Construction of D.C.

Machine
Fig.1 A cross section of typical d.c. machine
• It consists of the following parts :
1.1 Yoke
a) Functions :
• It serves the purpose of outermost cover of the d.c. machine. So that the
insulating materials get protected from harmful atmospheric elements like
moisture, dust and various gases like SO2, acidic fumes etc.
• It provides mechanical support to the poles.
• It forms a part of the magnetic circuit. It provides a path of low reluctance
for magnetic flux. The low reluctance path is important to avoid wastage
of power to provide same flux. Large current and hence the power is
necessary if the path has high reluctance, to produce the same flux.
b) Choice of Material : To provide low reluctance path, it must be made up of
some magnetic material. It is prepared by using cast iron because it is
cheapest. For large machines rolled steel, cast steel, silicon steel is used
which provides high permeability i.e. low reluctance and gives good
mechanical strength.
1.2 Poles :-
Each pole is divided into two parts namely, I) Pole core and II) Pole shoe.
This is shown in the Fig. 2.

Fig. 2 Pole Structure

a) Functions of pole core and pole shoe :

• Pole core basically carries a field winding which is necessary to produce
the flux.
• It directs the flux produced through air gap to armature core, to the next
pole.
• Pole shoe enlarges the area of armature core to come across the flux,
which is necessary to produce larger induced e.m.f. To achieve this, pole
shoe has been given a particular shape.
b) Choice of Material : It is made up of magnetic material like cast iron
or cast steel. As it requires a definite shape and size, laminated
construction is used. The laminations of required size and shape are
stamped together to get a pole which is then bolted to the yoke.
• 1.3 Field Winding (F1-F2)
• The field winding is wound on the pole core with a definite
direction.
• a) Functions : To carry current due to which pole core, on which the
field winding is placed behaves as an electromagnet, producing
necessary flux.
• As it helps in producing the magnetic field i.e. exciting the pole as
an electromagnet it is called Field winding or Exciting winding.
• b) Choice of material : It has to carry current hence obviously made
up of some conducting material. So aluminium or copper is the
choice. But field coils are required to take any type of shape and bend
about pole core and copper has good pliability i.e. it can bend easily.
So copper is the proper choice.
• Note : Field winding is divided into various coils called field coils.
These are connected in series with each other and in such a
direction around pole cores, such that alternate 'N' and 'S' poles are
formed.
By using right hand thumb rule for current carrying circular
conductor, it can be easily determined that how a particular core is
going to behave as 'N' or 'S' for a particular winding direction
around it. The direction of winding and flux can be observed in the
Fig 3.
1.4 Armature
It is further divided into two parts namely,
I) Armature core and II) Armature winding
I) Armature core : Armature core is cylindrical in shape mounted on the shaft. It
consists of slots on its periphery and the air ducts to permit the air flow
through armature which serves cooling purpose.
a) Functions :
• Armature core provides house for armature winding i.e. armature
conductors.
• To provide a path of low reluctance to the magnetic flux produced by the
field winding.
b) Choice of Material : As it has to provide a low reluctance path to the flux, it is
made up of magnetic material like cast iron or cast steel.
• It is made up of laminated construction to keep eddy current loss as low as
possible. A single circular lamination used for the construction of the
armature core is shown in the Fig. 4.
Fig. 4 Single Circular lamination of Armature core
II) Armature winding : Armature winding is nothing but the interconnection
of the armature conductors, placed in the slots provided on the armature
core periphery. When the armature is rotated, in case of generator,
magnetic flux gets cut by armature conductors and e.m.f. gets induced in
them.
a) Functions :
• Generation of e.m.f takes place in the armature winding in case of
generators.
• To carry the current supplied in case of d.c. motors.
• To do the useful work in the external circuit.
b) Choice of material : As armature winding carries entire current which
depends on external load, it has to be made up of conducting material,
which is copper.
• Armature winding is generally former wound. The conductors are placed
in the armature slots which are lined with tough insulating material.
1.5 Commutator :-
We have seen earlier that the basic nature of e.m.f. induced in the armature
conductors is alternating. This needs rectification in case of d.c. generator,
which is possible by a device called commutator.
a) Functions :
• To facilitate the collection of current from the armature conductors.
• To convert internally developed alternating e.m.f. to unidirectional (d.c.)
e.m.f.
• To produce unidirectional torque in case of motors.
b) Choice of material : As it collects current from armature, it is also made up
of copper segments.
It is cylindrical in shape and is made up of wedge shaped segments of the
hard drawn, high conductivity copper. These segments are insulated from
each other by thin layer of mica. Each commutator segment is connected to
the armature conductor by means of copper lug or strip. This connection is
shown in the Fig. 5.
Fig. 5 Commutator
1.6 Brushes and Brush Gear
Brushes are stationary and resting on the surface of the
commutator.
a) Function : To collect current from commutator and make it available to
the stationary external circuit.
b) Choice of material : Brushes are normally made up of soft material like
carbon.
Brushes are rectangular in shape. They are housed in brush holders,
which are usually of box type. The brushes are made to press on the
commutator surface by means of a spring, whose tension can be adjusted
with the help of lever. A flexible copper conductor called pig tail is used to
connect the brush to the external circuit. To avoid wear and tear of
commutator, the brushes are made up of soft material like carbon.
1.7 Bearings
Ball-bearings are usually used as they are more reliable. For
heavy duty machines, roller bearings are preferred.