ELEMENTARY

ELECTRICAL
ENGINEERING
DC GENERATORS
 GENERATORS
Generators are electrical components that convert mechanical energy into electrical energy by
electromagnetic induction. It supply the needed electrical energy for the operation of most electrical
equipment on aircrafts.

There are two types of generators, namely: DC Generator (Dynamo) and AC Generator (Alternator).

Dynamos are electrical generators that create direct current, converts the alternating current to a
direct current, using a commutator; it allows the current flow in one direction only.

Alternators are electrical generators that convert mechanical energy to electrical energy in the form
of alternating current. In an alternator, the electrical current periodically reverses its direction.
DC GENERATOR (DYNAMO)
CONSTRUCTION

The outer frame of a DC generator (dynamo)

is called as the yoke/field frame. It is made
up of cast iron or steel. It provides
mechanical strength to the whole assembly
and also carries the magnetic flux produced
by the field winding.

The magnetizing force inside a generator is

produced by an electromagnet consisting of
a wire coil called as field coil/field winding,
and a core called as pole/pole shoe/field
pole.
Field winding/field coil is an electromagnet that produces
the flux cut by the armature. It is made up of many turns of
wire that are securely fastened over the iron core of the pole
shoes.

Field poles are joined to the yoke with the help of bolts or
welding. Pole shoes serve two purposes:
1) they support field coils and;
2) spread out the flux in air gap uniformly.

The armature assembly consists of the armature core,

armature coils/armature windings, commutator, and other
associated mechanical parts.
The armature core is considered as the rotor of a DC
generator (dynamo), it is mounted on a shaft that rotates in
bearings located in the generator's end frames. It acts as a
conductor when it is rotated in the magnetic field and it is
laminated to reduce the eddy current losses. It may be
provided with air ducts for the axial air flow for cooling
purposes.

The armature coil/armature winding is a former wound

copper coil which rests in armature slots. The armature
winding can be wound by one of the two methods:
1) Lap winding or;
a) simplex, duplex, or triplex.
2) Wave winding.
 A commutator is used to convert the alternating current
flowing in its armature into the direct current at its terminals.
The commutator consists of copper segments with one pair of
segments for each armature coil.

The segments are held in place by steel V-rings or clamping

flanges or lock rings. Each commutator segment is insulated
from the others by mica. The raised portion of each segment is
called the riser, and the leads from the armature coils are
soldered to each riser.
Brushes are usually made from carbon or graphite. They rest
on commutator segments and slide on the segments when the
commutator rotates keeping the physical contact to collect or
supply the current. A flexible braided-copper conductor, called a
pig-tail, connects each brush to the external circuit.
 TYPES OF DC GENERATOR (DYNAMO)
DC generators can be classified in two main categories:
1) Separately excited, where field coils are energized or excited from an independent external DC
source.
2) Self-excited, where the generator supplies its own excitation; field coils are energized from the
current produced by the generator itself.
a) Series-wound, where the field winding in series with armature winding.
b) Shunt-wound, where the field winding in parallel with armature winding.
c) Compound-wound, or the combination of series and shunt winding.
i. Short-shunt, with the shunt field in parallel only with the armature.
ii. Long-shunt, with the shunt field in parallel with both the armature and series field.
 TYPES OF SELF-EXCITED
DC GENERATOR
Series-wound

The field winding of a series-wound generator is connected

in series with the external load circuit. Magnetic field strength
in a series-wound generator is created more because of the
large current flow than the number of turns in the coil.
Because of the way series-wound generators are constructed,
they possess poor voltage regulation capabilities.
One way to control the output voltage of a series-wound
generator is to install a rheostat in parallel with the field
windings. This limits the amount of current that flows through
the field coils, thereby limiting the voltage output.
Since series-wound generators have such poor voltage
regulation capabilities, they are not suitable for use in aircraft.
However, they are suitable for situations where a constant
RPM and constant load are applied to the generator.
 TYPES OF SELF-EXCITED
DC GENERATOR
Shunt-wound

A generator having a field winding connected in parallel

with the external circuit is called a shunt-wound generator. In
a shunt-wound generator, the armature and the load are
connected in series; therefore, all the current flowing in the
external circuit passes through the armature winding.
However, due to resistance in the armature winding, some
voltage is lost. This action is cumulative and, if allowed, the
output voltage would rise to a point called field saturation. At
this point there is no further increase in output voltage.
Because of this, a shunt-wound generator is not desired for
rapidly fluctuating loads.
To control the output voltage of a shunt generator, a
rheostat is inserted in series with the field winding. In this
configuration, as armature resistance increases, the rheostat
reduces the field current, which decreases the output voltage.
 TYPES OF SELF-EXCITED
DC GENERATOR
Compound-wound

A compound-wound generator combines a series

winding and a shunt winding so that characteristics of
each are used.
Series field coils are connected in series with the
armature circuit. These coils are mounted on the same
poles as the shunt field coils and, therefore, contribute to
the magnetizing force, or magnetomotive force, which
influences the generator's main field flux.
If the shunt field of a compound-wound generator is
connected across both the armature and the series field, it
is known as a long-shunt connection. However, if the
shunt field is connected across the armature alone, it is
called a short-shunt connection. These connections
produce essentially the same generator characteristics.
 SERVICE AND MAINTENANCE
The routine inspection and service done at each 100-hour or annual inspection interval is
generally all that is required to keep a generator in good working order. Generator overhaul is
often accomplished at the same time as engine overhaul.

ROUTINE INSPECTION AND SERVICING

The 100-hour and annual inspection of a generator should include the following items:
1) Inspect the generator for security of mounting; check the mounting flange for cracks and
loose mounting bolts.
2) Inspect the mounting flange area for oil leaks.
3) Inspect the generator electrical connections for cleanliness and security of attachment.
4) Remove the band covering the brushes and commutator. Use compressed air to blow out
accumulated dust. Inspect the brushes for wear, and freedom of movement. Check tension of
the brush springs, using a spring scale.
5) Inspect commutator for cleanliness, wear, and pitting.
6) Inspect the area around the commutator, and brush assemblies for any solder particles. The
presence of solder indicates that the generator has overheated and melted the solder attaching
the armature coils to the risers. When this happens, an open is created in the armature.
 SERVICE AND MAINTENANCE
GENERATOR OVERHAUL
Generator overhaul is accomplished any time a generator is determined to be inoperative, or at
the same time the aircraft engine is overhauled. Although an overhaul can be done in some
aircraft repair facilities, it is more often the job of an FAA Certified Repair Station licensed for
that operation.
The steps involved in the overhaul of a generator are the same for the overhaul of any unit:
1) disassembly
2) cleaning
3) inspection and repair
4) reassembly
5) testing

DISASSEMBLY
Disassembly instructions for specific units are covered in the manufacturer's overhaul manual
and must be followed exactly.
 SERVICE AND MAINTENANCE
CLEANING
Care must be taken when cleaning electrical parts. The proper solvents must be used, and, in
general, parts are not submerged in solvent tanks. Using the wrong solvent could remove the
lacquer-type insulation used on field coils and armatures, resulting in short circuits after the
generator is reassembled.

INSPECTION AND REPAIR

Inspect components for physical damage, corrosion or wear, and repair or replace as required.
Testing for proper operation of electrical components is accomplished using a growler and an
electrical multimeter.

A growler is a specially designed test unit for DC generators and motors and a variety of tests on
the armature and field coils is performed using this equipment.

REASSEMBLY
Prior to reassembly, the painted finish on the exterior of the frame is restored. In certain cases
the special insulated coatings on the interior surfaces are renewed. Furthermore, all defective
parts are replaced in accordance with the reassembly procedure specified by the manufacturer.
 SERVICE AND MAINTENANCE
TESTING
Operational testing of generators is accomplished on test benches built for that purpose. Bench
testing allows the technician the opportunity to flash the field, and ensure proper operation of the
unit before installation. Generator manufacturers supply test specifications in their overhaul
instructions that should be followed exactly.