11-Feb-20

DC MACHINERY FUNDAMENTALS 2
IR. DR. DAVID BONG

INTERNAL GENERATED VOLTAGE AND INDUCED

TORQUE EQUATION FOR REAL DC MACHINE
• The induced voltage in any machine depends on:
1. The flux in the machine
2. The speed of the machine’s rotor
3. A constant depending on the construction of the machine
• The voltage in any single conductor under the pole faces is

• The voltage out of the armature is (Z is the total number of conductors, a is the
number of current paths)

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• Velocity of each conductor is v=rωm, so

• The flux of a pole is

• The machine is shaped like a cylinder, so its area is

• The total flux per pole is

• Hence, the internal generated voltage can be expressed as

• Conversion from rpm to rad/s is

• In terms of rpm:

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• The torque in a machine depends on:

1. The flux in the machine
2. The armature (rotor) current in the machine
3. A constant depending on the construction of the machine

• The torque for a single conductor under the pole faces is:

• The total armature current IA is split among a current paths. The current in a
single conductor is

• The torque for a single conductor can be expressed as

• Since there are Z conductors, the total torque is

• The flux per pole in the machine is

• So, the total induced torque can be expressed as

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THE CONSTRUCTION OF DC MACHINES

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• Stator – the stationary part which consists of the frame and pole pieces.
• Rotor / Armature – the rotating part
• Pole shoes – the ends of pole pieces that are near to the rotor
• Pole face – the exposed surface of a pole shoe
• Air gap – the distance between the pole face and the rotor
• Armature windings – the windings in which a voltage is induced, located on
the rotor
• Field windings – the windings that produce the main magnetic flux, located on
the stator

• The main poles are made of laminated material.

• The rotor/armature consists of a shaft with a laminated core built up over it.
• The commutator is made of copper bars insulated by a mica-type material.
• The brushes are made of carbon, graphite, metal graphite or a mixture of
carbon and graphite – high conductivity and low friction. The brush pressure
on the commutator surface must be carefully adjusted for maximum life.
• The most critical part is the insulation of windings. If the insulation breaks
down (usually due to overheating), the machine shorts out. The life expectancy
of a machine with a given insulation is halved for each 10 percent rise in
winding temperature. Circulation of cooling air and other mechanisms are
used to limit the temperature of the windings.

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POWER FLOW AND LOSSES IN DC MACHINE

• The difference between the input power and the output power of a machine is the
losses that occur inside it.
• The efficiency of a dc machine is

• The losses in a dc machine can be categorized as:

1. Electrical or copper losses (I2R losses)
2. Brush losses
3. Core losses
4. Mechanical losses
5. Stray load losses

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1. ELECTRICAL OR COPPER LOSSES

• Occur in the armature and field windings of the machine.

2. BRUSH LOSSES

• This is the power lost across the contact potential at the brushes of the
machine.

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3. CORE LOSSES

• The core losses are the hysteresis losses and eddy current losses occurring in
the core.

4. MECHANICAL LOSSES

• Losses from mechanical effects due to friction and windage.

• Friction losses are the losses caused by the friction of the bearings in the
machine.
• Windage losses are caused by the friction between the moving parts of the
machine and the air inside the motor’s casing.

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5. STRAY LOSSES (MISCELLANEOUS LOSSES)

• Any other losses that cannot be placed in the other 4 categories.

• The conventional estimate is to assume 1 percent of full load.

• Power flow diagram:

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