Title: Study of Direct Current Motor – Part I.
Abstract:
This experiment characterizes the construction and electrical parameters of a DC machine to
support performance [Link] primary objectives were to examine the internal components
of a DC motor module, identify the neutral brush position, and measure the electrical resistance
and power losses of the shunt-field, series-field, and armature windings. Using the voltmeter-
ammeter method, the resistances were calculated under nominal current conditions. Furthermore,
the variation of armature resistance concerning rotor position was investigated. The findings
provide foundational insights into the physical and electrical properties of DC machines, which
are critical for understanding motor efficiency, thermal limits, and overall performance.
Introduction:
Direct current (DC) motors are commonly used in situations that need variable-speed control
and high torque. They work by converting electrical energy into mechanical energy through
electromagnetic interactions. A standard DC motor has a stationary stator that creates the main
magnetic field, a rotating rotor (armature) that carries the current to create torque, and a
commutator and brush assembly that keeps the rotor turning in one direction by reversing the
rotor current [1]. This experiment aims to give a clear understanding of these machines. It will
look closely at the physical construction of a DC motor, measure the electrical resistance of its
shunt, series, and armature windings, and calculate the power losses. These factors are important
for determining the current limits and thermal limits of the motor [3]
Theory and Methodology:
The operation of any electric motor is based on the principle of electromagnetism. When a
current-carrying conductor is placed in an external magnetic field, it experiences a mechanical
force proportional to the current and the magnetic field strength [2].
Every DC motor comprises six basic parts: the axle, rotor (armature), stator, commutator, field
windings, and brushes. The stator contains the shunt and series field windings, which are
designed to carry direct current to establish the magnetic field. The rotor consists of windings
connected to the commutator. The use of an iron core for the armature is common because it
provides rigid support for the windings and conducts heat away from the rotor. However, iron
core construction also introduces disadvantages, such as high mechanical inertia (which limits
acceleration) and high winding inductance (which can limit brush and commutator life) [3]
The resistance of the motor windings dictates the power losses, primarily dissipated as [Link]
resistance (𝑅) and power loss (𝑃) can be determined using the voltmeter-ammeter method,
governed by the following equations [1]:
E
R= (1)
I
P=E × I (2)
Where E is the voltage across the winding and I is the current flowing through it.
Apparatus:
The experiment was conducted using the laboratory apparatus listed in Table 1 [3]
Equipment description Model Number
DC Motor/Generator 8211
DC Voltmeter/Ammeter 8412
Power Supply 8821
Connection Leads 8941
Table I. Apparatus Used in Experiment 3
Experimental Procedure:
First, the physical construction of the DC Motor/Generator was examined to identify the
armature winding, stator poles, shunt-field winding, series-field winding, commutator, and
brushes. The brushes were aligned to the neutral position indicator mark on the motor housing
[3].
Next, the voltmeter-ammeter method was utilized to measure the resistance of the windings.
1. Shunt-Field Winding: A circuit was constructed connecting the Power Supply to
the shunt-field winding (terminals 5 and 6) in series with the 0–300 mA DC
ammeter, with the 0–400 V DC voltmeter connected across the shunt-field
winding. The Power Supply voltage was slowly increased until the ammeter
indicated 0.3 A DC (the nominal current). The voltage across the winding was
recorded, and the resistance and power loss were calculated.
Fig. 1. Circuit diagram for shunt-field winding resistance measurement [3]
2. Series-Field Winding: The circuit was reconfigured to connect to the series-field
winding (terminals 3 and 4), with the 0–1.5A DC ammeter replacing the
milliammeter and the 0–40 V DC voltmeter scale used. The voltage was
increased slowly (as only a few volts are required) until the current reached 1.5 A
DC (nominal). The winding voltage was recorded and resistance and power loss
were calculated.
Fig. 2. Circuit diagram for series-field winding resistance measurement with
1.5 A nominal current [3].
3. Armature Winding: The circuit was further modified to connect to the armature
winding (terminals 1 and 2), with the 0–1.5 A DC ammeter and 0–400 V DC
voltmeter. Current was increased to 1.5 A DC and the voltage was recorded.
Fig. 3. Circuit diagram for armature winding (including brushes) resistance
measurement at neutral position [3].
4. Positional Variation: To observe the effect of commutator segment contact, the
armature was rotated 90° to the left, and the measurement was repeated. It was
then rotated an additional 15° (105° total from the initial position), and the
measurement was recorded again.
Experimental setup:
Fig.4. Experimental setup Direct Current Motor
Result and Calculation:
The following tables summarize the measurements and calculated values obtained during the
experiment.
Motor Construction Observations:
Parameter Observed Value
Approximate commutator bars (segments) 76
Number of brushes 2
Shunt-field winding terminals 5 and 6
Series-1 field winding terminals 3 and 4
Rheostat terminals 7 and 8
Rheostat rated resistance 1000 Ω
Armature (brushes) terminals 1 and 2
Table II. Motor Construction Observations
Winding Resistance and Power Loss Results:
Winding Test Measured Resistance Power Loss P Terminals
Current Voltage E R = E/I (Ω) = I²R (W)
I(A) (V)
Shunt-Field 300mA 210V 700 Ω 63W 5 and 6
Series-Field 1.5A 10V 6.67 Ω 15.07W 3 and 4
Armature (Neutral Pos.) 1.5A 50V 33.34 Ω 75.01W 1 and 2
Armature (+90° 1.5A 130V 86.87 Ω 195W 1 and 2
rotated)
Armature (+15° further) 1.5A 115V 76.67 Ω 172.5W 1 and 2
Discussion of Results
The shunt-field winding is made of thin wires. This makes it have a higher resistance compared
to the series-field winding. This is expected because of a steady current flows through the field
winding to create magnetic flux [1]. This current is usually not more than the current in the
armature circuit.
The current through the armature is much higher it's the rated current that drives the motor at
rated torque. When we take measurements at positions, they are slightly different. This happens
as the brushes move across the segment boundary. At these points more or less of the two paths
into the armature are shorted. This results in resistance. The measurement at the armature also
includes the resistance from the brushes themselves [2]. Losses is I 2 R at the windings represent a
source of heat When current flows through the windings it creates heat because of the resistance.
If there is no way to get rid of this heat the machine can overheat. This can cause the insulation
to break down. So, these measurements help us choose the circuit protection. This protection is,
for the continuous load that should not be used on a motor.
Conclusion
This experiment provided a thorough investigation of the DC motor's construction and winding
characteristics. The physical components stator poles, armature, commutator, shunt-field and
series-field windings, and brushes were successfully identified and their roles understood.
The resistance of each winding was measured using the voltmeter-ammeter method, confirming
that the shunt-field winding has a much higher resistance than the series-field and armature
windings. The corresponding I²R copper losses were quantified, highlighting the importance of
operating within nominal ratings.
The armature resistance measurement at three rotational positions demonstrated that resistance is
position-dependent due to the commutator and brush geometry. This variation is small under
normal conditions but becomes significant in precision applications.
Overall, the experiment established a strong foundational understanding of DC motor winding
parameters, which is essential for the subsequent experiments on DC motor operation, speed
control, and efficiency characterization.
Reference:
[1] [1] B. L. Theraja and A. K. Theraja, *A Textbook of Electrical Technology, Vol. II: AC
& DC Machines*, 23rd ed. New Delhi, India: S. Chand & Company Ltd., 2002..
[2] V. K. Mehta and R. Mehta, Principles of Electrical Machines, 2nd ed. New Delhi, India:
S. Chand & Company Ltd., 2009.
[3] Dept. of EEE, AIUB, EEE 2106 Electrical Machines 1 Laboratory Manual, Experiment
3: Study of Direct Current Motor – Part I. Dhaka, Bangladesh: American International
University-Bangladesh, 2024.