LESSON

DIRECT CURRENT MOTORS

LECTURE
SUB-OBJECTIVE
At the end of this lesson, the trainee will be able to :
1.

List and briefly describe major components of a typical DC motor.

2.

State the function of and briefly describe the construction of the

brush gear.

3.

Define each of the following DC motor variables and describe

general methods used for its control : a.
b.
c.
d.

4.
a.
b.
c.
5.
a.
b.

1.0

Torque
Starting current
Speed
Rotation direction

Using labeled diagrams, describe connections for each of the

following types of DC motors
Shunt
Series
Compound
Describe the following characteristics of each of the three types of
DC motors:
Speed
Torque

6.

State the function of the starting rheostats and briefly describe their
operation.

7.

Describe construction and operation of a typical DC motor speed

controller.

INTRODUCTION

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Very few DC motors are fitted in modern Power Plants, mainly due to the
economic reasons of having to provide the additional sources of supply and
control, over and above the standard AC systems.
However, some items of equipment are so essential to the safe and efficient
operation of the plant that, DC motors are fitted to act as, a final safeguard in
the event of a total loss of motive power due to failure of the AC systems.
These DC motors operate on a standby basis with the normal drive motor, an
AC powered machine, and are normally never used, except in cases of
emergency or when the machine is specifically started to prove its operational
capability.
2.0

DC MOTOR CONSTRUCTION (GENERAL)

The main component parts of a DC motor are the stationary outer casing
(yoke), the field or magnetizing assembly (poles), and the rotating prime mover
(armature).
The mechanical features of the DC motors are similar to the AC machines,
comprising motor central body, end shields, bearings and fan assemblies.
Figure. 2.1. shows the basic constructional outline and the path of the magnetic
circuit.

Figure 2.1. - Basic construction of DC motor.

2.1

Field Construction

Viewed externally, the casing of the DC motor is almost identical to the shell of a
similar rated AC motor, with cooling fins running axially along the solid casting
steel frame. Internal construction is somewhat different to that of an AC motor,
the magnetic field assembly is built up of separate coils or poles.
The poles of a DC machine are either built up from laminated steel sheet (0.4
0.5mm thick) or are solidly cast in steel in the shape of the pole core. These
pole assemblies are then mechanically attached to the yoke to form the outer
section of the machine's magnetic path. In some high-precision machines,
"liners" or thin steel plates are fitted between the pole base and the yoke, in
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order to adjust the air gap between the-pole shoe and the armature.
Figure 2.2. is illustrative of the internal assembly for a typical
small/medium-rating machine.

Figure. 2.2. DC Motor Yoke and Pole Assembly

The field coils are then fitted to the poles, the number of coils obviously being
dependent on the number of poles and the type of motor assembly. Field coils
are wound in similar fashion to AC motor stator winding coils, and in some DC
motors the completed coil will be finally covered in insulating tape or fabric.
The diagram in Figure 2.3 shows an assembled field coil for a large motor, fitted
to the pole shoe.

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Figure 2.3 Completed Coil and Pole Shoe

2.2

Armature Construction

Construction of the armature ( rotor) of a DC motor follows the same basic

mechanical principles as the rotor of an AC machine. The armature assembly is
build up onto machined solid steel shaft. A typical shaft showing machined sections
is shown in Figure 2.4.

Figure 2.4 - Machined armature shaft ( typical)

The armature is then build up onto the shaft by pressing the punched armature
laminations into position and locking the complete core sections by means of the
slotted key way. An armature lamination with cooling air passage holes is shown in
figure 2.5.

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Figure 2.5 - Armature lamination

The armature is then wound with required winding formation and the ends of the
winding coils are soldered to the appropriate commutator segment.
The commutator segments, which are manufactured from high quality copper, are
assembled and fitted to the shaft in the manner shown in the diagrams in figure
2.6.

Figure 2.6. - Commutator assembly ( typical)

With the fitting of the internal cooling air fan and the bearings to the
shaft, the armature assembly is completed, as shown in figure 2.7

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Figure 2.7 Outline of armature assembly

2.3

Brush Gear

The main mechanical difference between the DC motor and AC induction machine
is the brush gear assembly fitted to the DC units. The brush gear forms the means
of electrically connecting DC supply from the stationary part to the rotating section,
i.e. the armature. The minimum number of brush positions will correspond to the
number of poles, a 4 pole machine will have a minimum of 4 brush assemblies,
and so on.

Figure 2.8 - Brush assembly details ( typical)

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The brush gear is insulated from the frame and is supported on brush rod
assembly. A typical arrangement for a brush assembly shown above in Figure 2.8.
The brushes themselves are manufactured from high grade carbon and are
selected on the basis of their compatibility with machine operation. Care must be
taken when replacing brushes to use the correct grade of brushes as
recommended by the manufacturer.

2.4

OPERATING THEORY

DC motors are selected on the basis of the load application. The requirement for
the DC machines in the plant is for steady speed at constant load as encountered
in lubricating oil systems. For this reason most DC motors found in the plant are the
standard shunt wound type.
DC motors are rated in voltage, current, speed, and horsepower output.
2.4.1

TORQUE
The rotating force produced by the interaction of the magnetic field of the
armature ( rotor) and the field poles is known as torque. The greater the
magnetic force of the shaft the higher the torque. Since torque is the force
exerted upon a shaft, it is necessary to accurately define it as the product of
the force in kilograms and the radius of the shaft in meters.
Torque of the motor depends on the magnetic strength of the field and of
the armature. Since the armature flux depends on armature current, the
torque increases in proportion to the armature current and the strength of
magnetic field.
In motor work it is necessary to distinguish between the torque developed
by motor when operating at its rated speed (Ifl) and the torque developed at
the instant of starting(Ist). Certain types of motors have high running torque
but poor starting torque.

2.4.2 STARTING CURRENT

The staring current of a DC motor is much higher than the current input
while running freely at its rated speed. At the instant when power is applied,
the armature is motionless and only a low armature circuit resistance limits
the armature current. As the motor builds up to speed, the current input
decreases until motor reaches its rated speed. At this point the armature
current remains constant.
The mechanical load applied to the shaft will cause a reduction in speed
and in counter emf. The voltage differential however, increases and causes
an increased input current to the motor. Thus any increase in mechanical
load must be accompanied by an increase in armature current.
Since the starting current may be many times greater than the rated current
under full load, it is not permissible to start large DC motors by direct
connection to the power. Starters for such motors generally limit the starting
inrush current to 1.5 times full load current.
2.4.3 ROTATION
The rotation of a DC motor depends on the direction of the current in the
field circuit and in the armature circuit. To reverse the direction of rotation it
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is necessary to reverse the current direction in either the field or the

armature. Reversing power leads will not reverse direction of rotation as
both windings are reversed.
2.4.4

SPEED CONTROL
The speed of a DC motor can be changed by changing the voltage applied
to the motor. This method is not used because the reduction of speed is
accompanied by loss in torque.
DC motors are operated below normal speed by reducing the voltage
applied to the armature. Resistors connected in series with the armature
may be used for voltage reduction.
DC motors are operated above rated speed by reducing the strength of
the field flux. A rheostat placed in the field circuit will vary the field circuit
resistance, field current and in turn field flux. Reduction in flux reduces
counter emf permitting the applied voltage to increase armature current.
Since motor speed increases with decrease in field flux, it is never safe to
open field circuit of a motor in operation particularly when running freely
without load. Some motors are protected against damaging over speed by
disconnecting the motor from the power source if the field circuit opens.

3.0

THE SHUNT MOTOR

The suitability of a motor for a particular application is determined by two factors:

the variation in its speed with change in load

the variation in its torque with change in load

A shunt motor is essentially a constant speed device. If load is applied the motor
tends to slow down, but the reduction in speed also re duces counter emf and
results in an increase of armature current. This continues until the increased current
produces enough torque to meet demands of the increased load. Thus shunt motor
is in equilibrium because a change in load produces a change in armature current
that adapts power input to the change in load. The basic circuit for a shunt motor is
shown in figure 2.9.

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Figure 2.9 - Basic shunt motor connection

3.1

Characteristics Dc Shunt Motors

A DC shunt motor has excellent speed control. For operation above rated speed a
field rheostat is used to reduce the field current and field flux. For operation below
rated speed, resistors are used to reduce voltage applied to the armature circuit.
Reversing the direction of current in either the field circuit or the armature circuit can
change the direction of rotation.
A DC shunt motor has a high torque at any speed. At start, a DC shunt motor will
develop 150% of rated torque if the resistors are used in the starting mechanism.
For a very short period it will develop 350% of full load torque if necessary.
The speed regulation of a shunt motor drops from 5% to 10% from no load to full
load.
These characteristics are summarized in figure 2.10.

4.0

Figure 2.10 - DC shunt motor characteristics

THE DC SERIES MOTOR

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The DC series motor still finds extensive applications despite the wide use of AC for
generation and transmission. This type of motor is used as a starter motor in
modern automobiles and aircraft. They are also used as traction motors because of
their ability to provide high torque with moderate increase in power at reduced
speed.
The basic circuit of the series motor is shown in figure 2.11

Figure 2.11 - Basic series motor connection

4.1

Characteristics Dc Series Motors

A series motor will develop 500% of its full load torque at starting and is used for
railroads, cranes, and other heavy starting load applications for this reason. In a
series motor any increase in load brings an increase of current in both field and
armature circuits. Since torque depends on interaction of these fluxes, the series
motor will produce grater torque for the same increase in current but at a greater
reduction in speed.
The speed regulation of a series motor is poor. A reduction of mechanical load
causes a simultaneous reduction of current in both field and armature and allows
for a greater increase in speed than in shunt machines. If the mechanical load is
removed completely, the speed increases without limit and destruction of armature
through centrifugal forces may occur. For this reason, series motors are
permanently connected to their loads.
Varying the applied voltage controls the speed of a series motor. Controllers for this
type of motor are usually designed to start, stop, reverse, and regulate the speed.
The direction of rotation may be obtained by changing the direction of current in
either the field or armature.
Figure 2.12 shows typical; characteristics of the series motor.

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Figure 2.12. - Operating characteristics of a series motor.

5.0

THE DC COMPOUND MOTORS

Compound wound motors are used whenever it is necessary to obtain good speed
regulation characteristics not obtainable with either a shunt or series motors. Most
have a high starting torque and reasonable constant speed regulation under load.
The compound motor has a normal shunt winding and a series winding on each
field pole as shown in fig. 2.13 . When the series winding is connected to aid the
shunt winding, the machine is cumulative compound. If the series field opposes the
shunt field, it is differential compound.

Figure 2.13 - Basic compound motor connection

5.1

Characteristics Dc Compound Motors

The operating characteristics of a cumulative wound compound motor are a

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combination of the series and shunt motors. When a load is applied, the increasing
current through the series winding increases the field flux and causes torque to be
greater that it would be for a shunt motor.
However this flux increase causes the speed to decrease to a lower value than in a
shunt motor. Unlike a series motor, the cumulative compound machine has no load
speed inverse relation and will not build up to destructive speed if the load is
removed.
Reducing the applied voltage controls the speed of a cumulative compound motor
by use of resistors in the armature circuit.
Changing direction of the current in the armature only reverses the rotation.
5.2

Differential Compounded Motors

When a motor is connected as a differential compound machine, the series field

opposes the shunt filed so that shunt filed is decreased when the load is applied.
As a result, the speed remains constant with an increase in load. Since the field is
weakened with increase of the load this type of motor has a tendency to speed
instability and thus is not often used.
6.0

STARTING DC MOTORS
Two factors limit the current taken by a motor armature from a direct current source:

the counter emf

the armature resistance

Since there is no counter emf at standstill, the current taken by the armature would
be abnormally high. Therefore it is necessary to limit the armature current by
means of an external resistor. Using a starting rheostat does this.
A typical starting rheostat connected to a shunt motor is shown in figure 2.14. Note
that the starter has three terminals or connection points. Because it is housed in a
box like structure, it is often called a three TERMINAL STATING BOX.

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Figure 2.14. - Three terminal starting rheostat

When the arm is moved to the first contact A, the armature, in series with all the
starting resistors is connected across the source. The shunt field, in series with the
holding coil is also connected across the source. The initial inrush current is limited
to a safe value by the resistors. Further, the shunt field current is at maximum to
provide good starting torque.
As the arm is moved to the right toward contacts B, the starting resistance is
reduced and the motor accelerates to the rated speed.
The holding coil is connected in series with the shunt field to provide a no field
release. If the shunt field should become opened, the motor speed would become
dangerously high if the armature circuit remained connected across the source.
The three terminal starter is not suitable for use with a motor if it is necessary to
control the speed. A four, (4) terminal starting rheostat is used to obtain the desired
speed. This type of starter is shown in figure 2.15.

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Figure 2.15. - A four terminal starting rheostat

A motor is started with the four terminal rheostat in the same manner as with a
three terminal starter. Varying resistance of the field rheostat, which is in series with
the shunt field circuit, controls the speed of the motor.
6.1

Speed Controllers

It is often necessary to vary the speed of a DC motor. For speed above normal
rating, resistance can be inserted in the shunt field circuit. Below normal speeds
can be obtained by inserting resistance in the armature circuit. Although separate
controllers are available to get above and below rated speeds, one controller can
also be used to obtain both functions as shown in figure 2.16 and 2.17.
One arm is used to make connections with two rows of contacts. The contacts in
the lower row are relatively large and are connected to the armature circuit. The
contacts of the upper row are smaller and are connected to shunt field circuit.
Considerable current passes through the armature resistors when the motor is
operating under a heavy load at a low speed. Therefore the armature resistors
must be large size and provided with some form of cooling.

Figure 2.16. - Above and below normal speed controller (set for below normal
speed)

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Figure 2.17. - Above and below normal speed controller ( set for above normal
speed)
7.0

STOPPING OR BRAKING DC MOTORS

A DC motor will stop if it is disconnected from the supply. The time it takes to reach
standstill will depend on its inertia, its friction and wind-age losses. If fast braking is
required, then once the motor is disconnected from supply it is quickly reconnected
to a resistor. The inertia generated is dissipated in the connected resistance.

8.0

MAINTENANCE
The satisfactory performance of any rotating machine depends to a very large
extent on an efficient method of periodical inspection. These inspections will detect
any defect and will give warning to correct problem before extensive damage
occurs. This will sharply reduce cost of repairs, extent the life of equipment and
reduce down time.
Moisture, oil, dirt, grease, carbon or metallic dust etc. are well known causes of
electrical breakdowns and therefore machines must be kept clean and dry, both
inside and outside at all times. Cooling fins, ventilation holes, and ducts should be
kept free of all deposits of dirt and fluff.
8.1

Routine Inspection

It is not possible to specify the best interval between inspection and overhauls
without experience of the actual operating conditions. The following procedures
may be used as a guide until operating experience becomes available. A record
should be kept of all faults, replacements and repairs.
a.

After 500 operating hours

Examine the commutator. A good commutator should have a shiny skin, which is
different from clean raw copper. A good skin should not be treated in any way
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except that the surface may be wiped with a lint free, moist cloth to remove any
carbon dust or foreign material.
b.

Every 3,000 hours or every 6 months

Examine the commutator as described previously.

Clean and inspect the brushgear and insulators, particularly on the brush studs.
Check that all bolts and nuts are tight.
8.3
a.

Troubleshooting And Repair

If the motor fails to start when switch is turned ON check for :

b.

If the motor runs slowly, the trouble may be :

c.

Shorted armature or commutator

Worn bearings
Open armature coils
Brushes set off neutral
Overload
Wrong voltage

If the motor runs faster than name plate speed, check :

d.

Open fuse
Dirty or clogged brushes
Open armature circuit
Open field circuit
Shorted or grounded field
Shorted armature or commutator
Worn bearing
Grounded brush holder
Overload
Defective controller

Open shunt field circuit

Series motor running without a load
Shorted or grounded field
Differential connection in a compound motor

If the motor sparks excessively, check :

Poor brush contact on the commutator

Dirty commutator
Open circuit on the armature
Wrong interpole polarity
Shorted or grounded field
Reverse armature leads
Wrong lead swing
Brushes set off neutral
Open field circuit

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e.

If the motor is noisy in operation, the trouble may be :

f.

High or low bars

Unbalanced armature

Worn bearing
High or low bars
Rough commutator
Unbalanced armature

If motor runs hot, check :

Overload
Sparking - see above
Tight bearings
Shorted coils
Too much brush pressure

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