Topic 5:: DC Generators/Motor Theory

UNIVERSITI KUALA LUMPIR
Malaysian Institute of Aviation Technology
TOPIC 5 :
DC GENERATORS/MOTOR THEORY
Subject Code AAB 10403 & AGD/AID/AHD10303

Revision : 00 Page No :1 Date : 14/01/ 08
Issue No : 01
5. DC Generators Theory
 Based on Faraday’s Law
Faraday’s Law state that when a conductor (loop) cut a
magnetic field or a magnetic field cut a conductor,
electromotive force (emf) is induced into the conductor.
Mechanical energy (rotation of the loop) is converted into electrical
energy (induced emf).
The magnitude of induced emf generated depend upon:
Magnetic field’s flux density or strength (B)
Length of conductor (l)
Relative motion or speed of cutting (v)
 Formula - Induced EMF (e) = B l v

Issue No : 01
5. DC Generators Theory (cont’d)

 Principle of Operation

Issue No : 01

A – The loop lies at right angle/perpendicular to the magnetic field. No
voltage induced since the loop’s movement is parallel to the flux
line.
B – As loop rotates and the cut flux lines to 90 degrees, voltage is
increasingly induced to the maximum.
C – When loop rotates from 90° to 180° , the cutting of the flux line will
be gradually reduced thus the voltage induced will drop to zero.
D – As loop rotate further to 270 degrees, the voltage induced will be
maximum again at negative value.
A - As rotation continues, the number of flux line cut decreases and
induced voltage reduces to zero thus return to the first position.
Issue No : 01

The direction of the
induced emf into the
conductor can be
determined by using:
Fleming’s Right Hand Rule –
Conventional flow (UK) .
Left Hand Rule – Electron flow
(US) .
Thumb – Motion.
1st Finger – Field.
2nd Finger – Current.

Issue No : 01

Principle of Operation
 The output of a simple generator is alternating current (AC).

Issue No : 01
 The AC is converted into direct current (DC) by a switching system known

as a commutator.
 A commutator is basically two half-cylinders and is connected to the
external circuit through stationary brushes.
Issue No : 01
As the loop rotate, the commutator allows one brush to contact with the
conductor that moves downward and the other brush in contact with the
conductor that moves upward as ‘B’ and ‘D’. This commutator action
produces pulsating DC voltage that varies from zero to maximum twice in
one revolution.
Issue No : 01

 To reduce the ripple of DC
voltage, more loops are
added.
 Increase in loops:
 will increase the number of
commutator segments.
 will smoothen the ripples and
generate enough DC power
supply.
 does not increase the maximum
value of the generated voltage.
 The value of the generated voltage can be increased by
increasing the number of turns in each loop.
Issue No : 01

 DC generators consists of:

Issue No : 01

1. Field frame or Yoke:
 made of iron, cast or rolled steel.
 highly permeable, low reluctance
and structurally strong.
 serve two purpose:
 completes the magnetic
circuit between the poles.
 acts as a mechanical
support for other parts such
as field poles, terminals,
end frames and sometimes
brush holder.

Issue No : 01

2. Commutator and Drive End
Frames or Covers:
 made from the same material and
construction as the field frame.
 housed roller bearings at
commutator end frame and ball
bearings at drive end frame.
 also sometimes serve as
mechanical support for brush
holder.

Issue No : 01

3. Field Poles or Shoes
 permanent magnet which made from
high quality magnetic iron or sheet
steel.
 bolted to the inside of the yoke.
 laminated to reduce eddy current losses
and concentrate the line of force.
 provide residual magnetism to initiate
generator’s operation.
 salient poles – design to project inwards
from the frame to reduce air gap
between poles and rotating armature
thus increase generator’s efficiency.
Issue No : 01
4. Field Coils or Windings

 pre-formed coils that are made of
many turns of insulated wire.
 securely mounted on the pole
shoes.
 used to produce magnetic field
around the shoes and increase
its strength by passing current
through the coils.

Issue No : 01

5. Brushes
 must have low contact and electrical
resistance, low coefficient of friction
and good lubricating properties.
 made from graphite carbon or
carbon mixed with molybdenum
disulphide (lubricating ingredient)
 ride on the surface of the commutator and act as the electrical contact
between armature coils and external circuit.
 pig-tail, a flexible braided copper conductor, connect each brush to
external circuit via brush holder and generator’s main terminals.
 brush holders held the brushes in place by spring pressure to
maintain good contact on the commutator.
Issue No : 01

6. The Armature Assembly
 The rotating part of the generator.
 Consists of a shaft, iron core, armature
or output winding and the commutator.
A. The shaft
 Rotates in bearings located in the generator’s end frame.
B. The iron core
 Provides a low reluctance path between field pole pieces.
 Increases flux density.
 Laminated to reduce eddy current.
 Provides longitudinal slots for armature winding which is kept in placed
by wooden or fiber wedges.
Issue No : 01

C. Armature or output winding
 Generate induced e.m.f.
 Wedged in the slot of the iron core to prevent being
thrown out due to centrifugal force.
 Two type of winding configurations:
Wave windings
 Employed in high voltage, low current output
applications.
 Each coils are connected to commutator segments
separated by the distance between poles.
 Allows the addition of voltages by connecting the
winding in series between brushes.
 Requires only one pair of brushes.
Issue No : 01
C. Armature or output winding

(cont)
Lap windings
 Employed in high current, low
voltage output applications.
 Each coils are connected to provide
several paths in parallel for current
in the armature.
 Requires several pairs of poles and
brushes.

Issue No : 01

D. Commutator
 Located at the non drive end of the
armature.
 Consists of wedge-shaped
segments of hard-drawn copper.
 Insulated from the shaft and from
each segment by a thin sheet of
mica.
 Held in place by steel V-rings or
clamping flanges fitted with bolts.
 Some assemblies have a raised portion called riser to which
armature winding leads are soldered for each segment.
 Mica insulations between each segment are undercut to about the
same depth as the mica’s thickness or approximately 0.02 inch.
Issue No : 01

 AFFECTING FACTORS
1. Heat
 Limits the output of a generator.
 Developed in the steel or iron of the
magnetic system due to flux
changes.
 Developed at the commutator and
brush gear due to current flow.
 Dissipate by ram air using external
scoop and ducting or an integral
electrically operated fan or
combination of both method.

Issue No : 01

2. Generator Armature Seizure
 Jamming of generator’s armature rotation due
to bearing failure.
 Generator drive system can be disconnected
from the gearbox by the use of ‘quill drive’.
 ‘ Quill drive’
 a drive shaft that has a smaller diameter
section between the spline drive that will
shear if excessive torque is applied.
 To prevent generator damage incase of
armature seizure happen.

Issue No : 01

3. Internal Voltage Drop IA RA
 Caused by resistances from EMF TERMINAL LOAD

the armature windings and (E) G pd (V)
brushes when supplying
current to the load.
 Due to this the terminal
voltage (V) is equal to “E – IA x Generator
RA. Terminal pd
(V) IA RA
 As load increases, the terminal at Full
voltage decreases further. load
 In practice, a voltage regulator V = Generator

keeps the generator output Terminal pd at Full
Load
voltage constant under all load
conditions. Full Load Current
Issue No : 01

4. Reactance Voltage
 Occur when the current collapses at
the plane or point of commutation
(the brush shorting the coil) which
produces a changing field and cuts
the coil to induce back e.m.f.
(reactance voltage)
 As the armature rotate to the next
commutator segment at no. 1, the
current produced on the coil is
opposed by the reactance voltage
and cause some of the current to
flow to segment 2 and jump to the
brush.

Issue No : 01

4. Reactance Voltage (cont.)
 This action is called reactive
sparking and occurs at each point
of commutation for every coil.
 Reactive sparking will cause brush
wear, commutator wear and
interference to radio system.
 One method to overcome this
problems is to use Interpoles.
Note: In some generator, interference with radio reception due to brush

sparking is prevented by installing suppressor, consists of capacitors
connected between generator casing and the main terminals.
Issue No : 01

 Interpoles:
 small poles located between the
main poles.
 windings are connected in series
with the armature.
 has the same polarity as the next
main pole ahead in the direction
of rotation.
 placed at the point of
commutation and carry the same
current as the armature winding.
Issue No : 01

 Interpoles:
 magnetic fields will attempt to
induce an e.m.f that is opposite
the magnetic fields which produce
the reactance voltage.
 Both fluxes cancel each other, thus
no reactance voltage and reactive
sparking.

Issue No : 01

5. Armature Reaction:
 The distortion of the main field caused by the interaction between the
main field and the armature field produced when current flow in the
armature windings.
 Will cause the shifting of the brush position from Geometric Neutral
Axis (GNA) to Magnetic Neutral Axis (MNA).

Issue No : 01

5. Armature Reaction (cont):
 The shifting depend on the load, the higher the load the more will be
the angle of lead.
 To prevent arcing, the brush position would have to be continually
adjusted.

Issue No : 01

 Methods used to overcome the problems are:
A. Compensating Windings
 placed into the slots in the main
pole faces and parallel to the
armature windings.
 connected in series with the
armature winding and its current
varies directly with load current.
 current is made to flow in the opposite direction of the armature
winding and the two magnetic fields produced will neutralize
each other thus preventing armature reaction.
Issue No : 01

B. Interpoles with Auxiliary or Bias Windings
 to obtain a correct interpole strength
over all load and speed ranges.
 auxiliary windings is wound on the
interpole and connected in series with
the main field.
 at high speed and heavy load, the bias winding gave little
opposition to the strong interpole magnetic field which is needed to
suppress reactance e.m.f.
 at low speed and heavy load, the bias windings will oppose the
interpole windings in reducing its strength and increase the
efficiency of the generator.
Issue No : 01

 DC generators are classified in accordance to the method
by which the magnetic circuit is energized.
 The methods are:
1. Permanent Magnet Generator.
 the field is provided by high grade
permanent magnets.
 the armature consists of iron core
carrying a single coil connected to 2
commutator segments.
 used in small generators and the older
type of meggar.
 characterized by a slight drop in voltage
as more load is applied due to armature
reaction and resistance losses.
Issue No : 01

2. Separately Excited Generator.
 the field winding is connected to an
independent source of DC supply .
 the field winding has a fairly high
resistance and the current can be
regulated by a variable resistor.
 no practical application on aircraft.
 characterised by a slight drop in voltage
as load current is increased due to
resistance losses.

Issue No : 01

3. Self Excited Generators.
 current initially obtained through residual magnetism from field poles to
start generator operation.
 further classified by the method the field winding is connected to the
armature.
A. Series wound
 field coils are wound in series with the
armature.
 consists of few turns of low resistance and
large cross sectional area copper wire.
 strength of magnetic field depends more on
current flow rather than number of turns in
the coil.
 possess poor voltage regulation capabilities.
Issue No : 01

A. Series wound (cont) – operation.
 initial rotation of the armature cuts the
residual magnetism and induced some
output voltage which is used to increase
field voltage.
 increase field voltage will increase output
voltage further.
 when approaching saturation point of the
magnetic circuit, the rise in terminal
becomes more gradual and maximum
terminal voltage is attained when
reaching the point.
 any further increase in load current will not increase in terminal voltage
due to increase in IR drop in the armature and field winding.
 not suitable for aircraft use except in application where a constant RPM
and load is warranted.
Issue No : 01

B. Shunt wound (most used on aircraft)
 field winding has many turns of fine high
resistance wires.
 magnetic strength is derived from large
numbers of turns rather than the amount
of current.
 field winding is connected in parallel with
the armature.
 used on aircraft with DC as its main
power source
 initial operation is similar to series
wound.
 Increase in field voltage will generate
the induced voltage further until a steady
open circuit value is attained.
Issue No : 01

B. Shunt wound (cont) - operation
 when load is applied, the terminal
voltage tends to drop due to IR drop in
armature winding.
 the IR drop will also reduces field
excitation and cause a further fall in
terminal voltage.
 if load current is increased above the
full load, the voltage will began to drop
to zero.
 the falling voltage will not be able to supply enough current to the
field winding in sustaining the load current which lead to a condition
called ‘tuck under’ or ‘turn under’.
 to avoid ‘turn under’ condition, the generator should be allowed to
build up to its correct voltage before load is applied.
Issue No : 01

C. Compound wound
 field windings are the combination
of series and parallel wound.
 the output voltage produced
depend on the degree of
compounding.
 degree of compounding depend on
the working relationship of both the
series and parallel winding.

Issue No : 01

C. Compound wound (cont)
 Flat or level compound
 the series wound is arranged so that
the output voltage at no- load and
full-load have the same value.
 Over-compound
 the series wound is increased so
that the full-load voltage is higher
than no-load voltage.
 Cumulative compounded generator
 the series field aids the shunt field in producing the output
voltage.
 Differential / under compounded generator
 the series field opposes the shunt field in producing output voltage.
 has a full-load voltage less than no-load voltage.
Issue No : 01

DC Generator Maintenance
 Purpose is to keep the generator in good working order.
 Maintenance work is carried out at each check interval as
specified in the aircraft maintenance schedule.
 Inspection and servicing is carried out in accordance with
manufacturer’s instruction.
 Overhaul is often accomplished at the same time as engine
overhaul thus minimize aircraft down time.
 Routine Inspection and Servicing
 Generally, routine inspection and servicing is carried out as follows:
• Inspect for security of mounting.
• Inspect mounting flange for oil leaks.
• Inspect electrical connections for cleanliness and security of attachments.
Issue No : 01

 Routine Inspection and Servicing (cont)
• Inspect area around the commutator and brush assemblies for any
solder particles. Loose solder particles indicate generator has
overheated.
• Use compressed air to blow out accumulated dust around the brushes
and commutator.
• Inspect brushes for wear and freedom of movement.
 Troubleshooting – based on systematic analysis of the
situation to determine the cause of malfunction and remedial
action:
 Generator not charging battery:
 Check the aircraft electrical system associated with the battery and
generator such as:
• Every connection in the generator and battery circuit.
• Condition of all fuses and circuit breakers.
Issue No : 01

 Generator not charging battery: (cont)
• Condition of all ground connections for battery, battery contacts,
and the generator control unit.
• With engine cranked, check armature rotation.
 Use voltmeter to check generator output by placing the probes
between ‘G’ terminal of voltage regulator and ground.
 Accomplished with engine running or on appropriate test stand.
 Performed in accordance with the manufacturer’s
recommendations and observe proper safety precautions.
 Check for residual voltage – around 1 or 2 volts.
 If no residual voltage – can be restored by an operation known as
‘flashing the field’.
• The operation is accomplished by momentarily passing current
through the field coils in the same way that is normally flows.
Issue No : 01

 Generator not charging battery: (cont)
 If there is residual voltage but no output voltage – the trouble
could be with the generator or the regulator.
• Operate the engine at a speed the generator can produce an
output.
• Bypass or short circuit the voltage regulator.
• If generator produced voltage, the problem is with the regulator
and vice versa.
• If the generator is the problem, send generator for overhaul or
replaced with a serviceable unit.

Issue No : 01

 Generator Overhaul
 Steps involved in the overhaul of a generator are:
Disassembly
 Follow instructions as
specified in
manufacturer’s overhaul
manual.
 Generally use proper
tools and procedures to
disassemble the parts.

Issue No : 01

 Generator Overhaul (cont)
2. Cleaning
 Proper solvent must be used as wrong solvent could remove the lacquer-
type insulation used on field and armature coils resulting in short circuit.
 Generally do not submerged parts in the solvent.
3. Inspection and Repair
 Testing for proper operation of electrical
components is accomplished using a
growler and a multimeter.
 Growler – a test unit specially design for
DC generators and motors.
 Consists of a laminated core wound with
many turns of wire and form the primary
coil of a transformer.
 Some include a test lamp which illuminates
if the circuit is complete.
Issue No : 01

 Armature Coil Testing - place
armature on energized growler.
 Use test lamp with probes placed
on each commutator segment to
check for open coil failure.
If test lamp fail to illuminate – coil
open.
 Open coil can also be checked
using ohmmeter which will indicate
infinity if open exists.

Issue No : 01

 Armature Coil Testing - place
armature on energized
growler.
 Use a thin steel strip or a
hacksaw blade and placed
slightly above the armature
and rotate armature to check
for shorting failure.
 Indicated by the blade
vibrates vigorously.

Issue No : 01

 Armature Coil Testing
 Use test lamp or ohmmeter with one
probe placed on each commutator
segment and the other on shaft to
check for ground failure.
 Test lamp illuminates indicate ground
exists.
 Ohmmeter indicate continuity for
ground failure.

Issue No : 01

 Field Coil Testing
 Use test lamp with one probe placed at field
coil and the other at generator frame to check
for shorting failure.
Test lamp illuminates indicate short exists.
 Use ohmmeter with probes placed between
field coil terminals to check for continuity.
 Shunt field – indicated by resistance
between 2 to 30 ohms.
 Series field – almost no resistance.
 Open indicated by infinity.
Issue No : 01

 Commutator Inspection
 Checked for irregularities and pitting.
Slight roughness can be smoothen by using number ‘000’ sandpaper.
Never use emery cloth or other conductive material as these could
cause shorting.
Mica should be undercut about the same depth as mica’s thickness or
approximately 0.002 inch.
 Brush Inspection
 Generally brushes is replaced at overhaul or when half worn.
• Ensure the new brush is seated or contoured to maximize the
contact area on the commutator.
• Accomplished by using no. 000 sandpaper inserted under the
brush between the commutator and pulled in the direction of
rotation to shape the brush contour.
 Checked spring tension using spring scale.
Issue No : 01

4. Reassembly
 Prior assembly, ensure exterior paintwork is restored.
 Ensure internal electrical connection is secured.
 Checked pigtails on the brushes for freedom and ensure they do
not restrict the brushes free motion.
 After assembly, run the generator for a short period and reinspect
to ensure no sands are imbedded in the brush.
5. Operational Testing
 Accomplished on test benches built for the purpose.
 Operated in accordance to manufacturer’s instruction.
Issue No : 01
5. DC Motors Theory
 Principle of operation
 Converts electrical energy to mechanical energy
 When current flow through a conductor, magnetic field is set up
around the conductor.
 The direction of these magnetic field encircle the conductor
depends on the direction of current flow.
Corkscrew rule: To determine direction of

magnetic field on conventional flow current.
Issue No : 01
5. DC Motors Theory (cont’d)

 When the current carrying conductor is placed
in the magnetic field, an interaction between
the conductor field and pole field occurs.
 The conductor field that is in the same direction
as the pole field will strengthen the main field
while those oppose will weaken the field.
 The resultant outcome is the stronger field will
push the conductor in the direction of the
weaker field and force out from the main field.
 This magnetic force can be calculated using
the formula F = B L I.
Note: F - Force in Newtons, B - Flux density in
Teslar, L – Length of conductor in metres, I –
Current flowing in conductor in Amperes.
Issue No : 01

 When a current- carrying coil or loop is
placed in the magnetic field, the resultant
magnetic force will produce a torque that
rotate the coil.
 The amount of torque developed
depends on:
 strength of magnetic field.
 number of turns in the coil.
 the coil’s position in the field.
 Torque (T) is directly proportional to (∝)
magnetic field strength (ϕ) and current  The Torque loss vary in
(IA). speed.
Output Torque (Shaft Torque) =
 Equation: T ∝ ϕ x IA (Nm) Armature Torque – Lost Torque
Issue No : 01

 To determine the direction of conductor’s movement:
 UK – use Flemings Left Hand Rule
 US – use Right Hand Motor Rule

Issue No : 01

 Basic DC Motor Operation
 The coil is powered by DC supply.
 DC is supplied to the coil through
the brushes and commutator.
 Magnetic field is setup in the coil
and the interaction between the two
fields will produce a torque to turn
the motor.
 The commutator will reverse the
current at each half of the
revolution to maintain the torque
rotating the coil in the same
direction.
 In practice, motor needs a starting
circuit to start the motor turning.
Issue No : 01

 The construction of DC motor is identical to DC generator.
 Armature Assembly.
 Soft-iron core - laminated and insulated from each other to reduce
eddy current effect and excessive heat.
 Armature copper windings - larger and shorter conductors than in
a generator and connected to the commutator segment.
 commutator segment -
insulated from each other
and the shaft by mica.
 steel shaft – where the
iron core and commutator
are mounted.

Issue No : 01

 Field Assembly.
 Field Frame or Case - mount for field
poles and terminals
 Pole pieces - can be permanent or
temporary magnet.
 field coils - several turns of insulated wire
fit over each pole pieces
 Brush Assembly.
 Brushes – made from graphite carbon
due to its long service life.
 Brush holders – allow the brushes to
move and utilize springs to hold them
against the commutator for better contact.
 End Frames – the parts where the armature assembly rotates in.
Issue No : 01

 Back EMF or Voltage
 Induced in the armature when it rotates
and cuts the main magnetic fields.
Sometimes called ‘Generator action in
a motor’.
 Opposed the applied voltage to the
armature and reduces the effective or
armature voltage.
 Control the current in the motor.
 Formula:
Effective Volt. = Applied Volt. – Back EMF
IA RA = V - EB
Issue No : 01

 Back EMF or Voltage inherently control the speed of the motor with
respect to load conditions.
 Reduce load:
 armature torque becomes greater than load torque which cause the
motor to speed up and increase back emf.
 increased back emf will reduce armature current which in turn reduce
the armature torque to eventually equal the load torque and cause the
motor speed to stabilize.
 Increase load:
 armature torque is less than load torque which cause the motor to slow
down and reduce back emf.
 less back emf will increase the armature current to cause the increase in
armature torque until both torque is balanced to stabilize the motor
speed.
Issue No : 01

 Torque Loss
 Due to friction in the bearings and wind resistance of the armature or
fan if fitted.
 Will vary with speed.
 Formula: Output Torque (Shaft Torque) = Armature Torque – Lost Torque
 Output Power (P)
 Proportional to torque (T) and speed (N).
 Formula: P ∝ T x N
 To maintain a given power, a motor can either has a strong torque at low
speed or low torque at high speed.
 To maintain the same speed with increase torque, the motor must develop
increased power.
Issue No : 01

 Reactive Sparking and Armature Reaction
 Occurs in motor for the same reasons as in generator.
 Reactive sparking
 Due to the collapse of armature current at the plane of commutation
and induces an e.m.f that opposes the build up of the initial current.
 Armature Reaction
 Due to the distortion of the main field by the armature field but unlike in
the generator, the MNA is moved backwards against the direction of
rotation.
 In some larger motors interpoles are used to counteract the effect of both
Reactive Sparking and Armature Reaction.
 Motors that require a high standard of commutation use compensating winding
to counteract armature reaction.
Issue No : 01

 Motors are classified:
1. By the type of connection between field and armature.
2. By the type of duty they are designed for
1. Type of Connection
 Series DC Motor
 the field windings are connected in
series with the armature.
 all current flow through both field coil and
the armature and create strong magnetic
flux in both parts (I armature = I field).
 field winding consist of heavy wires (thick)
and relatively few turns.
Issue No : 01

 Series DC Motor (cont)
 high starting torque due to high starting
current that flow in both armature and
field winding.
 poor speed control - speed depends
on load applied and any changes in
load cause change in speed.
 NEVER runs ‘OFF LOAD’.
 ‘off load’ operation will cause
excessive high speed of the armature.
 often use as starters, loading gears
cowl and wing flaps.

Issue No : 01
 Shunt DC Motor
 the field winding are connected in
parallel with the armature.
 the field winding consist of many
turns of fine copper wires and has
higher resistance than the armature
windings.
 since the field winding is connected
directly across the supply, current
flow through the field is constant.

Issue No : 01

 Shunt DC Motor (cont)
 low/medium starting torque due to only
the armature producing a strong
magnetic flux.
 self regulating machine which
automatically adjust its speed when
subjected to new load.
 as load increase:
i. motor slows down initially.
ii. back emf decreases.
iii. armature voltage and current increases.
iv. torque increases to match new load and
speed increases to its original value.
Issue No : 01

 Shunt DC Motor (cont)
 as load decreases, the opposite
will happen.
 operated initially on light load or
‘off load’ condition until reaching
its full speed before the load is
applied.
 used on applications that require
constant speed, such as inverter
drives, windscreen wipers and
fuel pumps

Issue No : 01

 Compound DC Motor
 contains both series and shunt field
winding.
 Two types:
A. Cummulative Compound Motor
 Both fields are wound to assist each other.
 Can be either series or shunt predominate.
 If series field predominate, the motor has
all the characteristic of a series motor with
the shunt field preventing any ‘off load’
speed condition.
 Used to start aircraft engine where high torque at low speed is required.
Issue No : 01

A. Cummulative Compound Motor
(cont)
 If shunt field predominate, the
motor has all the characteristic of
a shunt motor with the series
field provide a fairly high starting
torque and allowed the motor to
be started on reasonable load
condition.
 This type of motor is also known
as a normal compound motor.
 Used on DC systems for inverter
drives and fuel pumps as well as
heavy duty actuators.
Issue No : 01

B. Differential Compound Motor
 The shunt and series field windings
are wound to oppose one another.
 Characterized by a constant motor
speed at low and middle load but
increase in speed as load increases
further.
 Problems:
 If overloaded, the field strength of
both fields will cancel each other and
no torque is produced to rotate the
motor.
 The tendency to start in the reverse direction due to build up of
magnetic fields at series winding first before the shunt winding.
Usually avoided by short circuiting the series winding on start.
Issue No : 01

2. Type of Duty
 Intermittent Duty
 Operated for short period only.
 Allowed to cool down before being
operated again.
 Example: Starter motor.
 Continuous Duty
 Operable at their rated power for
long period.
 Example: Hydraulic Motor

Issue No : 01
 The direction of a motor can be

reverse:
 by reversing the flow of current to
either the armature winding or field
winding.
 This will reverse the magnetism of
either the armature or field poles.
 On aircraft it is normal to reverse
current flow through the armature
by means of reversing relay.

Issue No : 01
 by employing two field windings wound in opposite direction on

the same pole.
 This type of motor is known as split field motor.
Issue No : 01

 Split field motor – Series field
 Used extensively on aircraft.
 Operated to move an actuator up
or down; or in or out by selector
switch.
 Operation:
i. Selector switch in close position.
ii. Open limit switch will be open, close
limit switch will be closed.
iii. Current flow to the close/ccw coil to the motor and energized the
brake solenoid to free the brake.
iv. Motor starts to run until the end of its travel of which the actuator
opened the close limit switch.
v. With circuit opened, the current stopped flowing and the brake
solenoid de-energized to automatically stopped the motor
Issue No : 01

Energy Losses
 When energy being converted from electrical to
mechanical (motor) or mechanical to electrical
(generator), some losses occur.
 In order for the machine to be efficient, the losses must be kept
to the minimum.
 Energy losses divide into 2 classes :
 Electrical losses
 Mechanical losses

Issue No : 01

 Electrical Losses
 Copper Loss
• when electron flow through copper armature and field
winding, heat (power) is dissipated i.e. P = I²R.
• increase as current increase and heat generated,
R = Length
Area
• to minimize losses, use larger diameter wire.
 Iron Losses –
• Hysteresis losses
• result form the armature revolving in an alternating magnetic
field and becoming magnetized in 2 directions.
• Some residual magnetism remains after change in direction
• to change this residual magnetism it required energy thus
energy losses.
Issue No : 01

 Eddy current losses
 occur because the armature iron core acts as conductor.
 Induced Emf cause current to flow within the core.
 the current heat the core and can damage the winding if
excessive.
 to reduce heat generation, the iron core is laminated and
insulated.
 Mechanical losses
 Friction on various moving parts.
 between commutator and carbon brush.
 between both end bearing to hold the armature.

Issue No : 01

Starter Generator
 The combination of a starter motor and a generator.
 The starter is supplied with DC current to start an
engine.
 Once started, the motor becomes a generator and
supplies current to the operating systems via bus bars.
 Consists of self-excited compound wound machine
with low resistance series field winding and high
resistance shunt field winding.
 Compensating and interpole windings is included to
prevent armature reaction and reactance voltage.
 The machine is cooled by an integral cooling fan and when airborne cooled
by ram air.
Issue No : 01

 Starter Generator Operation:
 In starting mode, the machine acts as a series
wound motor to provide the necessary torque
and acceleration to the engine.
 A speed sensor is used to signal starter cut-off
when the engine is nearing self sustaining
speed.
 At changeover, the starter drive to the engine is
disconnected and the machine becomes a
generator, self exciting its own shunt field.
 When the voltage is sufficient, it will be automatically connected to the
bus bar to power the aircraft.
 Advantage – weight saving as compare to a system having a separate
starter and generator.
Issue No : 01

Long Shunt & Short Shunt
 Two possible connection methods
for compound generator and
motor.
 Purpose is to obtain a specific
characteristics of the machine.
 Long shunt – the shunt field
winding is parallel to both
armature and series field winding.
 Short shunt – the shunt field
winding is parallel to the armature
winding only.

Issue No : 01

Voltage Regulation
 Generator output voltage can be
conveniently controlled by controlling
the strength of the field current that flow
to the field coils.
 To control this field current a voltage
regulator is used and is connected in
series with the field coils.
 To illustrate the working principle
of a voltage regulator, a rheostat
is installed in the field circuit of a
simple generator.

Issue No : 01

Voltage Regulation (cont’d)
 Rheostat resistance increased
 Less current flows through the field
winding.
 The field magnetic strength is
decreased and reduces the current
induced at the armature windings.
 The generator’s voltage output is
consequently decreases.
 The opposite will happen if the rheostat resistance is decreased.
 The circuit is improved by adding a solenoid to control the field
current in order to keep the output voltage constant.
Issue No : 01

 Vibrating-type :
 Consists of a voltage coil which
is in parallel to the field coil and
contact points in series with the
coil.
 When the supply is under or at
the required voltage, the
contact points remain closed as
the magnetic strength from the
voltage coil is not enough to
overcome spring tension to
open the points.
 More current will flow through the contact points rather than the resistor
to the shunt field and cause more voltage to be developed further.
Issue No : 01

 When the supply is more than the
required voltage, the voltage coil will
have enough magnetic strength to
overcome the spring tension and open
the contact points.
 The current has no choice but to flow
through the resistor and cause less
current to flow to the shunt field.
 Less voltage will be developed at the armature and the output voltage
is reduced.
 The effect of reduced voltage will cause the voltage coil magnetic
strength to be weaken and contact points are closed by spring
tension.
 This process will be repeated in keeping the output voltage constant.
Issue No : 01

 Three – Unit Regulator
 consists of the following
units:
 Voltage regulator (VR) –
to maintain output voltage
constant.
 Actuated by increase in
line voltage.
 Current Limiter (CL) – to
limit the output current of
the generator.
 Actuated by increase in line current.
 Reverse Current Cutout (RCC) – to prevent the battery from discharging
through the generator if output voltage falls below the battery output.
 Employed in many light aircraft.
Issue No : 01

 Operation:
 Initial starting, the
armature supply current
to:
 Field coil through VR n/c
contact points and CL n/c
contact points; and back
to the armature,
 VR voltage coil and back
to armature.
 CL current coil and RCC voltage coil and back to the armature.
 The magnetic field produced by the coils is not enough to open or
close the respective coils.
Issue No : 01

 Operation:
 When the terminal voltage rise
at predetermined value, the
supply current will flow to:
 RCC current coil to close the
contact points.
 Busbar through CL current coil,
RCC current coil, RCC contact
points.
 From busbar, the current is distributed to the loads and charging the
battery .

Issue No : 01

 Overvoltage condition:
 VR voltage coil produces
enough magnetic field to open
the points.
 The current is directed to the
lower half of the VR coil and
flow to VR resistor and CL
points before flowing to the
field coil.
 The field coil will produce less magnetic field to reduce the armature
voltage and thus maintain output voltage at predetermined value.
 The cycle to maintain the output voltage occurs many times per
seconds and cause the points to open and close rapidly.
Issue No : 01

 Overcurrent condition:
due to increase in load
 CL current coil produced
enough magnetic field to
open the points.
 From the VR points the
current flow to CL
resistor before flowing to
the field coil.
 The field coil will produce less magnetic field to reduce the output
current and maintain to its predetermined value.
 Similar to VR, the points will vibrate to close and open in maintaining the
generator’s output.
Issue No : 01

 Undervoltage condition:
output voltage less than
battery voltage.
 Initial current from the
battery flow to the RCC
current coil and
neutralize the magnetic
field from the voltage
coil.
 The RCC contact points is opened by the spring and prevent the
battery from discharging through the armature and motor the
generator.
 The current is then routed to the generator warning light to warn the
pilot of the generator low voltage.
Issue No : 01

 Carbon-Pile Voltage Regulator
 Use in generators that require high
field current.
 Consists of:
 Carbon stack – a series of disks
arranged in a stack or pile.
In series with field coil.
 Rheostat - controlled the amount of
current to electromagnet coils.
 Electromagnet – exerts a pull on the carbon stack to increase
resistance thus reduce field current.
 Leaf Spring – compress the carbon stack to reduce the resistance
thus increase field current.
Issue No : 01
Operation:
 Overvoltage condition
 Current from the armature flow
to the electromagnet coil and
provide the magnetic field
strong enough to pull the
carbon pile against spring
tension and increase the
resistance.
 Field current passing through the carbon pile is decreased and there is
corresponding decrease in the field coil magnetic strength which result
in a drop in generator output.
 The opposite will happen if undervoltage condition exists.
Issue No : 01
END OF TOPIC 5
DC GENERATORS/MOTORS

Issue No : 01

Topic 5:: DC Generators/Motor Theory

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UNIVERSITI KUALA LUMPIR

Malaysian Institute of Aviation Technology

Subject Code AAB 10403 & AGD/AID/AHD10303

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

 The AC is converted into direct current (DC) by a switching system known

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

4. Field Coils or Windings

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

C. Armature or output winding

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

 Caused by resistances from EMF TERMINAL LOAD

 In practice, a voltage regulator V = Generator

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Note: In some generator, interference with radio reception due to brush

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)

Subject Code AAB 10403 & AGD/AID/AHD10303

5. DC Generators Theory (cont’d)

5. DC Generators Theory (cont’d)