Always leading the pack

SERIES EXCITED DC MOTOR

DL 1023S

Unilab Laboratory
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CONTENTS

1 - Rated features Page 1

2 - The direct current machine Page 3

3 - DC motor Page 7

4 - Armature reaction Page 11

Operating data of series DC motor Page 15

Test Nº 1 - Direct test with eddy currents electromagnetic brake Page 17

Test Nº 2 - Direct test with braking dc generator Page 21

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1 - RATED FEATURES

The rated features of the machines under test are provided by the manufacturer and are generally
reported on a plate.

They represent the “Identity Card” of the machine, so that the user is able to recognize their most
important operating features.

These rated values, of course, are the result of tests that the manufacturer has performed on several
prototypes at the beginning of the series production; each manufactured machine may show performances
which are slightly different from the rated values, due to the unavoidable manufacturing tolerances.

To perform the checking test on a series machine, therefore, is to verify when the standard performances
reported on the plate are really respected and to measure those special operating characteristics that,
through not reported on the plate, are nevertheless important for the practical use of the machines.

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NOTE

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2 - THE DIRECT CURRENT MACHINE

To obtain a monodirectional torque from DC currents, a mechanical switch is used, which is called
commutator.

In DC machines the field winding is steady, while the set of conductors and commutator is mobile.

To understand the operation of the commutator, let’s consider the following figure:

B ωt
fq ωt
0 π
-

+ e
i

In the shown instant, the electromotive force of the coil is decreasing and, at ωt = π/2 the electromotive
force is zero; therefore the coil is short-circuited through the brushes.

Immediately after, the lower conductor starts to cut the flux and the generated electromotive force
changes its direction; in the meantime, it is switched to the negative brush, so the polarity of the output
voltage is unchanged.

Therefore, the commutator behaves like a synchronous full-wave rectifier.

In the practical realization, the armature conductors are packed in an iron cylindrical rotor, while the
stator windings generate a high and almost uniform induction in the air gap.

Next figure shows the situation at the instant ta and the corresponding electromotive force that is
generated across conductor nr. 1, while immediately after conductor nr. 1 is leaving the S pole.

Starting from the negative brush and following the circuit, conductors nr. 1, 2, 3 and 4 are in series
connected: the total sum of the individual electromotive forces is therefore available on the positive
brush.

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From the negative brush, following the opposite direction, the other conductors nr. 5, 6, 7 and 8 are in
series connected, therefore the winding is composed of two parallel connected circuits.

ω
4

6 1

N 5 7
S

8 3

e
e1

0
t
ta

e
e1 + e2 + e3 + e4 Rectified Voltage
e1 e3
e2
ωt

When the armature turns driving the commutator, conductor nr.1 is switched from a circuit to the other
and conductor nr.8 takes its place.

In a real machine there are many conductors and many switching segments: at any time many coils are
in series connected between the brushes and few of them are short-circuited, when switched from a
circuit to the other.

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When a coil is switching, there is a temporary drop of the output voltage, giving rise to a switching
ripple; this effect can be neglected against when compared to the total effect generated by the many
coils in series connected at the same time.

Let’s indicate with (+) the current entering into the sheet for all the conductors moving upward and with
(.) the current coming out of the sheet for all the conductors moving downward. The total result of all
the currents is an induction vector pointing upward. When the armature is turning, this induction is
steady in space with an optimum torque angle δ = 90°.

The developed resulting torque is clockwise directed. In any generator, this torque has to be balanced
by the source of mechanical power.

On the other hand, when a current from an electric source is entered through the brushes, a
monodirectional and constant torque is generated and the machine performs like a motor.

Being the induction in the air gap constant, the mechanical constant is equal to the electric constant, i.e.:

Γ E
KM = = KE =
I ω

where with capital letters the instant or average values are indicated of the torque (Γ ), the armature
current (I), the electromotive force (E) and the angular speed (ω).

When the total flux per pole ϕ is variable due to the field current and therefore to the induction, the
torque and electromotive expressions become:

Γ =Kϕ I

E = K ϕω

therefore the steady state model of the commutator machine is

Γ R I
Kϕl
+
ω+ DR Kϕω V+

In the steady state, the terms associated to the energy accumulation aren’t considered; only the mechanical
friction due to rotation (DR) and the electric resistance (R) are considered.

The value of K is a function of the machine construction and of the electric connections.

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NOTE

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3 - DC MOTOR

The stator or “field” of a DC motor is composed of a even number of magnetic poles arranged along a
circle with north and south alternancy.

The generation of these magnetic poles is obtained through a DC current flowing into the field windings.

ω
4
Commutator
6 1
Inductor Pole

N 2 7
S

8 3

5 Armature

The rotor or “armature” is composed of an iron cylindrical core supporting the conductors arranged in
slots and connected to the commutator segments.

The DC current is driven from the armature by means of fixed brushes sliding on the commutator.

The commutator automatically switches the conductors, so that the current of the motor is permanent
and monodirectional.

The position of the brushes ensures that the torque angle δ is of 90°.

The electromotive force generated across any conductor can be calculated using the formula

e=Blv

and the total electromotive is given at any time by the number of conductors in series connected.

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The torque developed in every conductor is given by the relationship

τd = B l i r

and the total torque is given by the contribution of the individual conductors.
For a DC machine in steady state condition, the fundamental relationships are the following:

E = K ϕω

Γ d = K ϕ IA

where:
E = electromotive force (V)
j = flux per pole in the air gap (Wb)
ω = angular speed (rad/sec)
Γd = torque (Nm)
IA = armature current (A)
K = constant of the machine

The fundamental relationships are referred to the iron gap: the voltage across the terminals is different
from the electromotive force due to the voltage drop across the armature resistance; the torque on the
shaft is different from the torque due to mechanical friction.

The DC machine is a dual side energy converter; therefore, in the air gap the mechanical power is equal
to the electric power:

Γ d ω = E IA

The power in the air gap only represents the reversible part of the energy electromechanical conversion.
For a DC motor in steady state conditions, the following circuit model can be applied:

RA lA
K lA IA
+
+
D K V+

RF
IF VF+

In steady state conditions, the currents and the speeds are either constant or very slowly variable,
therefore neither mechanical energy variations, nor magnetic energy variations are considered.

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This means that the rotation inertia and the electric inductance aren’t included in the model.
When the efficiency is calculated, it is necessary to consider the field resistance RF .

In the linear model, the D term indicating the mechanical resistance represents all the rotation losses. It
can be calculated by measuring the input power under no-load conditions with the machine operating at
rated speed and rated voltage, therefore with rated flux in the air gap.

Among the rotation losses also included are the losses due to:
- friction in the bearings and on the brushes
- air friction (ventilation)
- core losses due to hysteresis and to eddy currents in the variable flux areas.

The RA term is an equivalent resistance for considering the DC resistance of the armature winding, the
effect of non uniform distribution of the current in the armature conductors, the contact losses of the
brushes and the resistance of the auxiliary windings in the armature circuit, when available.

In the shown circuit model we can assume D, RA, RF and K to be constant; the model is therefore linear.

The electric characteristic of the machine is therefore established by the relationship

V = E + IA RA = Kϕω + IA RA

and in given conditions, assuming the magnetic circuit to be linear, i.e. the flux to be proportional to the
field current, it follows that:

V − RA IA
ω=
Kϕ

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NOTE

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4 - ARMATURE REACTION

When the fundamental relationships have been calculated for a mobile conductor in the magnetic field,
we have assumed that the field due to the current in the same conductor is neglectable.

In reality, the armature current generates a non neglectable magnetic field in quadrature to the input
field; therefore a distortion of the flux distribution occurs.

N N

S S
The practical consequences of the armature reaction are:
a) The switching is deteriorated, because the position of the conductor with zero electromotive force is
displaced along the rotation direction when compared to the ideal position associated to a neglectable
armature reaction.
In some machines, the position of the brushes can be modified under load not to short-circuit turns
with non neglectable electromotive force.

More commonly, small auxiliary windings are arranged between the inductor poles, where the
armature current flows: therefore, they oppose themselves to the armature reaction, that can be
reduced to zero.
Another practical solution is to arrange conductors on the inductor pole faces, where the armature
current can flow (compensating windings).

b) The electromotive force is reduced due to the decrease of mean density of the flux.

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NOTE

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PRACTICAL TESTS

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NOTE

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OPERATING DATA OF SERIES DC MOTOR

A1 B2
(A2)
M (B1)

D1 D2

- Main winding: (armature) A1 - (A2)

- Auxiliary winding: (B1) - B2
- Series excitation winding: D1 - D2

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NOTE

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TEST Nº 1 - DIRECT TEST WITH EDDY CURRENTS

ELECTROMAGNETIC BRAKE

The purpose of this test is effective efficiency of the motor with direct test.
The motor is loaded with an electromagnetic brake equipped with arms and weights.

A1
+ A
Ra

V M

Af

+ -
-
D2 D1 B2

NOTE: For the test is required a tachometer for measuring the rotation speed

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PRACTICAL DIAGRAM

+ - + -

10A

300V
2A
A1 B2
(A2)
M (B1)

D1 D2
Optical

Electronic tachometer

rpm

K1 K2

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TEST PROCEDURE

After the set up of the motor under test and of the brake, make all the connections in accordance with
the attached diagrams and set the commands as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open
Output with about 220V

VARIABLE DC OUTPUT: Switch open

(excitation) Variac fully turned in counter clockwise direction

STARTING RESISTANCE: Max. resistance

2 Shunt the A-coils of the instruments (make the connections signed with dashed lines) to protect them
against the spike due to the starting current.

3 Balance the electromagnets corona by setting the measuring weight at the beginning of the scale of
its arm and by moving the balance weight until the level is equilibrated.
Lock the balance weight, it must not be moved during the test.

4 Set the main switch on ON and, acting on variac, adjust the power supply to the exact value shown
on the motor plate.
Gradually switch Ra off.
Verify that the rotation sense of the motor is correct with reference to the position weight and then
take out the shunt current.
Adjust with the variac voltage to exactly the motor’s rated value.

5 Set the measuring weight on the maximum testing arm and adjust the excitation output until the
balanced position of the electromagnets corona is reached.
Take up the instruments readouts and the motor r.p.m. through a tachometer (manual or electronic).

6 Set step by step the measuring weight on the other values of the testing arm adjusting the balance, at
each step, acting on the excitation and taking up the instruments readouts and the r.p.m.

7 Switch off the main switch which causes the stop of the motor.

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TABLE OF MEASURING RESULTS

b G C n U Iabs Pabs Pr Pl
η
(m) (N) (Nm) (rpm) (V) (A) (W) (W) (W)

1/4

2/4

3/4

4/4

Formulas to be used:

C=G•b
Pabs : U Iabs
Pr = (2πn/60) C
Pl = Pabs - Pr
η= 1 - (Pl/Pabs)

From the table, the following graph may be drawn:

nmax
C

Cmin
I
Imin In

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TEST Nº 2 - DIRECT TEST WITH BRAKING DC GENERATOR

The purpose of this test is effective efficiency of the motor with direct test.
The motor is loaded with a braking DC generator equipped with arms and weights.

ELECTRIC DIAGRAM
A1 A1
+ A1 A2
Ra

V1 M G V2 Rc

-
D2 D1 B2 B2

NOTE: For the test is required a tachometer for measuring the rotation speed.

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PRACTICAL DIAGRAM

+ - + -

300V

5A

A1 B2
(A2)
M (B1)
Optical
D1 D2

rp

K1 K2
300V

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TEST PROCEDURE

After the set up of the motor under test and of the DC braking generator make all the connections in
accordance with the attached diagrams and set the commands as follows:

1 Preset the module:

VARIABLE DC OUTPUT: Switch open
Output with about 220V

VARIABLE DC OUTPUT: Switch open

(excitation) Variac fully turned in counter clockwise direction

STARTING RESISTANCE: Max. resistance

LOAD RESISTANCE: Indifferent position

2 Shunt the A-coils of the instruments (make the connections signed with dashed lines) to protect them
against the spike due to the starting current.

3 Balance the DC generator by setting the measuring weight at the beginning of the scale of its arm and
by moving the balance weight until the level is equilibrated.
Lock the balance weight, it must not be moved during the test.

4 Set the main switch on ON and, acting on variac, adjust the voltage supply to the exact value shown
on the motor plate. Gradually switch Ra off.
Verify that the rotation sense of the motor is correct with reference to the position weight and then
take out the shunt current.
Adjust with the variac the supply voltage to exactly the motor’s rated value.

5 Set the measuring weight on the maximum testing arm and adjust the excitation output and the load
resistance until the balanced position of the brake generator.
Take up the instruments readouts and the motor r.p.m. through a tachometer (manual or electronic).

6 Set step by step the measuring weight on the other values of testing arm adjusting the balance, at
each step, acting on the excitation and taking up the instruments readouts and the r.p.m.

7 Switch off the main switch which causes the stop the motor.

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TABLE OF MEASURING RESULTS

b G C n U Iabs Pabs Pr Pl
η
(m) (N) (Nm) (rpm) (V) (A) (W) (W) (W)

1/4

2/4

3/4

4/4

Formulas to be used:

C=G•b
Pabs : U Iabs
Pr = (2πn/60) C
Pl = Pabs - Pr
η= 1 - (Pl/Pabs)

From the table, the following graph may be drawn:

nmax
C

Cmin
I
Imin In

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