DC_machine_construction

Introduction to DC Machines
1. Overview
2. Construction
Overview of Direct Current (DC) Machines:
1. A DC machine is an electromechanical device that is used to convert electrical
energy into mechanical energy or vice versa.
2. DC machines can be classified into two types namely DC motors as well as

DC generators.
3. Most DC machines are similar to Ac machines: i.e. they have AC voltages and
currents within them.
4. DC machines have DC outputs just because they have a mechanism converting

AC voltages to DC voltages at their terminals. This mechanism is called
commutation.
5. The main benefits of this machine include wide range of torque and good speed
regulation .
6. The applications of the DC machine is limited to trains, mills, and mines. For
example, underground subway cars, as well as trolleys, may utilize DC motors. In
the past, automobiles were designed with DC dynamos for charging their batteries.
Construction of a DC machine:
DC machine has two main parts
1.Rotor is the rotating part (armature)
2.Stator is the stationary part (field)
Magnetic frame or yoke:
The outer hollow cylindrical frame to which main poles and inter-poles are fixed
and by means of which the machine is fixed to the foundation is known as Yoke. It
is made of cast steel or rolled steel for the large machines and for the smaller size
machine the yoke is generally made of cast iron.
The two main purposes of the yoke are as follows:-

• It supports the pole cores and provides mechanical protection to the inner parts of
the machines.
• It provides a low reluctance path for the magnetic flux.
Pole core and pole shoe:
The Pole Core and Pole Shoes are
fixed to the magnetic frame or yoke
by bolts. Each pole core has a curved
surface. Usually, the pole core and
shoes are made of thin cast steel or
wrought iron laminations which are
riveted together under hydraulic
pressure. The poles are laminated to
reduce the Eddy Current loss.
The poles core serves the following purposes given below:

1. It supports the field or exciting coils.
2. They spread out the magnetic flux over the armature periphery more
uniformly.
3. It increases the cross-sectional area of the magnetic circuit, as a result, the
reluctance of the magnetic path is reduced.
Field winding:
Each pole core has one or more field coils (windings) placed over it to produce
a magnetic field. The enamelled copper wire is used for the construction of
field or exciting coils. The coils are wound on the former and then placed
around the pole core.
When direct current passes through the field winding, it magnetizes the poles,
which in turns produces the flux. The field coils of all the poles are connected
in series in such a way that when current flows through them, the adjacent poles
attain opposite polarity.
Armature core:
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 is a place where the conversion of power takes place.
In the case of a DC Generator here, mechanical power is converted into
electrical power. On the basis of connections, the windings are classified into
two types named as
1.Lap Winding and
2.Wave Winding.
Armature winding:
1. Lap winding: The conductors are connected in such a way that the number of
parallel paths is equal to the number of poles. Thus, if a machine has P poles and Z
armature conductors, then there will be P parallel paths, each path will have Z/P
conductors connected in series. In lap winding, the number of brushes is equal to
the number of parallel paths. Out of which half the brushes are positive and the
remaining half are negative.
2. Wave winding: In wave winding, the conductors are so connected that they are
divided into two parallel paths irrespective of the number of poles of the machine.
Thus, if the machine has Z armature conductors, there will be only two parallel
paths each having Z/2 conductors in series. In this case number of brushes is equal
to two, i.e. number of parallel paths.
Commutator:
It 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. It is the
most important part of a DC machine and serves the following purposes:
1. It connects the rotating armature conductors to the stationary external circuit

through brushes.
2. It converts the induced alternating current in the armature conductor into the
unidirectional current in the external load circuit in DC Generator action, whereas
it converts the alternating torque into unidirectional (continuous) torque produced
in the armature in motor action.
Brushes:
Brushes in the DC machine gather the current from the commutator and supply it
to the exterior load. Each brush is supported in a metal box called a brush
box or brush holder. The brushes are pressed upon the commutator and form the
connecting link between the armature winding and the external circuit. They rest
on commutator segments and slide on the segments when the commutator rotates
keeping the physical contact to collect or supply the current. They are usually
made of high-grade carbon because carbon is conducting material and at the
same time in powdered form provides a lubricating effect on the commutator
surface.
End housings:
End housings are attached to the ends of the Mainframe and provide support to the
bearings. The front housings support the bearing and the brush assemblies whereas
the rear housings usually support the bearings only.
Bearings:
The ball or roller bearings are fitted in the end housings. The function of
the bearings is to reduce friction between the rotating and stationary parts
of the machine. Mostly high carbon steel is used for the construction of
bearings as it is a very hard material.
Shaft:
The shaft is made of mild steel with a maximum breaking strength. The shaft is used to transfer
mechanical power from or to the machine. The rotating parts like armature core, commutator,
cooling fans, etc. are keyed to the shaft.

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Introduction to DC Machines

2. DC machines can be classified into two types namely DC motors as well as

4. DC machines have DC outputs just because they have a mechanism converting

The two main purposes of the yoke are as follows:-

The poles core serves the following purposes given below:

1.Lap Winding and

1. It connects the rotating armature conductors to the stationary external circuit

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