Development and modification of permanent magnet brushed DC motor for hybrid photovoltaic-operated solar systems

A modified brushed permanent magnet DC (PMDC) motor has been developed and fabricated for a photovoltaic (PV)-operated solar systems. The conventional PMDC motor has been plagued with constraints, the most critical being ingestion of vapours of working fluid inside the rotor and stator, damaging the insulation of windings and forming a thin film of moisture between commutator and brushes. This flaw results into a very low mean time between failures of the motor. In the past, many attempts have been made where-in variety of seals to isolate the working fluid vapours from inner parts of motor have been tried out, but to no avail. Even Brushless DC motors have been designed in the past but their exorbitant cost makes the entire arrangement not viable economically. The modification attempted in this article overcomes the problem of working fluid ingestion inside the motor. It is found that mass flow rate of working fluid obtained at maximum peak sunshine hours is 17.5 l/min at 3030 rpm of motor driven by a PV module of 40 W at 16.20 V. This low-cost modified PMDC motor has been robust with high mean time between failures as no breakdown observed during 18 months of operation.