The direct current (DC) machines have been from the beginning of electrical engineering studies, since the end of the 19th century. They are used in many different industries such as manufacturing and transportation, and they are still applicable even though the current age is digital. The quality performances and dependability of these machines are the most important factors during their whole lifespan. This is why they are subject to extensive testing.

Testing is a tool that helps us to determine the functions of the machine, show if there are any mistakes, and correct them if needed. It also serves to define the instrument, which is an important criterion of its energy conservation and cost-effectiveness. Here we will consider the DC machine’s test type, procedure, and value.

What is Testing of a DC Machine?

DC machine testing involves a review of the machine’s performance and attributes in varied operating situations. It conducts a set of tests that are aimed at evaluating such characteristics of the machine’s performance as voltage regulation and speed control as well as other main parameters. Such tests facilitate the machine to run reliably and efficiently, so it meets the specifications and the governing requirements. The implications of these tests can be used to decide about further actions in operations, maintenance, and troubleshooting of the equipment.

Types of Tests on DC Machine

Various kinds of tests are carried out on a DC machine where each of the types of tests is used for evaluation of a specific characteristic of the DC machine. These include:

• Open Circuit Test: This test is used for the analysis of the magnetic behavior of the DC machine. Here it includes the test of the machine at its rated speed, without any load at all and measuring the armature current at different field currents.
• Short Circuit Test: Conducting this test leads to getting the short circuit characteristic curve of the machine. Its working principle relies on internally short circuiting the armature terminals and the machine runs at a very low speed.
• Load Test: This test gives an idea about mode of operation of the DC machine as well as its voltage regulation. It consists of running the electric motor to its full capacity and measuring the total power used and generated.

Open Circuit Test

The open circuit test, also commonly called a no-load test, is designed for discovering the magnetic properties of a DC machine. For this test, the machine is operated at rated speed but without loading it. The armature current is measured with different field currents and is used to draw the open circuit characteristic curve.

Formula:

E_OC = V – I_a(R_a + R_s )

where

• E_OC is open circuit voltage,
• V is applied voltage,
• I_a is armature current,
• R_a is armature resistance,
• Rs is series field resistance.

Open Circuit Test

This curve is also a very useful tool that is used to analyze the magnetic properties of the machine, like the connection between field current and generated voltage. It enables ascertaining as well concerning any anomalies existing in the magnetic circuit of the machine, for example, air gap or magnetic saturation.

Short Circuit Test

The short-circuit test is performed to create the short-circuit characteristic curve of the machine. In this test, the end parts of the armature are short-circuited, and the machine is turning at a very low speed. The changing-flux variables and the corresponding armature current is measured.

Formula

E_SC = I_a(R_a + Rs)

where

• E_SC is short circuit voltage.
  
  

  Short Circuit Test

The resulting curve of the short circuit characteristic is shown, which demonstrates the armature resistance and reactance. The test is so significant in finding the machine performance under fault condition.

Load Test

The load test is conducted to evaluating the performance, voltage regulation of the DC machine. This test works by overloading the machine to the full capacity and the power generated is at the input and output.

Formula

Efficiency (η) = Input Power / Output Power

Load Test

The efficiency is calculated as the quotient of the output power to the input power, and the voltage regulation is based on the comparison of the no-load with full-load voltages. Through this test, the machine’s actual performance will be assessed while it is operated under normal conditions.

Determination of Efficiency

An efficient DC machine should be developed so that the relations between electrical and mechanical energy can be studied and understood. There are several methods used to determine the efficiency of DC machines: the Direct technique, the Indirect technique, and the Regenerative technique. undefined

Direct Method

• In a direct method, an efficiency is obtained through the measurement of input power and output power directly.
• Input Power (Pi) can be measured by connecting an ammeter and a voltmeter in the feed of the electric power to the machine. Pi = Vi × Ii, where Vi be the input voltage and Ii the input current.
• Mechanical Power (Pm) is defined as the pressure generated when a load is applied to the machine. Po = Vo × Io, where Vo is the output voltage and Io is the current of the output.

Efficiency (η) is then calculated as the ratio of output power to input power:

η = 100% × (Po / Pi).

Indirect Method

• One indirect method of measuring the efficiency of the cause-effect relationship involves measuring the losses in the machine separately and then using the principle of conservation of energy to calculate the efficiency.
• The common negative types of losses in DC machines are copper losses (due to resistance in windings), iron losses (due to hysteresis and eddy currents in the core), and mechanical losses (due to friction and winding).
• Copper losses Pcu can be calculated conducting a no-load test where the machine is supplied rated voltage but no mechanical load, the current is recorded. Pcu = I²R, since I is the no-load current and R is the windings’ resistance.
• The Pfe (iron losses) are determined by using a scenario where the rated voltage is applied to the stator while the rotor is held stationary in the form of a blocked rotor test. The power differently appears and the iron losses take place in this mode.
• Mechanical losses (Pmech) can be calculated through load free operation and reading the input power.

Efficiency is then calculated using the formula:

η = (Wout – Total Losses) / Wout.

Regenerative Method

• A dynamometer principle is considered to be an advanced technique which is exercised by applying load on the machine while allowing it to act as a generator.
• Speaking of the machine working as a generator, it holds some of the mechanical power back to the electrical supply system and therefore it decreases the amount of the power input that is used. This technique exploits the phenomenon of the regenerating braking.
• Efficiency refers to the ratio between electrical power that enters a machine when it acts as motor and electrical power that a machine delivers to the distribution grid when it runs as a generator. The dissimilitude between the varying energies denotes the power taken by the machine.

Efficiency is then calculated using the formula:

η = [(Output Power – Absorbed Power)] / Output Power.

Every technique has its own pros and cons and the decisions about methodologies depend on factors including the accuracy required, the equipment available, and the particular characteristics of the specific DC machine in question.

Applications

DC machines are applicable in a wide variety of applications thanks to their all-round functionality and efficiency. undefined

• Electric Vehicles: DC machines are often used in EV for powering the vehicles forward. One major fact which is the high efficiency and the excellent torque-speed ratios makes them suitable for this application.
• Industrial Drives: Numerous manufacturing processes depend on the exact speed and feedback of the torque of which the DC machines are used. They have many types of uses in industry, such as conveyor belts, cranes, and elevators.
• Power Generation: DC machines are utilized for power generation systems mainly in renewable energy systems such as wind farms and solar-power systems. They transfer mechanical to electrical energy.

Conclusion

Testing of DC machines goes beyond routine inspection and it is one of the important aspects of the machine’s optimal performance, reliability, and longevity. It gives such essential information about the machine condition, thus the easy identification and correction of slow brewing problems can be done. Secondly, it is the highly determinant variable in the quality of the machine that helps to reduce energy consumption and to make the process more cost-effective.

This is an era where both energy efficiency and reliability are considered of the utmost significance, which makes the relevance of the testing impossible to overstate. It is the fundament of quality assurance systems and of the factors which allow DC engines to continue giving the desired performance to industrial drives, wind turbines and electric vehicles.

FAQs on Testing of DC Machine

What is the purpose of testing a DC machine?

Examining a DC machine gives us an insight into its operational regime and performance. These traits help us to find the machine’s efficiency, voltage regulation, speed control, and other important parameters.

What is an open circuit test?

A no-load test, which is another name for the open circuit test is the tool for determining of the magnetic characteristics of DC motor. In this test, the machine is rotating at its rated speed but without any load.

What is a short circuit test?

In a short circuit test the short-circuit’s characteristic curve of the machine is determined. In the short circuit test, the armature terminals are short-circuited, and train is run at the lowest speed possible.

What is a load test?

The purpose of the DC machine load test is to establish the efficiency and voltage regulation. Testing of the machine is conducted with full loading, and the input and output power are recorded.

How is the efficiency of a DC machine determined?

As for the DC machine efficiency, it may be measured directly, indirectly, and regeneratively. These methods can be performing the input and output power analysis or loss estimation.