REPUBLIC OF THE PHILIPPINES

SOUTH CENTRAL MINDANAO COLLEGE OF SCIENCE AND TECHNOLOGY

Purok Rosal Barangay New Isabela
Tacurong City, Sultan Kudarat

COURSE NO. ET 123 Units: 3

Course Title: Direct Current Machine Prerequisite: NONE

VISION OF THE INSTITUTION

The academe envisions of providing graduates who are God fearing, patriotic, academically competent
and skillful individuals. It is committed to offer a safety environment with innovative approaches in teaching and
learning process and always be of service to its community.

MISSION OF THE INSTITUTION

The academe is fully committed to foster and sustain quality education, where students honed their
potential in a safe and caring environment.
Teachers passionately foster learning with competence and provide an avenue that may bring out
students’ skills in challenging and enjoyable way.
Administrators endeavor to be of help always to support and impose programs that will promote quality
teaching and learning.
Individuals in the locality are highly enjoined to share responsibility and be part of implementing
programs that will develop quality and skillful individuals.

CORE VALUES

DETERMINATION = determined to develop an institution that strive to achieve excellence

MOTIVATION = every individual in the academe is full of enthusiasm to pursue the objectives for the
betterment of the institution.
COOPERATION = working hand in hand and be sensitive with the needs of its stakeholders for the betterment
of the college.
CARING = emphatic to the welfare of every individual not only within the institution but with the constituents in
the locality.
LEARNING = we aspire of learning on the highest standard.
RESPECT = mutual respect should be afforded to every individual in the institution
COMMITMENT = we must be strongly committed to provide an academe that is conducive for teaching and
learning.

GRADING SYSTEM:
Module/Portfolio/activities 50%
Laboratory 30%
Exam 20%
100%

GRADE EQUIVALENT

PERCENTAGE NUMERICAL EQUIVALENT

GRADE DESCRIPTION
99-100 1.00 - Excellent
96-98 1.25
93-95 1.50
90-92 1.75
87-89 2.00 -Very Good
84-86 2.25
81-83 2.50
78-80 2.75
75-77 3.00
74 and Below FAILED
 Program/Course: ELECTRICAL INSTALLATION AND MAINTENANCE

Module Title: DC Machines

INTRODUCTION:
Welcome to the Module “DC Machines”. This module contains training materials and activities for you to
complete.
After completing this module ask your teacher to assess your competence. Result of your assessment will
be recorded in your competency profile. All the learning activities are designed for you to complete at your own
pace.

Inside this module you will find the activities for you to complete and relevant information sheets for each
learning outcome. Each learning outcome may have more than one learning activity.

This module is prepared to help you achieve the required competency, in receiving and relaying
information. This will be the source of information that will enable you to acquire the knowledge, skills and
attitude in learning about DC Machines.

This module consists of five (5) Learning Outcomes (LO’s) that contains learning activities for both
knowledge and skills supported with information sheets, job/operation sheets and self-check. Before
attempting to perform the manual exercises, see to it that you have already read and understood the
information/operation sheet and answered correctly the self-check provided in every Learning Activities.

LEARNING OUTCOMES:

Upon completion of this module, the students shall be able to:

LO1. Define What is a DC Machine

LO2. Define what is a DC Generator
LO3. Understand the working principle of DC Generator
LO4. Understand the construction of a DC Generator
LO5. Identify Armature Windings
LEARNING OUTCOME # 1:
DC MACHINES

What is a DC Machine?
A DC Machine is an electro-mechanical energy conversion device. There are two types of
DC machines; one is the DC generator, and another one is known as DC motor.

A DC generator converts mechanical power (ωT) into DC electrical power (EI), whereas, a DC
motor converts DC electrical power into mechanical power. The AC motor is invariably applied in the
industry for conversion of electrical power into mechanical power, but at the places where the wide
range of speeds and good speed regulation is required, like in electric traction system, a DC motor is
used.

The construction of the dc motor and generator is nearly the same. The generator is employed
in a very protected way. Hence there is an open construction type. But the motor is used in the
location where they are exposed to dust and moisture, and hence it requires enclosures for example
dirt proof, fireproof, etc. according to requirement.

Although the battery is an important source of DC electric power, it can only supply limited
power to any machines. There are some applications where large quantities of DC power are
required, such as electroplating, electrolysis, etc. Hence, at such places, DC generators are used to
deliver power.
Activity 1
DC machine applications
Direction: Draw or cut-out and paste at least 10 pictures of common house appliances found in our
homes that are/uses DC machines.
LEARNING OUTCOME # 2:
DC Generator

The initial electromagnetic generator (Faraday disk) was invented by British scientist namely

Michael Faraday in the year 1831. A DC generator is an electrical device used for
generating electrical energy. The main function of this device is to change mechanical energy into
electrical energy. There are several types of mechanical energy sources available such as hand
cranks, internal combustion engines, water turbines, gas and steam turbines. The generator provides
power to all the electrical power grids. The reverse function of the generator can be done by an
electric motor. The main function of the motor is to convert electrical energy to mechanical. Motors,
as well as generators, have similar features. This article discusses an overview of DC generators.

What is a DC Generator?
A DC generator or direct current generator is one kind of electrical machine, and the main
function of this machine is to convert mechanical energy into DC (direct current) electricity. The
energy alteration process uses the principle of energetically induced electromotive force. The dc
generator is shown below.
 DC Generator

When a conductor slashes magnetic flux, then energetically induced electromotive force will
be generated in it based on the Electromagnetic Induction principle of Faraday’s Laws. This
electromotive force can cause a flow of current when the conductor circuit is not opened.

Magnetic Flux
Before electrical machinery can be adequately discussed, it is essential that we first introduce
magnets in a manner which explains how they are employed in electrical machinery. It is helpful to
recap a few basic conclusions from physics. - Magnets may exist as permanently magnetized
materials, logically called permanent magnets, or as a temporary magnet, which exists only when
electric current is flowing, also logically called electromagnets. - All magnets have two poles, north
and south. These poles give rise to the familiar action between two magnets where opposite poles
attract while similar poles repel. - Lines of magnetic flux can be imagined which flow from the north
pole to the south pole. These lines of flux, while they do not physically exist, help us visualize the
direction and strength of the magnetic field between magnetic poles.

Magnetic flux is defined as the number of magnetic field lines passing through a given closed surface. It provides
the measurement of the total magnetic field that passes through a given surface area. Here, the area under
consideration can be of any size and under any orientation with respect to the direction of the magnetic field.
Activity 2
Brainstorming
Direction: Put your answers in the space provided.

1. Where are generators basically used?

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2. Why are DC Generators so important in the industry?

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3. How large is the impact of the invention of DC Generator to our industry?

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4. Imagine if DC generators were not invented. What would our industry look like today?
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5. Compare DC Generators from DC motors.

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LEARNING OUTCOME # 3:
WORKING PRINCIPLE OF A DC GENERATOR

The working principle of the DC generator is based on Faraday’s laws of electromagnetic

induction. When a conductor is located in an unstable magnetic field, an electromotive force gets
induced within the conductor. The induced EMF magnitude can be measured from the equation
of the electromotive force of a generator.
If the conductor is present with a closed lane, the current which is induced will flow in the lane.
In this generator, field coils will generate an electromagnetic field as well as the armature conductors
are turned into the field. Therefore, an electromagnetically induced electromotive force (EMF) will be
generated within the armature conductors. The path of induced current will be provided by Fleming’s
right-hand rule.

So, based on what we have said so far, the main requirements of a DC generator are the
magnetic field and a conductor. The conductor moves to cut the magnetic flux. Therefore, we can say
that a DC generator operates on the principle of the dynamically induced electromagnetic force. It is
what Faraday’s law of electromagnetic induction says: when a current-carrying conductor is put inside
a varying magnetic field, an EMF is induced in the conductor. On the other hand, and based on
Fleming’s right-hand rule, wherever the direction of the motion of the conductor changes, the direction
of the induced flow changes too.

Imagine an armature rotating clockwise and a conductor at the left moving upwards. Now
when the armature accomplishes a half rotation, the direction of the movement of the conductor will
be reversed downward. So, the direction of the current in every armature will be changing. But with a
split ring commutator, connections of the armature conductors get reversed when a current reversal
occurs. Therefore, we get unidirectional current at the terminals.
An Easy-to-understand Example of DC Generator Working Principle

Let us make the DC generator’s function and working principle simpler for you. You have to
notice if the generator is very small for example it is used for a shop, a small workshop, a cinema, or
a house, the prime mover or the mechanical energy supplier is a diesel engine. If the generator is
very big like in power plants, then the prime mover will be a water, steam, or gas turbine.

As the mechanical energy supplied by the prime mover is given to the generator, the generator
armature starts rotating. Usually, the poles on the yoke are made of permanent magnets. It means
that according to Faraday Laws of Electromagnetic Induction, the armature conductors cut the weak
magnetic field established by permanent magnets and a small amount of EMF is induced in the
armature winding. This induced electromagnetic force circulates a small amount of current through
the field winding and strengthens the magnetic flux supplied and hence the induced EMF. Thus, due
to the reinforcement of the flux and EMF, the generator provides the rated voltage.
Activity 3
Self-Discovery
Direction: Put your answers in the space provided.

1. Do some research about Faraday’s Law of Electromagnetic Induction. Summarize and discuss
to the class.
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2. Do some research about Fleming’s Right-Hand rule. Summarize and discuss to the class.
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3.
LEARNING OUTCOME # 4:
CONSTRUCTION OF A DC GENERATOR

A DC generator is also used as a DC motor without changing its construction. Therefore, a DC

motor otherwise a DC generator can be generally called a DC machine. The construction of a 4-pole
DC generator is shown below. This generator comprises of several parts like yoke, poles & pole
shoes, field winding, an armature core, armature winding, commutator & brushes. But the two
essential parts of this device are the stator as well as the rotor.

Yoke: The outer frame of a dc machine is called as yoke. It is made up of cast iron or steel. It
not only provides mechanical strength to the whole assembly but also carries the magnetic flux
produced by the field winding.
Poles and pole shoes: Poles are joined to the yoke with the help of bolts or welding. They carry
field winding and pole shoes are fastened to them. Pole shoes serve two purposes; (i) they
support field coils and (ii) spread out the flux in air gap uniformly.

Field winding: They are usually made of copper. Field coils are former wound and placed on
each pole and are connected in series. They are wound in such a way that, when energized,
they form alternate North and South poles.

Armature core: Armature core is the rotor of a dc machine. It is cylindrical in shape with slots to
carry armature winding. The armature is built up of thin laminated circular steel disks for
reducing eddy current losses. It may be provided with air ducts for the axial air flow for cooling
purposes. Armature is keyed to the shaft.

Armature core (rotor)

Armature winding: It is usually a former wound copper coil which rests in armature slots. The
armature conductors are insulated from each other and also from the armature core. Armature
winding can be wound by one of the two methods; lap winding or wave winding. Double layer lap
or wave windings are generally used. A double layer winding means that each armature slot will
carry two different coils.

Commutator and brushes: Physical connection to the armature winding is made through a

commutator-brush arrangement. The function of a commutator, in a dc generator, is to collect
the current generated in armature conductors. Whereas, in case of a dc motor, commutator
helps in providing current to the armature conductors. A commutator consists of a set of copper
segments which are insulated from each other. The number of segments is equal to the number
of armature coils. Each segment is connected to an armature coil and the commutator is keyed
to the shaft. Brushes are usually made from carbon or graphite. They rest on commutator
segments and slide on the segments when the commutator rotates keeping the physical contact
to collect or supply the current.
Activity 4
Label the Parts
Direction: Label/Name the corresponding parts of a DC Generator.

1. 2.

1. __________________ 2._________________

3. 4.

3.___________________ 4. ____________________

5. 6.
7.

5. ___________________ 6. ________________
7. ________________
LEARNING OUTCOME # 5:
ARMATURE WINDINGS

Armature winding is one of the most important parts of the DC Generator. In armature winding,
you have to be clear with several terms like coil sides, coil pitch, pole pitch, front pitch, back pitch,
commutator pitch, etc. Without a proper understanding of these terms, it is not possible to efficiently
design the winding.
So, in this section, we will be discussing the terms used in the armature winding of a DC
Generator. 

Terms used in the armature winding

Conductor
The conductor is an individual wire lying in the magnetic field. By relative motion of the
conductor, the field induces an emf in it. It may have one or two or more parallel strands. In the
following figure, AB and CD are the conductors .

Turn
A turn has two conductors in series lying in the magnetic field. In other words, a conductor in
one slot is connected to a conductor in another slot, it forms a turn.

Coil
The above said two conductors AB and CD along with their end connections constitute a coil
or winding. It may be a single turn coil or multi-turn coil. Single turn coils have only two conductors.
Whereas the multi-turn coil will have many conductors. The figure below (b) shows 3 turn coil, which
has 3 conductors on each coil side.

Coil Side
Each coil, either single turn or multi-turn, has two sides called the coil sides. A conductor can
also be called a coil side. AB and CD are said to be the two-coil side of the coil. A coil group may
have one or more single coils. The number of coils is arranged in coil groups called the winding.

Coil sides in (a) single turn winding (b) 3 turn coil

Front end and Back end connector
A wire that connects the end of a coil to a commutator segment is called a front-end connector.
The back-end connector is a wire that connects one coil side to the other side of the coil. Back
connections are opposite to that of the commutator.

Pole Pitch
Pole pitch is nothing but the peripheral distance between two adjacent poles. It is measured in
terms of armature slots or armature conductors. It can also be defined as the number of armature
slots (or armature conductors) per pole. Let there be 48 conductors and 4 poles in a dc generator,
then the pole pitch is 48/4 = 12.

Coil Pitch or Coil span

It is the angular distance between two sides of a coil, measured in terms of armature slots. For
example, if there are 36 slots and 4 poles, then the coil pitch is 36/4 = 9 slots.

Coil span or coil pitch

If the coil pitch is equal to the pole pitch, then it is called a  full pitch coil. For a full pitch coil,
each coil side lies under the opposite pole as shown in the figure below. It means the coil span is 180
electrical degrees. If the coil pitch is less than the pole pitch, it is said to be  short pitch coil or
fractional pitch coil.

(a) Full pitch coil (b) short pitch coil

Pitch of a winding or winding pitch

Winding pitch is defined as the distance between two successive conductors which are directly
connected together around the armature. It is the beginning of two successive coil sides and is
denoted by Y. For lap winding, Y = Yb – Yf and for wave winding, Y = Yb + Yf.
Back Pitch (Yb)
The distance at which a coil advances on the back of the armature is called back pitch,
denoted by Yb. It can also be defined as the distance between the first and the last conductors of a
coil. i t is equal to the number difference of the conductor connected to a given segment of the
commutator.

Front Pitch (Yf)

It is the distance between the second conductor of one coil and the first conductor of the next
coil. Both the coils should be connected to the same commutator segments on the front, as shown in
the figure (a) and (b) below. It is denoted by Y f.

Pitch in (a) Lap winding (b) Wave winding

Resultant Pitch (Yr)

It is the distance between the beginning of one coil and the beginning of the next coil to which
it is connected. It is illustrated in the above figure (a) and (b), denoted by Y r.

Commutator Pitch
It is the distance between the Commutator segments to which the two ends of a coil are
connected. From the figure, you can observe, for lap winding, Commutator pitch (Y c) is the difference
of back pitch (Yb) and front pitch(Yf). For wave winding, it is the sum of the back pitch and front pitch.

Single Layer Armature Winding

We place armature coil sides in the armature slots differently. In some arrangement, each one
side of an armature coil occupies a single slot.

In other words, we place one coil side in each armature slot. We refer to this arrangement as
single-layer winding.
Two Layer Armature Winding
In other types of armature winding, arrangement two coil sides occupy every armature slot;
one occupies the upper half, and another one occupies the lower half of the slot.

We so place the coils in two layers winding that if one side occupies upper half, then another
side occupies the lower half of some other slot at a distance of one coil pitch away.
Activity 4
Multiple Choice
Direction: Encircle the letter of the correct answer.

1.It is the distance between the Commutator segments to which the two ends of a coil are connected.
a. Resultant pitch b. Commutator pitch
c. Front pitch d. Back pitch

2. A type of armature winding where each one side of an armature coil occupies a single slot.
a. Two-layer armature winding b. Multi-layer armature winding
c. Single layer armature winding d. Coil pitch

3. The distance between the first and the last conductors of a coil is called ______________.
a. Back pitch b. Front pitch
c. Resultant pitch d. Commutator pitch

4. A conductor in one slot is connected to a conductor in another slot forms a _________.

a. Conductor b. Coil
c. Turn d. Coil slide

5. It is the angular distance between two sides of a coil.

a. Coil pitch b. Coil span
c. Pole pitch c. Both A and B

6. The conductor is an individual wire lying in the magnetic field. It may have one or two or more
parallel strands.
a. Coil b. Turn
c. Conductor d. Coil slide

7. A wire that connects the end of a coil to a commutator segment is called a ___________.
a. Back-end connector b. Coil connector
c. Front-end connector d. None of the above

8. __________ is the peripheral distance between two adjacent poles.

a. Coil pitch b. Coil span
c. Both A and B d. Pole pitch

9. The ____________ is a wire that connects one coil side to the other side of the coil.
a. Back-end connector b. Coil Connector
c. Front-end connector d. None of the above
10. The number of coils is arranged in coil groups called the ___________.
a. Coil span b. Windings
c. Poles d. Pole pitch