DC Generators Notes
DC Generators Notes
1. Principle of Operation
A DC generator works on the principle of Faraday's Law of Electromagnetic Induction, which states that whenever a conductor cuts magnetic
flux lines, a dynamically induced EMF is produced in the conductor. The direction of the induced EMF is given by Fleming's Right-Hand Rule. A
DC generator is thus an electrical machine that converts mechanical energy into direct current electrical energy using this principle, along with a
commutator that rectifies the internally generated AC into DC at the output terminals.
2. Construction
A DC generator consists of two main parts — the stator (stationary part) and the rotor (rotating part, called the armature). The main
constructional parts are described below.
Yoke
Pole core
Field winding N
Air gap
Fig 1.1 — Cross-sectional view of a DC generator showing yoke, poles, field winding, armature, commutator and brushes
(a) Yoke
The outer frame of the machine, usually made of cast iron or fabricated steel. It provides mechanical support to the poles, protects the machine,
and provides a low-reluctance path for the magnetic flux produced by the field poles.
Poles are fixed to the yoke and project inward. Each pole consists of a pole core and a pole shoe. The pole shoe spreads the flux over the air gap
and reduces its reluctance. Poles are laminated to reduce eddy current losses and carry the field winding.
(f) Commutator
A cylindrical assembly of wedge-shaped copper segments insulated from each other by mica, mounted on the shaft. It converts the alternating EMF
generated in the armature conductors into unidirectional (DC) EMF at the brushes, acting as a mechanical rectifier.
(g) Brushes
Made of carbon or graphite, brushes rest on the commutator surface and collect current from it, connecting the rotating armature to the stationary
external circuit.
3. Working of a DC Generator
When the armature is rotated by a prime mover (diesel engine, turbine, etc.) inside the magnetic field produced by the poles, each armature
conductor cuts the magnetic flux lines and an EMF is induced in it as per Faraday's Law. The magnitude of the induced EMF depends on the rate of
change of flux linkage, and its direction is given by Fleming's Right-Hand Rule (thumb = direction of motion, forefinger = direction of field, middle
finger = direction of induced current).
As the armature conductor moves under a N-pole, current flows in one direction; when the same conductor moves under the next S-pole, the
current in it reverses. Thus, the EMF induced in each armature conductor is alternating in nature. The commutator, rotating along with the
armature, automatically reverses the connection of each coil to the external circuit at the exact instant the current in that coil reverses. As a result,
the current collected by the stationary brushes always flows in the same direction, giving a unidirectional (DC) output at the terminals — although
it is pulsating, not perfectly smooth, unless a large number of coils/segments are used.
EMF
Fig 1.2 — Pulsating unidirectional output of a single coil rectified by the commutator; with many armature coils the ripples overlap and the output becomes almost pure DC
In practice, an armature has many coils spaced around the periphery and connected to many commutator segments, so at any instant several coils
are feeding the brushes together. The pulsations from individual coils overlap, producing a nearly ripple-free, steady DC voltage at the output
terminals.
Q2. Derive the EMF Equation of a DC Generator [16 Marks]
1. Notation
Symbol Meaning
P Number of poles
2. Derivation
Consider a single conductor on the armature. In one complete revolution of the armature, this conductor sweeps through and cuts the flux of all P
poles.
t = 60 / N seconds
By Faraday's Law, the average EMF induced in one conductor equals the rate of change of flux linkage:
The total number of armature conductors is Z, arranged into A parallel paths (A depends on the type of winding). The number of conductors in
series in each parallel path is therefore:
Since the generated EMF equals the EMF across one parallel path (all paths are identical and connected in parallel between the two brushes), the
total generated EMF is the EMF of one conductor multiplied by the number of conductors in series per path:
Eg = (Φ Z N P) / (60 A) volts
3. Special Cases
Eg = (P Φ Z ω) / (2π A) volts
5. Key Observations
The generated EMF is directly proportional to flux per pole (Φ) and speed (N).
For a fixed machine (P, Z, A fixed), Eg ∝ ΦN.
This equation underlies speed control, voltage build-up analysis, and machine design calculations.
Q3. Explain Armature Reaction in a DC Generator [16 Marks]
1. Definition
When a DC generator is on no-load, only the main field (produced by the field winding) exists in the machine, and this flux is symmetrically
distributed about the pole axis. When the generator is loaded, current flows through the armature conductors, and this current also produces its
own magnetic flux — the armature flux. The effect of this armature flux on the main field flux (its interaction, distortion, and weakening of the
main field) is called Armature Reaction.
3. Flux Diagrams
(a) Main field alone (b) Armature flux alone (c) Resultant (distorted)
Cross-magnetising flux
S
MNA = GNA GNA New MNA (shifted)
Fig 3.1 — (a) Main flux only, symmetrical about pole axis; (b) Armature flux alone, cross-magnetising in nature; (c) Resultant flux is distorted and the MNA shifts in the
direction of rotation (for a generator)
where ATa per pole = (Z × Iz) / (2 × P), Z = total armature conductors, Iz = current per conductor, P = number of poles.
1. What is Commutation?
Commutation is the process by which the alternating current induced in an armature coil is reversed as the coil passes from one parallel path to
another (i.e., as the coil moves from under one pole to the next), while it is short-circuited momentarily by a brush bridging two adjacent
commutator segments. The period during which this reversal takes place is called the commutation period, Tc, typically a few thousandths of a
second (e.g., 0.001–0.002 s).
Tc = Wb / Vc seconds
where Wb = width of brush (equal to commutator segment + mica width), Vc = peripheral velocity of the commutator.
Segment a Segment b
Over-commutation
+I
Coil current = +I
(before commutation) Under-commutation
Fig 4.1 — During commutation the coil current changes from +I to −I as the brush moves from segment a to segment b. Ideally this is a straight line; departures cause
sparking
As the commutator segment (and the coil connected to it) moves under the brush, the coil is short-circuited. During this short period, the current in
that coil must reverse from +I to −I. If this reversal is linear (straight-line, "ideal" commutation), current density under the whole brush surface
remains uniform and there is no sparking. In practice, the coil has self-inductance, which opposes the rapid change of current and produces a
reactance voltage, delaying the reversal — this is called under-commutation (delayed commutation), and it causes sparking at the trailing tip
of the brush.
3. Reactance Voltage
Er = L × (dI / dt) = L × (2I / Tc) volts (approx., for linear commutation reference)
This self-induced EMF opposes the change of current in the coil undergoing commutation and is the primary cause of sparking. It must be
neutralised for good commutation.
Achieved by using high-resistance carbon brushes instead of low-resistance copper brushes. As the coil short-circuit progresses, contact
resistance under the leading tip decreases while that under the trailing tip increases, forcing current to shift naturally towards the new segment
and assisting reversal. This is simple and used in most small/medium machines, but does not fully compensate the reactance voltage at high loads.
5. Summary Table
Resistance commutation High-resistance carbon brushes Simple, used generally; partial solution
If
O
Fig 5.1 — OCC and field resistance lines. The generator voltage builds up along the OCC until it meets the field resistance line at the stable operating point
The intersection of the OCC and the field-resistance line gives the point at which the generated EMF exactly equals the voltage drop required to
drive the corresponding field current through the field resistance — this is the stable, final build-up voltage for that value of Rf and speed.
1. Shunt Generator
Field winding (many turns, thin wire, high resistance) is connected in parallel with the armature. Field current If = V/Rf is small and depends on
terminal voltage.
Breakdown point
IL
Fig 6.1 — Shunt generator external characteristic: voltage droops gradually with load due to armature resistance drop, armature reaction and reduced field current (V falls),
and drops sharply (foldback) beyond the breakdown point due to a short-circuit-like condition
As load current increases: (i) armature IR drop increases, (ii) armature reaction weakens the flux, (iii) reduced terminal voltage V further reduces
field current If = V/Rf, which reduces E further — a cumulative drooping effect. Beyond a certain critical load, V collapses rapidly, and under a dead
short-circuit, current actually falls to a small value (limited only by residual magnetism).
2. Series Generator
Field winding (few turns, thick wire, low resistance) is connected in series with the armature and load, so field current = armature current = load
current.
E, V
Internal characteristic E
External characteristic V
IL = Ia
Fig 6.2 — Series generator: E and V rise with load current as flux increases (unsaturated region), reach a maximum, then fall as the core saturates and armature/series-field
IR drop dominates
At light loads, increasing load current increases field flux almost proportionally, so both E and V rise steeply. As the magnetic circuit saturates,
further increase in current gives little increase in flux, while the IR drop (armature + series field resistance) continues to grow, so the curve
reaches a maximum and then falls. Series generators are rarely used for constant-voltage supply; they find use in applications such as boosters.
3. Compound Generator
Has both a shunt field and a series field. Depending on whether the series field aids (cumulative compounding) or opposes (differential
compounding) the shunt field, three types of external characteristics are obtained:
Over-compounded
Flat / Level-compounded
Under-compounded
IL
Differential compound (drooping fast)
Fig 6.3 — Compound generator external characteristics for different degrees of cumulative compounding, and for differential compounding
Level (flat) compound Full-load voltage ≈ no-load voltage General power supply at constant distance
Over-compound Full-load voltage > no-load voltage (rises with load) Supply with long feeders (compensates line drop)
Under-compound Full-load voltage < no-load voltage but better than plain shunt General use where a shunt-like but improved drop is acceptable
Differential compound Voltage drops sharply with load (series field opposes shunt field) Arc welding generators (constant current requirement)
Q7. Distinguish Between Lap Winding and Wave Winding [16 Marks]
1. Basic Idea
Armature winding connects the individual armature coils to the commutator segments in a specific systematic pattern. The two basic patterns are
Lap winding and Wave winding. The way successive coils progress around the armature determines the number of parallel paths (A), which —
from the EMF equation Eg = ΦZNP/60A — directly affects the voltage and current rating of the machine.
Successive coils overlap ("lap") back near start Successive coils progress ("wave") around periphery
Fig 7.1 — Schematic pattern of lap winding (coil ends return near the starting point, giving many parallel paths) vs wave winding (coil ends progress steadily around the
periphery, giving only two parallel paths)
2. Comparison Table
Number of parallel paths (A) A = P (equal to number of poles) A = 2 (always, regardless of poles)
EMF generated Lower EMF, more current capacity Higher EMF, lower current capacity
Required (to counter unequal EMF in parallel paths caused by unequal pole
Equaliser rings Not required
flux)
where YB, YF are back and front pitches (in terms of armature conductors), and YC is the commutator pitch (in terms of commutator segments).
4. Practical Choice
Lap winding is chosen for machines that must supply large currents at relatively low voltage (e.g., large DC motors/generators for traction,
plating), since the many parallel paths share the total current. Wave winding is chosen for machines needing higher voltage at lower current,
since only two parallel paths mean each path carries a larger share of the series-connected conductors, generating a higher EMF for the same Z, P,
N, Φ.
Q8. Explain Critical Resistance and Critical Speed of a DC Shunt Generator [16 Marks]
If
Fig 8.1 — Critical resistance line: the field resistance line drawn tangential to the initial straight portion of the OCC
Because at constant If, E ∝ N, the OCC at any other speed N2 can be obtained from a known OCC at N1 using:
E2 = E1 × (N2 / N1) (for the same field current)
This relation is used to redraw or rescale the OCC for any other speed, and hence to determine the critical speed for a given field resistance
graphically — by rescaling OCC curves until the given Rf line is just tangential to the curve.
3. Practical Significance
A self-excited shunt generator must always run above its critical speed (for the existing field resistance) or with field resistance below the
critical resistance (for the existing speed) to build up rated voltage.
If the field rheostat resistance is increased too much, or the machine is run too slowly, the generator will fail to excite (voltage will not
build up), a common practical fault when commissioning shunt/compound generators.
The critical resistance/speed concept explains why shunt generator voltage regulation is sensitive to field-circuit resistance settings.
Q9. Numerical Problems on the EMF Equation [16 Marks]
Formula used throughout: Eg = ΦZNP / (60A), with A = P for lap winding and A = 2 for wave winding.
Problem 1. A 4-pole, lap-wound DC generator has 250 armature conductors and a flux per pole of 0.02 Wb. Find the EMF generated if the
armature is driven at 1200 rpm.
Given: P = 4, A = P = 4 (lap), Z = 250, Φ = 0.02 Wb, N = 1200 rpm
Eg = ΦZNP / 60A = (0.02 × 250 × 1200 × 4) / (60 × 4)
Eg = (0.02 × 250 × 1200) / 60 (P and A cancel for lap winding)
Eg = 6000 / 60 = 100 V
Problem 2. A 6-pole, wave-wound armature has 800 conductors and is driven at 500 rpm. If the flux per pole is 0.05 Wb, find the generated
EMF.
Given: P = 6, A = 2 (wave), Z = 800, Φ = 0.05 Wb, N = 500 rpm
Eg = ΦZNP / 60A = (0.05 × 800 × 500 × 6) / (60 × 2)
Eg = 120000 / 120 = 1000 V
Problem 3. A 4-pole, lap-wound DC generator running at 750 rpm with a flux per pole of 0.025 Wb is required to generate an EMF of 220 V.
Find the number of armature conductors required.
Given: P = 4, A = 4 (lap), N = 750 rpm, Φ = 0.025 Wb, Eg = 220 V
From Eg = ΦZNP/60A, and P/A = 1 for lap winding: Z = Eg × 60 / (Φ × N)
Z = (220 × 60) / (0.025 × 750) = 13200 / 18.75
Z = 704 conductors
Problem 4. A 4-pole, wave-wound DC generator with 600 armature conductors and a flux per pole of 0.025 Wb is required to generate 440 V.
Find the speed at which it must be run.
Given: P = 4, A = 2 (wave), Z = 600, Φ = 0.025 Wb, Eg = 440 V
N = Eg × 60A / (ΦZP) = (440 × 60 × 2) / (0.025 × 600 × 4)
N = 52800 / 60
N = 880 rpm
Problem 5 (on load — internal characteristic). A shunt generator delivers a load current of 50 A at a terminal voltage of 220 V. The
armature resistance is 0.1 Ω and the shunt field resistance is 110 Ω. Find the generated EMF, neglecting brush contact drop.
Given: V = 220 V, IL = 50 A, Ra = 0.1 Ω, Rf = 110 Ω
Field current: If = V / Rf = 220 / 110 = 2 A
Armature current: Ia = IL + If = 50 + 2 = 52 A
Generated EMF: Eg = V + IaRa = 220 + (52 × 0.1) = 220 + 5.2
Eg = 225.2 V
Q10. Explain Interpoles and Compensating Winding [16 Marks]
1. Need
As explained under commutation and armature reaction, the coil undergoing commutation has a self-induced reactance voltage that delays current
reversal, causing sparking at the brushes; and the armature MMF distorts the main flux. Interpoles and compensating windings are the standard
constructional solutions to these two related problems.
Interpole Interpole
i Armature i
Fig 10.1 — Interpoles located on the geometrical neutral axis between the main poles, with windings in series with the armature
Advantages
Since interpole flux is proportional to armature current, the corrective EMF automatically matches the reactance voltage at all loads —
no manual brush adjustment is needed.
Provides sparkless commutation over the full load range and is the standard method in almost all modern DC machines above a small
rating.
3. Compensating Winding
Interpoles neutralise armature reaction only in the narrow commutating zone (near the brush axis). In large machines subject to rapidly fluctuating
heavy loads, the cross-magnetising effect of armature reaction under the entire pole face can still cause flux distortion and even flashover. A
compensating winding addresses this directly.
It consists of conductors embedded in slots cut into the pole shoe faces, connected in series with the armature circuit, carrying a current in the
direction opposite to the armature conductors directly below them. Its MMF is designed to be equal and opposite to the armature MMF at every
point under the pole face, so the flux distribution under the poles remains essentially undistorted, even at full load.
4. Comparison
Location Between main poles (on GNA) In slots on the main pole shoe faces
Function Neutralises reactance voltage; assists commutation Neutralises armature MMF (cross-magnetisation) under pole face
Used in Almost all DC machines (except very small ones) Large machines with heavy, rapidly fluctuating loads
5. Conclusion
Interpoles and compensating windings together ensure sparkless commutation and undistorted air-gap flux, improving machine efficiency,
commutator/brush life, and overall performance under varying load conditions — making them essential features of modern, well-designed DC
machines.