DC GENERATOR

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.

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.

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.

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.

Parts of dc generator

The key parts of DC generators are yoke, poles, pole shoes, armature core, armature winding,
commutator, brushes, magnetic field system, commutator, end housings, bearings, and Shafts.

Stator

The stator is an essential part of the DC generator, and the main function of this is to provide the
magnetic fields where the coils spin. This includes stable magnets, where two of them are with reverse
poles facing. These magnets are located to fit in the region of the rotor.

Rotor or Armature Core

Rotor or armature core is the second essential part of the DC generator, and it includes slotted iron
laminations with slots that are stacked to shape a cylindrical armature core. Generally, these
laminations are offered to decrease the loss because of the eddy current.

Bearings

Bearings are used in a system to achieve a smooth movement between the different components. The
main function of bearings is to minimize the friction between the rotating and stationary parts of the
machine. Thanks to these parts, there is no need for the continual lubrication of the system components
and they would also last longer due to the reduction in friction.

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Yoke

If we divide the DC generator parts in two, Yoke is the outer cover that not only provides mechanical
protection to the whole inner assembly and fixes them to the foundation of the machine, but also
creates a path for the magnetic flow that the field winding produces.

Poles

These are mainly used to hold the field windings. Usually, these windings are wound on the poles, &
they are connected in series otherwise parallel by the armature windings. In addition, the poles will give
joint toward the yoke with the welding method otherwise by using screws. To reduce the Eddy Current
loss, the poles of a DC machine are laminated.

These poles are one of the parts of the DC machine whose job is to support the field coils, and ensure a
more integrated magnetic flow over the armature.

Pole Shoe

The pole shoe is an iron or steel plate that used primarily to disperse or spreading the magnetic flow or
flux and avoid the spinning field coil from falling.

Commutator

The operation of the commutator is like a

rectifier to convert AC voltage to DC voltage
in the reinforcement of the armature
winding. This conductive metal ring has a
copper segment and each copper segment
with the aid of mica sheets is shielded from
each other.

This cylindrical electrical switch sits on the

machine’s shaft and contributes in
connecting theconductors of the rotating
armchair to the external circuit that is fixed.

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Brushes

Brushes are one of the essential parts of the DM generator. With the aid of these carbon blocks, the
electrical connection between the commutator and the external load circuit can be assured.

The electrical connections can be ensured between the commutator as well as the exterior load circuit
with the help of brushes.

Shaft

The shaft is a mechanical piece in a DC machine that produces the rotational of a force known as torque
and brings about rotation. It is made from mild steel and has a maximum breaking strength. Of parts of
DC generator, the shaft helps the generator to transfer mechanical energy through the shaft. The
spinning parts are keyed into the shaft like the armature center, a commutator, a cooling fan, etc.

Magnetic Field

This is a permanent magnet that generates a magnetic field that is used to rotate the coil.

Armature Windings

For holding the armature windings, the armature core slots are primarily used. They are connected in a
closed-circuit winding form in series to increase the amount of produced current; and they are parallel.
This special arrangement of conductors is called the armature winding that is known to be the heart of a
DC generator. Depending on the kind of connections, armature windings are either lap winding or wave
winding.

All the armature windings, whether lap or wave, are the centers of power conversion inside the
machine. In the case of armature windings of a DC generator, this energy conversion occurs from
mechanical power to electrical power.

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Working principles of a DC GENERATOR

The working principle of DC generators is based on Faraday’s laws of electromagnetic induction. Within
the parts of dc generator, when a conductor is in a dynamic magnetic field, an electromotive force is
generated within the conductor. The magnitude caused by EMF can be measured using the
electromotive power equation of a generator.

When the conductor has a closed path, the induced current flows in the path. The field coils produce an
electromagnetic field and the armature conductors are converted to the field in the generator.
Therefore, inside the armature conductors, an electromagnetically induced electromotive force (EMF) is
produced. Fleming’s right-hand rule specifies the direction of induced current.

DC generators can be classified into two main categories (separately excited and self-excited). There is
also a third type of DC generators which is called, “Permanent-magnet DC generator”. Each type has its
unique features, frameworks, and advantages.

The function of parts of DC generators in separately-excited type is in a way that field coils are driven
from an independent external DC source in a separately excited form generator. On the other hand, in
self-excited DC generators, the field coils are energized from the produced current in the generator in a
self- excited form. Such generators can also be identified as the series wound, shunt-wound, and
compound wound.

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Generated emf of DC GENERATOR:

E = ZPΦN/60a

E = kNΦ

k = ZP/60a

E = generated emf (volts)

P = no. of poles

Φ = flux per pole (weber)

N = speed of rotation (rpm)

a = no. of armature current paths

k = proportionality constant

* 1weber = 1 x 10⁸ maxwell

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Types of DC GENERATOR (according to excitation)

Separately Excited

In separately excited type, the field coils are strengthened from an autonomous exterior DC source.

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Self Excited

In the self-excited type, the field coils are strengthened from the generated current with the
generator. The generation of the first electromotive force will occur because of its outstanding
magnetism within field poles.

The produced electromotive force will cause a fraction of current to supply in the field coils, therefore
which will increase the field flux as well as electromotive force generation. Further, these types of dc
generators can be classified into three types namely series wound, shunt-wound, and compound
wound.

In a series wound, both the field winding & armature winding are connected in series with each other.

In shunt-wound, both the field winding & armature winding are connected in parallel with each other.

The compound winding is the blend of series winding & shunt winding.

Series Generator

In case of a series generator, the field winding is connected

in series with the armature of the generator so that whole
armature current would flow through the field winding as
well as the load. Since the load current flows through the
field winding of the generator, so the field winding has a
few turns of thick wire having low resistance. The DC series generators are used in special applications
like boosters.

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Shunt Generator

In case of a shunt generator, the field

winding is connected in parallel with the
armature of the generator so that terminal
voltage of the generator is applied across
it. The shunt field winding has many turns
of thin wire having high resistance so that
only a fraction of armature current flows
through the shunt field winding and the
rest flows through the load.

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Short Shunt Compound Generator

In a short shunt generator, only shunt field winding is connected in parallel with the armature.

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Long Shunt Compound Generator

In a long shunt generator, the shunt field winding is connected in parallel with both series field and
armature winding.

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*Losses in DC Generator

-Copper Loss (Pcu)

In armature copper loss (I a2Ra), where the armature current is ‘Ia’ & the armature resistance is ‘Ra’. For
generators like shunt-wound, the field copper loss is equivalent to Ish2Rsh which is almost stable. For
generators like a series wound, the field copper loss is equivalent to Ise2 Rse which is also almost stable.
For generators like compound-wound, the filed copper loss is similar to Icomp2 Rcomp which is also nearly
stable. In full load losses, copper losses occur 20-30% because of the brush contact.

-Core or Iron or Magnetic Loss (Pcore = Peddy + Physteresis)

The classification of core losses can be done into two types like hysteresis and eddy current

-Hysteresis Loss

This loss mainly occurs because of the reversal of the armature core. Every part of the rotor core passed
below the two poles like north & south alternately & achieves S & N polarity correspondingly. Whenever
the core supplies below one set of poles, then the core will finish one series of frequency reversal.

-Eddy Current Loss

The armature core slashes the magnetic flux throughout its revolution & e.m.f can be induced within the
outside of the core, based on the electromagnetic induction laws, this emf is extremely tiny, however, it
sets up a large current in the surface of the core. This huge current is known as eddy current whereas
the loss is called the eddy current loss.

Core losses are stable for compound & shunt generators because their field currents are nearly stable.
This loss mainly occurs 20 % to 30 % in full-load losses.

-Mechanical Loss (Pfw)

Mechanical loss can be defined as the rotating armature’s air friction or windage losses. Friction loss
mainly occurs 10 % to 20 % of full load losses at bearings & commutator.

-Stray Loss (Pstray)

Stray losses mainly occur by combining the losses like core as well as mechanical. These losses are also
called rotational losses.

Plosses = Pcu + Pcore + Pfw + Pstray

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*The Efficiency of DC Generator

DC generators are very reliable with efficiency ratings of 85-95%

*Maximum Efficiency ( Pcu = Pk )

Efficiency is highest once variable loss (Pcu) is equivalent to the constant loss (Pk)

The load current equivalent to the highest efficiency is IL2Ra = Pcore, otherwise IL = √(Pcore/Ra)

-At max efficiency: Ploss becomes 2Pk or 2Pcu

-Pk : friction and windage loss, core loss, brush contact loss, stray loss.

*Voltage Regulation of DC GENERATOR

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*Operating Characteristic of DC GENERATOR

ΔV/ΔI = (VNL - VFL)/IFL

= %VR (VFL)(100)/IFL

* Parallel Operation of DC GENERATOR

Condition or Requirements:

1. Same external characteristics

2. Same Terminal polarity
3. Equal magnitude of terminal voltage

* Parallel Operation with external characteristics given can be analyzed by Triangle characteristics

* Parallel Operation with internal characteristic given can be analyzed by Nodal method or other
circuit analysis method.

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*ADVANTAGES AND DISADVANTAGES

Advantages of DC GENERATOR

The advantages of a dc generator include the following.

• DC generators generate large output.

• The terminal load of these generators is high.
• The designing of dc generators are very simple
• These are used to generate uneven output power.
• These are extremely consistent with 85-95%.of efficiency ratings
• They give a reliable output.
• They are lightweight as well as compact.

Disadvantages of DC GENERATOR

The disadvantages of a dc generator include the following.

• DC generator cannot be used with a transformer

• The efficiency of this generator is low due to many losses like copper, mechanical, eddy, etc.
• A voltage drop can occur over long distances
• It uses a split ring commutator so it will complicate the machine design
• Expensive
• High maintenance
• The sparks will be generated while generating energy
• More energy will be lost while transmission

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