Introduction

A direct current (DC) motor is the oldest type of electrical motor that has
gained widespread use in a variety of electronic devices and equipment. DC
motors have different arrangements and operation peculiarities.

The common feature and the essential condition of all DC motors is the
generation of a variable magnetic field that provides their non-stop operation.
In an alternating current (AC) motor, a magnetic field changes polarity on
its own.

A DC motor has some significant advantages, and one of them is the

simplicity of its control system. Here, we’ll tell you how a DC motor
controller works and how you can use it. In addition, we’ll share our personal
experience and brief you on the design and challenges that you can meet
while building your own controller.

In this article, we have focused mainly on brushed DC (BDC) motor

controllers. To learn more about a BLDC motor controller, its design, and
working principles, you can check a related article on our blog.
 What Is a DC Motor Controller?
The intended use of a motor controller is to manage the performance of an
electrical motor. Irrespective of the motor type, this electronic device can
fulfill the following functions:

 start/stop the motor;

 change the rotation direction;
 control the speed and torque;
 provide overload protection;
 prevent electrical faults.
DC motor controllers may have different specifics defined by their
type (brushed, brushless, stepper) and the device in which the motor is
used. For instance, a DC motor controller for an industrial brushed motor
uses different working principles and has a different design compared to a
controller for DC motors in electric vehicles.
All direct-current motors must have two core elements: a stator and
a rotor (armature), although critical functions can be performed by other
components as well. A brushed DC motor comprises the following units:

 a stator with windings or permanent magnets;

 an armature, or rotor, with windings;
 a commutator, or collector, with brushes connecting the armature with a
DC power supply.
When applied to the rotor, the electric current generates an electromagnetic
field and makes the armature rotate. The similar poles of the field around the
stator and rotor repel each other, which causes a unidirectional motion.

As soon as the opposite poles meet, the commutator switches the current
supplied to the armature. This creates the reverse polarity of the magnetic
field, and the armature keeps rotating.
DC MOTOR CONTROLLER

DC MOTOR CONTROLLER
 Types of DC Motor Controllers
There are different types of DC motor controllers along with the principles of
their classification. The infographic below shows this variety.

Pri
nciples of DC motor controller classifications
 DC Motor Type
First, controllers vary according to the type of DC motor. For example, unlike
a brushed DC motor, a brushless DC (BLDC) motor has an electronic
commutator without brushes. It has a rotor with permanent magnets and a
stator with windings.

A brushless DC motor controller uses sensors to specify the rotor’s position.

It switches the current in the windings with the help of transistors. In our
article dedicated to a BLDC motor controller, we provide a detailed
description of its working principles and design features.
A stepper motor belongs to the group of brushless DC motors, but its
distinguishing feature is that it rotates in stages or steps. After each step, the
rotor stops at a certain angle. It allows the device powered by this motor to
shift and fix positions with high precision. A stepper motor controller
provides current in pulses, energizing poles of the stator and making the rotor
move.

The other classifications are typical of almost any electrical motor’s

controller. Let’s briefly go over them through the example of a brushed DC
motor controller.

Type of Power Regulation

In a BDC motor controller, the speed and torque are regulated by changing
the power supply with the help of voltage regulators. They can be either a
separate system or a part of the controller. For different purposes, engineers
can use linear or switching regulators.

A linear regulator keeps the output voltage at a constant level with a resistive
load. The output is stable no matter what input voltage is supplied by the
power source. In a switching regulator, the output is stabilized through pulse-
width modulation (PWM). You can read more about linear and switching
regulators in our article on DC-DC converters .
Motor Power
Motor power relies on the current supplied by the power source. Thus, a low-
power BDC motor needs a low current controller and vice versa. A high
current DC motor controller typically uses a switching regulator .

Motor’s Operating Voltage

Depending on the voltage necessary for the motor’s operation, you can
choose a low or high voltage controller. A switching regulator works well for
controllers with a wide operating voltage range. A linear regulator better suits
a low voltage DC motor controller because the excessive input voltage may
cause power loss and even thermal overload .

Type of Control Signal

Controllers are classified into digital and analog versions. The main
difference between a digital DC motor controller and its analog variant is that
the former comprises microcontroller (MCU) based hardware and firmware.

Type of Control
Controllers that receive no feedback from the motor are called open-loop,
or non-feedback, controllers. They operate blindly, so to speak, as they
cannot detect the results of their commands. That’s why such controllers are
used in simple systems that don’t require automatic control.

Application Area of DC Motors and

Controllers
DC motors may find use in different devices and systems depending on their
characteristics. Thus, stepper and servo motors power machines that require
precision positioning such as:

 robots;
 printers;
 cameras;
 CNC machines.
In addition to closed-loop control, advanced DC servo motors with a variable
speed DC motor controller show high performance and reliability in complex
industrial applications.

The absence of brushes, which are wear-prone parts, makes BLDC motors
more durable. Apart from that, the electronic commutator doesn’t make
sparks and reduces electromagnetic interference (EMI). So these motors are
widely applied in electric vehicles, heating, and ventilation systems because
of their reliability. You can learn more about the construction and application
of brushless motors in our article on a BLDC motor controller.
Brushed DC motors have been in use for about two hundred years. Although
more recent technologies have partially replaced them, they are still popular
in different industries and applications.

BDC motors may have a very simple design and are easy to control (some of
them may not even need a controller). This is a cost-effective solution that
can perfectly fit low voltage devices powered by lithium-ion batteries,
including robotics and consumer electronics.
Building an autonomous robotic lawn mower, we installed a reversible DC
motor controller with a PWM switching regulator for a brushed DC motor
chosen by the customer. The idea was to develop a low power consumption
and budget-friendly system.

BDC Motor Controller Circuit Design

A traditional BDC motor controller circuit is an H-bridge. This is an
electronic circuit with four open/close switches that supply positive and
negative voltage by turns. By closing high-side and low-side switches in a
diagonal pattern, the motor rotates in one direction. The rotational direction
will change as soon as these switches are open and the opposite switches are
closed.

If you need a motor with a unidirectional rotation, you can build a BDC
motor controller using a simpler circuit with only one open/close switch.
Choosing a transistor switch, make sure it meets the required parameters of
the motor, for example, the maximum current. Otherwise, the transistor will
burn out.

Compliance with the system requirements is the basic principle you should
follow while selecting components for your DC motor controller schematic.
This relates to an MCU, gate drivers necessary to control the transistors, and
other components.

You can use either an integrated circuit (IC) or discrete components. From a
developer’s point of view, a DC motor controller IC is a simpler and more
convenient solution. With a discrete circuit, it will take you the time and
effort to assemble and solder the components. The design of an integrated
circuit, however, is quite expensive, and it can earn its keep only in case of
mass production.
BDC motor controller circuit design depends on the type of signal, power
regulation, control system, and other features. You can choose among various
options based on your technical specifications and budget limits.

Cooperating with Basicmicro Motion Control, we created brushed BDC

motor controllers for DIY robot kits. It was a variable DC motor controller
with a switching voltage regulator. An important feature of the controller is
that it can use both an open-loop and a closed-loop system.
With the help of our 2-channel BDC motor controllers, users can control
robots remotely via a wireless communication module. Our team
provided electronic design and embedded software development for the
project.
Challenges of Making a BDC Motor Controller
Building a BDC motor controller can be quite simple, but it still involves
some challenges. These can relate to both circuit design and firmware
development. Let’s take a look at the things that may need your special
attention.

As we have mentioned earlier, switches are open and closed diagonally in an

H-bridge circuit, but these actions can’t go on simultaneously. There will
always be a moment when all the transistors are open. It may lead to voltage
and power loss, or even short-out if the opposite upper and lower switches are
in the on position.

To avoid this situation, you can introduce dead time. This is a short period of
time when all switches of an H-bridge circuit are closed. Using dead time,
you can make sure the upper switch will open only after the lower switch is
closed.
PWM frequency (the number of pulse periods per second) is an important
parameter that you should adjust in a proper way. The lower the frequency,
the higher the power loss, and vice versa. However, in case the PWM
frequency is too high, the MCU may have problems with generating PWM
signals of the required value. In addition, the very high frequency may lead to
the malfunction of the gate driver and transistor switches as they may not be
compatible with it.

When writing firmware, remember to set up the correct PWM frequency to

ensure the smooth operation of your motor controller.

As you deal with a brushed DC motor, you might come across the problem of
excessive electromagnetic interference. Generated because of the constant
switching of the commutator, it affects neighboring electronic components.
To reduce it, you could implement different filters that protect the wires from
EMI.

Designing BDC motor controllers for our robotics project, we had to meet
some challenges.

The basic customer requirements included the wide operating voltage and
current ranges. At that moment, there were no suitable off-the-shelf
integrated gate drivers or GaN semiconductors. In addition, this range was
too low for an IGBT. Thus, we had to search for a solution among discrete
power MOSFETs.

Our team considered several circuit options and chose a standard gate driver
with external MOSFETs. By implementing this discrete component solution,
we simplified the schematic design and cut development costs. As a result,
Integra’s engineers achieved stable operation of the BDC motor controller in
the range of 6 up to 24 volts and up to 25 amps.

As soon as we used a discrete circuit, the responsibility for the major

functions of the BDC motor controller rested with the MCU.
 Conclusion
A brushed DC motor is one of the most common types of electrical motors. It
is widely used in consumer electronics, robotics , low-power industrial and
automotive applications. A BDC motor, as well as its control system, has a
simple construction and easy implementation.
With some viable alternatives available now, it’s becoming hard for a BDC
motor to stay competitive in high-power electronics. Besides, its controller
has brushes, and you will have to replace these wearable parts with time.
However, with proper use and maintenance, it can provide an efficient and
long-lasting performance.

If you need a controller for a BDC motor, you can use an off-the-shelf device
that fully meets your requirements. Or you can build your own solution with
a tailor-made circuit design and custom firmware . Electronics and
semiconductor manufacturers offer a rich selection of hardware and software
components that you can use in your project. For example, in building a BDC
motor controller circuit for the robotic lawn mower , we used STM32F4,
which is part of the STM32 ecosystem for motor control .
Entrusting your project to an external engineering team, make sure they have
relevant skills and expertise. An experienced developer will consider each
nuance and figure out how to design a DC motor controller for your particular
project.

Integra has provided schematic design, PCB layout, and firmware

development services for 250+ projects, including power converters, voltage
regulators, and motor controls. During our 9+ years of experience, we have
worked with a wide range of microcontrollers and semiconductor devices. We
have created circuits for applications that operate over a full range of current,
voltage, and switching frequency.
 REFERENCE
1. https://www.integrasources.com/blog/dc-motor-controller-design-
principles/#:~:text=A%20traditional%20BDC%20motor
%20controller,motor%20rotates%20in%20one%20direction .
2. https://en.wikipedia.org/wiki/Motor_controller
3. TECHMAX TEXTBOOK
4. https://wiki.st.com/stm32mcu/wiki/
STM32MotorControl:Introduction_to_Motor_Control_with_STM32