Construction of D.C.

Machine
Fig.1A cross section of typical d.c. machine
 It consists of the following parts :
1.1Yoke
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
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
w hich is then bolted to the yoke.
1.3 Field W inding (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 w inding is divided into various coils called field
coils. These are connected in series w ith 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 w inding
direction around it. The direction of w inding 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
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. W hen 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
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.
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.