Construction of A DC Motor

Name of The Project: Lighting an LED by a DC generator with the help of
constructing a DC motor.
Objectives: After this project we will be able to-

1. To get core understanding of how the motor behaves on different geometry
of winding.
2. To understand the current flow cycle between brush to commutator and
armature winding.
3. To understand how a motor can be reversed as a generator.
Theory:
The term ‘DC motor’ is used to refer to any rotary electrical machine that
converts direct current electrical energy into mechanical energy. DC motors can
vary in size and power from small motors in toys and appliances to large
mechanisms that power vehicles, pull elevators and hoists, and drive steel rolling
mills.
DC motors include two key components: a stator and an armature. The stator is the
stationary part of a motor, while the armature rotates. In a DC motor, the stator
provides a magnetic field that drives the armature to rotate.
A simple DC motor uses a stationary set of magnets in the stator, and a coil of wire
with a current running through it to generate an electromagnetic field aligned with
the center of the coil. One or more windings of insulated wire are wrapped around
the core of the motor to concentrate the magnetic field.
The windings of insulated wire are connected to a commutator (a rotary electrical
switch), that applies an electrical current to the windings. The commutator allows
each armature coil to be energized in turn, creating a steady rotating force (known
as torque).
When the coils are turned on and off in sequence, a rotating magnetic field is
created that interacts with the differing fields of the stationary magnets in the stator
to create torque, which causes it to rotate. These key operating principles of DC
motors allow them to convert the electrical energy from direct current into
mechanical energy through the rotating movement, which can then be used for the
propulsion of objects.
Figure: Simplified diagram of a DC motor.
On the other hand, a generator (alternator) is a machine that uses electromagnetic

induction to convert mechanical energy into electrical energy. A direct current
(DC) generator works on the principle that a voltage is induced in a conductor coil
when it is rotated in a magnetic field. The rate at which the coil rotates in the
magnetic field determines the amount of voltage induced in the coil. When a
conductor coil rotates at a constant rate in a magnetic field, the voltage induced in
the coil is proportional to the rate of change of magnetic flux through the coil loops
at any given instant of time. DC generators are made up of field windings, an
armature, a commutator, brushes, and a frame.
A DC motor can be altered as a DC generator if we rotate the rotor by an external
source and connect a multimeter across the terminals of the motor, we will get a
current flow. This principle is used in this project.
Circuit Diagram:
Here is a practical circuit diagram of the constructed motor.
Figure: Circuit diagram of a DC motor.
Required Equipment:
1. Copper wire.
2. Copper tube.
3. Permanent magnet (2 pieces).
4. Card board.
5. A 3.7V DC motor.
6. Glue.
7. Bicycle spoke.
8. Soldering iron.
9. Metal Cutter.
10. Metal hook.
11. A switch.
12. A set of MTF connectors.
13. DC power source.
14. Screws.
15. Screwdriver.
Details about the equipment:
1. Copper wire is used to create the armature winding.
2. Copper tube is used to create the commutator.
3. Permanent magnet is used for the magnetic field generation.

4. Card board is used to create the basement and the armature internal
structure.
5. A 3.7V DC motor is used to make a generator for lighting the LED.
6. Glue is used for the internal joints.

7. Bicycle spoke is used to make the shaft of the motor.
8. Soldering iron is used to join the armature wires to the commutator.

9. Metal cutter is used to cut the copper tube into desired shape for the
commutator.
10. Metal hook is used to hang the shaft of the motor.
11. An electrical switch is used to I/O the total system.
12. Some MTF connectors are used to connect the internal circuit.
13. DC power source is used to power the whole system.
14. Screws are used to join the elements.
15. Screwdriver is used to insert the screws.

Procedure:
1. Firstly, we created a skeleton for the armature and commutator by
cardboard, bicycle spoke in the middle and copper tube cut as commutator
plates.
2. Secondly, we have winded the armature. We used three sides clockwise
winding at each side 138 turns.
3. We carefully attached the tip of the windings with the three-pole
commutator
4. Then we created a basement for the whole setup with two sides holder for
the permanent magnets.
5. Then we attached the magnets on the holders.
6. We attached a metal hook to insert the armature.
7. We inserted the armature and connected the tip of the armature with a 3.7V
DC motor used as generator.
8. Then we connected the poles of the motor with an LED.
9. We used thick copper wire as brush to give power supply to the commutator.
10. Finally, we connected the power source and also inserted a switch in
between the circuit
Discussion & Conclusion:

The motor runs perfectly and by the mechanical power of the motor the
generator gets energized. Thus, electricity starts flowing in a closed circuit with the
LED and the LED flashes.
Precautions:
1. The magnet should be handled carefully.
2. The soldering iron should be operated carefully.
3. The windings of the armature should be winded perfectly.
4. For a three-pole winding each pole should be perfectly 1200 apart.
5. The brush and the commutator should be designed as a manner that they
always stay in contact.

Construction of A DC Motor

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Construction of A DC Motor

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Name of The Project: Lighting an LED by a DC generator with the help of

Objectives: After this project we will be able to-

Figure: Simplified diagram of a DC motor.

On the other hand, a generator (alternator) is a machine that uses electromagnetic

Figure: Circuit diagram of a DC motor.

2. Copper tube is used to create the commutator.

3. Permanent magnet is used for the magnetic field generation.

5. A 3.7V DC motor is used to make a generator for lighting the LED.

6. Glue is used for the internal joints.

8. Soldering iron is used to join the armature wires to the commutator.

10. Metal hook is used to hang the shaft of the motor.

11. An electrical switch is used to I/O the total system.

14. Screws are used to join the elements.

15. Screwdriver is used to insert the screws.

Discussion & Conclusion:

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