Dr.

Adel Gastli

Electromechanical Systems & Actuators

DC MACHINES
These slides are the contributions of: Dr. A. Gastli, Dr. A. Al-Badi, and Dr. Amer Al-Hinai

DC Machines
LEARNING GOALS Introduction
Application of DC Machine Advantages & Disadvantages of DC Machine

Construction of DC Machine
Field System Armature Commentator Brush

Principle of Operation
Faradays Law Armature Voltage & Developed Torque

Classification of DC Machine
Permanent Magnet Self-Excited Separately-Excited

DC Machine Representation Magnetization Curve (Saturation) DC Motor & Generator Equations Power Flow & Efficiency Torque-Speed Characteristics
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators Starting of DC Machine 2

Introduction
Most of the electrical machine in service are AC type. DC machine are of considerable industrial importance. DC machine mainly used as DC motors and the DC generators are rarely used. DC motors provides a fine control of the speed which can not be attained by AC motors. DC motors can developed rated torque at all speeds from standstill to rated speed. Developed torque at standstill is many times greater than the torque developed by an AC motor of equal power and speed rating.
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 3

Application of DC Machines

The d.c. machine can operate as either a motor or a generator, at present its use as a generator is limited because of the widespread use of ac power. Large d.c. motors are used in machine tools, printing presses, fans, pumps, cranes, paper mill, traction, textile mills and so forth. Small d.c. machines (fractional horsepower rating) are used primarily as control device-such as tachogenerators for speed sensing and servomotors for position and tracking.
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 4

Application of DC Machines
DC Motor Paper Mills Oil Rigs

Steel Mills

Robots

Dr. Adel GastliMining

MCTE3210: Machine Electromechanical ToolsSystems & Actuators

Petrochemical

Advantages & Disadvantages Of D.C. Motors

Advantages High starting torque Rapid acceleration and deceleration. Speed can be easily controlled over wide speed range. Used in tough gobs (traction motors, electric trains, electric cars,.) Built in wide range of sizes. Disadvantages Needs regular maintenance Cannot be used in explosive area High cost
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 6

Introduction
Electric Machine

Mechanical Input

Generator

Electrical Output

Electrical Input

Motor

Mechanical Output

Electromechanical Energy Conversion

+ Electrical system v _ i
Ideal Electric Machine T Mechanical system

Motor Energy Flow Generator

v i=T

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

Construction of DC Machine

Parts of a DC Machine
Armature winding Armature core Leading pole tip Field coil Rotation Pole axis Shaft Pole core Trailing pole tip Pole face Field yoke

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

Construction of DC Machine
Shaft

Armature

Commutator

Stator

Field coil

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators 2 Pole DC Machine

Construction of DC Machine: Field System

The field system is to produce uniform magnetic field within which the armature rotates. This consists of Yoke or frame: Acts as a mechanical support of the machine

2000HP DC Motor field System

Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 10

Construction of DC Machine: Armature

The rotor or the armature core, which carries the rotor or armature winding, is made of sheet-steel laminations. The laminations are stacked together to form a cylindrical structure
Slots Slots for wedges Teeth

The armature coils that make the armature winding are located in the slots Non-conducting slot liners are wedged in between the coil and the slot walls for protection from abrasion, electrical insulation and mechanical support
Cooling ducts for air circulation

Portion of an armature lamination of a dc machine showing slots and teeth

Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 11

Construction of DC Machine: Armature

Armature of a DC Machine
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 12

Construction of DC Machine: Commutator

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.

Commutator
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 13

Construction of DC Machine: Brush

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.

Commutator and Brushes

Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 14

Construction of DC Machine: Armature Winding

Top coil sides

Top coil sides

Bottom coil sides

Commutator

3 Brush

2 Brush

Elements of Lap Winding

Elements of Wave Winding

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Construction of DC Machine: Armature Winding

End connection

Conductors

Turn

Coil

Winding

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Construction of DC Machine: Armature Winding Lap Winding a b c d e a b c d

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

N
f g h

S
f g h

19 20 21 1 +

6 -

9 10 11 12 13 14 15 16 17 18 19 + -

Ia + Icoil // paths

a=b= p
brushes poles
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+
Dr. Adel Gastli

- Systems - & Actuators MCTE3210: Electromechanical

Construction of DC Machine: Armature Winding

a b c d e

Wave Winding
4 5 6 7 8 9 10

2 3

11 12 13 14 15 16 17 18 19 20 21

N
i h g f j k

S
f g h j k

17 18 19 20 21 1 -

6 +

9 10 11 12 13 14 15 16 17 18 19 +

Ia + Icoil

a=2
Nb. of // paths
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Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators -

Principle of Operation
The Faraday Disk and Faradays Law
An emf is induced in a circuit placed in a magnetic field if either: the magnetic flux linking the circuit is time varying or there is a relative motion between the circuit and the magnetic field such that the conductors comprising the circuit cut a cross the magnetic flux lines. 1st form of the law is the basis of transformers. 2nd form is the basic principle of operation of electric generators.
Magnet + N S Brush Copper disk Conducting shaft _ V

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Principle of Operation
The right-hand rule and generator action
Velocity, u

V
Voltmeter

Flux density, B

Conductor rails u
emf, e

= B.A = B.l.s

d dB .l.s = dt dt ds ds e = B.l. ,u = dt dt e=
Faradays law or flux cutting rule
Dr. Adel Gastli

Moving conductor

e=Blu
MCTE3210: Electromechanical Systems & Actuators 20

Principle of Operation

Without Commutator
N

l1

S Field pole

Slip rings

N-turn coil

brushes

v t

External circuit

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Principle of Operation

With Commutator
N

v
b Commutator segments a

coil

brushes

t v

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Single-Phase Full wave Rectifier

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Multi-Pole Machines

If p is the number of poles, then p/2 cycles of variation of the flux are encountered every complete mechanical rotation.

360 o md One pole pitch = 180 ed = p

o

B() Pole pitch

ed

p = md 2

N S

ed md

ed : electrical degrees or angular measure in cycles md : mechanical degrees or angular measure in space

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Principle of Operation: Armature Voltage

Emf conductor = p. . N m Flux / Re v. p. = = 60 time / Re v. (60 / N m )

Emf Total =

Emf conductor Number of conductor / path p. . N m Z p. .Z . N m Emf Total = / = 60 60 a a

where p = number of poles Z = total number of armature conductors a = number of parallel paths, 2 for wave and p for lab. = flux per pole (Weber) Nm = speed of the motor in the revolutions per minute (rpm) time of 1 revolution = 60/Nm (sec)

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Principle of Operation: Armature Voltage

Let

m =

2 . . N m .60 Nm = m 60 2 .

m= speed of the motor in radians per second

Emf Total =

p. .Z . m p. .Z m .60 = . 60 a 2 . 2 . .a
Ka: armature constant

Emf Total = K a . . m

Ka =

p .Z 2 . .a

Generated voltage : generator operation Back emf : motor operation

MCTE3210: Electromechanical Systems & Actuators

Dr. Adel Gastli

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Developed (or Electromagnetic) Torque

Consider the turn shown in the following Figure.

Area per pole A =

2rl p
p = A 2 r l
Ic = Ia a Ia a

Flux density

B=

Current / conductor is

The force on a conductor is

fc = B l

The torque developed by a conductor is The total torque developed is

Tc = f c r = B l

p Ia Ia r = a 2 a

Te =

Zp I a E I = K a I a = a a m 2 a
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Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

Production of Unidirectional Torque and Operation of an Elementary

a a I 1 b b F S N F F a I 1 b a S

N F

+b

Position of conductor a under N-pole

B I

Position of conductor a under S-pole

F Left-hand rule
Dr. Adel Gastli

With this configuration the torque is unidirectional and independent of conductor position

MCTE3210: Electromechanical Systems & Actuators

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Classification of DC Machine

Separately excited

Shunt

Long Shunt

Short Shunt

DC Machine

Self-excited

Series Cumulative Differential

Permanent magnet

Compound

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Classification of DC Machine
Field Armature

Field

Armature

Field Armature

Separately excited

Shunt

Series

f
F1 F2

A1 S1 A2

s
S2 F1

f
F2

A1 S1 A2

s
S2

Short-shunt

Motor operation Generator operation

Long-shunt

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Classification of DC Machine

f
F1 F2

A1 S1 A2

s
S2 F1

f
F2

A1 S1 A2

s
S2

Cumulative compound

Differential compound

Motor operation Generator operation

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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DC Machine Representation
q-axis d-axis Field Armature d-axis q-axis Armature mmf Flux-mmf relation in a dc machine The mmfs produced by the field circuit and the armature circuit are in quadrature.

Field mmf

Armature mmf

Saturation Linear

Field mmf

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

Fp

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Magnetization (or Saturation) Curve of a DC Machine

Saturation Linear

Ea
Speed m 0.5 m

Flux-mmf relation in a dc machine

If Nf

If
Magnetization curve

The magnetizing curve is obtained experimentally by rotating the the dc machine at a given speed and measuring the open-circuit armature terminal voltage as the current in the field winding is changed.
Magnetization Curve
Dr. Adel Gastli

Represents the saturation level in the magnetic system of the dc machine for various values of excitation mmf .
MCTE3210: Electromechanical Systems & Actuators 33

Dc Motors Equations
Separately Excited DC Motor
It Ia Ra Rfw m Rfc If + Vf Vt +

Vf = Rf I f E a = Vt I a R a E a= K am Te = K a I a

Rfw: resistance of field winding. Rfc: resistance of control rheostat used in field circuit. Rf=Rfw+Rfc: total field resistance Ra: resistance of armature circuit, including the effect of brushes. Sometimes

Ra is shown as the resistance of armature winding alone; the brush-contact voltage drop is considered separately and is usually assumed to be about 2V.
Dr. Adel Gastli MCTE3210: Electromechanical Systems & Actuators 34

Dc Motors Equations
Shunt or Self-Excited DC Motor
Rfc If Ia Ra Rfw m + Vt It +

V f = R f I f = Vt E a = Vt I a R a E a= K a m , Vt = I t R L , Te = K a I a Ia = It I f

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Dc Generator Equations
Separately Excited DC Generator

Ia + ra + m Rfw Rfc If Ea

IL

Vf =(Rfw + Rfc)I f = Rf I f Ea =Vt + Iara

RL

Vt

Ea= Ka m Vt = ILRL Ia = IL

+ Vf

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Dc Generator Equations
Self-Excited DC Generators

1. Shunt generator
If Ia Rfc Rfw m ra + Ea Vt RL IL +

Vf = RfI

= Vt

E a = V t + I a ra E a= K a m Vt = I L RL Ia = IL + I
f

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Dc Generator Equations
2. Series Generator

Ia ra + Ea

IL + Rs Vt

Vt = Ea Ia (ra + Rs )
RL

I L = Ia = I f Ea = Kasm

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Dc Generator Equations
3. Compound DC Generator
If IL Ia Ra + Ea Rfw Rs Vt Rfw Ea + Rfc If Ia Ra + Rs Vt IL +

Rfc

Short Shunt

Long Shunt

Vt = Ea I a Ra I L Rs IL = Ia I f If = Ea I a Ra R fw + R fc

E a = K a (

sh

Vt = Ea I a (Ra + Rs ) IL = Ia I f If = Vt R fw + R fc
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Cumulative

Differential

a a Dr. Adel Gastli

E = K ( sh s )m

MCTE3210: Electromechanical Systems & Actuators

Ea = K a ( sh s )m

Power Flow and Efficiency

If IL Ia Ea Rfw + Ra + Rs Vt

DC Generators
Rfc

Pinput= Pmech = Pshaft

Rotational losses

Ea I a

Va I a

Va I L

Vt I L

Poutput= Pelectrical

2 Ia Ra

2 I2 f R f I L Rs

= = =

Poutput Pinput

Poutput Poutput + Losses Vt I L I 2 R + Rotational Losses

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Vt I L +

Dr. Adel Gastli

Vt I L Electromechanical Systems & Actuators EMCTE3210: I + Rotational Losses a a

Power Flow and Efficiency

DC Motors
Rfc If Ia Ea Rfw IL + Ra + Rs Vt

Pinput = Pelectrical

Vt IL

Va IL

Va Ia

Ea Ia

Poutput= Pmech= Pshaft

2 IL Rs

I2 f Rf

2 Ia Ra Rotational losses

= = =

Poutput Pinput

Pinput Losses Pinput I 2 R Rotational Vt I L Losses

Vt I L

Dr. Adel Gastli

E a I a Rotational Losses MCTE3210: Electromechanical Systems & Actuators Vt I L

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Torque-Speed Characteristics

Separately excited & Shunt motors

( is independent of the load torque )
Ia

V t = E a + I a ra E a = K a m
T = K a I a

m =

Vt I a ra K a
m

Vt K a
Therefore ,

V ra m = t T K a (K a)2

Slope ( K ) 2 a T

ra

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Torque-Speed Characteristics

Series motors
E a = Vt I a ( R a + R s ) E a = K a m
Neglecting saturation

= K1I f = K1I a

E a = K a K 1 I a m = K s I a m
m =
Vt R + Rs a KsIa Ks Vt Ks T Ra + Rs Ks

But T = K a I a = K a K 1 I a2 = K s I a2 m =

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Torque-Speed Characteristics

Compound motors
Cumulative Compound

AT t = AT shunt AT series
Differential Compound

t = shunt series
m =
Vt ra T K a t ( K a t ) 2

Shunt motor

Dr. Adel Gastli

MCTE3210: Electromechanical Systems & Actuators

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Starting of DC Machine
If a d.c. motor is directly connected to a d.c. power supply, the starting current will be dangerously high.

Ia =

Vt E a ra

at starting

= 0 Ea = 0

Ia

Starting

Vt ra

Since ra is small, the starting current is very large. The starting current can be limited by the following methods: 1- Use a variable-voltage supply. 2- Insert an external resistance at start, as MCTE3210: Electromechanical Systems & Actuators Dr. Adel Gastli shown in the Figure.

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