ELE 096: Electrical Machines 1

Students’ Activity Sheets #7

Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

Lesson title: DC Motor Efficiency Calculations Materials:

Pen
Lesson Objectives: Calculator
At the end of this module, you should be able to: Short bond paper
1. Differentiate the different losses in a DC Motor.
2. Calculate the efficiency of a DC Motor. References:
A Textbook Of Electrical
Technology in SI Units (Volume
3. II) by B.L. Theraja and A.K.
Theraja

Electrical Machines: Direct and

Alternating Currents by Charles
Seymour Siskind

Electric Machinery
Fundamentals (4th Edition) by
Stephen J. Chapman

Productivity Tip:
If you pass the quiz in this module, reward yourself with a simple treat!

A. LESSON PREVIEW/REVIEW
1) Introduction (2 mins)

Let’s go back to Module 3: Power Flow and Electrical losses. In this module, we will be studying and calculating
the efficiency of a motor. In module 3 we study that the efficiency formula is:
𝑃𝑜𝑢𝑡
𝜂= × 100
𝑃𝑖𝑛
To calculate the efficiency of a dc motor, the following losses must be determined:
1. Copper Losses
2. Brush drop Losses
3. Mechanical Losses
4. Core Losses
5. Stray Losses

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 ELE 096: Electrical Machines 1
Students’ Activity Sheets #7

Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

2) Activity 1: What I Know Chart, part 1 (3 mins)

What I Know Questions: What I Learned (Activity 4)

1. What are the electrical losses in
a motor?

2. What are losses in a DC Motor?

3. What is the condition for

maximum efficiency?

B.MAIN LESSON
1) Activity 2: Content Notes (13 mins)

The losses taking place in the motor are the same as in generators. These are (i) Copper losses, (ii) Magnetic
Losses and (iii) Mechanical Losses.

The condition for maximum power developed by the motor is

𝑉
𝐼𝑎 𝑅𝑎 = = 𝐸𝐵
2
The condition for maximum efficiency is the armature copper losses are equal to constant losses.

The Power Stages

The various stages of energy transformation in a motor and also the various losses occurring in are
shown in the flowing diagram below. The efficiency is given in the following formula based on the power
stages in Figure 1.

 Over-all or commercial efficiency

𝐶
𝜂𝑐 = × 100
𝐴
 Electrical efficiency
𝐵
𝜂𝑒 = × 100
𝐴
 Mechanical efficiency
𝐶
𝜂𝑚 = × 100
𝐵

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 ELE 096: Electrical Machines 1
Students’ Activity Sheets #7

Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

A B C

Driving
Power in
Motor Input Motor
Armature
Output in
𝑷𝒊𝒏 = 𝑽𝑰 Cu Iron WATTS
𝑷𝒅 = 𝑬𝑩 𝑰𝒂
Losses and
Watts Watts Friction
Losses

Figure 1. Power Flow Diagram

It is seen that A-B= copper losses and B-C= iron and friction losses.

Problem 1. One of the two similar 500V shunt machines A and B running light takes 3 A. When A is mechanically
coupled to B, the input to A is 3.5A with B unexcited and 4.5A when B is separately-excited to generate 500V.
Calculate the friction and windage loss and core loss of each machine.

Solution. When running light, machine input is used to meet the following losses (i) armature Cu Loss, (ii) shunt
Cu loss, (iii) iron loss (iv) mechanical loss i.e. friction and windage losses. Obviously, these no-load losses for
each machine equal 500𝑉 × 3𝐴 = 1500𝑊.

(a) With B unexcited

In this case, only mechanical losses take place in B, there being neither Cu loss nor iron-loss
because B is un-excited. Since machine A draws 0.5A more current.
∴ Friction and windage loss of B = 500𝑉 × 0.5𝐴 = 𝟐𝟓𝟎𝑾
(b) With B excited
In this case, both iron losses as well as mechanical losses take place in the machine B. Now,
machine A draws, 4.5𝐴 − 3𝐴 = 1.5𝐴 more current.
Iron and mechanical losses of B = 1.5𝐴 × 500𝑉 = 750𝑊
Iron losses of B= 750𝑊 − 250𝑊 = 𝟓𝟎𝟎𝑾

Problem 2. A dc shunt machine while running as generator develops a voltage of 250V at 1000 rpm on no-load.
It has armature resistance of 0.5 ohm and field resistance of 250 ohms. When the machine runs as motor, input
to it at no-load is 4A at 250V. Calculate the speed and efficiency of the machine when it runs as a motor taking
40A at 250V. Armature weakens the field by 4%.
𝑵𝟐 𝑬𝑩𝟐 ∅𝟏
Solution. = ×
𝑵𝟏 𝑬𝑩𝟏 ∅𝟐

Now, when running as generator, the machine gives 250V at 1000 rpm. If this machine was running as
motor at 1000rpm, it will, obviously, have a back emf of 250V produced in its armature. Hence 𝑁1 = 1000𝑟𝑝𝑚 and
𝐸𝐵1 = 250𝑉.

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When it runs as a motor, drawing 40 A, the back emf induced in its armature is

𝐸𝐵2 = 250 − (40 − 1)(0.5) = 230.5𝑉; Also ∅2 = 0.96∅1 , 𝑁2 =?

Using the above equation we have

𝑁2 230.5 ∅
= × 1 ; ∴ 𝑵𝟐 = 𝟗𝟔𝟎 rpm
1000 250 0.96∅1

For EFFICIENCY:

At no-load input represent motor losses which consist of (a) Armature Cu loss 𝑃𝑎 = 𝐼𝑎2 𝑅𝑎 which is
variable. (b) Constant losses 𝑃𝑐 which consist of (i) shunt Cu loss (ii) magnetic losses and (iii) mechanical
losses.

No-load input or total losses 𝑃𝑙𝑜𝑠𝑠𝑁𝐿 = 250𝑉 × 4𝐴 = 1000 W

Armature Cu Loss, 𝑃𝑎𝑁𝐿 = 32 (0.5) = 4.5 W

Constant losses 𝑃𝑐 = 1000 − 4.5 = 995.5 W

When motor draws a line current of 40A, its armature current is 𝐼𝑎 = 40 − 1 = 39𝐴

Armature Cu loss: 𝑃𝑎 = 392 (0.5) = 760.5 𝑊;

Total losses = constant loss + variable loss 𝑃𝑙𝑜𝑠𝑠𝐹𝐿 = 995.5 + 760.5𝑊 = 1756𝑊

Power input: 𝑃𝑖𝑛 = 𝑉𝑡 𝐼𝐿 = 250(40) = 10,000𝑊

𝑃𝑜𝑢𝑡 𝑃𝑖𝑛 − 𝑃𝑙𝑜𝑠𝑠𝐹𝐿
𝜂= =
𝑃𝑖𝑛 𝑃𝑜𝑢𝑡
10000 − 1756
𝜂= × 100
10000
∴ 𝜼 = 𝟖𝟐. 𝟒𝟒%

Problem 3. A 50hp (37.3kW), 460V dc shunt motor running light takes a current of 4A and runs at a speed of
660 rpm. The resistance of the armature circuit (including brushes) is 0.3 ohm and that of the shunt field circuit
270 ohms. Determine the motor is running at full load

(i) The current input

(ii) The speed
(iii) Determine the armature current at which the efficiency is maximum. Ignore the effect of armature
reaction.

Solution.
460
𝐼𝑠ℎ = = 1.704 𝐴
270

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 ELE 096: Electrical Machines 1
Students’ Activity Sheets #7

Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

Field Cu loss: 𝑃𝑠ℎ = 460(1.704) = 783.84 𝑊

When running light:

𝐼𝑎 = 4 − 1.704 = 2.296𝐴; 𝑃𝑎 = 2.2962 (0.3) = 1.5𝑊 (negligible)

No load armature input = 460(2.296) = 1058𝑊

As armature Cu loss is negligible, hence 1,058W represents iron, friction and windage losses which will be
assumed to be constant.

Let full-load armature current be 𝐼𝑎 , then

Armature input = 460𝐼𝐿 ; Armature Cu loss = 0.3𝐼𝑎2
Output = 37,300 𝑊
𝑃𝑖𝑛 = 𝑃𝑜𝑢𝑡 + 𝑃𝑎 + 𝑃𝑠ℎ + 𝑃𝑠𝑡𝑟𝑎𝑦
𝑉𝑇 (𝐼𝑠ℎ + 𝐼𝑎 ) = 𝑃𝑜𝑢𝑡 + 𝐼𝑎2 𝑅𝑎 + 𝑉𝑇 𝐼𝑠ℎ + 𝑃𝑠𝑡𝑟𝑎𝑦
𝑉𝑇 𝐼𝑎 = 𝑃𝑜𝑢𝑡 + 𝐼𝑎2 𝑅𝑎 + 𝑃𝑠𝑡𝑟𝑎𝑦
460𝐼𝑎 = 37300 + 1058 + 0.3𝐼𝑎2
𝐼𝑎 = 88.45𝐴
(i) ∴ 𝐼𝐿 = 𝐼𝑎 + 𝐼𝐿 = 88.5 + 1.7 = 𝟗𝟎. 𝟐 𝑨
(ii) 𝐸𝑏1 = 460 − (2.3)(0.3) = 459.3 𝑉; 𝐸𝑏2 = 460 − (88.5)(0.3) = 433.5𝑉
433.5
𝑁2 = 660 × ( ) = 𝟔𝟐𝟒 rpm
459.3
2
(iii) For maximum efficiency, 𝐼𝑎 𝑅𝑎 =constant losses
0.3𝐼𝑎2 = 1058 + 783 = 1,841
∴ Ia=78.33 A

Problem 4. A 7.46kW, 250V shunt motor takes a line current of 5A when running light. Calculate the efficiency
as a motor when delivering full load output, if the armature and field resistance are 0.5 ohm and 250 ohms
respectively. At what output power will the efficiency be maximum? Is it possible to obtain this output from the
machine?

Solution.

When loaded lightly

Total motor input (or no-load losses) 𝑃𝑙𝑜𝑠𝑠𝑁𝐿 = 250𝑉 × 5𝐴 = 1,250 W

250
𝐼𝑠ℎ = = 1𝐴 ; 𝐼𝑎 = 5 − 1 = 4𝐴
250
Field Cu loss 𝑃𝑠ℎ = 𝑉𝑠ℎ 𝐼𝑠ℎ = 250(1) = 250𝑊
Armature Cu loss 𝑃𝑎 = 𝐼𝑎2 𝑅𝑎 = 42 (0.5) = 8𝑊
∴ Iron losses and friction losses 𝑃𝑖𝑓 = 1250 − 250 − 8 = 992𝑊
These losses would be assumed constant.
Let 𝐼𝑎 be the full load armature current, then armature power input 𝑃𝑖𝑛 = 250𝐼𝐿 Watts
FL output 𝑃𝑜𝑢𝑡 = 7.46 × 1000 = 7460𝑊

The losses in the armature are:

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Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

(a) Iron and Friction losses 𝑃𝑖𝑓 = 992𝑊

(b) Armature Cu loss 𝑃𝑎 = 𝐼𝑎2 𝑅𝑎 = 0.5𝐼𝑎2
∴ 250(𝐼𝑎 + 𝐼𝑠ℎ ) = 7460 + 992 + 250 + 0.5𝐼𝑎2 → 0.5𝐼𝑎2 − 250𝐼𝑎 + 8452 = 0
∴ 𝐼𝑎 = 36.5𝐴

Full load input current 𝐼𝐿 = 𝐼𝑎 + 𝐼𝑠ℎ = 36.5 + 1 = 37.5 𝐴

Motor power input
Full load power output
∴ Full-load efficiency
𝑃𝑖𝑛 = 𝑉𝐿 𝐼𝐿 = 250(37.5) = 9375𝑊
𝑃𝑜𝑢𝑡 = 7460𝑊
𝑃 7460
𝜂 = 𝑜𝑢𝑡 × 100 = × 100 = 𝟕𝟗. 𝟓𝟕%
𝑃𝑖𝑛 9375

For MAXIMUM EFFICIENCY: The armature copper loss equals constant loss.

Constant losses are Shunt Copper loss and Iron and Friction losses.

𝑃𝑎 = 𝐼𝑎2 𝑅𝑎 = 𝑃𝑠ℎ + 𝑃𝑖𝑓

0.5𝐼𝑎2 = 250 + 992
∴ The armature current 𝐼𝑎 = 49.84 𝐴

Armature input power = 250(49.84) = 12,460𝑊

The armature Copper loss 𝑃𝑎 = (49.842 )(0.5) = 1242𝑊; Iron and friction losses = 992 W

Armature power output =12460 − (1242 + 992) = 𝟏𝟎, 𝟐𝟐𝟔 𝑾

∴ As the input current for maximum efficiency is beyond the full-load motor current, it is never realised
in practice.

2) Activity 3: Skill-building Activities (with answer key) (18 mins + 2 mins checking)

Problem Solving. Solve the following problems completely. Write your solution in a separate short bond paper.
BOX your final answer.

Problem 1. 1 50hp, 550V shunt wound motor draws a line current of 4.5A at no-load. The shunt field resistance
is 275 ohms and the armature resistance exclusive of brushes is 0.3 ohm, the brush drop at full load is 2V. at
full load, the motor draws a line current of 84A. Calculate the efficiency at full load.

Problem 2. A shunt motor running on no-load takes 5A at 200V. The resistance of the field circuit is 150 ohms
and the armature 0.1ohm. Determine the output and efficiency of the motor when the input current is 120A at
200V. State any conditions assumed.

Problem 3. The input current to a 220V, short shunt compound motor at no-load is 6A. The shunt field circuit
resistance is 220 ohms; the armature resistance is 0.10 ohm and the series field resistance is 0.08ohm. What is
the stray power loss?

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 ELE 096: Electrical Machines 1
Students’ Activity Sheets #7

Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

3) Activity 4: What I Know Chart, part 2 (2 mins)

Now answer the “What I Learned” column in Activity 1.

4) Activity 5: Check for Understanding (5 mins)

Problem Solving. Solve the following problems completely. Write your solution in a separate short bond
paper. BOX your final answer.

Problem 1. A 2-pole dc shunt motor operating from a 200V supply takes a full-load current of 35A, the
no-load current being 2A. The field resistance is 500 ohms and the armature has a resistance of 0.6
ohm. Calculate the efficiency of the motor on full-load. Take the brush drop as being equal to 1.5V per
brush arm. Neglect temperature rise.

Problem 2. A 4-pole, dc series motor has a wave-wound armature with 496 conductors. Calculate:
(a) The gross torque
(b) The output torque
(c) The speed
(d) The efficiency, if the motor current is 50A
The value of the flux per pole under these conditions is 22mWb and the corresponding iron, friction
and windage losses total 810W. Armature resistance = 0.19 ohm, field resistance = 0.14 ohm.

C. LESSON WRAP-UP
1) Activity 6: Thinking about Learning (5 mins)

Three things I learned:

1.

2.

3.

Two things I like to learn more:

1.

2.

One question you still have:

1.

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 ELE 096: Electrical Machines 1
Students’ Activity Sheets #7

Name:______________________________________________________________ Class number: _______

Section: ____________ Schedule:________________________________________ Date:________________

FAQs

Q: What are two main classification of power losses?

A: The two main classification of power losses in a DC machine are:

 Constant Losses
 Variable Losses

Q: What is the condition for maximum efficiency?

A: The variable power loss must be equal to constant losses.

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