AMT 211 AIRCRAFT ELECTRICAL AND IGNITION SYSTEM

(FINALS)

GENERATOR
Energy for the operation of most electrical equipment on large aircraft and some small aircraft is
supplied by a generator. A generator is any piece of equipment which converts mechanical
energy into electrical energy by electromagnetic induction. Generators designed to produce
direct current are called DC generators whereas generators that produce alternating current are
called AC generators.
On many older aircraft, the DC generator is the source of electrical energy. With this type of
system, one or more DC generators are driven by the engine(s) to supply power for all
electrical equipment as well as for charging the battery. In most cases only one generator is
driven by each engine; however, some large aircraft have two generators that are driven by a
single engine.

Cross section of a typical 24-volt generator

with major parts labeled

Construction Features of DC
Generators
Generators used on aircraft may differ
somewhat in design, since various
manufacturers make them. All,
however, are of the same general
construction and operate similarly.
The major parts, or assemblies, of a
DC generator are a field frame (or
yoke), a rotating armature, and a
brush assembly.
Field Frame
The field frame is also called the yoke,

which is the foundation or frame for the generator. The frame has two functions: It completes the
magnetic circuit between the poles and acts as a mechanical support for the other parts of the
generator. In small generators, the frame is made of one piece of iron, but in larger generators,
it is usually made up of two parts bolted together. The frame has high magnetic properties and,
together with the pole pieces, forms the major part of the magnetic circuit.
A practical DC generator uses electromagnets instead of permanent magnets. To produce a
magnetic field of the necessary strength with permanent magnets would greatly increase the
physical size of the generator. The field coils are made up of many turns of insulated wire and
are usually wound on a form that fits over the iron core of the pole to which it is securely
fastened.
The exciting current, which is used to produce the magnetic field and which flows through the
field coils, is obtained from an external source or from the generated DC of the machine. No

electrical connection exists between the windings of the field coils and the pole pieces.

Armature
The armature assembly of a generator consists of many armature coils wound on an iron core,
a commutator, and associated mechanical parts. These additional loops of wire are actually
called windings and are evenly spaced around the armature so that the distance between each
winding is the same. Mounted on a shaft, it rotates through the magnetic field produced by the
field coils. The core of the armature acts as an iron conductor in the magnetic field and, for this
reason, is laminated to prevent the circulation of eddy currents.

The armature rotates within the frame assembly and current is

induced into it by the electromagnetic field created by the
field coils and pole shoes.

Commutators
The commutator is located at one end of the armature and consists of wedge-shaped segments of harddrawn copper. Each segment is insulated from the other by a thin sheet of mica. The segments are held in
place by steel V-rings or clamping flanges fitted with bolts. Rings of mica also insulate the segments from
the flanges. The raised portion of each segment is called the riser, and the leads from the armature coils
are soldered to each riser. In some generators, the segments have no risers. In this situation the leads
are soldered to short slits in the ends of the segments.

Each segment of a commutator is mounted to an inner wedge and

separated by thin pieces of insulating mica. The risers on each segment hold the leads coming from the armature coils.

Brushes
Brushes ride on the surface of the commutator and act as the electrical contact between
armature coils and an external circuit. A flexible braided-copper conductor, called a pig-tail,
connects each brush to the external circuit. The brushes are made of high-grade carbon and
held in place by spring-loaded brush holders that are insulated from the frame. The brushes are
free to slide up and down in their holders so they can follow any irregularities in the
commutator's surface and allow for wear. A brushes' position is typically adjustable so that the
pressure on the commutator can be varied, and so the brush position with respect to the risers
can be changed as necessary.

Carbon brushes connect to an external circuit through pig tails.

The brushes are typically adjustable to allow varied pressure
on the commutator and position on the segments.

STARTER-GENERATORS
Many small turbine engines are equipped with starter generators rather than separate
starters and generators. This saves appreciably in weight, as both starters and generators are
very heavy. A typical starter generator consists of at least two sets of windings and one armature
winding. When acting as a starter, a high current flow through both sets of field windings and
the armature to produce the torque required to start the engine. However, in the generator
mode, only the high resistance shunt-winding receives current while the series-winding
receives no current. The current flowing through the shunt-winding is necessary to produce the
magnetic field that induces voltage into the armature. Once power is produced, it flows to the
primary bus.
GENERATOR RATINGS
A generator is rated according to its power output. Since a generator is designed to operate at a
specified voltage, the rating is usually given as the number of amperes the generator can safely
supply at its rated voltage. For example, a typical generator rating is 300 amps at 28.5 volts. A
generator's rating and performance data are stamped on the name plate attached to the
generator. When replacing a generator make sure it is the proper rating.
The rotation of generators is termed as either clockwise or counterclockwise, as viewed from the
driven end. If no direction is stamped on the data plate, the rotation is marked by an arrow

on the cover plate of the brush housing. To maintain the correct polarity, it is important to use a
generator with the correct direction of rotation.
The speed of an aircraft engine varies from idle rpm to takeoff rpm; however, the majority of flight,
is conducted at a constant cruising speed. The generator drive is usually geared between 1-1/8
and 1-1/2 times the engine crankshaft speed. Most aircraft generators have a speed at which
they begin to produce their normal voltage. This is termed the coming-in speed, and is typically
around 1,500 rpm.
DC GENERATOR SERVICE AND MAINTENANCE
Because of their relative simplicity and durable construction, generators operate many hours
without trouble. 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. This minimizes aircraft down time
and increases the likelihood of trouble free operation when the aircraft is placed back in service.
ROUTINE INSPECTION AND SERVICING
The 100-hour and annual inspection of a generator should include the following items:
1. Inspect generator for security of mounting, check the mounting flange for cracks and loose
mounting bolts.
2. Inspect mounting flange area for oil leaks.
3. Inspect generator electrical connections for cleanliness and security of attachment.
4. Remove band covering the brushes and commutator. Use compressed air to blow out
accumulated dust. Inspect 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 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.