(EE 330)

Engr. Gil Tuban

John Lloyd A. Vincoy

BSME lll
 1
Types of DC Motors
The “DC” in DC motor stands for “direct current.” A DC motor is any type of rotary
electrical machine that adapts this type of electrical energy, direct current, into
mechanical energy. The definition of direct current is an electric current flowing in only
one direction. The most popular types of DC motors rely on the forces created by
magnetic fields. Nearly all types of DC motors have an internal mechanism, either
electromechanical or electronic, to regularly change the current’s direction in part of the
motor.

The first form of motor widely used were DC motors, as direct currents were the first
form of electrical power. A DC motor's speed can be regulated over a wide range, using
either a variable supply voltage or by changing the strength of the current in its field
windings. Some applications of small DC motors are tools, toys, and appliances. Larger
DC motors run electric vehicles, elevators, and hoists. The growing popularity of power
electronics has led to the replacement of DC motors with AC motors in many
applications.

Permanent Magnet DC Motor

Permanent magnet DC Motors, or PMDC motors, use permanent magnets to cause
field flux. They have excellent starting torque and have strong speed regulation, but the
torque is limited, so they are generally found in low horsepower applications.
Series Wound DC Motors
Series DC motors, or Series wound DC Motors, have a field wound with a few coils of a
large wire that carries the full armature current. Typically, series wound DC motors have
a large amount of starting torque, but cannot control their speed and running with no
load causes them damage. These limitations mean that if a variable speed drive is
needed, they are not a reliable option.

Shunt DC Motors
Shunt DC motors have a field connected in parallel with the armature windings. “Shunt”
is another term for this field. These motors have high-speed regulation because the
shunt field can be excited separately from the armature windings, which also offers
simplified reversing controls. There are long and short shunt DC motors. If the shunt
field winding is parallel to the armature winding but not to the series field winding, then,
it's known as short shunt DC moto. If the shunt field winding is parallel to both windings,
then it’s known as a long shunt DC motor.
Compound DC Motors
Compound DC motors, like shunt DC motors, have a separately excited shunt field. The
motor attaches the armature and fields windings in a shunt and a series combination,
giving it the characteristics of both a shunt and a series DC motor. Compound DC
motors have strong starting torque but may experience control problems in variable
speed drive applications. The motor connects in two different arrangements:
cumulatively and differentially. Cumulative compound motors attach the series field to
the shunt field, which causes higher starting torque but less speed regulation.
Differential compound DC motors have high-speed regulation and usually operate at a
constant speed.

Brushless DC Motors
Brushless DC motors have one or more permanent magnets in the rotor
and electromagnets on the motor housing for the stator. A motor controller changes DC
to AC. This design gets rid of the complication of transferring power from outside the
motor to the spinning rotor. The motor controller senses the rotor's position through
sensors and can precisely control the timing and phase of the current in the rotor coils
to optimize torque, conserve power, regulate speed, and apply some braking. Brushless
motors have a long life span, require little or no maintenance, and have high efficiency.
They do have some disadvantages, including their high
initial cost and more complicated motor speed controllers.
 2
Principles of DC MOTOR

In any electric motor, operation is based on simple electromagnetism. A current-carrying

conductor generates a magnetic field; when this is then placed in an external magnetic field, it
will experience a force proportional to the current in the conductor, and to the strength of the
external magnetic field. As you are well aware of from playing with magnets as a kid, opposite
(North and South) polarities attract, while like polarities (North and North, South and South)
repel. The internal configuration of a DC motor is designed to harness the magnetic interaction
between a current-carrying conductor and an external magnetic field to generate rotational
motion.

Let's start by looking at a simple 2-pole DC electric motor (here red represents a magnet or
winding with a "North" polarization, while green represents a magnet or winding with a
"South" polarization).

Every DC motor has six basic parts -- axle, rotor (a.k.a., armature), stator, commutator, field
magnet(s), and brushes. In most common DC motors (and all that BEAMers will see), the
external magnetic field is produced by high-strength permanent magnets1. The stator is the
stationary part of the motor -- this includes the motor casing, as well as two or more permanent
magnet pole pieces. The rotor (together with the axle and attached commutator) rotate with
respect to the stator. The rotor consists of windings (generally on a core), the windings being
electrically connected to the commutator. The above diagram shows a common motor layout --
with the rotor inside the stator (field) magnets.

The geometry of the brushes, commutator contacts, and rotor

windings are such that when power is applied, the polarities of
the energized winding and the stator magnet(s) are misaligned,
and the rotor will rotate until it is almost aligned with the
stator's field magnets. As the rotor reaches alignment, the
brushes move to the next commutator contacts, and energize
the next winding. Given our example two-pole motor, the
rotation reverses the direction of current through the rotor
winding, leading to a "flip" of the rotor's magnetic field,
driving it to continue rotating.

In real life, though, DC motors will always have more than

two poles (three is a very common number). In particular, this
avoids "dead spots" in the commutator. You can imagine how
with our example two-pole motor, if the rotor is exactly at the
middle of its rotation (perfectly aligned with the field
magnets), it will get "stuck" there. Meanwhile, with a two-
pole motor, there is a moment where the commutator shorts
out the power supply (i.e., both brushes touch both
commutator contacts simultaneously). This would be bad for
the power supply, waste energy, and damage motor
components as well. Yet another disadvantage of such a
simple motor is that it would exhibit a high amount
of torque "ripple" (the amount of torque it could produce is
cyclic with the position of the rotor).

So since most small DC motors are of a three-pole design, let's tinker with the workings of one
via an interactive animation (JavaScript required):

You'll notice a few things from this -- namely, one pole is fully energized at a time (but two
others are "partially" energized). As each brush transitions from one commutator contact to the
next, one coil's field will rapidly collapse, as the next coil's field will rapidly charge up (this
occurs within a few microsecond). We'll see more about the effects of this later, but in the
meantime you can see that this is a direct result of the coil windings' series wiring:
 There's probably no better way to see how an average DC motor
is put together, than by just opening one up. Unfortunately this
is tedious work, as well as requiring the destruction of a
perfectly good motor.

Luckily for you, I've gone ahead and done this in your stead.
The guts of a disassembled Mabuchi FF-030-PN motor
(the same model that Solarbotics sells) are available for you to
see here (on 10 lines / cm graph paper). This is a basic 3-
pole DC motor, with 2 brushes and three commutator contacts.

The use of an iron core armature (as in the Mabuchi, above) is quite common, and has a number
of advantages2. First off, the iron core provides a strong, rigid support for the windings -- a
particularly important consideration for high-torque motors. The core also conducts heat away
from the rotor windings, allowing the motor to be driven harder than might otherwise be the
case. Iron core construction is also relatively inexpensive compared with other construction
types.

But iron core construction also has several disadvantages. The iron armature has a relatively
high inertia which limits motor acceleration. This construction also results in high
winding inductances which limit brush and commutator life.

In small motors, an alternative design is often used which features a 'coreless' armature
winding. This design depends upon the coil wire itself for structural integrity. As a result, the
armature is hollow, and the permanent magnet can be mounted inside the rotor coil.
Coreless DC motors have much lower armature inductance than iron-core motors of
comparable size, extending brush and commutator life.
 Diagram courtesy of MicroMo

The coreless design also allows manufacturers to build smaller motors; meanwhile, due to the
lack of iron in their rotors, coreless motors are somewhat prone to overheating. As a result, this
design is generally used just in small, low-power motors. BEAMers will most often see
coreless DC motors in the form of pager motors.

Again, disassembling a coreless motor can be instructive --

in this case, my hapless victim was a cheap pager vibrator
motor. The guts of this disassembled motor are available for
you to see here (on 10 lines / cm graph paper). This is (or
more accurately, was) a 3-pole coreless DC motor.

I disembowel 'em so you don't have to...

 3
1. Separately Excited DC Motors
Characteristics of Separately Excited DC Motors

▪ Separately excited Dc motors got very accurate speed

▪ These type of motors are much suitable for applications which need speed variation
from low speed to higher speed.

Applications of Separately Excited DC Motors

▪ Paper Machines
▪ Rolling Units
▪ Electric Populations of Ships

2. Shunt DC Motors
Dc shunt motor is the parallel combination of armature winding is connect
with dc power supply. The resistance of shunt type of winding is great than
the armature wingdings.

Characteristic of Shunt DC Motors

▪ Shunt motors are normally got constant speed.

▪ The starting torque of this motor is medium which is limited to nearly 200% by
commutation.
▪ Speed control of shunt motor done by decreasing armature voltage control

Applications of Shunt DC Motors

Shunt Motors are normally used for constant speed applications such as
followings

▪ Lathe Machines
▪ Fans and Blowers
▪ Reciprocating Pumps
▪ Printing machines
▪ Wood working machines
▪ Centrifugal pumps
Normally speed regulation of shunt dc motors is normally 10% to 15%. The
speed control raged by field control 6:1

3. DC Series Motors
Characteristics of DC Series Motors

Unlike DC Shunt Motors this DC Series motors got variable speed. and the
starting torque of this dc motor is quite high. Normally it can high up to 500%.
speed regulation is widely variable at no load. This DC series motor speed
control done by using series resistance method. In Dc series motors its
essential to connect the load positively.

Applications of DC Series Motors

DC series motors are much suitable for applications which require high
starting torque and variable speed applications. Following are some several
applications of DC series motors.

▪ Electrical Cranes
▪ Trolley Cars
▪ Conveyors Belt Drives
▪ Electric locomotives

4. Compound DC Motors
DC Compound motors can mainly classify as Cumulative compound wound
motors and Differential compound wound motors.

Characteristic of Cumulative compound wound motors

Normally these type of DC motor is god for adjustable varying speed. The
speed regulation is varying 25%-30%. The starting torque of this dc motor is
also high like DC series Motors.

Characteristic of Differential compound wound motors

Torque and Speed of this Differential compound wound motors are almost
constant. This motor also got the tendency toward speed instability with a
possible motor running away.
Application of Compound DC Motors

DC compound motors are much suitable for places where need higher starting
torque on the constant speed. The applications of DC Compound motors are as
following.

▪ Electrical Elevators
▪ Conveyor Belt Drive
▪ Heavy Planes
▪ Rolling Mills
▪ Punches
▪ Shears

Commutator in a DC Motor
The operating principle of a DC motor is based on the interaction between the magnetic field of a
rotating armature and the magnetic field of a fixed stator. As the north pole of the armature is attracted to
the south pole of the stator (and vice-versa), a force is produced on the armature, causing it to turn.
Commutation is the process of switching the field in the armature windings to produce constant torque in
one direction, and the commutator is a device connected to the armature, which enables this switching of
current.
The commutator itself is a split ring, typically made of copper, with each segment of the ring
attached to each end of the armature coil. If the armature has multiple coils, the commutator will similarly
have multiple segments—one for each end of each coil. Spring-loaded brushes sit on each side of the
commutator and make contact with the commutator as it turns, supplying the commutator segments and the
corresponding armature coils with voltage.
 5
DC Motor Tourque, Horsepower, Efficiency, Back(counter) EMF, and Speed Regulation

When armature conductors of a DC motor carry current in the presence of stator field flux,
a mechanical torque is developed between the armature and the stator. Torque is given by
the product of the force and the radius at which this force acts. ➢ Torque T = F × r (N-m)
…where, F = force and r = radius of the armature
➢ Work done by this force in once revolution = Force × distance = F × 2πr (where, 2πr =
circumference of the armature)
➢ Net power developed in the armature = word done / time = (force × circumference × no.
of revolutions) / time = (F × 2πr × N) / 60 (Joules per second)
DC Motor Horsepower Formula:
HP = (E x I x Eff) / 746
Where, HP = Horsepower E = Voltage I = Current Eff = Efficiency
Typically, the efficiency of DC Motors be in the range of 70 to 85%. Larger the machine
higher will be the efficiency.
Efficiency of DC motor
= (output- mechanical)/ (input – electrical)
As it is easy to measure electrical quantities more accurately and easily, it is written
as
= (Input – Losses) / Input
Input = VI=supply voltage x line current
Losses consist of Armature and field copper losses, core loss, friction and windage
loss.

Back(counter) EMF
A motor has coils turning inside magnetic fields, and a coil turning inside a
magnetic field induces an emf. This emf, known as the back emf, acts against the applied
voltage that's causing the motor to spin in the first place, and reduces the current flowing
through the coils of the motor.
 The back emf Eb(= PΦZN/60 A) is always less than the applied voltage V, although
this difference is small when the motor is running under normal conditions.
Speed Regulation
The speed regulation of a DC Motor is defined as the change in speed from no load to
full load. It is expressed as a fraction or a percentage of the full load speed.

Where,
Nnl is the no-load speed
Nfl is the full load speed
A motor which has nearly, constant speed or the difference between no-load and full
load is very less is said to have a good speed regulation.

6
DC Motor and DC Generator Armature Reaction
The armature reaction simply shows the effect of armature field on the main field. In other
words, the armature reaction represents the impact of the armature flux on the main field flux. The
armature field is produced by the armature conductors when current flows through them. And the
main field is produced by the magnetic poles. The armature flux causes two effects on the main
field flux. The armature reaction distorted the main field flux It reduces the magnitude of the main
field flux. The armature reaction is the effect of the armature flux on the main flux. In case of a
DC motor the resultant flux is strengthened at the leading pole and weakened at the trailing pole
tips.
 7
Schematic diagrams of each types of DC Motor
Permanent Magnet DC Motor

Series DC Motors

Shunt DC Motors
 Compound DC Motors

8
Construction and the
Exploded view with label of
the main parts of DC Motor