Construction and Working Principle of DC Generator

CONSTRUCTION & WORKING PRINCIPLE OF DC GENERATOR
CONSTRUCTION OF DC GENERATOR
A DC generator has the following parts
1. Yoke
2. Pole of generator
3. Field winding
4. Armature of DC generator
5. Brushes of generator & Commutator
6. Bearing
Yoke of DC Generator
Yoke or the outer frame of DC generator serves two purposes,
1. It holds the magnetic pole cores of the generator and acts as cover of the generator.
2. It carries the magnetic field flux.
In small generator, yoke are made of cast iron. Cast iron is cheaper in cost but heavier than
steel. But for large construction of DC generator, where weight of the machine is concerned,
lighter cast steel or rolled steel is preferable for constructing yoke of DC generator. Normally
larger yokes are formed by rounding a rectangular steel slab and the edges are welded
together at the bottom. Then feet, terminal box and hangers are welded to the outer periphery
of the yoke frame.
Pole Cores and Pole Shoes of DC Generator
There are mainly two types of construction available. One: Solid pole core, where it is made
of a solid single piece of cast iron or cast steel. Two: Laminated pole core, where it made of
numbers of thin, limitations of annealed steel which are riveted together. The thickness of the
lamination is in the range of 0.04" to 0.01". The pole core is fixed to the inner periphery of
the yoke by means of bolts through the yoke and into the pole body. Since the poles project
inwards they are called salient poles.
Armature Core of DC Generator
The purpose of armature core is to hold the armature winding and provide low reluctance
path for the flux through the armature from N pole to S pole. Although a DC generator
provides direct current but induced current in the armature is alternating in nature. That is
why, cylindrical or drum shaped armature core is build up of circular laminated sheet. In
every circular lamination, slots are either die - cut or punched on the outer periphery and the
key way is located on the inner periphery as shown. Air ducts are also punched of cut on each
lamination for circulation of air through the core for providing better cooling. Up to diameter
of 40", the circular stampings are cut out in one piece of lamination sheet. But above 40",
diameter, number of suitable sections of a circle is cut. A complete circle of lamination is
formed by four or six or even eight such segment.
Armature Winding of DC Generator
Armature winding are generally formed wound. These are first wound in the form of flat
rectangular coils and are then pulled into their proper shape in a coil puller. Various
conductors of the coils are insulated from each other. The conductors are placed in the
armature slots, which are lined with tough insulating material. This slot insulation is folded
over above the armature conductors placed in it and secured in place by special hard wooden
or fiber wedges. Two types of armature windings are used – Lap winding & Wave winding.
Commutator of DC Generator
The commutator plays a vital role in DC generator. It collects current from armature and
sends it to the load as direct current. It actually takes alternating current from armature and
converts it to direct current and then send it to external load. It is cylindrical structured and is
build up of wedge - shaped segments of high conductivity, hard drawn or drop forged copper.
Each segment is insulated from the shaft by means of insulated commutator segment shown
below. Each commutator segment is connected with corresponding armature conductor
through segment riser or lug.
Brushes of DC Generator
The brushes are made of carbon. These are rectangular block shaped. The only function of
these carbon brushes of DC generator is to collect current from commutator segments. The
brushes are housed in the rectangular box shaped brush holder or brush box. As shown in
figure, the brush face is placed on the commutator segment which is attached to the brush
holder.
Bearing of DC Generator
For small machine, ball bearing is used and for heavy duty DC generator, roller bearing is
used. The bearing must always be lubricated properly for smooth operation and long life of
generator.
WORKING PRINCIPLE OF DC GENERATOR
It is seen that in the first half of the revolution current flows always along ABLMCD i.e.
brush no 1 in contact with segment a. In the next half revolution, in the figure the direction of
the induced current in the coil is reversed. But at the same time the position of the segments a
and b are also reversed which results that brush no 1 comes in touch with the segment b.
Hence, the current in the load resistance again flows from L to M. The wave from of the
current through the load circuit is as shown in the figure. This current is unidirectional.
This is basic working principle of DC generator, explained by single loop generator model.
The position of the brushes of DC generator is so arranged that the change over of the
segments a and b from one brush to other takes place when the plane of rotating coil is at
right angle to the plane of the lines of force. It is so become in that position, the induced emf
in the coil is zero.

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CONSTRUCTION & WORKING PRINCIPLE OF DC GENERATOR

A DC generator has the following parts

Yoke or the outer frame of DC generator serves two purposes,

Armature Core of DC Generator

Armature Winding of DC Generator

WORKING PRINCIPLE OF DC GENERATOR

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