TECHNICAL REPORT

EE-404
(DC MACHINERY)

SUBMITTED BY:
REENMART D. TATAD
BSEE-4B

SUBMITTED TO:
ENGR. JOSEPH MAGHANOY
INSTRUCTOR
 INTRODUCTION

There are many portable home appliances which can be find as a DC Motor. Each one
have a unique process, operation and contractions. With this report we can understand how DC
motor works, the parts and material used, the application and advance application of the
machine. DC motor operate because of this two important parts, the stator and the rotor. Where
the armature is connected to a dc power source through a pair of commutator. In order to make
the operation more reliable, more efficient and less noisy, the recent trend use brushless dc
motor. With the same power output with the brushed motor dc motor, more reliable than brushed
motor because brushless motor does not spark and with a unique coil arrangement and the rotor
is a permanent magnet. Lastly the most ingenious invention in electrical world the Three Coil
DC motor, the contractions of this motor unique and simple but the operation is complex. It can
be easily understand the details about the winding by just following the current flow. While the
rotor coil is connected with the three commutator rings, each commutator rings ha a pair of
brushes. You can easily identify the differences of some DC motor by observing the motor
process and operation.

PARTS
DC MOTOR
STATOR

As the name signifies stator means the part which does not move or the stationary part of the DC
machine. Stator is mainly constituted of yoke, field poles, pole shoe, field windings etc.

 Yoke is the outer covering of the DC machine. Its main function is to provide the
mechanical support and the return path to flux. In large machines, yoke is composed in
two halves while for smaller machine in single form.
 Field poles are usually laminated in order to reduce the eddy current loss. Its main
function is setup the necessary flux and to provide the support to the field windings.
 Poles shoes have surface area larger than the poles and are always laminated to reduce
eddy current losses. Pole shoes are jointed over the poles by of screws. It provide
support to the field windings.
 Field windings are the wires or coils which remain wound over the poles in the DC
machine. When current flows through the windings it acts like a electromagnet. It
remains connected with the armature either in series or in parallel according to the type
of DC machine.
  Brushes it connects the rotating armature and the external circuit. Brushes are
employed to collect current from the commutator and deliver it to the load. These are
rectangular in shape and made of carbon graphite.
ROTOR

The rotor is constituted of an armature core, armature windings and a commutator.

 Armature core is the rotating part of the DC machine. It is made up of thin lamination
having thickness about 0.35–0.5 mm. In order to reduce eddy current losses the
laminations are insulated from each other by polish or varnish. Solts are cut on the
upper periphery of the core. The slots are usually placed parallel to the axis of armature
but sometimes skewed at an angle to reduced the vibrations of the teeth.
 Armature windings are wires or coils which are wound on the armature core and
placed inside the slots of the core. The armature winding coil ends are connected to the
commutator segments.
 Commutator plays a very important role in the DC machine. Its main function is to
convert the ac voltage induced in the armature windings to the DC voltage in the
external circuit, in case of generator operation and to produce the unidirectional
torque in case of motor operation. The ends of the armature coils are joined to the
commutator consisting of a small wedge-shaped segment. Commutator segments are
insulated from each other by the layers of mica strips. The segments are assembled
side by side to form a ring. The commutator is pressed onto the shaft.

Stator - There are three classifications of the BLDC motor: single-phase, two-phase and three-
phase. This discussion assumes that the stator for each type has the same number of windings.
The single-phase and three-phase motors are the most widely used. The simplified cross section
of a single-phase and a three-phase BLDC motor. The rotor has permanent magnets to form 2
magnetic pole pairs, and surrounds the stator, which has the windings. A single-phase motor has
one stator winding—wound either clockwise or counter-clockwise along each arm of the stator—
to produce four magnetic poles. By comparison, a three phase motor has three windings. Each
phase turns on sequentially to make the rotor revolve. There are two types of stator windings:
trapezoidal and sinusoidal, which refers to the shape of the back electromotive force (BEMF)
signal. The shape of the BEMF is determined by different coil interconnections and the distance
of the air gap. In addition to the BEMF, the phase current also follows a trapezoidal and
sinusoidal shape. A sinusoidal motor produces smoother electromagnetic torque than a
trapezoidal motor, though at a higher cost due to their use of extra copper windings. A BLDC
motor uses a simplified structure with trapezoidal stator windings.
Rotor - A rotor consists of a shaft and a hub with permanent magnets arranged to form between
two to eight pole pairs that alternate between north and south poles. Cross sections of three kinds
of magnets arrangements in a rotor. There are multiple magnet materials, such as ferrous
mixtures and rare-earth alloys. Ferrite magnets are traditional and relatively inexpensive, though
rare-earth alloy magnets are becoming increasingly popular because of their high magnetic
density. The higher density.
 APPLICATION

Motor works when current flows through the coil, an electromagnetic force is induced on
it according to Lorenz law and the coil will start to rotate. The commutator rings is connected
with the power source of the opposite polarity as the result on the south pole side of the coil, the
electricity will always flow away and the north pole side of the coil, the electricity will always
flow towards. As the coil continue rotating it ensures that the torques is also in the same direction
throughout the motor. when the coil is nearly perpendicular to the magnetic flux the torque
action nears zero, if this happens there will be a irregular motion of the rotor. But there such way
to overcome this problem. Simply add one more loop to the rotor, with separate commutator pair
for it. The first loop is vertical position and the second loop will be connected to the power
source so the motor force is always present in the system. The rotation is smoother if there are
one more loop on the rotor. Field coils can be connected into two different ways, parallel and
series connection, as a result two different kinds of dc motor contraction the shunt and series
motor. a shunt motor has low starting torque but it is able to run almost at a constant. The series
wound dc motor has good starting point, but speed drops drastically with the load. The back
EMF reduces armature current by a large amount. It is proportional to the speed of the rotor and
the starting of the motor back emf is too slow. And a universal motor can be the most interesting
variation of dc motor because this motor is capablecto run under both AC and DC power
sources.

The operation of a brushless dc motor is based on a simple interaction between the

permanent magnet and electromagnet, which the stator and rotor is attracted to each other.
Brushless dc motor works in a unique process. The brushless DC motor is driven by an
electronic drive which switches the supply voltage between the stator windings as the rotor turns.
The rotor position is monitored by the transducer (optical or magnetic) which supplies
information to the electronic controller and based on this position, the stator winding to be
energized is determined.  This electronic drive consists of transistors (2 for each phase) which
are operated via a microprocessor. The magnetic field generated by the permanent magnets
interacts with the field induced by the current in the stator windings, creating a mechanical
torque. The electronic switching circuit or the drive switches the supply current to the stator so as
to maintain a constant angle 0 to 90 degrees between the interacting fields.  Hall Sensors are
mostly mounted on the stator or on the rotor. When the rotor passes through the hall sensor,
based on the North or South Pole, it generates a high or low signal. Based on the combination of
these signals, the winding to be energized is defined. In order to keep the motor running, the
magnetic field produced by the windings should shift position, as the rotor moves to catch up
with the stator field. In a 4 pole, 2 phase brushless dc motor, a single hall sensor is used, which is
embedded on the stator. As the rotor rotates, the hall sensor senses the position and develops a
high or low signal, depending on the pole of the magnet (North or South). The hall sensor is
connected via a resistor to the transistors. When a high voltage signal occurs at the output of the
sensor, the transistor connected to coil A starts conducting, providing the path for the current to
flow and thus energizing coil A. The capacitor starts charging to the full supply voltage. When
the hall sensor detects a change in polarity of the rotor, it develops a low voltage signal at its
output and since the transistor 1 doesn’t get any supply, it is in cutoff condition. The voltage
developed around the capacitor is Vcc, which is the supply voltage to the 2 nd transistor and coil B
is now energized, as current passes through it.
BLDC motors have fixed permanent magnets, which rotate and a fixed armature, eliminating the
problems of connecting current to the moving armature. And possibly more poles on the rotor
than the stator or reluctance motors. The latter may be without permanent magnets, just poles
that are induced on the rotor then pulled into arrangement by timed stator windings. An
electronic controller replaces the brush/commutator assembly of the brushed DC motor, which
continually switches the phase to the windings to keep the motor turning. The controller
performs comparative timed power distribution by using a solid-state circuit instead of the
brush/commutator system.

A Three coil DC motor generates a rotating force via attraction and repulsion of magnetic
fields. The magnetic fields in a three pole DC motor are generated by three electromagnets and
two permanent magnets, A section of the motor, called the commutator, connects the brushes to
the coils and allows for current to flow from the power source, through the coils and back to the
power source. It has another very important function and that is, it reverses the flow
of current through the coils and so allows for a constant torque to be generated in one direction.

Notice how the poles of the electromagnets change as the commutator rotates around the
brushes. This reversal of current flow allows for the generation of magnetic forces of attraction
and repulsion which rotates the rotor in one direction with some force. This force is known as
torque.

ADVANCED APLLICATION
DC MOTOR

The cost of the Brushless DC Motor has declined since its presentation, because of progressions
in materials and design. This decrease in cost, coupled with the numerous focal points it has over
the Brush DC Motor, makes the Brushless DC Motor a popular component in numerous
distinctive applications. Applications that use the BLDC Motor include, yet are not constrained
to:

 Consumer electronics
 Transport
 Heating and ventilation
 Industrial engineering
 Model engineering

CONCLUSION
Although Three coil dc motor contractions is unique and simple, can be easily understand
the details and many ways to operate this motor and DC series motor have has a good starting
torque but speed drops drastically with the load and the shunt motor maybe a low starting but it
is able to run almost at a constant speed but it is wise to use Brushless dc motor because this
motor is more reliable, more efficient and less noisy. This are some advantages of this Brushless
dc motor, Better speed versus torque characteristics, High dynamic response, High efficiency,
Long operating life due to a lack of electrical and friction losses, Noiseless operation, Higher
speed ranges. This is why it is wise to use brushless dc motor because of this advantages.