COMPOUND EXCITED DC MOTOR

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Unilab Laboratory
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CONTENTS

1 - Rated features Page 1

2 - The direct current machine Page 3

3 - DC motor Page 7

4 - Armature reaction Page 11

PRACTICAL TESTS

Operating data of shunt dc motor Page 15

Test Nr. 1 - Measuring the winding resistances Page 17

Test Nr. 2 - No load losses Page 23

Test Nr. 3 - Conventional efficiency Page 27

Test Nr. 4 - Direct test with eddy currents electromagnetic brake Page 29

Test Nr. 5 - Direct test with braking DC generator Page 33

Test Nr. 6 – Electromechanical characteristic Page 37

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1 - RATED FEATURES

The rated features of the machines under test are provided by the manufacturer and are generally
reported on a plate.

They represent the “Identity Card” of the machine, so that the user is able to recognize their most
important operating features.

These rated values, of course, are the result of tests that the manufacturer has performed on several
prototypes at the beginning of the series production; each manufactured machine may show
performances which are slightly different from the rated values, due to the unavoidable
manufacturing tolerances.

To perform the checking test on a series machine, therefore, is to verify when the standard
performances reported on the plate are really respected and to measure those special operating
characteristics that, through not reported on the plate, are nevertheless important for the practical
use of the machines.

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2 - THE DIRECT CURRENT MACHINE

To obtain a monodirectional torque from DC currents, a mechanical switch is used, which is called
commutator.

In DC machines the field winding is steady, while the set of conductors and commutator is mobile.

To understand the operation of the commutator, let’s consider the following figure:

B ωt
fq ωt
0 π
-

+ e
i

In the shown instant, the electromotive force of the coil is decreasing and, at ωt = π/2 the
electromotive force is zero; therefore the coil is short-circuited through the brushes.

Immediately after, the lower conductor starts to cut the flux and the generated electromotive force
changes its direction; in the meantime, it is switched to the negative brush, so the polarity of the
output voltage is unchanged.

Therefore, the commutator behaves like a synchronous full-wave rectifier.

In the practical realization, the armature conductors are packed in an iron cylindrical rotor, while
the stator windings generate a high and almost uniform induction in the air gap.

Next figure shows the situation at the instant ta and the corresponding electromotive force that is
generated across conductor nr. 1, while immediately after conductor nr. 1 is leaving the S pole.

Starting from the negative brush and following the circuit, conductors nr. 1, 2, 3 and 4 are in series
connected: the total sum of the individual electromotive forces is therefore available on the positive
brush.

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From the negative brush, following the opposite direction, the other conductors nr. 5, 6, 7 and 8 are
in series connected, therefore the winding is composed of two parallel connected circuits.

ω
4

6 1

N 5 7
S

8 3

e
e1

0
t
ta

e
e1 + e2 + e3 + e4 Rectified voltage
e1 e3
e2
ωt

When the armature turns driving the commutator, conductor nr.1 is switched from a circuit to the
other and conductor nr.8 takes its place.

In a real machine there are many conductors and many switching segments: at any time many coils
are in series connected between the brushes and few of them are short-circuited, when switched
from a circuit to the other.

When a coil is switching, there is a temporary drop of the output voltage, giving rise to a switching
ripple; this effect can be neglected against when compared to the total effect generated by the many
coils in series connected at the same time.

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Let’s indicate with (+) the current entering into the sheet for all the conductors moving upward and
with (.) the current coming out of the sheet for all the conductors moving downward.

The total result of all the currents is an induction vector pointing upward. When the armature is
turning, this induction is steady in space with an optimum torque angle δ = 90°.

The developed resulting torque is clockwise directed. In any generator, this torque has to be
balanced by the source of mechanical power.

On the other hand, when a current from an electric source is entered through the brushes, a
monodirectional and constant torque is generated and the machine performs like a motor.

Being the induction in the air gap constant, the mechanical constant is equal to the electric constant,
i.e.:
Γ E
KM = = KE =
I ω

where with capital letters the instant or average values are indicated of the torque (Γ), the armature
current (I), the electromotive force (E) and the angular speed (ω).

When the total flux per pole ϕ is variable due to the field current and therefore to the induction, the
torque and electromotive expressions become:

Γ = Kϕ I

E = Kϕω

therefore the steady state model of the commutator machine is

Γ R I
Kϕ l
+
ω
+
DR Kϕω V
+

In the steady state, the terms associated to the energy accumulation aren’t considered; only the
mechanical friction due to rotation (DR) and the electric resistance (R) are considered.

The value of K is a function of the machine construction and of the electric connections.

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3 - DC MOTOR

The stator or “field” of a DC motor is composed of a even number of magnetic poles arranged along
a circle with north and south alternancy.

The generation of these magnetic poles is obtained through a DC current flowing into the field
windings.

ω
4
Commutator
6 1
Inductor pole

N 5 7
S

8 3

5 Armature

The rotor or “armature” is composed of an iron cylindrical core supporting the conductors arranged
in slots and connected to the commutator segments.

The DC current is driven from the armature by means of fixed brushes sliding on the commutator.

The commutator automatically switches the conductors, so that the current of the motor is
permanent and monodirectional.

The position of the brushes ensures that the torque angle d is of 90°.

The electromotive force generated across any conductor can be calculated using the formula

e=Blv

and the total electromotive is given at any time by the number of conductors in series connected.

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The torque developed in every conductor is given by the relationship

τd = B l i r

and the total torque is given by the contribution of the individual conductors.

For a DC machine in steady state condition, the fundamental relationships are the following:

E = Kϕω

Γd = KϕIA

where:
E = electromotive force (V)
ϕ = flux per pole in the air gap (Wb)
ω = angular speed (rad/sec)
Γd = torque (Nm)
IA = armature current (A)
K = constant of the machine

The fundamental relationships are referred to the iron gap: the voltage across the terminals is
different from the electromotive force due to the voltage drop across the armature resistance; the
torque on the shaft is different from the torque due to mechanical friction.

The DC machine is a dual side energy converter; therefore, in the air gap the mechanical power is
equal to the electric power:

Γdω = E IA

The power in the air gap only represents the reversible part of the energy electromechanical
conversion. For a DC motor in steady state conditions, the following circuit model can be applied:

Γ RA

Kφ lA IA
+
ω+ D Kφω +
V RL

RF
IF VF+

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In steady state conditions, the currents and the speeds are either constant or very slowly variable,
therefore neither mechanical energy variations, nor magnetic energy variations are considered.

This means that the rotation inertia and the electric inductance aren’t included in the model.

When the efficiency is calculated, it is necessary to consider the field resistance RF.

In the linear model, the D term indicating the mechanical resistance represents all the rotation
losses. It can be calculated by measuring the input power under no-load conditions with the
machine operating at rated speed and rated voltage, therefore with rated flux in the air gap.

Among the rotation losses also included are the losses due to:
• friction in the bearings and on the brushes
• air friction (ventilation)
• core losses due to hysteresis and to eddy currents in the variable flux areas.

The RA term is an equivalent resistance for considering the DC resistance of the armature winding,
the effect of non uniform distribution of the current in the armature conductors, the contact losses of
the brushes and the resistance of the auxiliary windings in the armature circuit, when available.

In the shown circuit model we can assume D, RA, RF and K to be constant; the model is therefore
linear.

The electric characteristic of the machine is therefore established by the relationship

V = E + IA RA = Kϕω + IA RA

and in given conditions, assuming the magnetic circuit to be linear, i.e. the flux to be proportional to
the field current, it follows that:

V − RA IA
ω=
Kϕ

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4 - ARMATURE REACTION

When the fundamental relationships have been calculated for a mobile conductor in the magnetic
field, we have assumed that the field due to the current in the same conductor is neglectable.

In reality, the armature current generates a non neglectable magnetic field in quadrature to the input
field; therefore a distortion of the flux distribution occurs.

N N

S S
The practical consequences of the armature reaction are:

a) The switching is deteriorated, because the position of the conductor with zero electromotive
force is displaced along the rotation direction when compared to the ideal position associated to a
neglectable armature reaction.
In some machines, the position of the brushes can be modified under load not to short-circuit
turns with non neglectable electromotive force.
More commonly, small auxiliary windings are arranged between the inductor poles, where the
armature current flows:therefore, they oppose themselves to the armature reaction, that can be
reduced to zero.
Another practical solution is to arrange conductors on the inductor pole faces, where the
armature current can flow (compensating windings).

b) The electromotive force is reduced due to the decrease of mean density of the flux.

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PRATICAL EXERCISE

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OPERATING DATA OF SHUNT DC MOTOR

A1 B2
(A2)
M (B1)

D1 D2

E1 E2

DE LORENZO

- Main winding: (armature) A1 - (A2)

- Auxiliary winding: (B1) - B2
- Shunt excitation winding: E1 - E2

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TEST NR. 1 - MEASURING THE WINDING RESISTANCES

Of course, the measurement has to be performed in DC conditions and with steady machine; in any
case, it is necessary to operate with “cold” machine, i.e. not working since several hours, to be sure
that every part of it has achieved the room temperature.

In this case, when the measuring method will not produce an appreciable heating, it will be possible
to say that the measured resistance values are referred to a winding temperature equal to the testing
room temperature (which may easily measured by means of a thermometer).

Among the several possible methods, for sake of convenience we’ll select the Volt-Ampermetric
method.

ELECTRIC DIAGRAM NR. 1A

I1 V1
D1
+ A D2
Ra A1
V2 M

B1 A2

V3

-
B2

V1
= Resistance of series excitation winding
I1

V2
= Resistance of armature winding
I1

V3
= Resistance of auxiliary poles winding
I1

NOTE: For this test is sufficient only a voltmeter to move on position V1, V2, V3.

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PRACTICAL DIAGRAM NR.1A

VARIABLE DC OUTPUT

2A
Starting rheostat

V2 V1 V3

3V 1.5V 1.5V

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TEST PROCEDURE

After the set up of the motor under test, make all the connections in accordance with the attached
diagrams and set the command as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open
Variac fully turned in counter clockwise direction.

STARTING RESISTANCE: Max. resistance

2 Close the switch in variable DC output section

3 Rotate the variac until a current of approximately 1.5A

4 Wire to the voltmeter a pair of conductors with measuring tips and connect it between the
terminal D1 - D2. Read the V1 indication.

5 Wire to the voltmeter a pair of conductors with measuring tips and connect it to the commutator
segments under the brushes "a" and "b" (you may access the commutator by removing the
protecting cap of the motor's inspecting window).
Read the V2 indication.

6 Connect the negative terminal of the voltmeter to the B2 terminal and search with other terminal
the relative excitation pole winding.
The connection that will show the smaller voltmeter reading will concern the B1 brush and,
therefore, will be the right one.

7 Open the switch

TABLE OF MEASURING RESULTS

V
R=
I

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ELECTRIC DIAGRAM NR. 1B

+ A E1

V E2

-
Re

Resistance of the shunt excitation winding

PRACTICAL DIAGRAM NR. 2

VARIABLE DC OUTPUT
(EXCITATION)

V A

200V 0.3A
Excitation rheostat

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TEST PROCEDURE

After make all the connections in accordance with the attached diagrams and set the commands as
follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open

(Excitation) Output with about 200V

EXCITATION RESISTANCE: Max resistance

Voltmeter non inserted

2 Close the switch in variable DC output section

3 Rotate Re until a current of approximately 0.1A

4 Insert the voltmeter and read the value

5 Disconnect the voltmeter and open the switch

TABLE OF MEASURING

Temperature: °C

Ammeter Voltmeter
N K div I K div V R
(A/div) (A) (V/div) (V) (Ω)

V
R=
I

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TEST NR. 2 - NO LOAD LOSSES

The purpose of this test is to determine the mechanical losses (friction and ventilation) and iron
losses (hysteresis and eddy currents) of the motor. In the hypotesis that their sum is equal to the
necessary power to make work the motor in no-load condition at it’s rated speed and that the losses
in excitation circuit be negligible.

A1
A1

+ A2

E1

M V

E2

-
Re

Ra B2

NOTE: The test can’t be performed to very small voltage values, as the decrease of the excitation,
required to keep the speed constant though the voltage reduction, generates a too high
reduction of the poles flux.
At very low voltages, therefore, to generate the torque required to rotate, the motor has to
absorb currents which aren’t neglectable anymore, due to their Joule and voltage drop
effects.
Therefore, it is suggested not to reduce the test voltage under the 50% of the rated value.

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PRACTICAL DIAGRAM

+ -

rpm

K1 K2

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TEST PROCEDURE

After the set up of the motor under test, make all the connections in accordance with the attached
diagrams and set the commands as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open

Output with about 220V

STARTING RESISTANCE: Max. resistance

EXCITATION RESISTANCE: Min. resistance

2 Shunt the A-coils of the instruments (make the connections signed with dashed lines) to protect
them against the spike due to the starting current

3 Close the switch allowing the set to rotate

4 Gradually switch Ra off

5 Remove the short-circuit jumper from the ammeter A1

6 Adjust the variac of DC variable output until the rated power supply of the motor, acting on Re,
bring the motor speed to exactly nominal speed; measure the instruments readings

7 Through the variac of DC variable output adjust the power supply voltage to sequentially
decreasing values, to approx. 120V. For each of them adjust again the speed to exactly nominal
speed and read the instruments indications

8 Open the switch to stop the motor

Abs.
Supply Voltage Absorbed current Excitation current Notes
power
div K V div K Io div K Iexc
(V/div) (A/div) (A) (a/div) (A) (W)

n = ......... rpm = const

Where
Abs • Power = Pir + Pm = VIo

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Graph

2
P = f (Vo)
Pabs n = 3000 rpm = const

Pout = 0 P = f (Vo)

Iron losses

B
Mechanical losses

A Vo
2
220V Vo

NOTES: Drawing in the diagram the absorbed power as a function of the voltage, an almost
parabolic curve is obtained, which has an offset with respect to the axis origin.

The ordinate of the curve’s origin isn’t experimentally measurable, but can be obtained
by graphic extrapolation from the measured section of the curve (heavy section).

As this extrapolation isn’t always simple, a graphic contrivance may be followed,

showing the absorbed power as a function of V (exp2) instead of V.

In this way, the graph parabola will be converted into a straight line, which may be
easily extrapolated. The ordinate of the origin determines, due to the reasons described
in “Theoretic background”, the value of the mechanical losses.

The remaining section of the curve, therefore, will represent the iron losses (which vary
following an almost quadratic relationship with the power supply voltage).

At the rated voltage it is possible to obtain:

AB = mechanical losses = ........ W = ........ % of rated power
BC = iron losses = ........ W = ........ % of rated power

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TEST NR. 3 - CONVENTIONAL EFFICIENCY

The conventional efficiency of DC motor can be calculated using the data measured in the previous
tests.

3.1 Friction and ventilation losses, at rated speed, measured through the method of no-load motor
operation (test 2)
Pm = ........

3.2 No-load iron losses, at rated voltage and speed, measured through the method of no-load
motor operation (point 2)
Pir = ........

3.3 Joule effect losses in inductor windings and in rheostats, at rated voltage and power.
From the no - load test the excitation current is calculated corresponding to the rated voltage,
then the excitation losses are calculated.
Pe = Vr Iexcr

3.4 Joule effect losses in armature windings. The ohmic resistance of the armature, measured at
room temperature (test 1), has to be referred to the conventional temperature of 75°C.
Ra75 = Rart [1 + 0.004 (75 - rt)]
When the rated absorbed current of the dc motor is indicated with I2r, the total armature
current is given by Ia = I2r - Iexcr.
The armature losses can be therefore calculated
Pa = Ra75 Ia2

3.5 Electric losses due to brush contacts.

As the contact resistance between brush and commutator follows an anomalous behaviour, the
brush losses are conventionally evaluated
Pb = 2 Ia (carbon or graphite brushes)
Pb = 0.6 Ia (metal brushes)
Where Ia is the total armature current.

3.6 Additional losses.

As the switching from no-load to load condition implies an alteration of the pole flux
distribution due to the armature reaction, this is kept into account through additional losses
that are conventionally evaluated
Padd = 0.5% Vr Ia

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3.7 Conventional efficiency

The total losses of the DC motor operating at rated voltage and load are given by
Pl = Pm + Pir + Pe + Pa + Pb + Padd
the conventional efficiency can be therefore calculated:

Pl
η =1−
Pabs
where Pabs = Vr • Iar

3.8 Efficiency curve.

To draw the conventional efficiency curve, it is necessary to repeat the evaluations of points
3.1 to 3.7 for different load conditions, normally of 0, 1/4Ia, 2/4Ia, 3/4Ia, 4/4Ia, 5/4Ia.

V = Vr
n = nr

Iar Ia

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TEST NR. 4 - DIRECT TEST WITH EDDY CURRENTS

ELECTROMAGNETIC BRAKE

The purpose of this test is effective efficiency of the motor with direct test.

The motor is loaded with an electromagnetic brake equipped with arms and weights.

A1

+ A1
Ra

Re E1

V M

E2 Af
A2

+ -
-
D2 D1 B2

NOTE: For the test is required a tachometer for measuring the rotation speed

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PRACTICAL DIAGRAM

+ - + -

rpm

K1 K2

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TEST PROCEDURE

After the set up of the motor under test and of the brake, make all the connections in accordance
with the attached diagrams and set the commands as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open

Output with about 220V

VARIABLE DC OUTPUT: Switch open

(excitation) Variac fully turned in counter
clockwise direction

EXCITATION RESISTANCE: Min. resistance

STARTING RESISTANCE: Max. resistance

2 Shunt the A-coils of the instruments (make the connections signed with dashed lines) to protect
them against the spike due to the starting current.

3 Balance the electromagnets corona by setting the measuring weight at the beginning of the scale
of its arm and by moving the balance weight until the level is equilibrated.
Lock the balance weight, it must not be moved during the test.

4 Set the main switch on ON and, acting on variac, adjust the power supply to the exact value
shown on the motor plate.
Gradually switch Ra off.
Verify that the rotation sense of the motor is correct with reference to the position weight and
then take out the shunt current.
Adjust with the variac voltage to exactly the motor’s rated value. Acting on Re adjust the speed
to exactly the rated value.

5 Set the measuring weight on the maximum testing arm and adjust the excitation output until the
balanced position of the electromagnets corona is reached.
Take up the instruments readouts and the motor r.p.m. through a tachometer (manual or
electronic).

6 Set step by step the measuring weight on the other values of the testing arm adjusting the
balance, at each step, acting on the excitation and taking up the instruments readouts and the
r.p.m.

7 Switch off the main switch which causes the stop of the motor.

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TABLE OF MEASURING RESULTS

b G C n Pr U Iind Iexc Pabs

η
(m) (N) (Nm) (prm) (W) (V) (A) (A) (W)

1/4

2/1

3/4

4/4

Formulas to be used:
C=G•b
Pr = (2πn/60) C
Pabs : U (Iind + Iexc)
η = Pr/Pabs
Iabs = Iind + Iexc

From the table, the following graph may be drawn:

Iabs

Pr
Pn

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TEST NR. 5 - DIRECT TEST WITH BRAKING DC GENERATOR

The purpose of this test is effective efficiency of the motor with direct test.

The motor is loaded with a braking DC generator equipped with arms and weights.

ELECTRIC DIAGRAM

A1 A1
+ A1 A3
Ra

Re E1

V1 M G V2 Rc

E2

A2

-
D2 D1 B2 B2

NOTE: For the test is required a tachometer for measuring the rotation speed.

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PRACTICAL DIAGRAM

+ - + -

rpm

K1 K2

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TEST PROCEDURE

After the set up of the motor under test and of the DC braking generator make all the connections in
accordance with the attached diagrams and set the commands as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open

Output with about 220V

VARIABLE DC OUTPUT: Switch open

(excitation) Variac fully turned in counter
clockwise direction

EXCITATION RESISTANCE: Min. resistance

STARTING RESISTANCE: Max. resistance

LOAD RESISTANCE: Indifferent position

2 Shunt the A-coils of the instruments (make the connections signed with dashed lines) to protect
them against the spike due to the starting current.

3 Balance the DC generator by setting the measuring weight at the beginning of the scale of its arm
and by moving the balance weight until the level is equilibrated.
Lock the balance weight, it must not be moved during the test.

4 Set the main switch on ON and, acting on variac, adjust the power supply to the exact value
shown on the motor plate. Gradually switch Ra off.
Verify that the rotation sense of the motor is correct with reference to the position weight and
then take out the shunt current.
Adjust with the variac the supply voltage to exactly the motor’s rated value.
Acting on Re adjust the speed to exactly the rated value.

5 Set the measuring weight on the maximum testing arm and adjust the excitation output and the
load resistance until the balanced position of the braking generator.
Take up the instruments readouts and the motor r.p.m. through a tachometer (manual or
electronic).

6 Set step by step the measuring weight on the other values of testing arm adjusting the balance, at
each step, acting on the excitation and taking up the instruments readouts and the r.p.m.

7 Switch off the main switch which causes the stop the motor.

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TABLE OF MEASURING RESULTS

b G C n Pr U Iind Iexc Pabs

η
(m) (N) (Nm) (prm) (W) (V) (A) (A) (W)

1/4

2/1

3/4

4/4

Formulas to be used:
C=G•b
Pr = (2πn/60) C
Pabs : U (Iind + Iexc)
η = Pr/Pabs
Iabs = Iind + Iexc

From the table it is possible to draw the following graphs:

Iabs

Pr
Pn

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TEST NR. 6 – ELECTROMECHANIC CHARACTERISTIC

The test purpose is to determinate the electromechanic characteristic speed-absorbed current n = f(I)
with rated shunt excitation current in the functioning as shunt excitation compound wound with
additive and subtractive series motor through a direct measure.

For convenience the motor is charged with an electromagnetic brake even if it possible to use other
load kinds (brake, dynamo, alternator).

ELECTRIC DIAGRAM A) SHUNT EXCITATION DC MOTOR

A1

+ A1
Ra

Re E1

V M

E2
Af
A2

+ -
-
D2 D1 B2

ELECTRIC DIAGRAM B) COMPOUND EXCITATION DC MOTORADDITIVE

SERIES
A1

+ A1
Ra

Re E1

V M

E2
Af
A2

+ -
-
D2 D1 B2

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ELECTRIC DIAGRAM C) COMPOUND EXCITATION DC MOTORDEDUCTIVE

SERIES

A1
+ A1
Ra

Re E1

V M

E2
Af
A2

+ -
-
D2 D1 A2

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PRACTICAL DIAGRAM A

SHUNT EXCITATION DC MOTOR

+ - + -

rpm

K1 K2

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PRACTICAL DIAGRAM B

COMPOUND EXCITATION DC MOTOR ADDITIVE SERIES

+ - + -

rpm

K1 K2

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PRACTICAL DIAGRAM C

COMPOUND EXCITATION DC MOTOR DEDUCTIVE SERIES

+ - + -

rpm

K1 K2

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TEST PROCEDURE

After the set up of the motor under test and of the braking make all the connections in accordance
with the attached diagrams and set the commands as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open

Output with about 220V

VARIABLE DC OUTPUT: Switch open

(excitation) Variac fully turned in counter clockwise direction

EXCITATION RESISTANCE: Min. resistance

STARTING RESISTANCE: Max. resistance

2 Shunt the A-coils of the instruments (make the connections signed with dashed lines) to protect
them against the spike due to the starting current.

3 Set the main switch on ON and, acting on variac, adjust the power supply to the exact value
shown on the motor plate.
Gradually switch Ra off.
Verify that the rotation sense of the motor is correct.
Adjust with the variac the supply voltage to exactly the motor's rated value.
Acting on Re adjust the speed to exactly the rated value.
Take out the shunt current.

4 Set step by step the load acting on the excitation brake and, at each step, take upthe instruments
readouts and the r.p.m.

5 Switch off the main switch which causes the stop the motor.

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TABLE OF MEASURING

GRAPH

DEDUCTIVE SERIES

no

SHUNT

ADDITIVE SERIES

Iar Ia

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