CEP

Electrical Machines
REPORT

Submitted By: Munesh Rana

INTRODCTION

Brushed DC motors are commonly used lots of electrical systems or control systems.
Such as brushed DC motor is found at automotive control systems, ink jet printers,
robotic applications, electric trains, disabled wheelchairs and battery powered hand-
drills. Brushed DC motors are preferred commonly due to its simplicity and cost [1]. DC
motors have to be controlled at the DC motor applications DC motor is needed to be
operated with desired speeds, reverse or forward motion for different time periods to
control these types of parameters of the motor, the drive circuit is needed to design. A
brushed DC motor is very easy to control and DC motor does not require an external
driver to operate. Speed control of brushed DC motor is also easy because the voltage-
speed characteristic of brushed DC motor is relatively linear [1]. Generally, DC motors
try to control with a variable potentiometer or variable resistor connected to a
transistor. In the control method where transistors are used the main problem is
heating of these transistors. Because of heating the transistors system waste the power
to outside so this situation is decreasing the efficiency of this motor driving system. To
remove this disadvantage Pulse Width Modulation PWM DC motor control method can
be used. PWM DC motor control method adjusts the motor speed by short pulses. These
PWM pulses fill rate is named as “Duty Cycle”.
According to Duty Cycle speed of the motor can be changed. If the Duty Cycle is high,
the motor turns faster if it is low then motor turns more slowly [2]. In the past works
there can be seen lots of works related with DC brushed motor speed control. But these
driver circuits work in only one direction. The polarity of the voltage applied to the
motor must be changed to change the direction of rotation of the motor. However
suddenly change the direction of the motor may damage the motor. This situation can
cause a big current surge on the system. Motor driver can be burned out also this
current surge causes big electrical and mechanical stresses on the DC motor itself [3-6].
Jamal A. Mohammed designed and implemented motor bi-directional DC control circuit
using Pulse Width Modulation (PWM) based on an operational amplifier model LM324
[7]. Nicolai and Castanet have shown in their study how a microcontroller can be used
for speed control. The operation of the system can be summarized as: the drive forms a
rectified voltage; it consists of chopper driven by a PWM signal generated from a
microcontroller unit [8]. M. Rylee discussed how to use the Enhanced, Capture,
Compare, and PWM (ECCP) on the PIC16F684 for bi-directional brushed DC (BDC) motor
control [9]. R. Karthick designed a circuit allowed controlling the speed of a DC motor
from PC’s parallel port [10]. The PC used a software program to control the speed of the
motor. M. George proposed the speed controller of a separately excited DC motor with
varying armature voltage [11]. In this study contains a designed brushed DC motor H
bridge control circuit. Designed circuit overcomes big electrical and mechanical stresses
problems due to current surge at DC motor. The objective of this paper is to explore the
approach of designing a microcontroller based closed loop controller. The interface
circuit and the software are all designed to achieve a better performance. Motor speed
is controlled using a potentiometer and direction of the motor is controlled by means of
button on the control card. If the button is pressed the motor slow down first and stop
before changing direction. This DC motor driver circuit contains a current sensor. This
sensor used for measuring DC motor current and to prevent drawing high current from
source. Hence DC motor is protected from high current due to short circuiting or
overloading.
H-BRIDGE
Now that you know how DC motors work, how you can reverse their direction by
changing polarity and how you can change their speed using pulse width modulation,
let’s examine an easy way to do this using a very common circuit configuration called an
“H-Bridge”.
An “H-Bridge” is simply an arrangement of switching the polarity of the voltage applied
to a DC motor, thus controlling its direction of rotation. To visualize how this all works
I’ll use some switches, although in real life an H-Bridge is usually built using transistors.
Using transistors also allows you to control the motor speed with PWM, as described
above.
In the first diagram we can see four switches which are all in the open or “off” position.
In the center of the circuit is a DC motor. If you look at the circuit as it is drawn here you
can distinctly see a letter “H”, with the motor attached in the center or “bridge” section
– thus the term “H-Bridge”.
 LITERATURE REVIEW

1) Design of a transistor-based H-bridge DC motor drive circuit

This paper presents the design of an H-bridge DC motor drive circuit to be applied to an elevator used
for transporting car doors in a motor plant industry. The circuit will drive two DC motors simultaneously
clockwise and anti-clockwise. The direction of these motors will be controlled by two separate push
button switches. The H-bridge circuit will be designed using 4 transistors each connected to its own
diode for protection against back emf voltage produced by the motors. This carrier elevator will be
pulled or pushed (up and down) by the motors in the bridge circuit and when the elevator reaches a
certain height above ground level it will transport the car doors horizontally towards the vehicle which
awaits installation.

METHODOLOGY
The transistor-based H-bridge DC motors drive was designed using 4 bipolar transistors and 4 diodes.
The diodes are connected to each transistor to protect them against overvoltage or undervoltage from
the DC motors. Resistors will be connected to limit the base current of the transistor. Two push button
switches were used for the purpose of controlling the forward and backward movement of the two DC
motors simultaneously. A PC board was used for the prototype design. The circuit will be supplied by 9V.
The design is simulated using proteus software. Fig. 1 shows the simulation of the H-bridge DC motors
drive circuit in proteus software. In this case the left push button switch is kept open and the right push
button switch is closed these drives the motors anticlockwise. In the clockwise drive the left push button
switch is closed, and the right push button switch is opened. These relate to forward and backwards
movement respectively.
Fig 1

Figure 2 shows the block diagram of the overall design indicating how the bridge circuit and the elevator
will be linked together
 2) DC Motor Control Using H Bridge

It is very simple. Most of mini-DC motors have two terminals because they are series type
(armature and field windings are connected in series) DC motors. Please refer the figure given
below.

Fig. 1: Image showing H-Bridge circuit used for controlling direction of

As shown in figure there are two terminals ‘A’ and ‘B’ of DC motor. Now if we connect terminal A with
+Ve supply and terminal B with –Ve supply or ground the current will flow from motor from A to B and
motor will rotate in one direction – say clockwise (CW) or forward direction. Now as shown in second
figure we change the supply terminals. Now B is connected with +Ve and A is connected to ground. The
current will flow from motor from B to A and motor will rotate in other direction (counter clockwise –
CCW or reverse).

The arrangement is shown in right side of figure. Four switches are connected in between +Ve supply
and ground and DC motor is connected in between two switches as shown. Such circuit arrangement is
known as H-bridge because it looks like letter ‘H’ (H-bridge circuits are most widely used in DC motor
drivers). Let us see how it gives reverse supply to motor.

If SW1 and SW4 are pressed simultaneously then current will flow from +Ve – SW1 – A – B – SW4 – Gnd.
So motor will rotate in one direction. Open (release) SW1 and SW4 to stop motor. Now if SW2 and SW3
are pressed current will flow from +Ve – SW2 – B – A – SW3 – Gnd. So motor gets reverse supply and it
will rotate in another direction.

Fig. 2: Circuit Diagram of H-Bridge built by transistor for controlling DC

The circuit replaces the switches with NPN type transistors. We all know that transistor works as switch.
For NPN transistor if we give +Ve input to base it will turn ON and if we give 0 input it will be turned OFF.

So in this circuit if Q1 and Q4 are turned ON simultaneously the motor will rotate forward and if Q2 and
Q3 are turned ON then motor will rotate reverse.
 Connections: IC NE555 is connected in astable mode. +12 biasing is given to Vcc pin (8). Reset pin
(4) is also given +Ve supply to enable internal flip flop. Two diodes connected back-to-back at discharge
pin (7). One 1K resistor is connected between Vcc and discharge pin. A 10 K pot along with two diodes
D1 and D2 is connected between threshold pin (6) and discharge pin in such a way that as it is increased,
the resistance for charging capacitor increases and resistance for discharging capacitor decreases.

Operation: when supply is given to circuit, the capacitor charges through R2-D2-R1A. The
output of circuit is high. When capacitor charges to 2/3 Vcc, the internal threshold comparator
gives output that makes circuit output low. So, if R1 is increased – R1A is more – capacitor
charging time increased – high output time (Ton) is more – duty cycle is more. Afterwards
capacitor discharges through R1B – D1. So, if R1 is decreased – R1B is more – capacitor
discharging time is increased – low output time (Toff) is more – duty cycle is less.
So, this circuit generates PWM and width of pulse varies as pot R1 is varied.
Finally, we need transistor H bridge circuit to alter the direction of DC motor and IC NE555
based PWM generator circuit to vary the speed of DC motor. Here is the complete circuit.
The output of PWM generator circuit is given to H-Bridge circuit through SPDT switch. As we
change the position of SPDT switch, the signal is either applied to Q1 and Q4 or Q2 and Q3. So
the SPDT switch alters the direction of motor. And the pot R1 varies width of output pulse
applied to H-bridge circuit. So, it varies the speed of motor.
 HARDWARE DESIGN AND
METHODOLOGY

DC Motor control system was included DC Power Supply, dSPIC30f4011 Controller Card
and LCD Screen, H Bridge DC Motor Driver Card and DC Motor. Controller Card and
driver supplied with same power supply. Femsan brand DC Motor was used. DC Motor
power was 300W and nominal rotation rate was 1500 rpm. System block diagram is
given at Figure 3.

Figure 3. DC Motor Driver System Block Diagram

DC Motor driver circuit was evaluated as two main circuit. The first circuit was power
part of driver and second part was H Bridge DC Motor control circuit. These two circuits
are shown respectively at Figure 4 and Figure 5.
 Figure 4. DC Motor Driver Power Circuit

Designed H bridge curcuit contains two NPN (Q1, Q2) and two PNP (Q3,Q4) type Power
Mosfets. Direction of rotation and DC motor speed can be varied these mosfets. PWM
signals are applied by means of mosfet driver TLP250 to NPN type Q1 and Q2 mosfets.
According the duty rate of PWM signals DC motor speed can be increased or decreased.
And steady +5V applied to PNP type Q3 and Q4 mosfets. While DC motor is rotated to
right direction Q3 and Q2 mosfets have to be swithed. If DC motor want to rotate left
direction, then Q4 and Q1 mosfets have to be switched. When H1 signal applied Q5
BC337 transistor is switched and +24V is grounded. So PNP type Q3 mosfet is switched.
At the same time when PWM signal is applied to L2 NPN type Q2 is switched. So, DC
motor is turned right direction. The same operations are performed to when Q4 and Q1
switched. And DC motor current can be flow on ACS-712 current sensor. By means of
this sensor DC motor current level can be determined. Such as rush current and short
circuit situations are can be identified and blocked. Hence DC motor can be protected.

RESULTS:

DC Motor driver in a H bridge configuration drove the 300W DC Motor. The experimental results for the
DC Motor control system are shown as in Figures. (7-9). When the DC motor rotated to forward rotation
Back Emf Voltage signal is seen at Figure 7(a). And NPN type Mosfet Gate switching signal can be seen at
Figure 7(b). According to Figure 7(b) Mosfet was switched nearly 80 ns. When the motor is loaded with
DC motor, the output voltage waveforms across the motor terminals in the forward direction and drawn
current value has shown in Figure (8).

(a) Back Emf Signal (b) NPN Mosfet Gate-Source Switching Signal

Figure 7. (a) DC Motor Back Emf Voltage, (b) NPN Mosfet Gate-Source Switching Signal
 (a) 30% PWM, Forward, 0.5 A (c) 75% PWM, Forward, 1.5 A

(b) 50% PWM, Forward, 1 A (d) 100% PWM, Forward, 1.7 A

Figure 8. (a-d) The input voltage waveforms across the motor terminals with 30%, 50%, 75% and 100%
PWM in the forward direction.

CONCLUSION

The designed PWM controlling DC motor driver circuit acts as a low-cost, efficient, and
short circuit protected. Designed DC motor driver can control DC motor in both forward
and reverse direction, from fully off to fully on. There is a common power supply used
for DC motor driver and controller card. The PWM waveform is created using an
dsPIC30f4011 microcontroller card. NPN and PNP type Mosfets were used for H bridge
driver. PNP type Mosfets switched directly logic 1. So, this technique reduced switching
losses caused by excessive switching. Also, the advantage of this topology is that two
MOSFET drivers are used to DC motor speed control the operation. The proposed circuit
can used for motor running at 12V or 24V and dawning up to about 10A. This designed
DC motor driver can run a DC motor in clockwise or anti-clockwise direction. The motor
is protected by a soft switching to prevent damage to the motor and the motor driver
during the sudden change of rotation of the motor.

REFERENCES

[1] Hughes,A. Electric Motors and Drives Fundamentals, Types and Applications, 3rd Edition, Austin
Hughes, Published by Elsevier Ltd, 2006.

[2] Vibhor Gupta, “Working and Analysis of the H – Bridge Motor Driver Circuit Designed for Wheeled
Mobile Robots, Advanced Computer Control (ICACC), 2010 2nd International Conference, 27-29 March
2010, Shenyang, China

[3] Payal P.Raval, Prof.C.R.mehta, “Modeling, Simulation and Implementation of Speed Control of DC
Motor Using PIC 16F877A”, International Journal of Emerging Technology and Advanced Engineering,,
ISSN 2250-2459, Volume 2, Issue 3, March 2012

[4] Y. S. E. Ali, S. B. M. Noor, S. M. Uashi and M. K Hassan, “Microcontroller Performance for DC Motor
Speed Control System”, National Power and Energy Conference (PECon) 2003 Proceedings, Bangi,
Malaysia

[5] Vibhor Gupta, “Working and Analysis of the H – Bridge Motor Driver Circuit Designed for Wheeled
Mobile Robots, Advanced Computer Control (ICACC), 2010 2nd International Conference, 27-29 March
2010, Shenyang, China
[6] Snehlata Sanjay Thakare1, Prof.Santosh Kompelli, “Design and implementation of dc motor speed
control based on PIC microcontroller”, International Journal Of Engineering And Computer Science
ISSN:2319-7242 Volume - 3 Issue -9 September, 2014 Page No. 8075-8079

[7] Jamal A. Mohammed, “PulseWidth Modulation for DC Motor Control Based on LM324”, Eng. &Tech.
Journal, Vol. 31,Part (A), No.10, 2013, 1882-1896

[8] J. Nicolai and T. Castagnel, "A Flexible Microcontroller Based Chopper Driving a Permanent Magnet
DC Motor," The European Power Electronics Application. 1993.

[9] Mike Rylee, Low-Cost Bidirectional Brushed DC Motor Control Using the PIC16F684,Microchip
Technology Inc., AN 893, 2003

[10] Karthick,R. PC Based Speed Controlling of a DC Motor, Report, Circuit Ideas, Electronics for you, June
2004, pp. 67.

[11] Moleykutty George, “Speed Control of Separately Excited DC Motor”, American Journal of Applied
Sciences 5 (3): 227-233, 2008.

[12] Muhammad H. Rashid, “Power Electronics, Devices, and Applications,” 3rd Edition, Pearson
Prentice Hall, NJ, USA, 2004. [13] http://www.ermicro.com/blog/wp-
content/uploads/2009/01/picpwm_03a.jpg 23.04.2017/17.31