CONSTRUCTION OF DC MOTOR AND DISCUSS

ITS PRINCIPLE WITH SUITABLE DIAGRAM

A Project Work

Submitted to the Department of Physics, National School of Sciences,

Lainchour, Kathmandu in the partial fulfillment for requirement of
Grade-XII of science in physics.

Submitted By:
Aaditya Patel
Roll No.:-821
Grade-XII
Sub-group:-P2
(2080/07/18)

I
 Acknowledgement

It is my good fortune to get very cooperative teacher Mr.Dhanik Kushwaha.During

the work in progress, his support, helpfulness and constant encouragement kept me
motivated in research work. He provided invaluable interest, guidance during the course
of the work. I have not only learned but also got important suggestions regarding
scientific writing and other related matters. I am very much grateful to him.
I would like to thank all the faculty members who have provided encouragement and
suggestions during the course of work and special thanks to lab assistants.
Further, I would also like to extend my gratitude to the principal Dr. Madhav Prasad
Baral and NSS executive director Ma’am Pranita Sharma Baral for providing me all
the facility that was required.
Finally, I would like to express my deep gratitude to the greatest mentor, my parents.
All the thanks are due to them for everything that I have achieved.
Aaditya Patel
Date:-2080/07/18

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 Evalutation

It is certified that Mr.Aaditya Patel has carried out the project work entitled
“Construction of DC motor and discuss its principle with suitable diagram”.
This Project Work is the result of his/her endeavors and research. It is finalized under
our guidance and supervision in the academic year 2022-2024.

Supervisors Subject Coordinator

Department of Physics Department of Physics

National School of Sciences National School of Sciences

Lainchour, Kathmandu, Nepal Lainchour, Kathmandu, Nepal

Date: ……………………. Date: …………………….

External Examiner Principal

NEB Board, Nepal National School of Sciences

Date: ……………………. Lainchour, Kathmandu, Nepal

Date: …………………….

III
Contents Pages
Title of project work …………………………………………………...…………. I
Acknowledgement ………………………………………………………...………. II
Certificate ……………..……………………………………………….…….….… III
Table of contents ………………………………………………………….………. IV
1. Introduction ……………………………………………………………………. 1
2. Apparatus required …………………………………………………………….. 1
3. Theory …………………………………………………………………....….…. 1-4
(AC, DC, Motor Principle, Generator Principle, Torque, Fleming left hand
rule, Reflector)
4.Construction……………………………………………………………….……. 4-6
5. Methodology………..………………………………………………….………. 7-8
(Construction, Step to step explanation)
6. Result ……………………………………………………………………..……. 8
7.Applications…………………………………………………………………...… 8-9
8. Conclusion ………………………………………………………….….………. 10
9. Bibliography/ References ………………………………..…………...…..…….. 11

IV
Introduction:
A DC motor is defined as a class of electrical
motors that convert direct current electrical
energy into mechanical energy. From the above
definition, we can conclude that any electric
motor that is operated using direct current or
DC is called a DC motor. We will understand
the DC motor construction and how a DC
motor converts the supplied DC electrical
energy into mechanical energy in the next few
sections.
Apparatus Required:
A DC motor like we all know is a device that deals in the conversion of electrical energy
to mechanical energy and this is essentially brought about by two major parts required
for the construction of dc motor, namely.
 Stator – The static part that houses the field windings and receives the supply.
 Rotor – The rotating part that brings about the mechanical rotations. Other than
that there are several subsidiary parts
 Yoke of dc motor
 Poles of dc motor
 Field winding of dc motor
 Armature winding of dc motor
 Commutator of dc motor
 Brushes of dc motor
All these parts put together configures the total construction of a dc motor. Now let’s
do a detailed discussion about all the essential parts of dc motor.
Theory:
AC Motors:
This motor converts the alternating current into mechanical power by using the
phenomena of electromagnetic induction. This motor is run by alternating current. Its two
main parts are the stator and rotor. The stator is the stationary part of the motor, whereas
the rotor is the rotating part of the motor. AC motors are of two categories one is single-
phase and the other is three-phase. The three-phase AC motors are useful in the industry
for bulk power conversion from electrical to mechanical. For small power conversion, the
single-phase AC motors are suitable. The single-phase AC motor is small in size, and it
provides different kinds of services in the home, office, factories, etc. For most of the
domestic appliances such as refrigerators, fans, washing machine, hairdryers, mixers, etc.,
use single-phase AC motor.

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DC Motors:
A direct current i.e. DC motor is a type of electric machine which converts the electrical
energy into mechanical energy. DC motors are consuming the electrical power through
the direct current, and it converts this energy into the mechanical rotation. These motors
use the magnetic which is occurring from the electrical currents generated. It is further
getting powers for the movement of a rotor fixed within the output shaft. This term ‘DC
motor’ is used to refer to any rotary electrical machine that converts direct current
electrical energy into mechanical energy.

DC motors are varying in size and power from the small motors in toys and appliances to
large mechanisms that power vehicles. DC motors have two key components as stator and
armature. The stator is the stationary part of the motor, whereas the armature rotates. In
motor, the stator provides a rotating magnetic field that drives the armature to rotate.

Motor Principle:
An electric motor (dc motor) works on the principle that when an electric current is
passed through a conductor placed normally in a magnetic field, a force acts on the
conductor as a result of which the conductor begins to move and mechanical energy is
obtained.

Generator Principle:
Electric generator:- The device that is used to convert mechanical energy to electrical
energy is called a generator.
Working principle of an electric generator:
The electric generator works on the principle of electromagnetic induction i.e., when a
coil is rotated in the presence of a uniform magnetic field, the current is induced in it.

Torque on DC Motors:
The total force acting on the armature equals to the force acting on a single turn of
coils multiplied by the number of total turns.

F=nIlBsinθ

Recall that torque equals the product of the force and the distance from the pivot,
with θ being the angle between the lever arm and the force vector.

τ=rFsinθ

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Since in a DC motor, the motor force is always perpendicular to the current (by right
hand palm rule), then it is also always perpendicular to the conductor.
Hence, θ=90°giving:

τ =rF

In a DC motor, we consider r to be the distance from each arm to the midline of the
coil. As such, r equals half the width (w)of the coil.

τ =w/2F

Since the force is a motor force, then:

τ =w2nIlBsinθ

However, remember that there are two arms experiencing this torque, so the total
torque will be:

τ =2×w/2 nIlBsinθ
=wnIlBsinθ
=nIBsinθ×(lw)

Since l (length of coil) times w (width of coil) equals the area (A) of the coil:

τ =nIABsinθ
where,

 n is the number of coil turns in the armature

 B is the magnetic field strength of flux density (in Tesla)
 I is the magnitude of current flowing through the armature (in Amperes)
 A is the total area created by the coil (in m2)
 θ is the angle between the area vector (a vector perpendicular to the plane of the
coil) and the magnetic field lines.

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Fleming’s left hand rule: Fleming’s left hand rule says that if we extend the index
finger, middle finger and thumb of our left hand
in such a way that the current carrying
conductor is placed in a magnetic field
(represented by the index finger) is
perpendicular to the direction of current
(represented by the middle finger), then the
conductor experiences a force in the direction
(represented by the thumb) mutually
perpendicular to both the direction of field and
the current in the conductor.

Construction:
A DC motor or machine consists of two windings namely field winding
and armature winding. The field winding is stationary and the armature
winding can rotate.

Magnetic Field System

The magnetic field system of a DC motor is the stationary part of the machine. It
produces the main magnetic flux in the motor. It consists of an even number of pole
cores bolted to the yoke and field winding wound around the pole core. The field system
of DC motor has salient poles i.e. the poles project inwards and each pole core has a
pole shoe having a curved surface. The pole shoe serves two purposes

 It provides support to the field coils.

 It reduces the reluctance of magnetic circuit by increasing the cross-sectional
area of it.

The pole cores are made of thin laminations of sheet steel which are insulated from
each other to reduce the eddy current loss. The field coils are connected in series with
one another such that when the current flows through the coils, alternate north and south
poles are produced.

The field winding produces a magnetic flux in the air gap between the
armature and field windings and the armature is placed in this
magnetic field. The construction of DC motor or machine is shown in
the following Figure.

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Parts used in DC motors:

The main parts used in the construction of DC motor are the yoke,
poles, field winding, commutator, carbon brushes bearings, etc. A brief
description of the various parts is as follows:

Yoke: The yoke acts as the outer cover of a DC motor and it is also
known as the frame. The yoke is an iron body, made up of low
reluctance magnetic material such as cast iron, silicon steel, rolled
steel, etc.

Yoke serves two purposes, firstly it provides mechanical protection to

the outer parts of the machine secondly it provides a low reluctance
path for the magnetic flux.

Poles and Poles shoe: The pole and pole shoe are fixed on the yoke
by bolts. These are made of thin cast steel or wrought iron laminations
that are riveted together. Poles produce the magnetic flux when the
field winding is excited.

A Pole shoe is an extended part of a pole. Due to its shape, the pole
area is enlarged and more flux can pass through the air gap to the
armature.

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Field Winding: The coils around the poles are known as field (or
exciting) coils and are connected in series to form the field winding.
Copper wire is used for the construction of field coils. When the DC is
passed through the field windings, it magnetizes poles that produce
magnetic flux.

The connection of the field winding and the armature winding is done
according to the type of the motor and decides the characteristics of
the motor.

Commutator: It is mounted on the shaft. It is made up of a large

number of wedge-shaped segments of hard drawn copper, insulated
from each other by a thin layer of mica.

The commutator connects the rotating armature conductor to the

stationary external circuit through carbon brushes. It converts
alternating torque into unidirectional torque produced in the
armature.

Carbon Brushes: The current is conducted from the voltage source

to the armature by the carbon brushes which are held against the
surface of the commutator by springs. They are made of high-grade
carbon steel and are rectangular.

Bearings: The ball or roller bearings are fitted in the end housings.
The friction between stationary and rotating parts of the motor is
reduced by bearing. Mostly high carbon steel is used for making the
bearings as it is a very hard material.

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Methodology:
Step 1:
Initially considering the armature is in its starting point or reference position where the
angle α = 0.
τ = BILw * cos 0o = BILw
Since α = 0, the term cos α = 1, or the maximum value, hence torque at this position is
maximum given by τ = BILw. This high starting torque helps in overcoming the initial
inertia of rest of the armature and sets it into rotation.

Step 2:
Once the armature is set in motion, the angle α between the actual position of the armature and
its reference initial position goes on increasing in the path of its rotation until it becomes 90°
from its initial position. Consequently the term cosα decreases and also the value of torque.
The torque in this case is given by τ = BILwcosα which is less than BIL w when α is greater
than 0°.

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Step 3:
In the path of the rotation of the armature a point is reached where the actual position
of the rotor is exactly perpendicular to its initial position, i.e. α = 90°, and as a result
the term cosα = 0.
τ = BILw * cos 90o = 0
The torque acting on the conductor at this position is given by,

Results:
Thus,we successfully demonstrated the fundamental principles of a DC
motor, converting electrical energy into mechanical motion and
showcasing the importance of electromagnetic interactions within the
motor. While this was a basic model, it provided valuable insights into the
workings of more complex DC motors found in various applications.

Applications:
The principles you've learned from constructing and studying a simple DC motor have
various practical applications in real-world technology and industry. Here are some key
applications of DC motors:

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Electric Vehicles: DC motors are commonly used in electric vehicles (EVs) to drive
wheels, providing efficient and controlled motion. They are found in both traditional
battery-electric vehicles and hybrid vehicles.
Industrial Automation: DC motors are used in various automated systems, including
conveyor belts, robotic arms, and CNC machines. Their precise control and torque
characteristics make them valuable in manufacturing and assembly processes.
Household Appliances: Many household appliances, such as washing machines,
vacuum cleaners, and food processors, employ DC motors for their reliable
performance and energy efficiency.
Computer Hard Disk Drives: Brushless DC motors are used to drive the platters in
computer hard disk drives, providing fast and accurate data storage.
Aerospace: DC motors are used in aircraft and spacecraft for tasks like actuating flaps,
landing gear, and control surfaces. Their reliability is crucial in aviation.
Medical Devices: Precision and reliability make DC motors suitable for medical
equipment like ventilators, infusion pumps, and laboratory instruments.
Power Tools: Cordless power tools like drills, saws, and screwdrivers often use DC
motors for their portability and consistent power output.
Solar Tracking Systems: DC motors can be used in solar tracking systems to adjust
the angle of solar panels, optimizing energy capture from the sun.
Automated Guided Vehicles (AGVs): AGVs used in manufacturing and warehousing
rely on DC motors for movement, enabling them to transport materials autonomously.
Model Trains and Toys: Many model trains and remote-controlled toys use small DC
motors for propulsion and control.
Actuators in Robotics: In robotics, DC motors are used as actuators to control the
movement of robot arms, grippers, and other parts of robots.
Marine Applications: DC motors are used in boating and marine applications, such as
for winches, sail furling systems, and anchor handling.
Textile Industry: In textile machinery, DC motors are used in various stages of
production, from spinning and weaving to dyeing and finishing.
Elevators and Escalators: Some elevator and escalator systems use DC motors for
their efficient and smooth operation, especially in modern buildings and facilities.
Automotive Accessories: DC motors are employed in various automotive accessories,
including power windows, power seats, windshield wipers, and sunroofs.
These applications demonstrate the versatility and importance of DC motors across a
wide range of industries, from transportation to manufacturing to consumer electronics.
Understanding the principles of DC motors is essential for engineers and technicians
working with these technologies

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Conclusion:
In this project, we embarked on a journey to construct a simple DC motor and explore
the underlying principles governing its operation. Through this hands-on experience,
we gained valuable insights into the world of electromagnetism and the fundamental
workings of direct current motors. Our project yielded several key findings and
takeaways:
Electromagnetic Principles: We successfully harnessed the fundamental principles
of electromagnetism, understanding how the interaction between a magnetic field and
an electrical current leads to the creation of rotational motion. This is at the heart of DC
motor operation.
Role of the Commutator: Our project highlighted the importance of the commutator
in reversing the direction of current flow in the coil, which is essential for sustained
rotation. This concept is central to the operation of DC motors.
Energy Conversion: We observed the conversion of electrical energy into mechanical
motion in our constructed motor. This transformation of energy is a central feature of
DC motors and underlies their utility in various applications.
Applicability: While our constructed motor was rudimentary, it demonstrated the core
principles applicable to more advanced and efficient DC motors used in everyday
devices such as fans, drills, and electric vehicles.
Educational Value: This project offered a hands-on learning experience that deepened
our understanding of science and engineering concepts. It emphasized the value of
practical experimentation and application of theoretical knowledge.
In conclusion, our project successfully achieved its objectives of constructing a basic
DC motor and elucidating the principles guiding its operation. By observing our motor
in action, we enhanced our comprehension of electromagnetism and the essential role
DC motors play in modern technology. This project serves as a foundational step in
appreciating the significance of electric motors in our daily lives and the exciting world
of electromechanical systems.

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Bibliography/References:

1. Pioneer Practical Physics, Dreamland Publication.

2. Principles of Physics, Ayam Publication.
3. chat.openai.com
4. byjus.com
5. toppr.com
6. scienceready.com
7. linquip.com
8. yourelectricalguide.com

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