittent load applications
where the duration of low speed operation forms only a
small proportion of total running time, for example in
traction. It has, however, been replaced by armature voltage
control in all these applications.
 A 230 V 500 rpm, 100 A separetly excited DC motor has Ra  0.1 . The motor is
driving at a rated conditions, a load whose torque is constant and independent of
speed. The speeds below the rated speed are obtained with armature voltage control
(with full field) and the speeds above the rated speed are obtained by field control
(with rated armature voltage).
(a) Calculate the motor terminal voltage when the speed is 400 rpm.
(b) by what amount should flux be reduced to get a motor speed of 800 rpm?

E1  Vt  Ra I a1  230  0.1 *100  220

E2 N 2 E2 400
    E2  176V
E1 N1 220 500
V2  E2  I a 2 Ra
 176  100 * 0.1  186V
 .b
E3 I f 3 * N 3 E3 800 If3
  x x
E1 I f 1 * N1 220 500 I f1
 E3  352 x
T3 I f 3 I a 3 I a3
 *  x* I a 3  I a1 / x
T1 I f 1 I a1 I a1
V3  E3  I a 3 Ra 100 * 0.1
230  352 x 
x
2
312 x  230 x  10  0
 x1  0.61 x2  0.05
 A220 V 600 rpm, 100 A separetly excited DC motor has Ra  0.12 . The motor is driving
at a rated conditions, a load whose torque is constant and independent of speed at speeds
below the rated speed and the mechanical power is constant and independent of speed at
speeds higher than the rated speed. The speeds below the rated speed are obtained with
armature voltage control (with full field) and the speeds above the rated speed are obtained
by field control (with rated armature voltage).
(a) Calculate the motor terminal voltage when the speed is 500 rpm.
(b) by what amount should flux be reduced to get a motor speed of 900 rpm?

E1  Vt  I a1 Ra  220  0.12 *100  208V

E2 N 2 E 500
 Then, 2  Then, E2  173.3V
E1 N1 208 600
Then, V2  E2  I a 2 Ra  173.3  100 * 0.12  185.33V
 E3 I f 3 * N 3 E 900 If3
(b)  Then, 3  x , Where x 
E1 I f 1 * N 1 208 600 I f1
Then E3  312 x (1)
P  T but, as we know from the data P =constant above rated speed.
1 T N
Then T but  N Then, 3  1 (2)
 T1 N 3
T3 I f 3 I a 3 I
But  *  x * a 3 (3)
T1 I f 1 I a1 I a1
Substitute from (2) into (3) we get:
N1 I
 x * a3 (4)
N3 I a1
V3  E3 220  E3
But V3  E3  I a 3 Ra Then, I a 3   (5)
Ra 0.12
Substitute from (5) into (4) we get the following equation:
600 220  E3
 x* (6)
900 100 * 0.12
Substitute from (1) into (6) then,
600 220  312 x
 x*
900 100 * 0.12
Then, 312 x 2  220 x  8  0
Then, x1  0.6667 and x2  0.0385
Armature Resistance Control
Separately or shunt field
V Ra  Rext
m   T
K e K e 2
m m

TR

In cre a sin g
Re

Re Torque
 Armature Resistance Control
V 1 Ra
Series field m  
Ke K f T Ke K f
m

In cre a sin g
Re Torque
 (b) A DC series motor drives an elevator load that requires a constant torque of 200
N.m. The DC supply voltage is 400 V and the combined resistance of the armature and
series field winding is 0.75 ohm. Neglect rotational losses and armature reaction effect.
(i) The speed of the elevator is controlled by variating the supply DC voltage. At 220V
input voltage and 40A motor current, determine the speed and the horsepower output of
the motor and the efficiency of the system.
(ii) The elevator is controlled by inserting resistance in series with the armature of the
series motor. For the speed of part (i), determine the values of the series resistance,
horsepower output of the motor, and efficiency of the system.
(i) Ea  VT  I a Ra  Rs   220  40 * 0.75  190V
T 200
Ea  k a  m , T  ka  I a , k a     5
I a 40
Ea 190
 m    38 rad / sec  363rpm
k a 5
Ea I a 190 * 40
Pout , HP    10.188 HP
746 746
Pin  220 * 40  8800 Watt
Pout 190 * 40
  *100  86.364%
Pin 8800
(ii) Ea  VT  I a Ra  Rs  Rexternal 
400  190
Ra  Rs  Rexternal    5.25
40
Rexternal  5.25  0.75  4.5
Pout 190 * 40
  *100  47.5%
Pin 400 * 40
(b) A DC series motor drives an elevator load that requires a constant torque of 200 N.m.
The DC supply voltage is 400 V and the combined resistance of the armature and series
field winding is 0.75 ohms.
(i) The speed of the elevator is controlled by buck converter. At 50% duty cycle (i.e., D=0.5)
of the chopper, the motor current is 40 amps. Determine the speed and the horsepower
output of the motor and the efficiency of the system.
(ii) Compare between the scheme in part(i) and the method of inserting resistance in
series with the armature of the series motor for the same speed.
TS V d 400 * 0.5 * (1  0.5)
(i) I LB  D (1  D )   25 A
2L 2 * 0.0001 * 20000
It is clear that the load current (40A) greater than the inductor boundary current.
So, this chopper works in continuous conduction mode.
VT  DV s  0.5 * 400  200V
T 200
Ea  k a  m , T  k a  I a , k a    5
I a 40
Ea 170
m    34 rad / sec  324.8rpm
k a 5
E I 170 * 40
Pout , HP  a a   9.12 HP
746 746
Pin  200 * 40  8000 Watt
P 170 * 40
  out  * 100  85%
Pin 8000
(ii) Ea  VT  I a Ra  Rs  Rexternal ,
400  170
Ra  Rs  Rexternal    5.75
40
Rexternal  5.75  0.75  5 ,
Pout 170 * 40
  * 100  42.5%
Pin 400 * 40
It is clear that in using the method of inserting
resistance in series with the armature of the series
motor the efficiency get much lower than using
buck converter in DC motor control