ELECTRICAL MACIIINES

LIST OF CONTENTS PAGE

IN-SITU MAINTENANCE

OVERHAUL
ARMATURE TESTING

MACHINE REASSEMBLY

BRUSHGEAR

FAULT CHART
ACTUATORS

SELF-APPRAISAL QUESTIONS
OBJECTIVES ELECTRICAL MACHINES

On completion of this lesson the student will.

Identify t h e i n components)of a d. c . machine
and s t a t e their function.
List t h e main tasks i n electrical machine(overhau1.
1
Recall t h e two methods used to t e s t the(continuity
of armature windings 9 '

Recall the t y p e s of(armature fault and t h e tesgindi-

cations.

C
List the post -overhaul tes ts)on motors and generators.
L i s t the typica~pplicationsof d. c. motors 9
RECOMMENDED FURTHER READING

2 ELECTRICAL TECHNOLOGY E. HUGHES

CHAPTER 6,7.
3 A.P. 3275, P t . l A , SECT. 5 CH.1.
4 AIRCRAFT ELECTRICAL PRACTICE PP174 - 182.
5 A.P. 4343A, VOL. 1.
6 k , P , 4343D VOL. 6.
7 Air craft Electric21 Systems PAZ,LETT,
 A (0') 8 (.II0)
position position

c( 1 8 0 0 ) ~ ,

position
 armature, this means that"therewill be an interaction between the main
field and the armature field. This will cause the electrical neutral a x i s
to move in the direction of rotation) FIG. 8 .

Neutral
Plane p@*
I jihgiV

The effect of armature reaction i s that it will cause excessive

CONSTANT Gparking a t the brushes, resulting in e power loss due to overheating
and e x c e s s i v e wear) This loss can be minimised if the load is constant
LOAD. by merely rotating t h e h to reduce sparking but
this does n-cime the problem for varying load conditions.
The effectof armature reaction for var ing load current can be
' minimised by%'cornpensatlnywinding&?These windings are connected
in series with the armature)and wound in the faces of the pole pieces.
VARY IN G The windings(carry the load current in opposition to the armature
current .)FIG. 9 .

To Load
 i
. I
REACTIVE: SPARKING I1
4.' 7
Correct COMMUTATION should occur when the armature coil has zero .. '
induced e.m.f .W Due to the fact that the armature coils
effectively possess self inductance ,' the collg induced e .m. f will
not fall instantaneously. This means that a t an instant after the
commutator segments passes the brushes, there will still be a voltage
in the coil, which will cause sparking a t the h s h e s . This form of
sparking is called REACTIVE SPARKING.

Reactive Sparking is reduced by using .................;. .....

Gterpoles are connected In series with the armature but wound on
separatk poles, so a s to aid the armature coil to fall to zero at the
instant of The magnetic polarity of the interpole, is
pole ahead, Ln the direction of rotation.
FIG, 10.

S hunl l n l t rpsles
or
Cornpcnullrq
W lndrngs
Armature

* *
T o Load
6.3 llouble-layer drunk ivindings l .ij!. 6.7 s l ~ o Su Ilic* :uli;~lw01' (lie ~ . ~ ~ ( I - c ~ ~ ~ ~ t01'i c c:I -st ii~oi gr ~l ccoil
s coil-
sir.li~lj!ol :l IIIIIII~)CI. of' ~ ~ I I . I ~ ;111(1
s, lig, 6.8 (I!) slro\vs 11ow Ilircc coils, s

Let us ctlllsidcr n four-polc i i r ~ l i i ~ t u rwitll,

c soy, II slots, as in fig.
1 - l ' , 2 2' : ~ r l t l 3 3', ii1.c ;~~-r.;~til!ctl ill tlic slots s o tli:~t I l ~ c i rend-
6.6. In ordcr thilt all the coils Inay be silnil;w in s i ~ a p eand thercforc
~ ~ o ~ l ~ l r r clrrrli~l)
i i i t ~ ~ so l l r :IIIO~~ICI-, l l ~ cc l l d c l ~ \ ~ : t l i of
w ~ t~l l c clid-
r o ~ r n c ~ ~ ~of ~ i ~ . l-
i r coils ; I ' i t t l r l 3 -3' I x i ~ l ils
g sllowl~in lig. 6.8 ((1). The
~ t ~c.oil 2 2' h;is been orlliticd f r t r t ~fig.
c ~ r t~l r . o n ~ l r c . i i cor ~ 6.8 (a) 10

111:ty 111* \ \ v d ~ ~to~ ~(IIC

~ t ~l . o r ~ . c SII~I))C
ct ~ l crllc
l r i ~ i~i ~g ~ ~ l l l lon
OPO~C d
Il;we 10
c " ) l c . ~III.). [)c iii:\do sc~cliil1:lt i l siilc I of :l ctlil IICCLI~I~CS l l l e
011ir1.li;~ll'01' (II~C slot, the 01Jicr side l ' o c c i t ~ ~ i c~ sI I C i1111crJI;IIS o f
~I ~
; I I I ~ ~ I\ I II \ II .~'I it k i i i k it] [ l i t ~ ~ ~ t j - c o ~ ill
I ~ SI~CCCL~I~:I[CS i ~order
~ ~ c [ i ~ ~ ~ s
tIti11 tlic r o i l s 111i1yOYCI~:I~I onc nl~cllllrr;IS i l i c y :IC h i i i g nsscmbled. '

l'ip. 6.7 Arr nr.~~l;llr~rc

coil.
 1 iiird l ' arc 10 iissist cacll o ~ l l c r ,l ' JII~IS~ bc l ~ ~ i b v i i~i g~ i i i l ;Ic rS p l c
I r l l c ~I i~s ruoviiig under i t N pole; t IIIIS,by n l l ~ ~ l ) . i l~IIC l g llil!lr~l~:~~lJ
1 ~ 1 1 1( s~c c ~ ~ O I2.1u)
~ t0 fig. 6.6 i111tI :~S~~IIII~II~; [ I ~ c ~I~III~IIIIIC 1,~
rolntcd clucku.isc, WC l i ~ i dIII;IIi l l c t l i r c u ~ i o i(i3 1 1 1 1 ~ c.ln.1; g c ~ i c r a l ~int l
C O I ~ ~ I I C I O ~1 i s to\\.ards l l l e p;ipcr i \ l ~ c i - r ; ~tlr;~i
s l ! c ~ ~ r i : i I c ill
d cu~itli~c-
lor I' i s ouhvnnls f r o i ~ the l p;lllcr. Ilrllce, i i ~ ct l i s i i ~ ~ l cilcl\\ccil c ccbil
sitlts l i11rd l' ~ I I L ~ bc S ~ app~-oxii~~:; c l y l ~ i ~ c l Yi .i [ l i 1 1 sl1~lsi t i s
~Iipole
i ; ~ l ~ ~ ~ s s10i b i11:1kc
lc tlic dis(;~llccIICI\\~CCII 1 :111d 1 * ex;lcllp ;I p ~ l c
~ i l c l i ,a i d i i ~ liy. 6.6 oric s i l k o l coil 1-1' i s s l l o ~ v nin slot l i ~ i i~l l cd
u t l l c r sidc is ill slot 4. 7l1c r o i l i s t l l r i i s:litl ~ o ' l i n v cn roil sprrtc of
4 - l, II~IIIICI~ 3. 111praclicc i1ils[ ;l ~ y l l ~ i~ l~c ~ ~ i l ~ ~ ~ c ~

iilld is i l ~ ~ j ~ l ' ~ ) ~cijt1;ll

i I l l ; l ~ ~ ~ ~

hrr siiii jllicily bcctl clioscll. 111;~clti;~li ~ ~ ; ~ c l ~ iIllc

t r u s~ l t ~ r l i l >or
cr sl~lls
L
M AC~

per pole asu;~llylics h c b r c c ~ l10 iii~il I5 i l i ~ t llrc

l c o i l spin is s l i g l t ~ l y
lcss 111iln tlre valoe given l l y tlie ;~l)tl\,ee.il~~.cssit?i~.
Lct 11s 110\1~r c l u r n to llrc ci)~~si[lc.r;il i t i i i 14 llrc Il-slot ;rrrlr;~ltirc.
l l ~ cIl coils 31-eo s s c ~ ~ ~ bill
lcdtllc shblc \r~ilha cthil sp;il\ or 3, ;11n1 \\c
i11.c11ow L I W ~i ~ i l lltc
l ~ ~ ~ r o l ) I cc l.( l ~c o~i l ~ i c c t i ~ rlo
p tllc cotuiirul;~lur

b) ONLY 2 UKLISI~ES ARE ECJSEN-TIAL

C) GIVES H~GCIEIZV O L ~ G E
,g/t/fl L~G--QZ~~CU&F~/
7 W

c\ ~ E N T ~ I C A T I O NCP MAJOR COMPONENTS

d. C. ,GIZNERATOR - ITS STRUCTURE & FUNCTION

To obtaia an intense magnetic field D.C. machines are coastructeJ

f i of feno-magnetic materials. With the exception oi a mall air gap,
separatjng the rotating armature from the stationary field s y s t a n ,
a complete magnetic circuit is fomed. T h e dragram shows the magnetic
circuit of a +pole machine. The component parts of t h e mac-etic field
are as follows :-
The Yoke is the circular frame
of the machine and is made of
cast kon, cast steel or rolled
steel.
The E&-Pitt* are built up of
steel la?nifiations,and bolted
on the inside of the yoke.
Solid mild steel pole pieces
with laminated pole shoes arc
sometimes used.
D.C. machines have at least 2
or 4 p o k , but may have up to
!M poles according to the size
and outpur of the machine.
T h - Fizid tVilsdiqs are
mounted on the pole pieces,
in such a manner that the
pokri& of the main 'poles is
MAGNETIC CIRCUIT OF 4PUI.E MACHINE dternatelvso& =d South.

W
CONSTZUCIlON OF A D.C MACHINE

sectioned assenbly (Fig.4)

/ b ~' 0~ ~ *e/e4-m
A s ,>,H,*# A TYPICAL ~ K I
WD.C. GENERATOR

A-
SERVICING /A/ :-
M A I N T E N A N C ~ofScleaning and visual inspection with the minimum of dismantling.
COMMUTATOR
Remove the commutator cover. Examine the inside
-
of the cover for signs of engine oil, and copper o r
solder particles.

- mica.
o r proud
-
Inspect the commutator for signs of exbessive arcing

Remove any carbon dust with clean dry compressed air.

--
-W-+----

I BRUSHES
Withdraw each brush. Check the brush lenath.
E w mine each brush far contamination, fitting ,
r;corincl or bum marks .
Clean the brush boxes and ensure that the brushes
are a sliding fit.
Check t h e spring pressure with a suitably calibrated
spring balance. Adjust the pressure i f necessary.
Replace each brush in the box from which it was
removed.
Replace the commutator cover.
 SERVICING

MAINTENANCE

TERMINAL BOX

Remove t h e t e r m i n a l / s uppres S or box cover.

Examine t h e t e r m i n a l block for cracks.

Ewmine the t e r m i w o s t s for stripped threads.

-
Examine t h e external--
or damaged leads.
leads. Renew any frayed

The insulation r e s i s t a n c e should not be l e s s than

2 M n - . Allowance should be made for climatic
conditions. The r e s i s t a n c e will be low i n damp or
humid climates. Discretion m u s t be exercised when
considering the S erviceability of t h e generator.
@ INSULATION TEST Reconnect t h e l e a d s and replace t h e cover,

@is connect t h e leads and measure the insulation

insulation t e s t , >-
between each terminal and t h e f r a m e , U s e a 250v
Carry out voltaqe and load s h a r e c h e c k s i n
accordance with
OVERHAUL

The following deals, generally, with the main aspects of d. c . and a . c . machine overhaul. The Maintenance Manual must
b e referred t o at all t i m e s .

DISMANTLING
STATOR UNIT

Clean the machine thoroughly.

The workbench must b e clean,

-
COMMUTATOR END

Always us e the correct tool. Box , ring or S ocket ARMATURE

spanners are preferable to open spanners,

If a component proyes "'bfficultto separate from

the machine always look for the cause before BALL BEARING
resorting to force. A single screw is easily over-
looked. -
I

W h e n driving off end plates, e t c . , u s e a hide-faced

hammer.
OVERHAUL

REMOVAL OF BWINGS FITTING NEW BEARINGS

Screw the studs to the inner bearing plate. The new bearing should be checked for serviceability
Ensure that t h e shaft is free from burrs etc.
Place a brass pad over t h e end of the armature Smear the shaft with lubricating oil and assemble the
shaft. Adjust the extractor plate s o that the point inner bearing plate.
of the set screw is in the centre of the brass pad. Heat t h e bearing i n a n oil bath to 90°C.
Slide the bearing onto the s h a f t and secure with t h e
r m HER 0EACUMC
retaining nu t.
Lubricate t h e bearing when i t has cooled thoroughly.
PLATE BRASS
PAD

BALL 0
BEARIYC

If it is not possible to use the hot-and-cold method

TYPICAL BEARING WITHDRAWAL TOOL
Tighten t h e s e t screw, holding the plate of t h e extractor
by a tommy bar, s o that the m ce is gmdually withdrawn
by the inner bearing plate.
The bearing when removed should be discarded.
bearings may be fitted with a press and a suitable
hollow drift (brass). If a press is not available t h e
drift should be struck lightly but squarely with a
mallet.
N. B. The hot-and-cold method should always be
used on aircraft generators.
OVERHAUL

YOKE AND FIELD ASSEMBLY

Examine all connections for security and damage to

insulation,
Check that the field coils fit snugly on the pole pieces.
Examine the field coils for signs of overheating.
Examine the pole faces for signs of abrasion.

RESISTANCE CHECKS

The resistance of shunt windings must b e measured

with a suitable ohmmeter,

The resistance check of series field, interpole and

compensating. windings requires S pecialis e d equipment
and procedures .

INSULATION CHECK

Each field, interpole and compensating winding must

have a n insulation test, Remove any links and test
each winding S epamtely.
The minimum resistance should be 2 M a .
OVERrnU L
ARMATURE Insulation test

Examine the armature for signs of Connect the tester between any S egrnent and the
shaft. The minimum resistance is 2 M n .
a thrown S older
b loosebindings o r s l o t w e d g e s
c rubbing or abrasion of the circumference
d damage to the shaft coupling.

Examine the commutator for

a flats or fitting caused by continuous sparki ng

b grooves due t o excessive brush preFsure
c proudmica
d loosecommutatorbars
e burred trailing edges on the commutator bars

W rnaged commutators must be skimmed.

The mica must then be undercut to its specified
depth.
OVERHAUL ARMATURE TESTING
/ 9'
THE ARMATURE: DROP TESTER
VEE
The Armature Drop Tester was developed to detect 'BLOCK

a an open-circuit armature winding

b partial short -circuits of individual coils
c short circuits between adjacent segments of
t h e commutator.

These faults cause localised sparking on t h e

commutator.

7
STANDARD DROP TESTER

PRINCIPLE OF DROP TESTING

Current will flow through every coil in t h e winding

when a source of supply is connected to two points
of the commutator.

Since a l l coils are of equal resistance the voltage

drop a cross each coil will be equal.
POWER SUPPLY
This similarity of voltage drop is measured with
the milli-voltmeter to determine the S ewiceability
This is a 6v or 12v battery with exposed intercell
of the armature winding.
connectors.

N. B. Ensure that t h e selectors are 'OFFBbefore

connecting t h e clips,
OVERHAUL ARMATURE TESTING

OPEN CIRCUIT TEST This test must be carried out first .Select t h e appropriate switch to position 1. Press the test
lever t o allow t h e test contacts to bridge adjacent segments. Adjust t h e selector switch
until the millivoltmeter reads 10 mv. Mark t h e position of t h e indicating pointer with a chalk
mark. Turn t h e armature until t h e indicating pointer coincides with the next commutator slot.
Check each coil.

MOTOR

s€L€CTOR I I
SW ITCHES

THEORETICAL CIRCUIT OF DROP TESTER

The millivoltmeter should indicate
lOmV when each pair of commutator
segments is bridged.
-
4 A R
When a n open-circuit coil comes <when t h e open-circuit is bridged
1 s current t h e meter will read the supply voltage
will cease t o flow i n the lower This indicates t h e LOCATION of the
'.
circuit. r ~ h millivoltrneter
e will
read zero when connected a cross
open-circuit coil. Mark the segments
with chalk.
a @deadtcoil3
 OVERHAUL ARMATURE TESTING

S HORT-CIRCUIT TEST The armature must be t e s t e d for short-circuits between coil turns or between commutator seg-
ments. Adjust t h e s e l e c t o r switch until t h e meter indicates 20 mV when t h e tester lever is pres:
Test ea ch coil.

MOTOR MOTOR

The rnillivoltrneter will indicate
20mV for each serviceable coil.
If t h e indication is slightly less
than 19mV clean t h e s l o t between
the segments a n d repeat t h e t e s t s .
(when a short-circuited coil (The LOCATION of t h e snort-circuit
is brought between t h e contact is indicated by a zero indication)
plates t h e p.d. when t h e short-circuit is bridged
coil will by the test prods. Mark t h e
S egments .Dispos e of t h e ar-
mature in accordance with t h e
repair instructions .
OVERHAUL ARMATURE TESTING

THE GROWER ARMATURE TEST The 'DROPB t e s t e r gave erratic indications when t h e surface of a commutator was not
absoluately tme. This led t o t h e rejection of serviceable armatures. Errors of this
nature a r e avoided by using t h e sGrowlerBArmature Tester,

AMMETER

CONSTRUCTION

The t e s t e r is a n electromagnet with 'open-ringB laminations. The

ends of t h e laminations form a V-shaped opening i n which t h e armatur
rests during t e s t . The windings a r e i n two sections and can be
connected i n s e r i e s or i n parallel by t h e rotary switch.

PRINCIPLE OF OPERATION. Place t h e armature in t h e V-shaped jaws: This brings a number of armature coils under t h e
influence of t h e electromagnet. Switch on t h e tester. T h e a . c. in t h e electromagnet will induce an e. m. f. i n t h e armature
windings. Current will flow through a l l t h e (unshorted) coils. Bridge two adjacent commutator segments with t h e test prods
and adjust t h e resistance until the ammeter reads 1A. Turn t h e armature slowly and note t h e ammeter indications a s each
pair of segments is bridged. The indications should be similar for each pair of segments The hum from t h e 'Growler should
b e reasonably constant'.
 ARMATURE TESTING

OPEN-CIRCUIT COIL An open circuit coil in the armature winding would correspond to an open circuit in a transformer
secondary i . e. the high impedance in the secondary is 'reflectedb into the primary. The current
in the t e s t e r will be reduced to such an extent that the hum from the 'Growler' will be less t h a n
inaudible.
o.8. +.
>
, &,-??#&@/

The ammeter will indicate zero when the test prods bridge adjacent When the open-circuit coil is
pairs of segments. Adjust the ammeter resistance to MAXIMUM and bridged the ammeter will give a
follow the normal test proceed, high reading .
WERHAUL ARMATURE TESTING

OPEN-CIRCUIT SEGMENT Normal current will flow through the armature winding, all the coils are still connected in
series, and a preliminary warning will not be given.

The ammeter will indicate normally when The ammeter will indicate zero when one test prod i s moved to the
.
connected a cros S the normal S egments open-circuit segment. A similar result will be obtained on the
next inters egment test. Two zero indications usually indicates an
open-circuit S egment.
16
OVERHAUL ARMATURE TESTING

t h e shorted coil enters the flux of the tester. The 'growling' is

caused by t h e intense vibration of the t e s t laminations.

If t h e tester 'growls' during the t e s t turn the armature immediately

until the 'growl' subsides. Keep the test prods on t h e last pair of
S egments tested, Continue the inters egment t e s t without moving t h e
armature until t h e t e s t prods are again at the top of the commutator.

Mark t h e segments. Continue the test to ascertain i f other coils a r e

defective.

A quicker, less accurate, test is a l s o possible e.g.

a Placethearmatureinthetesterjawandswitch'on'.
b Holdasteelruleorhacksawbladeover q e t o p o f t h e a r m a t u r e ,
\
parallel with the shaft, a t a distance of from the surface.
c Turn the armature slowly, keep the rule a t t h e top.
The defective coil is indicated by a n
d If the rule is attracted strongly t o a particular slot then that slot
abnormally low reading when the ends are
contains one side of the defective coil. Continue the t e s t until
bridged by t h e t e s t prods.
the other side of the defective coil is located,
OVERHAUL MACHINE REASSEMBLY

The component parts of a d i s mantled machine a r e generally re-

a s s embled i n t h e reverse order t o which they were dismantled.
The following should be noted:-

Inspect every nut, screw, stud, bush or other minor component

before using it, i f i n doubt about t h e serviceability of any part,
reject it,

Locking devices must be employed for a l l nuts, s c r e w s , etc.

The l a s t components t o be replaced, apart from covers, etc,

should always be t h e brushes. New brushes must be bedded.
The brush springs must b e t e s t e d for correct tension with a spring
balance. The spring tension must be adjusted (if necessary) or
t h e spring must be replaced i f adjustment is not possible.

The index marks on t h e rocker and t h e end of t h e yoke of non-

interpole and uncompensated machines must always be checked
after reassembly t o ensure that they coincide, If t h e rocker is
unmarked, or i f the marking is indistrict it is essential that a
check for brush position is carried out before t h e machine is run
u p for t e s t .

FINAL CHECK

Check that t h e armature revolves freely without e x c e s s i v e end

play. Check t h e security of connections, nuts, bolts etc. Carry
out a n insulation t e s t , The general minimum figure is ~ M A .
v CLAMPING NUT
 .
OVERHAUL BRUS HGEAR

BRUSHGEAR
Examine the brus hgear for damaged insulation
( e . g . charring caused by current flowing
through low resistance paths formed by carbon
dust).

INSULATION TEST
Test the insulation between one brush holder
of each polarity and the end plate.

SPRING PRESSURE CHECK

BRUSHES After the brushgear has been reassembled
the spring pressure must b e checked with
Before the brushes are removed they should be marked a spring balance..
s o that each brush can b e returned t o its original
position.
Disconnect each brush and examine for length, burning
at the trailing edge, scoring 00 the s i d e s and conta-
mination by grease. Contaminated brushes must be
dis carded.
PRELIMINARY BRUSH BEDDING
Cut a piece of glass -paper t o the width of t h e commutator
and long enough t o pass completely round it.
Wrap t h e g l a s s -paper round t h e commutator i n a direction
opposite t o t h e direction o f rotation. When t h e armature
is turned t h e friction of t h e brushes will tighten t h e
g l a s s -paper on t h e commutator,
Rotate t h e armature by hand with t h e brushes in position
and normal spring pres S ure applied.
It is ess ential that good preliminary bedding of brushes
is achieved o t h e w i s e final brush bedding will be unduly
prolonged.
FINAL BEDDING
Run t h e machine on light load until the b d s h e s a r e
bedded over their full width of a r c and at l e a s t 90%
of their contact area.
N. B. Remove a n y surplus carbon with dry compressed
air,
POST OVERHAUL TESTS
GENERATORS
Overspeed test:- Run t h e generator a t approximately
125% of maximum mted s p e e d for 2 minutes on no load -
no undue vibration. Check t h e commutator with a dial
test indicator,
Full load or heating check:- Run, with cooling, a t
normal continuous s p e e d (at rated load) for 45 minute^
Check t h e maximum field current and temperature ris e
Commutation check:- At t h e end of t h e heating check
(at rated load with cooling) run at:-
Minimum rated speed - sparkless commutation
Mid-rated speed range -
very occasional slight spark
Maximum rated speed - occasional slight sparkling,
Standard of worst brush t o be taken,
Insulation test:- Carry out a normal insulation test
while t h e machine is still hot,
M OTORS
No load test:- Run for 2 minutes - check s p e e d and
current consumption - allow t o cool.
Half load test:- Apply half rated load by using the
braking effect. Check S peed and current consurnptior.
allow t o cool.
Full load test;- Apply full mted load by using t h e
braking effect. Check speed and current consumptior
allow t o cool.
Overload test:- Apply twice the mted load. Check
S peed and current consumption.
Insulation test.
4
FAULT CHART
4
b

DEFECT POSSIBLE CAUSE APPROPRIATE ACTION DEFECT POSSIBLE CAUSE A P f ROPRIATE ACTION

Failure t o Loss of residual Remagnetis e. Dis connect 3. Revers ed Residual magnetis m Remagnetis e ,
excite rnagnetis m the shunt winding and Polarity. revers ed.
connect a batteryacross p

t h e winding. 4. Insufficient (a) Excessiveload, Reduceload.

voltage.
Voltagefails (a) Dirtycommu- Clean a s described (b) W e a k field Reduce resistance of
to build up tator S hunt field rheostat,

(b) Glazed contact Clean contact surface (c) Insufficient Increase speed of
surface on brushes, of brushes with Grade
Speed. prime mover,
due to prolonged 00 glass paper.
running 'off-load" . S Excessive (a) Excessive field Increas e resistance of
strength, shunt field rheostat.
(c) B r u s h e s n o t i n Cleanbrushboxes.
contact with commu- (b) Excessive speed Reduce speed of prime
tator. mover.

(d) Incorrect brush Check brush position. 6 Uniform (a) Dirty commutator Clean t h e commutator
pos iti on. S parking a t a l l
brushes
(e) Open-circuit Check a l l connections
field. and field winding for
(c) Incorrect brush Check brush position,
continuity
position.

(f) Revers ed field Reconnect correctly

(g) Incorrect dir- Reverse drive

ection of
rotation
(h) Machine runs up Dis connect load. Run up
on load (shunt on load. 21s
I generators only) I I I I I
 -
ACTUATORS

Actuators are designed to perform limited rotary or linear motion.

Motor driven actuators are usual1y S elf -contained and are classified
according to the nature of t h e output force i.e. linear or rotary. The
drives (via gearing) a lead S crew which extends or
'retracts a ram or plunger whereas the rotary actuator rotates the out-
put S haft (via gearing). Both types h a v v m o t ors .

LINEAR ACTUATORS

Linear actuators capable of developing thrust or tension between 20

and 20,000 lb are available. The stroke can mnge from a n inch to
several inches and the operating t i m e is normally a matter of seconds.
Linear actuators are used to operate flaps, t r i m tabs, f u e l valves, etc.

An actuator of the type shown is designed t o operate with a load of 135

lb. A l l the component parts are ranged along a common axis with the
exception of the l i m i t switches and the connector plug. The power from
the motor is transmitted to t h e ram b y a single plate clutch, a three
stage epicyclic gearbox and the mm screw shaft. A spring-loaded elect-
romagnetic brake operates automatically when t h e circuit is made or
broken. The range of ram travel is limited by limit switches to ensure
that t h e flaps or whatever the actuator operates will not be driven be-
yond the permis sjble l i m i t s .
A TYPICAL LINEAR ACTUATOR
 ACTUATORS

OPERATION
6 7
9 I
WhenJhe m m is fully
brake is de-energised

With t h e control switch in position 1,current will flow through the 'OUT1 limit switch, field, brake and armature. The brake
coil will energise and allow the armature and, through the clutch, the brake drum to rotate. The sun gear on the bmke sun
transmits the motion through the epicyclic gearbox to the ram screw to extend the mm.

As soon a s the ram moves it c l o s e s , the 'IN1 switch s o that both limit switches are closed at any i n t e r m e d i a t e position of
the mm.

W h e n the m m reaches, the limit of i t s travel the cam opens the I0UTa limit switch. The motor will switch 'off1. T h e
brake solenoid will de-energise and the brake will bring the motor to a standstill very rapidly.

Ram retraction is similar to ram extension except that the 'OUT' limit switch c l o s e s a s soon as the ram starts to move,
 ACTUATORS

Actuators do not normally rsquire maintenance between overha'uls

other than t'he relevant points covered in Electrical Machines.

MOTOR LOAD TEST

This t e s t is conducted prior t o assembly of t h e actuator. The test

II
rig consists of a light metal pulley, t h e diameter of which is deter-
mined by the s i z e of the motor. A cord is positioned around t h e
pulley with one end weighed and t h e other attached t o a spring bal-
ance.

The load t e s t s must b e for clockwise and anti-clockwise rotation at

a terminal P.D. of 24 volts. Note. - Readings should b e taken be-
fore the temperature r i s e can affect their accuracy.

Run t h e actuator with no load; the current must not exceed 1.3
amperes and the s p e e d not less than 2,300 r.p .m. MOTOR

Connect up to t h e b m k e test rig and run t h e motor at a 2 oz. in load.

The current must not exceed 2.9 amperes and t h e s p e e d must not be
less than 900 rpm,

MOTOR AND BRAKE

When the brake has been assembled to t h e motor t h e brake coil should
be connected through a control resistance and switch t o a 24 volt supply
and the resistance adjusted so that t h e current i n t h e machine does not
exceed 0.5 amps. Increase t h e current until all four brake shoes a r e WEIGHT
retracted and t h e armature and brake drum will s p i n freely when turned
by hand. T h e current must not exceed 1.4 anips .
LOW VOLTAGE TEST
With t h e bmke coil connected run t h e unit light at 16 volts for t e n
periods of 15 seconds each, in each direction of rotation. The cunent
must not exceed 1.5 amps,
ACTUATOR TESTS
NO LOAD TEST
The actuator must be t e s t e d on n o load in both direct-
ions. The ctirrent must not exceed 1.85A and t h e r a m
speed must be within t h e specified limits. The applied
voltage must b e 24V.
RATED LOAD TEST
The a c t u a t o r must b e given ten opemtions , five on
tension and five on compression, a g a i n s t a l o a d of
135 l b at 24v. The c u n e n t must not exceed 2.7A and
t h e r a t e of ram travel must not b e less than 1" in 5.5
seconds ,
ACTUATORS
OVERLOAD TEST
The actuator must be t e s t e d on a load of 270 lb.
The current must not exceed 3.2A and t h e r a m s p e e d
must not be less than l" i n 10 seconds. This must
be carried out i n both directions. Cooling may be
employed during load t e s t .
MINIMUM VOLTAGE TEST
The actuator must operate on 18v. at t h e rated load.
OVER-RUN TESTS 4
Run t h e actuator to its full extension on 24v a n d then
measure t h e length between shackles. Repeat t h i s
a t minimum speed, i.e. on t h e lowest possible
voltage, and inch just before t h e l i m i t switch opens
and again measure t h e length between S hackles.
The difference between t h e two measurements must
not be greater than 0.020 i n s .
 1 The expected spring tension on the brushes of a 6 An azmature drop test is to
*.m

6 KW dc generator would be approximately

4 detect open or short circuited coils
a 32 lbs b check the end play of a n armature
32ozs c balance the armature
/c 32gms

2 Excessive brush sparking is caused by
low brush spring pres S ure
A brushes in alignment with M. N.A.
c revers ed armature connections
3 The windings embedded in the pole faces of a
generator are
a interpoles
b comnlutating coils
c compensating coils
/ a
4 An indication of good commutation on a d c machine
would be
a silent operation of the machine
-4 little or no sparking at the commutator
p<.-H
7 When using a n armature drop tester the location
of a n open circuit on the armature under test is
indicated by a
a loudhumfromthetester
full scale reading on the rnilli-volt meter
8 The armature mustrbe placed i n t h e V shaped
jaws of a 'growler1 armature tester before the
s u p p l y is switched on t o
avoid damage to the lgrowler' windings
b eliminate full s c a l e readings on the mill-
volt meter
c prevent overloading the battery
9 A low pitch hum from a 'growle? armature

c high armature currents indicates that the coil is

5 A dc machine is cleaned using a open circuit

b short circuit
/a lead free petroleum c in good condition
b CTC
c Paraffin 10 Thebeddingofbrushesondcapparatus

must never be done on the aircraft

b must b e done on normal ground run
c can be done during one flight
 11 After the overhaul of a dc machine an inslilation 16 An open drcuit coil on a lap wound machine
check must be carried out, This. should be done would cause excessive

before the machine is function checked

a a current in the field
b during the function check sparwng
after a successful function check and while
c . c increase in speed
9'
the machine is still warm

12 An actuator is an electro-mechanical device

comprising
L

a split field, series windings , a brake and

is controlled by limit switches
b a series field, and the travel is controlled
by a brake and internal limit switches
c split field, S eries windings , a brake and
a'/; internal limit switches

13 While an actuator is travelling the position of

the l f rnit switches are: -
a OPEN is closed and CLOSED is open
b OPEN is open and CLOSED is closed
/ both OPEN and CLOSED are closed

14 If an actuator brake coil is open-circuitec! the

actuator will

a run at reduced speed

b over run
stop
rC ..- -.I

15 A suppressor is used in the output of a D.C.

generator to suppress

a inductive reactance
b distortion of the main field
c radio interference
'W