A rotary converter is a type of electrical machine which acts as a mechanical rectifier, inverter or frequency converter.
Rotary converters were used to convert alternating current (AC) to direct current (DC), or DC to AC power, before the advent of chemical or solid state power rectification and inverting. They were commonly used to provide DC power for commercial, industrial and railway electrification from an AC power source. [1]
The rotary converter can be thought of as a motor-generator, where the two machines share a single rotating armature and set of field coils. The basic construction of the rotary converter consists of a DC generator (dynamo) with a set of slip rings tapped into its rotor windings at evenly spaced intervals. When a dynamo is spun the electric currents in its rotor windings alternate as it rotates in the magnetic field of the stationary field windings. This alternating current is rectified by means of a commutator, which allows direct current to be extracted from the rotor. This principle is taken advantage of by energizing the same rotor windings with AC power, which causes the machine to act as a synchronous AC motor. The rotation of the energized coils excites the stationary field windings producing part of the direct current. The other part is alternating current from the slip rings, which is directly rectified into DC by the commutator. This makes the rotary converter a hybrid dynamo and mechanical rectifier. When used in this way it is referred to as a synchronous rotary converter or simply a synchronous converter. The AC slip rings also allow the machine to act as an alternator.
The device can be reversed and DC applied to the field and commutator windings to spin the machine and produce AC power. When operated as a DC to AC machine it is referred to as an inverted rotary converter.
One way to envision what is happening in an AC-to-DC rotary converter is to imagine a rotary reversing switch that is being driven at a speed that is synchronous with the power line. Such a switch could rectify the AC input waveform with no magnetic components at all save those driving the switch. The rotary converter is somewhat more complex than this trivial case because it delivers near-DC rather than the pulsating DC that would result from just the reversing switch, but the analogy may be helpful in understanding how the rotary converter avoids transforming all of the energy from electrical to mechanical and back to electrical.
The advantage of the rotary converter over the discrete motor-generator set is that the rotary converter avoids converting all of the power flow into mechanical energy and then back into electrical energy; some of the electrical energy instead flows directly from input to output, allowing the rotary converter to be much smaller and lighter than a motor-generator set of an equivalent power-handling capability. The advantages of a motor-generator set include adjustable voltage regulation, which can compensate for voltage drop in the supply network; it also provided complete power isolation, harmonics isolation, greater surge and transient protection, and sag (brownout) protection through increased momentum.
In this first illustration of a single-phase to direct-current rotary converter, it may be used five different ways: [5]
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The self-balancing dynamo is of similar construction to the single- and two-phase rotary converter. It was commonly used to create a completely balanced three-wire 120/240-volt AC electrical supply. The AC extracted from the slip rings was fed into a transformer with a single center-tapped winding. The center-tapped winding forms the DC neutral wire. It needed to be driven by a mechanical power source, such as a steam engine, diesel engine, or electric motor. It could be considered a rotary converter used as a double current generator; the alternating current was used to balance the DC neutral wire.
The rotary converter was invented by Charles S. Bradley in 1888. [6] A typical use for this type of AC/DC converter was for railway electrification, where utility power was supplied as alternating current. Trains were designed to work on direct current, since DC traction motors could be built with speed and torque characteristics suited to propulsion use, and could be controlled for variable speed. The AC induction motor was not as well suited to traction use when powered from a fixed frequency supply. Before the invention of mercury arc rectifiers and high-power semiconductor rectifiers, this conversion could only be accomplished using motor-generators or rotary converters.
Rotary converters soon filled the need to use all the competing electric power delivery systems that cropped up in the 1880s and early 1890s. These included single phase AC systems, poly-phase AC systems, low voltage incandescent lighting, high voltage arc lighting, and existing DC motors in factories and street cars. [7] [8] Most machinery and appliances at that time were operated by DC power, which was provided at the user level by rotary converter substations for residential, commercial and industrial consumption. Rotary converters provided high current DC power for industrial electrochemical processes such as electroplating. Steel mills needed large amounts of on-site DC power for their main roll drive motors. Similarly, paper mills and printing presses required direct current to start and stop their motors in perfect synchronization to prevent tearing the sheet.
The stopgap of needing to use rotary converters was slowly overcome as older systems were retired or upgraded to match the newer AC universal system. AC to DC synchronous rotary converters were made obsolete by mercury arc rectifiers in the 1930s and later on by semiconductor rectifiers in the 1960s. [9] : 54 Some of the original New York City Subway substations using synchronous rotary converters operated until 1999. [9] : 12 Compared to the rotary converter, the mercury arc and semiconductor rectifiers did not need daily maintenance, manual synchronizing for parallel operation, nor skilled personnel, and they provided clean DC power. This enabled the new substations to be unmanned, only requiring periodic visits from a technician for inspection and maintenance.
AC replaced DC in most applications and eventually the need for local DC substations diminished along with the need for rotary converters. Many DC customers converted to AC power, and on-site solid-state DC rectifiers were used to power the remaining DC equipment from the AC supply.
An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft. An electric generator is mechanically identical to an electric motor, but operates with a reversed flow of power, converting mechanical energy into electrical energy.
In electricity generation, a generator is a device that converts motive power or fuel-based power into electric power for use in an external circuit. Sources of mechanical energy include steam turbines, gas turbines, water turbines, internal combustion engines, wind turbines and even hand cranks. The first electromagnetic generator, the Faraday disk, was invented in 1831 by British scientist Michael Faraday. Generators provide nearly all of the power for electric power grids.
A commutator is a rotary electrical switch in certain types of electric motors and electrical generators that periodically reverses the current direction between the rotor and the external circuit. It consists of a cylinder composed of multiple metal contact segments on the rotating armature of the machine. Two or more electrical contacts called "brushes" made of a soft conductive material like carbon press against the commutator, making sliding contact with successive segments of the commutator as it rotates. The windings on the armature are connected to the commutator segments.
An alternator is an electrical generator that converts mechanical energy to electrical energy in the form of alternating current. For reasons of cost and simplicity, most alternators use a rotating magnetic field with a stationary armature. Occasionally, a linear alternator or a rotating armature with a stationary magnetic field is used. In principle, any AC electrical generator can be called an alternator, but usually the term refers to small rotating machines driven by automotive and other internal combustion engines.
The stator is the stationary part of a rotary system, found in electric generators, electric motors, sirens, mud motors or biological rotors. Energy flows through a stator to or from the rotating component of the system. In an electric motor, the stator provides a magnetic field that drives the rotating armature; in a generator, the stator converts the rotating magnetic field to electric current. In fluid powered devices, the stator guides the flow of fluid to or from the rotating part of the system.
A synchronous electric motor is an AC electric motor in which, at steady state, the rotation of the shaft is synchronized with the frequency of the supply current; the rotation period is exactly equal to an integral number of AC cycles. Synchronous motors use electromagnets as the stator of the motor which create a magnetic field that rotates in time with the oscillations of the current. The rotor with permanent magnets or electromagnets turns in step with the stator field at the same rate and as a result, provides the second synchronized rotating magnet field. A synchronous motor is termed doubly fed if it is supplied with independently excited multiphase AC electromagnets on both the rotor and stator.
A DC motor is any of a class of rotary electrical motors that converts direct current (DC) electrical energy into mechanical energy. The most common types rely on the forces produced by induced magnetic fields due to flowing current in the coil. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current in part of the motor.
A motor–generator is a device for converting electrical power to another form. Motor–generator sets are used to convert frequency, voltage, or phase of power. They may also be used to isolate electrical loads from the electrical power supply line. Large motor–generators were widely used to convert industrial amounts of power while smaller motor–generators were used to convert battery power to higher DC voltages.
In electrical engineering, the armature is the winding of an electric machine which carries alternating current. The armature windings conduct AC even on DC machines, due to the commutator action or due to electronic commutation, as in brushless DC motors. The armature can be on either the rotor or the stator, depending on the type of electric machine.
A field coil is an electromagnet used to generate a magnetic field in an electro-magnetic machine, typically a rotating electrical machine such as a motor or generator. It consists of a coil of wire through which a current flows.
A repulsion motor is a type of electric motor which runs on alternating current (AC). It was formerly used as a traction motor for electric trains but has been superseded by other types of motors. Repulsion motors are classified as single phase motors.
A Gramme machine, Gramme ring, Gramme magneto, or Gramme dynamo is an electrical generator that produces direct current, named for its Belgian inventor, Zénobe Gramme, and was built as either a dynamo or a magneto. It was the first generator to produce power on a commercial scale for industry. Inspired by a machine invented by Antonio Pacinotti in 1860, Gramme was the developer of a new induced rotor in form of a wire-wrapped ring and demonstrated this apparatus to the Academy of Sciences in Paris in 1871. Although popular in 19th century electrical machines, the Gramme winding principle is no longer used since it makes inefficient use of the conductors. The portion of the winding on the interior of the ring cuts no flux and does not contribute to energy conversion in the machine. The winding requires twice the number of turns and twice the number of commutator bars as an equivalent drum-wound armature.
An AC motor is an electric motor driven by an alternating current (AC). The AC motor commonly consists of two basic parts, an outside stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft producing a second rotating magnetic field. The rotor magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.
Doubly-fed electric machines also slip-ring generators are electric motors or electric generators, where both the field magnet windings and armature windings are separately connected to equipment outside the machine.
The rotor is a moving component of an electromagnetic system in the electric motor, electric generator, or alternator. Its rotation is due to the interaction between the windings and magnetic fields which produces a torque around the rotor's axis.
A brushed DC electric motor is an internally commutated electric motor designed to be run from a direct current power source and utilizing an electric brush for contact.
A dynamo is an electrical generator that creates direct current using a commutator. Dynamos were the first electrical generators capable of delivering power for industry, and the foundation upon which many other later electric-power conversion devices were based, including the electric motor, the alternating-current alternator, and the rotary converter.
In electrical engineering, electric machine is a general term for machines using electromagnetic forces, such as electric motors, electric generators, and others. They are electromechanical energy converters: an electric motor converts electricity to mechanical power while an electric generator converts mechanical power to electricity. The moving parts in a machine can be rotating or linear. Besides motors and generators, a third category often included is transformers, which although they do not have any moving parts are also energy converters, changing the voltage level of an alternating current.
A magneto is an electrical generator that uses permanent magnets to produce periodic pulses of alternating current. Unlike a dynamo, a magneto does not contain a commutator to produce direct current. It is categorized as a form of alternator, although it is usually considered distinct from most other alternators, which use field coils rather than permanent magnets.
An alternator is a type of electric generator used in modern automobiles to charge the battery and to power the electrical system when its engine is running.
