DC Generators

FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
BASIC GENERATOR THEORY

1. Generator is an electrical machine that convert mechanical energy to
electrical energy
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BASIC GENERATOR THEORY - cont

2. Faradays Law
When a conductor cuts a magnetic field an emf is induced into the conductor.
The magnitude of the emf induced depends on :
a. B the flux density of the magnetic field (Tesla) or field strength
b. l the length of the conductor in the field (metres) or number of turns
c. v the velocity of the conductor (metres/sec) moving through the field or
speed of cutting
Note :
e = Blv

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GENERATOR PRINCIPLE
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Current going IN Current going OUT
PRODUCTION OF A SINE WAVE

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3. Operation :
a. Positions 1 and 5 the conductor is moving along the flux lines and no
cutting takes place and no emf is induced
b. Positions 3 and 7 maximum cutting taking place and maximum emf is
induced
c. Other positions an emf is induced depending on the angle of cutting of the
flux
d. Emf induced at 2, 3 and 4 is opposite to that at 6, 7 and 8 i.e. this is an
alternating emf (a.c.) and is therefore the basis of the ac generator

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Basic Simple Generator Produce Alternating Current (A.C.)

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4. Flemings Right Hand Rule
To find direction of the induced emf when a coductor cut a magnetic field
a. First finger direction of magnetic field
from north to south
b. Second finger direction of current flow
in or out of a conductor
(conventional flow)
c. Thumb direction of conductor
movement

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DC GENERATOR
5. Simple DC Generator

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DC GENERATOR - cont
Operation :
- To convert ac inside the
armature to dc to the
external circuit via carbon
brush is by using an
automatic switching
known as a commutator.
- Stationary brushes rest
on the commutator
surface by spring tension.

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DC GENERATOR - cont
6. Single Loop DC Generator
a two segments of commutator
approaching the point of maximum
induced emf with current flowing in the
load

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DC GENERATOR - cont
b the segments approaching the point of zero
emf and approaching the brushes at the point
of changeover from one commutator segment
to the next

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DC GENERATOR - cont
c the changeover has occurred and the lower
brush is now in contact with segment 1 and not
segment 2 as it was prior to the changeover
Note :
i - The commutator ensures that whichever
conductor is passing the North pole (N) it is always
Negative (-) and conductor passing the South pole
(S) is positive (+)
ii - The current through the load remains in the

same direction i.e. dc output

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DC GENERATOR - cont
Action of commutator segment

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DC GENERATOR - cont
Action of commutator :
- which allow current to
flow to the load in one
direction only i.e. d.c.

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DC GENERATOR - cont
Single loop two segment generator :
- The output from commutator segment is dc but the current is not constant i.e. twice per
revolution and also at a maximum twice per revolution. The fluctuating current (and
voltage) called ripple

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DC GENERATOR - cont
7. DC Generators
- to generate smoother output, the practical generator must have many more coils
rotating in a magnetic field i.e. more loops reduce the ripple and more turns increase
the output
Multi Segment
DC Generator
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DC GENERATOR - cont
N
N
S
S
Multi Segment Generator

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DC GENERATOR - cont
8. Components Of A Generator
a Rotor
rotating part of a generator known
as armature consist of shaft, iron
core, the output windings (coils)
and the commutator
- iron core provides a low
reluctance path between the field
pole pieces

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DC GENERATOR - cont
- core laminated to reduce eddy current
- windings wound in slots in the iron core and wedged to prevent them being thrown
out due to centrifugal force

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DC GENERATOR - cont
DC Generator Details

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DC GENERATOR - cont
there are two types of windings namely
i Wave wound; for high voltage low current output
- two parallel paths irrespective of the number of poles each
supplying half the total current output
- only two brushes for the output
Wave Winding
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DC GENERATOR - cont
ii Lap Wound; for high current low voltage output
- there are as many paths in parallel as there are poles and many
sets of brushes as the machine has poles
- the total current divides equally between them
Lap Winding
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DC GENERATOR - cont
- commutator; located at non drive end of the
armature and consists a number
of copper segments monted on,
but insulated from the shaft
- each commutator segments are insulated by
mica and undercut to make their top
surface
slightly below the level of the commutator
segments

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DC GENERATOR - cont
- Brushes and Brush Holders; made of
low contact resistance, low specific
electrical resistance, low coefficient of
friction and good lubricating properties
i.e. graphite carbon
- some carbon brush with self lubricant
with molybdenum disulphide
- some machines may have chemicals such as barium fluoride added to form a film
(darkish brown) on the commutator to provide the lubrication between the brush
and commutator
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DC GENERATOR - cont
- brush holder hold the brush in position
and maintain good contact between
commutator by brush spring
- pigtail; provide electrical connection
from carbon brush to the main
generator terminals

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DC GENERATOR - cont
b. Stator Magnetic Field system
- use electromagnet to create North and
South pole and yoke as a return path
for its field
- winding are wound around the pole
pieces which bolted inside the yoke
- the numbers of poles always an even
number
- poles being laminated to minimise
eddy current
Magnetic Circuit Of 4 Poles Generator

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DC GENERATOR - cont
- by using electromagnet, the field strength can be vary by amount of current flow to
the field windings

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DC GENERATOR - cont
4 poles using electromagnet

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DC GENERATOR - cont
c. Bearing rotating armature is supported in ball or roller bearings at both end and
lubricated with high melting point grease or lubricating oil

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Typical DC
Generator
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FACTORS AFFECTING GENERATOR OUTPUT

1. Factors affecting generator output (limit) depend on
a) Heat
Ability to dissipate heat Heat developed in the steel or iron of the magnetic
system, commutator and brush gear
- cooling is by ram air from aircraft forward movement
via external scoop and ducting the generator or by
electrical fan or combination of both methods

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FACTORS AFFECTING GENERATOR OUTPUT - cont

b) Armature seizure
Generator drive system must have some method of disconnecting the
generator in the event of seizure of the generator
(bearing overheated)
- the drive shaft has a smaller diameter section
between the spline drives which will act as a weak
link in the drive system and shear (break) should
excessive torque be applied
Quill drive

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GENERATOR VOLTAGE AGAINST LOAD CURRENT
c) Internal Voltage Drop

1. When a generator are not
connected to a load, there will be
no current flow from the source
to the load.
2. Therefore, the terminal voltage is
equal to the generated emf.

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GENERATOR VOLTAGE AGAINST LOAD CURRENT - cont
3. When load connected, the load

current (IL) will flow to the load,
through the armature and back to
the source.
4. Due to the armature has its own
resistance, there will be some
internal voltage drop across it.
5. Therefore, the terminal voltage
slightly drop.
V = E - IARA

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6. As load current (IL) increased, the

terminal voltage falls further due to
the internal lost voltage.
V = E - IARA

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Terminal voltage drop as load current increased

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Terminal voltage drop as load current increased

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7. On an aircraft dc generating system,
the field current is adjusted to keep the
voltage constant under all load
conditions by a voltage regulator.

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REACTANCE VOLTAGE
d) Reactance Voltage
1. When the armature windings

cut the magnetic field, emf is
induced and current flow
through coil (1) and coil (2) via
commutator segment B,
brush and to the external load.

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REACTANCE VOLTAGE - cont
2. As commutator segment
rotate, coil (1) shorted out by
the carbon brush through
commutator segment A and
B which cause the magnetic
field to collapse.

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3. The collapsing of magnetic field

causes back emf (self induced) build
up across coil (1) thus current flow
through reactive sparking as soon as
the carbon brush leave commutator
segment B.
4. This Reactive Sparking occurs at each

point of commutatation for every coil.
This will cause brushwear,
commutator wear and radio
interference.

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5. To minimise reactive sparking

DOR
is by connecting interpoles
windings which are small
poles located midway
between the main poles.
6. The interpole windings are

connected in Series with the
armature and has a same
polarity as the next main pole
ahead in the direction of
rotation.

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7. The current flow in the armature

is same as current flow through
the interpole winding. Interpole
Flux
8. When the armature approach the

point of commutation, the
magnetic field across the coil is
oppose by the interpole field
winding thus two opposite fluxes Arm
Flux
cancelled, leaving no flux to
collapse and no reactance
voltage and therefore no reactive
sparking.
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ARMATURE REACTION
e) Armature Reaction
1. The main field of a dc generator is between the pole pieces.
2. When the generator is supplying to the load, a magnetic field is created
by current flow in the armature winding i.e. armature field

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ARMATURE REACTION - cont

3. The interaction of this two fields causes a
resultant field which is distorted and
weakened to an extent dependent on the
load.
4. This interaction and resultant distortion of
the main field by the armature field is called
Armature Reaction.
Current Going In Current Going Out

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5. A line drawn vertically at a point midway
between the poles is termed as the
Geometric Neutral Axis (GNA).
6. When no load, the Magnetic Neutral Axis
(MNA) coincide with the GNA. The
carbon brush should position at 900 to
the main field i.e at MNA.
7. When load connected, armature reaction
has caused the MNA to move in front of
GNA and as the load increases the MNA
will move further ahead of GNA.

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8. The angle between MNA and GNA is
called angle of lead.
9. Now the brush has to be position at
MNA i.e. 900 to the main field.
10. If the brush is position at GNA then
there will be a considerable arcing
across the brush. This will reduce the
generated emf.
11. To continually adjust the brush position
is not practical due to MNA keep on
changing depend on load.

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Angle of
lead

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12. To overcome this problem, a
Compensating Windings are used.
13. This winding wound in slots in the
pole faces and connected in series
with the armature windings.

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14. Since the compensating winding
and the armature winding in
series, the current flow to the
load is same as current flow to
the compensating winding.
15. The compensating winding is
wound to oppose the armature
winding thus neutralise each
other and armature reaction will
not exist.
16. The GNA and MNA position will
coincide at all times.

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The GNA and MNA position will coincide at all times due to the action of
compensating winding under all load condition.

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17. Interpoles with Auxiliary or Bias Windings :
a. Is to obtain a correct interpole strength over all load and speed ranges.
b. Auxiliary windings is wound over an interpole to oppose the effect of the
interpole and connected in series with the main field.

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c. At high speed and heavy load, the bias winding gave little opposition to the
strong interpole magnetic field which is needed to suppress reactance e.m.f.
d. At low speed and heavy load, the bias windings will oppose the interpole
windings in reducing its strength and increase the efficiency of the generator.

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FACTORS AFFECTING GENERATOR OUTPUT

a) Heat
Caused by high current flow and flux changes.
Dissipated by ram air.
b) Generator Armature Seizure

Jamming of generators armature rotation due to bearing failure.
Quill drive with weak point will break to prevent damage to the generator and gearbox.
c) Internal Voltage Drop

Caused by internal resistance of the generator.
Voltage regulator keeps output voltage constant under all load.
d) Reactance Voltage
Caused by changing current direction at the brush.
To overcome installed Interpoles windings.
e) Armature Reaction
Distortion of the main field caused by the interaction between the main field and the armature field
produced when current flow in the armature windings.
To overcome installed Compensating Windings and Interpoles Auxiliary Windings (for high speed)

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GENERATOR LOSSES
1. There are three generator losses :
a. Copper losses power loss due to I2R across armature windings and field
windings i.e. losses varies with load
b. Iron losses eddy current losses minimise by lamination and hyteresis
loss in the armature
c. Friction losses brush friction, bearing friction and air bearing resistance
(windage)

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GENERATORS CLASSIFICATION
1. Are classified by which the magnetic field circuit (field winding) is energised.
It comes as :
a. A permanent magnet generator
b. Separately excited generator and
c. Self excited generator

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GENERATORS CLASSIFICATION - cont

2. Permanent Magnet Generator
- the field is provided by the high grade permanent magnet and a rotating armature
connected to the commutator segments.
- the volt/load characteristic show a slight
drop off in voltage as more load is applied
due to armature reaction resistance losses.

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Permanent Magnet Generator

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3. Separately Excited Generator
- the armature winding and field
winding are not connected
- the field winding connected to
the external dc source, has
high resistance value and field
current is control by variable
resistor
- armature winding connected to
the load

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a. Operation
- the field current unaffected and remains constant when load connected
- the output voltage slightly drop as the load current increases due to resistance
losses i.e. IR drop inside
the armature
b. Not practical for aircraft use
Volt / Load Characteristic

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4. Self Excited Generators :
- its field winding and armature winding are internally connected
- no external source required and its initial field excitation comes from
residual magnetism (from previous magnetization)
- its field current comes from the generator output as soon the generator
rotates
- its classification depend on how the field and armature connected

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5. There are three types of Self Excited Generator ;
a. Self Excited Series Wound Generator
b. Self Excited Shunt Wound Generator
c. Self Excited Compound Wound Generator
Series Wound Shunt Wound Compound Wound

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6. Self Excited Series Wound Generator :
a. Construction
- the field coil connected in series with
armature field
- series coil has few turn thick copper
wire and has very low resistance
armature

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b. Operation :
- on no load, the generated output is
less due to weak residual magnetism
- as load connected, generator load
increases (IF = IA) therefore field
current increases the magnetism thus
generated emf rises
- as load current increases, the field
becomes saturation and no more
increases on the terminal voltage
Rising Volt / Load Characteristic
- voltage start to fall due to IR drop

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c. Application : not practical for aircraft use

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7. Self Excited Shunt Wound Generator :
a. Construction
- the field connected in parallel (shunt) with
the generator armature
- the shunt field has many turns of fine copper
wire and has very high resistance
field armature

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b. Operation :
- when armature rotates, a weak residual
magnetism induce onto the armature thus
induce small generated emf
- this small induce emf will supply the field field
windings, increasing the flux and increase the
generated emf and fed back to its field again
armature
so does the output

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- when load connected, the terminal voltage slightly fall due to IR drop across the
armature
- as load increases, the terminal voltage drop further due to reduces field excitation
- if the load demand is too great, the

votage will tuck under or turn
under which cause voltage drop to
zero
- this generator must be allowed to
build up first before load connected
Falling Volt / Load Characteristic

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c. Application : mostly use for aircraft d.c. power supply

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8. Self Excited Compound Wound Generator :
a. Construction
- combination of both series winding and shunt winding
- series winding are wound to assist the shunt winding known as cummulative
compound

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b. Operation
- if the number of series field turns is arranged so that the output voltage at no load
and full load is the same, it is said to be level compound (just compensate the IR
drop only)
- if the number of series turn is increased, the output voltage increases with load, it
said to be over compound (over compensate the IR drop)

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- if series winding is wound to oppose the shunt winding, it is said to be differential
compound generator i.e when no load the voltage is high but the voltage drop
steeply when load is apply and has no practical use for aircraft

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INTERFERENCE SUPPRESSION
1. Sparking at brushes causes radio intereference.
2. Radio interference can be
minimise by connecting
capacitor in parallel with the
generator output between
main terminal and earth known
as suppressor.

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STARTER GENERATOR
1. The combination of a starter motor and a generator in one unit.
2. The starter is supplied with DC current to start an engine. Once started, the motor
becomes a generator and supplies current to the operating systems via bus bars.
3. Consists of self-excited compound wound machine with low resistance series field
winding and high resistance shunt field winding.
4. Compensating and interpole windings is included to prevent armature reaction and
reactance voltage.
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STARTER GENERATOR- cont

5. The machine is cooled by an integral cooling fan and when airborne cooled by ram
air.
6. When used for starting, the starter-generator is connected as a series-wound DC
motor capable of producing a very high starting torque. However, when used as a
generator the connections are changed so that the unit operates as shunt-wound
generator producing reasonably constant current over a wide range of speed.
7. Starter-generator replaces two individual machines savings in size and weight.
8. Starter-generators are mainly found on turbine powered aircraft that maintain a
relatively high engine rpm
9. Operation :
a. In starting mode, current will flow to both series and shunt field which acts as a
compound wound motor to provide the necessary torque and acceleration to
the engine.
b. A speed sensor is used to signal starter cut-off when the engine is nearing self
sustaining speed.
c. In generator mode, only shunt field received current and act as shunt wound
generator to supply dc power automatically.
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STARTER GENERATOR - cont
Starter Generator Circuit

Start Mode current flow to both series field and shunt field as motor
Generator Mode current flow to the shunt field only as shunt wound generator

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STARTER GENERATOR - cont

7. There are two types of connection :
a Short Shunt; shunt field parallel across the armature only
b Long Shunt; shunt field parallel to both series field and armature
The arrangements is to obtain specific characteristic
- shunt field is connected - the voltage across

directly across the the shunt field =
armature terminals and the terminal
the armature connection voltage of the
= shunt field current + generator
the load current. - current in the
- the load current flows armature will be
through the series field the current in the
winding so that the load series field.
current and series field - armature current =
current are one and shunt field current
same. + load current.
Short Shunt Long Shunt
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VOLTAGE REGULATION
1. The only practical way to control the generator output is by controlling the field
current by the use of voltage regulator.
2. This voltage regulator connected in series with generator field.
3. There are several types of voltage regulator :
a. Voltage regulator using rheostat
- assume the output voltage is 28V at
constant speed and the rheostat is at
mid position

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VOLTAGE REGULATION - cont
b. When generator voltage

increased say 30V, the rheostat
has to increase its resistance
thus this will reduce current flow
to its shunt field.
c. Shunt field strength decrease
which will cause the generator
output to decrease.

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d. When generator voltage drop

say 26V, rheostat has to
decreased its resistance thus
more current flow to the shunt
field.
e. The strength of shunt field
increased thus increased the
generator output.
Note : Not suitable for aircraft use i.e. it is manually control to maintain its output
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4. Vibrating Type Voltage Regulator it is automatically control to maintain its output
a. Construction :
- voltage coil connect in parallel
with generator output
- contact point which is normally
closed by spring tension
- shunt resistance connect across
the contact point

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b. Operation :
- when generator voltage at 28V
the current will flow through
voltage coil and back to the
source
- current will also flow through
normally close contact, to the
shunt field and back to the
source
- no current flow through the
shunt resistance

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- when output voltage increased

say 30V, voltage coil enough
strength to pull the contact
point open
- now current must flow through
shunt resistance, shunt field
and back to source
- therefore less current flow to
the shunt field, field becomes
weak thus generator output will
slightly drop
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- when generator output drop

say 26V, voltage coil becomes
weak
- contact point closed by the
spring tension and shunt
resistance will be shorted out
- this allow more current to flow
to the shunt field to strengthen
its field
- therefore the generator output
will slightly increase, and this
cycle repeated
- the contact will keep vibrating
Note : It is automatically control by the voltage coil to maintain its output at 28V

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Notes :
- To vary the output voltage is by
varying the spring tension
- Increase the spring tension will
increase the output voltage
- Decrease the spring tension will
decrease the output

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5. Three Unit Regulator Type :
a. Construction :
- voltage regulator; to maintain output voltage constant by voltage coil
- current limiter (CL); to limit the output current of the generator
- reverse current cutout relay (RCCR); to prevent the battery from discharging
through the generator if output voltage falls below the battery voltage

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- gen warning light

illuminate
indicate gen off
line and
extinguish
indicate gen is
on line
- voltage regulator
contact and
current regulator
contact is
normally closed
- reverse current
contact is
normally open
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b. Operation :
When the generator at stationary, the generator warning light illuminate.

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When generator reaches 14.25 volt, the reverse current cut out contact close, thus
generator warning light extinguish
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When generator voltage above 14.25 volt, voltage regulator contact open. Now the
resistance in series with the generator field thus less field current. The output voltage will
reduce.
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When the load current exceeding the generator rating, the current coil contact open.
Now two resistance in series with the generator field thus limit the generator output.
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During engine shut down, the generator voltage is lower than battery voltage. The
reverse current from the battery through reverse current relay coil will oppose the
voltage coil thus weakening the field strength cause the contact open.
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When the generator voltage decreasing to zero, the generator warning light illuminate
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Reverse Current
Cutout Relay (RCCR)
Item (a): Generators field winding

Function: Current flow in the coil provides magnetic flux/field to be cut by the armature to induce
voltage.
Item (b): Shunt/voltage coil
Function: To energize the core to keep the contact closed/energize the armature closed.
Item (c): Series/current coil
Function: In series with the gens armature, assists the voltage coil in keeping the contact firmly
closed during normal operation.
Item (d): Spring
Function: Compensates the magnetic force of the relay to open the contact during under voltage
condition.
Item (e): Contact armature
Function: Open and close rapidly due to the magnetic field built up in the relays core.

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6. Carbon Pile Voltage Regulator : Use for heavy duty generator system which require a
high field current
a. Construction :
- carbon stack; a series of
disks arranged in a stack
or pile in series with the
field
- rheostat; controlled
amount of current to
electromagnet coils

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- electromagnet; exert a pull on
the carbon stack to increase
resistance thus reduce field
current
- leaf spring; compress the carbon
stack to reduce the resistance
thus increase field current

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b. Operation:
i Initial field excitation comes from residual magnetism inside the shunt field core.
ii When the armature rotate and cut this field, emf is induce inside the
iii armature and produce an output voltage (dc).
iv This low output voltage will flow to the rheostat and voltage coil. At this stage the voltage
coil is not enough strength to pull the armature leaf spring.
v At the same time current also flow to the shunt field through the carbon pile which is held
under maximum compress by the leaf spring thus cause less resistance.
vi More current flow to the shunt field which cause more induce emf (voltage) onto the
armature.
vii When output voltage above pre-determined value (>28V), the voltage coil will becomes
strong enough to pull the leaf spring which cause the carbon pile slightly decompress and
its resistance increase.
viii Less current flow to the shunt field which generate less induce emf (voltage) onto the
armature. Output voltage will slightly drop.
ix When output voltage less than the pre-determined value (<28V), the voltage coil
becomes weak which cause the leaf spring to compress more (maximum compress) on
the carbon pile thus its resistance decrease.
x Therefore more current flow to the shunt field to generate more output onto the armature.
xi Therefore the output voltage will be maintain at constant value (28V) by the action of pile
resistance which under maximum compress and minimum compress by the leaf spring.
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When generator at
constant speed

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When generator
speed increase
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When generator
speed decrease

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- To adjust output voltage is by adjusting the rheostat
- Increase rheostat resistance, increase the output voltage
- Decrease rheostat resistance, decrease the output voltage
Notes :
Advantages : - no contact point thus
no sparking
- no spring tension
- less maintenance but
high efficiency

Revision : Original
Issue No : 001
DC GENERATOR MAINTENANCE
Purpose is to keep the generator in good working order.
Maintenance work is carried out at each check interval as specified in
the aircraft maintenance schedule.
Inspection and servicing is carried out in accordance with
manufacturers instruction.
Overhaul is often accomplished at the same time as engine overhaul
thus minimize aircraft down time.
Routine Inspection and Servicing
Generally, routine inspection and servicing is carried out as follows:
Inspect for security of mounting.
Inspect mounting flange for oil leaks.
Inspect electrical connections for cleanliness and security of
attachments.

Revision : Original
Issue No : 001
DC GENERATOR MAINTENANCE - cont

Inspect area around the commutator and brush assemblies for any solder
particles. Loose solder particles indicate generator has overheated.
Use compressed air to blow out accumulated dust around the brushes
and commutator.
Inspect brushes for wear and freedom of movement.
Troubleshooting based on systematic analysis of the situation to

determine the cause of malfunction and remedial action:
Generator not charging battery:
Check the aircraft electrical system associated with the battery and
generator such as:
- every connection in the generator and battery circuit.
- condition of all fuses and circuit breakers.
- condition of all ground connections for battery, battery contacts, and
the generator control unit.

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Issue No : 001

With engine cranked, check armature rotation :
-use voltmeter to check generator output by placing the probes
betweenG terminal of voltage regulator and ground.
-accomplished with engine running or on appropriate test stand.
-performed in accordance with the manufacturers recommendations
and observe proper safety precautions.
-check for residual voltage around 1 or 2 volts.
-if no residual voltage can be restored by an operation known as
flashing the field.
-the operation is accomplished by momentarily passing current through
the field coils in the same way that is normally flows.

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Issue No : 001

- if there is residual voltage but no output voltage the trouble could be
with the generator or the regulator
- operate the engine at a speed the generator can produce an output.
- bypass or short circuit the voltage regulator
- if generator
produced voltage
depend on speed,
the problem is the
regulator, replace
regulator
- if there is no change
on generator voltage,
generator is bad and
replace generator

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Issue No : 001

DC Generator Overhaul :
a. Disassemble follow instruction i.a.w. manufacturers overhaul manual
- use proper tools and procedures to disassemble the parts

Revision : Original
Issue No : 001

b. Cleaning use proper solvent for cleaning as wrong solvent could remove the lacquer
type insulation used on field and armature coils resulting in short circuit
c. Inspection and Repair use of Armature Growler
- Armature Growler is a test unit to test for DC generator
armature and motor armature for Open Circuit, Short
Circuit and Ground
- consist of a laminated iron core as a primary and armature
being test as secondary
- some include with a test lamp which illuminates if the circuit
is completed

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d. Armature Coil Testing :
i - Test for Open Circuit :
- use test lamp with both probes touch
the adjacent commutator segment
- if the test lamp illuminate, the coil is
not open indicate it is good condition
- if the test lamp not illuminate, the coil
under test is open circuit
- if using ohmmeter, low resistance is
good and infinity indicate open circuit
Test for Open Circuit

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Issue No : 001

ii Test for Short Circuit :
- use thin steel strip or a hacksaw blade
and placed slightly above the armature
and rotate armature slowly
- if the blade vibrates vigorously, it
indicate the armature is short circuit
(bad)
- if the blade not vibrate, the armature is
not short circuit (good)
Test for Short Circuit

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Issue No : 001

iii Test for Ground :
- use test lamp or ohmmeter with one probe
touch the commutator segment and other
probe touch the armature shaft
- if the test lamp illuminates, the coil is
grounded (no good)
- if the test lamp not illuminates, the coil is
not grounded (good)
Test for Ground

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Issue No : 001

e. Field Coil Testing using Test Lamp or
Ohmmeter:
i Test for Open and Short Circuit :
- touch between both leads, if test lamp
illuminates indicate the coil is not open
(good) or ohmmeter indicate low
resistance
- if lamp not illuminate, indicate the coil is
open (bad) or ohmmeter indicate infinity
- shunt field resistance between 2 to 30
ohms
- series field resistance very low value

Revision : Original
Issue No : 001

ii Test for Ground :
- use test lamp with one probe
placed at field coil and the other at
generator frame to check for
ground
- test lamp illuminates
indicate the coil is
grounded (bad)
Test for Ground

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Issue No : 001

f. Commutator Inspection :
- checked for irregularities and pitting.
- slight roughness can be smoothen by using number 000 sandpaper.
- never use emery cloth or other conductive material as these could cause
shorting.
- mica should be undercut about the same depth as micas thickness or
approximately 0.002 inch.
g. Brush Inspection :
- generally brushes is replaced at overhaul or when half worn
- ensure the new brush is seated or contoured to maximize the contact area
on the commutator
- accomplished by using no. 000 sandpaper inserted under the brush
between the commutator and pulled in the direction of rotation to shape the
brush contour.
- checked spring tension using spring scale.

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Issue No : 001

h. Reassemble :
- prior assembly, ensure exterior paintwork is restored.
- ensure internal electrical connection is secured.
- checked pigtails on the brushes for freedom and ensure they do not restrict the
brushes free motion.
- after assemble, run the generator for a short period and reinspect to ensure no
sands are imbedded in the brush.
i - Operational Testing :
- accomplished on test benches built for the purpose.
- operated in accordance to manufacturers instruction.

Revision : Original
Issue No : 001
THANK YOU FOR ATTENTION
YOUR NEXT LESSON WILL BE
D.C. ALTERNATOR

Revision : Original
Issue No : 001

DC Generators

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FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

BASIC GENERATOR THEORY

Page No: 1 Subject Code AAB10403/AKD10203

BASIC GENERATOR THEORY - cont

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BASIC GENERATOR THEORY - cont

BASIC GENERATOR THEORY - cont

Current going IN Current going OUT

PRODUCTION OF A SINE WAVE

BASIC GENERATOR THEORY - cont

Page No: 5 Subject Code AAB10403/AKD10203

BASIC GENERATOR THEORY - cont

Basic Simple Generator Produce Alternating Current (A.C.)

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BASIC GENERATOR THEORY - cont

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ii - The current through the load remains in the

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Multi Segment Generator

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4 poles using electromagnet

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FACTORS AFFECTING GENERATOR OUTPUT

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FACTORS AFFECTING GENERATOR OUTPUT - cont

Page No: 32 Subject Code AAB10403/AKD10203

GENERATOR VOLTAGE AGAINST LOAD CURRENT

c) Internal Voltage Drop

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GENERATOR VOLTAGE AGAINST LOAD CURRENT - cont

3. When load connected, the load

Page No: 34 Subject Code AAB10403/AKD10203

GENERATOR VOLTAGE AGAINST LOAD CURRENT - cont

6. As load current (IL) increased, the

Page No: 35 Subject Code AAB10403/AKD10203

GENERATOR VOLTAGE AGAINST LOAD CURRENT - cont

Terminal voltage drop as load current increased

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GENERATOR VOLTAGE AGAINST LOAD CURRENT - cont

Terminal voltage drop as load current increased

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GENERATOR VOLTAGE AGAINST LOAD CURRENT - cont

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1. When the armature windings

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REACTANCE VOLTAGE - cont

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REACTANCE VOLTAGE - cont

3. The collapsing of magnetic field