Experiment No.

1
ELECTROMECHANICAL ENERGY CONVERSION EQUIPMENT, INSTRUMENTS AND DEVICES

1. Objective(s):

The course experiment aims to introduce the concept and principles of electromechanical conversion equipment
and devices and familiarize related testing instruments used in conducting analysis and simulation of energy
conversion equipment.

2. Intended Learning Outcomes (ILOs):

The student shall be able to:
2.1 Distinguish the different energy conversion equipment, devices, and instruments used in the operation
and testing of electrical machines.
2.2 Classify the parts and component of electrical machines.
2.3 Differentiate DC and AC rotors according to type of motor and application.

3. Principles and Discussion:

Electro-mechanical energy conversion utilizes the principles of transformation of electrical energy into
mechanical energy or vice versa which practically involves the operation of DC and AC electrical machines (rotating
machines). The operation involving electrical to mechanical energy conversion utilizes the principles of DC and AC
motor while the operation involving mechanical to electrical energy conversion utilizes the principles of DC and AC
generator. AC generators are usually called alternators aside from transformer. Majority of power plant station
utilizes AC generator that are mechanically attached to the prime mover, also known as turbine. Categorically, there
are two general types of power plant where energy conversion equipment and facilities are present. These are
renewable and non-renewable energy sources. Among the general types of renewable energy-based power plant
stations are water-power, wind energy, wave energy, and solar energy while non-renewable power plants are coal-
fired thermal energy, nuclear thermal energy, diesel power and bio-mass energy. On the other hand, power station
utilizes solar PV modules with energy conversion process takes from radiant energy of the sun into electrical energy.
Thermocouple is also performing energy conversion process as it transforms heat energy into electrical through its
special application. Figure 1 shows an electro-mechanical subsystem that generalized the concept of energy
conversion process involving motors and generators. The energy conversions between electrical and mechanical
forms with electromechanical devices are developed and utilized for efficient operation of electrical machines.
Generally, electromechanical energy conversion devices can be divided into three categories:

3.1 Transducers intended for measurement and control: Transducers transform the signals of different
forms like microphones, pickups and speakers.
3.2 Force producing devices or linear motion devices such as relays, solenoids (linear actuators)
and electromagnets.
3.3 Continuous energy conversion equipment: These devices operate in rotating mode
as electro- mechanical energy conversion.

Electro-mechanical Energy Conversion Subsystem Modeling

An electromechanical system consists of an electrical subsystem (electric circuits such as windings), a magnetic
subsystem (magnetic field in the magnetic cores and air gaps), and a mechanical subsystem (mechanically movable
parts such as a plunger in a linear actuator and a rotor in a rotating electrical machine). Voltages and currents are
used to describe the state of the electrical subsystem and they are governed by the basic circuital laws: Ohm's law
and Kirchoff’s Law.
The state of the mechanical subsystem can be described in terms of positions, velocities, and accelerations, and is
governed by Physical Law (Newton's laws). The magnetic subsystem or magnetic field fits between the electrical
and mechanical subsystems and acting as a "ferry" in energy transform and conversion. The field quantities such
as magnetic flux, flux density, and field strength, are governed by the Maxwell's equations. When coupled with an
electric circuit, the magnetic flux interacting with the current in the circuit would produce a force or torque on a
mechanically movable part.

Electromechanical Subsystem

Electrical System Magnetic System Mechanical System

Voltages and Current Magnetic Flux Position, Speed, & Accel

Electric Circuit Equations Force /Torques Equations

by Kirchoff’s Law by Newton’s Law

Figure 1 – Electromechanical subsystem model diagram

4. Resources:

1 set Open-Lab Machine 1 unit Data acquisition module (Portable SCADA)

1 pc Electronic speed transducer
1 unit DC Stator
1 unit AC Stator
1 unit Squirrel cage rotor
1 unit Split-ring rotor
1 set Rotor with commutator
1 set Brush holder with terminals
1 pc. Rubber hammer
1 unit Power supply module
1 unit Power measurement module
1 unit Phase detector
1 unit Frequency Meter
1 unit Digital VOM
15 pcs. Connecting Wires (Banana Type)
1 set Computer with software
1 set of Solar PV trainer
3 pcs of Thermocouple device (Peltier)

5. Procedures:

EXPERIMENT 1 - IDENTIFYING THE ENERGY CONVERSION EQUIPMENT. DEVICES AND

MEASURING INSTRUMENTS

5.1 Examine the external structure of equipment and measuring instruments.

5.2 Illustrate each equipment and device and indicate the model number on Table 1.1
5.3 Verify the rated specification / nameplate rating of each equipment and device on Table 1.1
5.4 Describe how each equipment and device is use in energy conversion machine.

Table 1.1 – ENERGY CONVERSION EQUIPMENT, DEVICES, AND INSTRUMENT FAMILIARIZATION

 Item / Model No. Illustration Specification Function / Purpose
Power Measurement
Module
Model No. ____________

Torque-Speed
Measurement Module
Model No. ____________

Power Supply Module

Model No. ____________

Load Rheostat / Starting

Resistor Module
Model No. ____________

Synchronizing Module
Model No. ___________

Data Acquisition Module

Model No. ___________
Dead-Weights for
Torque Measurement
Model No. ____________

Optical Tachometer
Model No. ____________

Phase Detector
Model No. ____________

Three-Phase Resistive Load

Model No. ____________

Three-Phase Capacitive
Load
Model No. ____________

Frequency Meter
Model No. ____________
Electronic Speed
Transducers
Model No. ____________

Thermocouple (Peltier)
Model No. ____________

Solar PV cell prototype

Model No. ____________

5.5 PARTS AND COMPONENT OF ELECTROMECHANICAL ENERGY CONVERSION MACHINE

5.5.1 Dismantle carefully the Open-Lab Machine using mechanical wrench and rubber hammer.
5.5.2 Distinguish the parts and component of an open-lab DC and AC machines as shown in Figure 4
through code number to be indicated on the space provided on Table 1.2.
Course: Experiment No.
Group No.: Section:
Group Members: Date Performed:
1. Date Submitted:
2. Instructor:
3.
4.
5.

6. Data and Results:

Figure 4 – Disassembled DC and AC electrical machine - Parts and Components

 Table 1.2 –PARTS AND COMPONENT OF ELECTRICAL MACHINES
Item No. Description of Item
Brush holder with 2 carbon brushes
Rotor with commutator
DC machine field windings
Electronic speed transducer
DC stator
Speed tape sensor
Base plate
Rotor with slip rings
Carbon brush for slip-ring rotor
Rotor shaft bearing support
Slip-ring terminal
Terminal block for AC machine
Coupling joints
Cage rotor
AC rotor shaft
Carbon brush holder for slip-ring rotor
Flexible coupling
AC stator
Terminal block for DC machine
AC machine field windings

7. Interpretation of Data and Results:

8. Conclusion:
9. Question(s) and Answer(s):

9.1 Discuss the main purpose of commutator?

9.2 Discuss the importance of back voltage in the armature windings during motor starting?
9.3 Differentiate thermocouple and transducers?
9.4 Explain how Physical Law, Circuital Laws, and Newton’s Law affects the principle of energy conversion
process in electric motor and generator.
9.5 What are the commercial applications of DC motors?
(Note: Support your answer on a separate sheet)

10. Assessment (Rubric for Laboratory Performance ):

 Experiment No. 2
DC MOTOR ASSEMBLY

1. Objective(s):

This course activity aims to introduce the concept, parts and assembly of a DC motor.

2. Intended Learning Outcomes (ILOs):

The student shall be able to:

a. assemble and disassemble a DC motor.
b. identify the components of a DC motor.
c. differentiate DC rotor from DC stator.

3. Principles and Discussion:

A direct current (DC) motor is a simple electric motor that uses electricity and a magnetic field to
produce torque, which causes it to turn. It requires two magnets of opposite polarity and an electric coil,
which acts as an electromagnet. The repellent and attractive electromagnetic forces of the magnets
provide the torque that causes the motor to turn.

A DC motor requires at least one electromagnet, which switches the current flow as the motor turns,
changing its polarity to keep it running. The other magnet or magnets can either be permanent magnets
or other electromagnets.

The main parts of a DC motor are stator and rotor. The stator is a mechanical device consisting of the
stationary part of a motor in or around which the rotor revolves. The rotor is the non-stationary part which
rotates because the wires and magnetic field of the motor are arranged so that a torque is developed about
the rotor's axis. In some designs, the rotor can act to serve as the motor's armature, across which the input
voltage is supplied.

4. Resources:

1 set Open-Lab machine trainer 1 pc. Allen wrench

1 unit Rotor with commutator 1 pc. steel tape
1 unit DC stator 1 pc. Vernier caliper
1 unit Mechanical power measurement module 1 pc Ruler
1 unit Electrical measurement module 1 pc Pencil (No.2)
5. Procedures:

ACTIVITY 1 – THE INTERNAL PARTS AND COMPONENT OF A DC MOTOR:

Figure 2.1. DC Motor Disassembly

5.1 Prepare the Open-Lab Machine, rubber hammer and wrenches.

5.2 Carefully separate the DC rotor from the DC stator using rubber hammer as shown in Figure 2-1.
Do not apply pressure to remove the rotor from stator.
5.3 Examine thoroughly the internal parts of DC rotor and stator.
5.4 List down the components and corresponding functions of a DC rotor and DC stator using Table 2-
1 and Table 2-2.
5.5 On Table 2-3, fill out the required data for each component of rotor and stator.
ACTIVITY 2 – CALCULATING THE AIR GAP OF DC STATOR AND EQUIVALENT HP RATING:

5.6 From Table 2-3, fill out the required data according to each component of rotor and stator
using the appropriate measuring tools.
5.7 Determine the thickness of the stator yoke using Table 2.4 based on the equation below;

T f = ( Do – D i ) ,mm
2
Where: Tf = thickness of stator’s yoke / frame
Do = outside diameter of stator’s yoke / frame
Di = inside diameter of stator’s yoke / frame

5.8 Calculate the air-gap between the rotor and stator using Table 2.4 based on the equation
below;

Air gap = ( Di – Dr ), mm
2

Where: Dr = diameter of rotor, mm

5.9 Then verify the wattage rating of DC machine based on the applicable parameters
determined by the group. (Note: Place your computation on Table 2.4)
Course: Experiment No.
Group No.: Section:
Group Members: Date Performed:
1. Date Submitted:
2. Instructor:
3.
4.
5.

6. Data and Results:

Table 2-1. DC Rotor Parts/Components and Functions

Parts/components of a DC Rotor Functions

Table 2-2. DC Stator Parts/Components and Functions

Components/Parts of a DC Stator Functions

Table 2.3. DC Machine Component and Parameters

Item Value
Number of field poles
Length of pole arc
Area of pole face
Distance between opposite pole faces
Number of teeth
Diameter of commutator
Length of commutator
Number of commutator bar
Number of commutator segment
Diameter of rotor
Diameter of shaft
Length of shaft
Outside diameter of stator’s frame ring
Inside diameter of stator’s frame ring
Length of stator’s frame
Number of carbon brush
 Table 2.4. Summary of Calculations
Stator’s Yoke Thickness Air Gap Power Rating of DC Machine

7. Interpretation of Data and Results:

8. Conclusion:

9. Question(s) and Answer(s):

9.1 Discuss the operating principle of mechanical rectifier.

9.2 A four-pole motor has an armature having 276 conductors. Each pole face is designed and constructed
with 25 square inches with flux density of 47,500 lines per square inch. If the armature current is
designed at 75 amperes and the structure of windings is wave (2 parallel paths), verify the rated torque
of this motor.
9.3 During operation of DC motor and DC generator, explain how rotor and stator works.
9.4 The car of Light Railway Transit (LRT) is propelled by a 660-volt DC motor connected to the DC feeder
lines of rectifier station. This car is required to exert a tractive effort of 4,500kg at a velocity of 50km/hr.
How much current will be drawn from the feeder lines if the overall efficiency of motor and the flywheel
drive is 65%? (Note: Support your answer in a separate sheet)
10. Assessment (Rubric for Laboratory Performance ):