EE 2092 – Laboratory Practice III

TEST ON DC MOTORS

Instructed by: Mr. Lathika Attanayaka

Group: 14 Name: V.I.P. Dasanayake

Group Members: Dasanayake V.I.P. Index No: 090075M

Dayarathne H.K.C.O. Field: EE

De Silva J.G.D.S. Date of Experiment: 01/12/2010

De Silva O.S.D. Date of Submission: 15/12/2010

 CALCULATIONS

Absorption Dynamometer

Considering radius of pulley as ‘r’;

2πr=73 cm
∴r=11.618cm=0.11618m
Armatur4e resistance (Ra) =4.1Ω, series field resistance (Rs) =3.3Ω
Sample Calculation
Considering first observation,

 Weight (W) = 0.4536 x 28lb=12.701kg & Weight (w)= 0.4536 x 14lb=6.350kg

 Speed (rad s-1) = 2 x л x Nr/60= 2 x л x 926/60=96.97rads-1
 Electrical Input Power = V x I = 202 x 14.4=2.909k W
 Torque produced (T) = (W-w).g.r = (12.701-6.350) kg x 9.81ms-2 x 0.11618m = 7.238 Nm
 Mechanical Output Power = Nrad/s .T = 96.97 x 7.238= 701.87W
Mech . output 701.87
 Efficiency= ×100 = ×100=24.13%
El ec .input 2908.8
 Copper loss= I2R=14.4A2 x (3.3+4.1)Ω=1534.464W
 Mech. loss= Elec. Input – Mech. output – Copper loss=(2908.8-701.87-1534.464)W=672.667W

Observations Calculations
Speed(Nr) Elec.i
Volt Curr nput Mech.outp
w Torque Efficenc copper Mech.a
W(kg) rp age ent Powe ut Power
(kg) rad/s (V) (A) (Nm) y loss(W) loss(W)
m r (W)
(kW)
12.701 6.35 926 96.97 202 14.4 2.909 7.238 701.869 24.13% 1534.46 672.667
13.608 6.35 940 98.437 202 14.2 2.868 8.272 814.271 28.39% 1492.14 561.593
14.515 6.35 940 98.437 203 14.4 2.923 9.306 916.055 31.34% 1534.46 472.481
15.422 6.8 930 97.389 203 14.8 3.004 9.822 956.555 31.84% 1620.9 426.549
16.33 6.8 910 95.295 205 15 3.075 10.86 1034.618 33.65% 1665 375.382
17.237 7.26 870 91.106 205 16 3.28 11.37 1036.149 31.59% 1894.4 349.451
18.144 7.26 850 89.012 203 16.4 3.329 12.41 1104.372 33.17% 1990.3 234.324
19.051 7.26 840 87.965 203 16.6 3.37 13.44 1182.338 35.08% 2039.14 148.518
19.958 7.26 830 86.917 202 17 3.434 14.48 1258.124 36.64% 2138.6 37.276
20.866 7.71 820 85.87 201 17 3.417 14.99 1287.449 37.68% 2138.6 -9.049
21.773 7.71 790 82.729 201 17.8 3.578 16.03 1325.898 37.06% 2344.62 -92.514
22.68 7.71 780 81.681 200 18 3.6 17.06 1393.56 38.71% 2397.6 -191.16

Separately Excited DC Motor

Armature Resistance (Ra) = 4.7 Ω

Sample Calculation
Considering first observation,

 Speed (rad s-1) = 2 x л x Nr/60= 2 x л x 1491.8/60=156.22rads-1

 Electrical Input Power(Pin) = V2 x I2 = 210 x 1=210W
  Copper loss= I22 .Ra = 12*(4.7) = 20.1W
 Mechanical loss= P2(0) = V2(0).I2(0) - I22(0).Ra =212x0.5-0.52*4.7=104.825
 Mechanical Output Power(Pout) = P2 – P2(0) = Mech. Power developed – Mech. Loss
= (Elec. input power– Armature copper loss) – Mech. Loss
= (Pin - I22.Ra) - P2(0) =[(210-12*4.7)-104.825]=100.475
P out 100.475
 Torque produced (T)= = = 0.643 Nm
Nr 156.22

Observation Calculations
Speed(Nr) Copper Mech.
V2
I2(A) I2(0)(A) V2(0)(V) Pin(W) loss Loss Pout (W) Torque(Nm)
(V) rpm rad/s (W) (W)

1 210 1491.8 156.22 0.5 212 210 4.7 104.825 100.475 0.643
2 208 1482 155.2 0.5 212 416 18.8 104.825 292.375 1.884
3 206 1480 154.99 0.5 212 618 42.3 104.825 470.875 3.038
4 206 1474.3 154.39 0.5 212 824 75.2 104.825 643.975 4.171
5 204 1466.4 153.56 0.5 212 1020 117.5 104.825 797.675 5.195
6 204 1461.4 153.04 0.5 212 1224 169.2 104.825 949.975 6.207
7 204 1455.8 152.45 0.5 212 1428 230.3 104.825 1092.88 7.169
8 200 1450.8 151.93 0.5 212 1600 300.8 104.825 1194.38 7.862
9 200 1443.1 151.12 0.5 212 1800 380.7 104.825 1314.48 8.698
10 198 1435.9 150.37 0.5 212 1980 470 104.825 1405.18 9.345

1) Series DC motor
 100

Torque(Nm
speed(rad/s) )
95 96.97 7.238
98.437 8.272
98.437 9.306
97.389 9.822
95.295 10.857
90
91.106 11.373
speed(rad/s)

89.012 12.407
87.965 13.441
86.917 14.475
85 85.87 14.993
82.729 16.027
81.681 17.061

80

75
5 7 9 11 13 15 17 19

Torque(Nm)

(i) Speed Vs Torque

(ii) Torque Vs Armature current

 18
100
Torque(Nm) Armature current(A)
7.238 14.4
17 8.272 14.2
9.306 14.4
16 9.822 14.8
10.857 15
95
11.373 16
15
12.407 16.4
13.441 16.6
14
14.475 17
Speed(rad/s)

14.993 17
Torque(Nm)

90
13 16.027 17.8
17.061 18

12

11
85

10

9
80
14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19
8
12 13 14 15 Armature16current(A)17 18 19 20

Armature current(A)

(iii)
Speed Vs Armature Current

speed (rad/s) Armature current(A)

96.97 14.4
98.437 14.2
98.437 14.4
97.389 14.8
95.295 15
91.106 16
89.012 16.4
87.965 16.6
86.917 17
85.87 17
82.729 17.8
81.681 18

(iv) Efficiency Vs Armature current

 39.0% Efficiency Armature current(A)
0.241 14.4

37.0% 0.284 14.2

0.313 14.4

35.0%
0.318 14.8
0.336 15
0.316 16
33.0%
0.332 16.4
Efficency

0.351 16.6
31.0%
0.366 17
0.377 17
29.0% 0.371 17.8
0.387 18
27.0%

25.0%

23.0%
14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19

Armature current(A)

(v) Copper loss Vs Armature current

Copper loss(W) Armature current(A)

1534.464 14.4
1492.136 14.2
1534.464 14.4
1620.896 14.8
1665 15
1894.4 16
1990.304 16.4
2039.144 16.6
2138.6 17
2138.6 17
2344.616 17.8
2397.6 18
 2450

2350

2250

2150

2050
copper loss

1950

1850

1750

1650

1550

1450
14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19

Armature current(A)

(vi) Mechanical loss Vs Speed

 680 Mechanical loss(W) Speed(rad/s)
672.667 96.97
561.593 98.437
580
472.481 98.437
426.549 97.389
375.382 95.295
480
349.451 91.106
234.324 89.012
380 148.518 87.965
37.276 86.917
-9.049 85.87
Mechanical loss(W)

280 -92.514 82.729

-191.16 81.681

180

80

-20 80 82 84 86 88 90 92 94 96 98

-120

-220

Speed(rad/s)

2) Separately excited DC motor

(vii) Speed Vs Torque
 sep. ex. DC motor
Sep. ex Dc motor series DC motor
Linear (Sep. ex Dc motor)
Speed(rad/s) Series DC motor
Torque(Nm)Exponential Speed(rad/s)
(Series DC motor) Torque(Nm)
156.221 0.643 96.97 7.238
155.195 1.884 98.437 8.272
175 154.985 3.038 98.437 9.306
154.388 4.171 97.389 9.822
153.561 5.195 95.295 10.857
153.037 6.207 91.106 11.373
152.451 7.169 89.012 12.407
151.927 7.862 87.965 13.441
155
151.121 8.698 86.917 14.475
150.367 9.345 85.87 14.993
82.729 16.027
81.681 17.061

135
Speed(rad/s)

115

95

75
0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5

Torque(Nm)
(viii) Speed Vs Armature current

sep. ex. DC motor series DC motor

speed(rad/s
) Armature current(A) Speed(rad/s) Armature current(A)
156.221 1 96.97 14.4
155.195 2 98.437 14.2
154.985 3 98.437 14.4
154.388 4 97.389 14.8
153.561 5 95.295 15
153.037 6 91.106 16
152.451 7 89.012 16.4
151.927 8 87.965 16.6
151.121 9 86.917 17
150.367 10 85.87 17
82.729 17.8
81.681 18
 sep. ex DC motor Linear (sep. ex DC motor)
Series DC motor Linear (Series DC motor)

175

155

135
Speed(rad/s)

115

95

75
0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 18.5

Amature current(A)

(ix) Pin Vs Pout

sep. ex. DC motor series DC motor

Pin(W) Pout(W) Pin(W) Pout(W)
210 100.475 2909 701.869
416 292.375 2868 814.271
618 470.875 2923 916.055
824 643.975 3004 956.555
1020 797.675 3075 1034.618
1224 949.975 3280 1036.149
1428 1092.88 3329 1104.372
1600 1194.38 3370 1182.338
1800 1314.48 3434 1258.124
1980 1405.18 3417 1287.449
3578 1325.898
3600 1393.56
 sep. ex DC motor Linear (sep. ex DC motor)
Series DC motor Linear (Series DC motor)

3650

3150

2650

2150
Pin(W)

1650

1150

650

150
0.5 200.5 400.5 600.5 800.5 1000.5 1200.5

Pout(W)

DISCUSSION

(1) Types of materials employed in construction

High grade steel: -Mainly there two advantages of using high graded steel. One is to keep
hysteresis loss low, which is due to cyclic change of magnetization caused by rotation of
the core in the magnetic field and the other one is to reduce the eddy currents in the core
which are induced by the rotation of the core in the magnetic field

Cupper (Cu): -Cu is used to make Field windings and Armature windings
 Carbon/Carbon graphite/ Graphite/Metal graphite: -Those are used to make brushes due
to its reluctance for deterioration

Insulating Material: -Insulating materials are used to provide electrical insulation between
parts at different potentials. An insulating material should have high resistivity, high
dielectric strength, low dielectric loss, good heat conductivity, sufficient mechanical
strength to withstand vibrations etc. These materials begin to deteriorate at relatively
small temperatures. For reliable operation, it is essential that the temperature rise in
electrical machines and equipment do not exceed the permissible temperature of the
insulating materials used therein.Some of the most important insulating materials used
for insulation in electrical machines and apparatus are mica, cotton, asbestos, paper and
glass

Cast iron/Cast steel/Fabricated steel: -Cast iron yokes are preferred in smaller machines;
because of its cheapness but yoke fabricated steel yokes are preferred in larger machines
due to its high permeability. Because weights of large machines are the main
considerable fact. As the permeability of cast steel is nearly twice of cast iron, the
weight of cast steel required will be only half of the cast iron if used for the same
reluctance. Pole cores are usually not laminated and made of cast steel.

(2) Part of the DC machine

Armature: -This is the rotating part of a DC motor and is built up in a cylindrical shape. The
purpose of the armature is to rotate the conductor in the uniform magnetic field. It consists of coils
of insulated wires wound around an iron and so arranged that electric currents are induced in these
wires when the armature is rotated in a magnetic field. It provide a path of very low reluctance to
the magnetic flux. The armature core is made from high permeability silicon-steel stampings, each
stamping, being separated from its neighbouring one by thin paper or thin coating of varnish as
insulation. Due to this the eddy currents in the core induced by the rotation of the core in the
magnetic field, is cut into several. The laminations should be perpendicular to the paths of eddy
currents and parallel to the flux.

Stator: -The stator is the stationary part of a rotor system. It mainly consists with stator poles pole
shoes field windings (winding that produces main magnetic flux.), etc.

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 such as armature core,
commutator, cooling fan etc. are keyed to the shaft.

Brushes: -The brushes are rectangular in shape and rest on the commutator.The function of
brushes is to collect current from the commutator and supply it to the external load circuit (the
armature of the machine being connected to the external load circuit via the commutator and
brushes). The brushes are rectangular in shape and rest on the commutator. Brushes are
manufacture in a variety of compositions and degrees of hardness to suit the commutation
requirements.

Commutator: -The commutator is a cylindrical structure and is built up of wedge shaped

segments of high conductivity hard drawn copper and the segments are insulated from each
 other. Commutator provides the electrical connections between the rotating armature coils and
the stationary external circuit, keeps the rotor or the armature mmf stationary in space, when the
rotor rotates perform switching action reversing the electrical connections between the external
circuit and each armature coil in turn so that the armature coil voltage add together and result in
a DC output voltage. So this is a main part of motor.

(3) Types of armature windings and their applications

There are several types of armature windings called Lap winding, wave winding, Non lap
winding. The difference between lap winding and wave winding is different arrangement of the end
connections at the front or commutator end of armature. Each winding can be arranged
progressively or retrogressively and connected in simplex, duplex and triplex.

 Commonly for windings these things should be considered

 The number of commutator segments is equal to the number of slots or coils because the front
ends of conductors are joined to the segments in pairs.
 The winding must close upon itself
 Both pitches should be odd, otherwise it would be difficult to place the coils properly on the
armature.
 As windings should be full-pitched the front and back pitch are each approximately equal to the
pole-pitch. This results in increased e.m.f round the coils

Lap Winding

In the case of lap winding, the end of a wire conductor is connected to the commutator, and then the
other wire end is connected to the beginning of the next coil segment. This winding configuration
refers to the fact that the wire "laps over" each segment as the winding structure reaches its
terminus.

Wave Winding

With wave winding, one wire conductor is wrapped under one pole, and then connected to the back
of the next pole. In this case, the series of wire conductors do not directly overlap, but when it's
completed, the structure looks like a series of copper "waves" wrapped around the commutator.
Non-Lapped Winding

Non-lapped winding refers to a wire process that does not employ overlapping at any point across
the commutator but employs a linear side-by-side configuration from the front to the rear of the
structure.

(4) Performance characteristics of the DC Series Motor

Rated load

EFFICIENCY IN PERCENTAGE

ARMATURE CURRENT IN A

SPEED IN rpm

TORQUE IN Nm

In the above figure, four important characteristics of a DC series motor, namely torque,
speed, current and efficiency, each plotted against useful output power, are shown.

Components of a series motor include the armature and the field. The same current is
impressed upon the armature and the series field. The coils in the series field are made of a few
turns of large gauge wire, to facilitate large current flow. This provides high starting torque,
approximately 2 ¼ times the rated load torque. Series motor armatures are usually lap wound. Lap
windings are good for high current, low voltage applications because they have additional parallel
paths for current flow. Series motors have very poor speed control, running slowly with heavy
loads and quickly with light loads.

A series motor should never drive machines with a belt. If the belt breaks, the load
would be removed and cause the motor to over speed and destroy itself in a matter of seconds.
Common uses of the series motor include crane hoists, where large heavy loads will be raised and
lowered and bridge and trolley drives on large overhead cranes. The series motor provides the
starting torque required for moving large loads. Traction motors used to drive trains are series
motors that provide the required torque and horsepower to get massive amounts of weight moving.
On the coldest days of winter the series motor that starts a car overcomes the extreme cold
temperatures and thick lubricant to get the car going.

(5) Performance characteristics of the separately excited DC motor

Mainly there are two methods to control the speed in safe operate region which are
called armature control and field control. In armature control there is a constant torque while
constant power in the field control

Т
Armature control Field Control

The separately excited DC motor is probably the most common dc motor used in industry
today. Components of the separately excited DC motors are the armature and the field. The coils in
the shunt field are composed of many turns of small wire, resulting in low shunt field current and
moderate armature current. This motor provides starting torque that varies with the load applied
and good speed regulation by controlling the shunt field voltage. If the separately excited DC
motor loses its field it will accelerate slightly until EMF rises to a value sufficient to shut off the
torque producing current. In other words, the shunt motor will not destroy itself if it loses its field,
but it won’t have the torque required to do the job it was designed for. Some of the common uses
of the shunt motor are machine shop lathes, and industry process lines where speed and tension
control are critical.

When comparing the advantages of the series and separately excited DC motor, the
series motor has greater torque capabilities while the separately excited DC motor has more
constant and controllable speed over various loads.

(6) Difference between performance characteristics of series DC motor and

separately excited DC motor.

Torque
Series DC motor
Separately excited DC motor
 Speed (ω)

When you increase the load, Speed of Separately excited DC Motors will nearly remain
constant where as speed of series DC Motors will drastically decrease. Therefore shunt DC Motors
is more suitable for traction applications. Separately excited DC meter has good speed
controllability, safe no load speed and good speed controllability.

In series DC motor it can give high torque at starting without demanding similar high power.
Series DC motor has high torque capability and reasonable good power cushioning ability. But
Unlike Separately excited DC motors, series DC motors can produce high starting torques.
Therefore series DC motors are more suitable for starter applications.

(7) Applications of motors with limitations

1. Shunt excited dc motors

These have fairly constant speeds against a varying load or torque. Therefore applications include
situations where a constant speed is required. (E.g. Lathes, Conveyors, Fans, Machine tool drives )

2. Compound excited dc motors

These have Combine characteristics of both shunt and series wound motors. The series winding
gives good starting torque and shunt winding ensures a comparatively constant speed. (E.g. Planers,
Shears, Guillotines, Printer machines, Power presses which needs peak loads at certain instances)

3. Permanent magnet motors

These are used for low power applications. (E.g. Automobiles, Starter motors, Wiper motors,
Lowering windows, Toys, Electric tooth brushes)

4. Adjustable speed DC shunt motor

Starting torque should be medium. Usually limited to 250% by a starting resistance but may be
increased. Maximum momentary operating torque-usually limited to about 200% by commutation.
Speed regulation-10-15%. Speed control-6:1 range by field control, lowered below normal speed by
armature voltage control.

Used for constant speed applications which require medium starting torque & which
require adjustable speed control, either constant torque or constant output.

5. Differential compound wound DC motor with relatively weak series field

 It has almost constant torque, constant speed and tendency towards speed instability with a
possibility of motor running away and strong possibility of motor starting in wrong direction.
Applications are mainly for experimental and research work

REFERENCES

Electrical Machines and Drive Systems, by C.B.Gray

Electrical Machines, by Draper

Machine Elements in Mechanical Design, by Robert L. Mott.

http://electricalandelectronics.org/2009/04/29/types-of-armature-windings/,