Ch14 Intro To Motor Controls

Bridging Theory in Practice
Transferring Technical Knowledge

to Practical Applications
Introduction to Motor Control
Intended Audience:
Individuals with an interest in learning about electric motors and how they are
controlled
A simple understanding of magnetics is assumed

Topics Covered:
What is an electric motor?
What are some common types of electric motors?
How do these electric motors work?
How these motors are controlled.

Expected Time:
Approximately 90 minutes
Agenda
Introduction to Electromagnets and Electric
Motors
What Is Motor Control?
What Are Some Common Types of
Motors?
Permanent Magnet DC Motors
Stepper Motors
Brushless DC Motors
Summary of Motors and Motor Control
Circuits

Agenda
Introduction to Electromagnets and Electric
Motors
What Are Some Common Types of Motors?

Stepper Motors
Brushless DC Motors
Summary of Motors and Motor Control Circuits

What Is a Permanent Magnet?
A piece of iron or steel which produces a magnetic
field
Found in nature as magnetite (Fe
3
O
4
) lodestones
Magnetic field causes the permanent magnet to
attract iron and some other materials
Two ends of the permanent magnet are usually
designated North and South
Opposite magnet ends attract and like magnet ends
repel

What Is an Electromagnet?
Electromagnets behave like permanent
magnets

but their magnetic field is not
permanent

Magnetic field is temporarily induced by an
electric current

How Do You Make an
Electromagnet?
Start with an iron bar
How Do You Make an
Electromagnet?
Wrap a wire around the iron bar
How Do You Make an
Electromagnet?
Connecting a battery causes a current to flow
in the wire
Current
+
-
How Do You Make an
Electromagnet?
Connecting a battery causes a current to flow in the wire
The current induces a magnetic field creating an
electromagnet
Current
SOUTH
NORTH
+
-
How Do You Make an
Electromagnet?
Reversing the current direction, reverses the
polarity
Current
+
-
NORTH
SOUTH
How Do You Make an
Electromagnet?
Reversing the current direction, reverses the
polarity
If the current is stopped, the induced magnetic field
decays to 0

Current
+
-
NORTH
SOUTH
Electromagnets and
Electric Motors
We can use electromagnets in electric motors to convert
electrical energy to mechanical work
+
Electric Motor
12V
-
Electric
Energy
Electric motors are used to
perform a mechanical task by
using electricity
Open a sunroof
Lift a power antenna
Control windshield wiper
What Is an Electric Motor?
STATOR
ROTOR
An electric motor has two basic parts:
The stationary part is called the stator.
The rotating part of the electric motor is called the
rotor.
STATOR
Electrical energy creates a rotating magnetic field
inside the motor causing the rotor to rotate,
creating mechanical motion

ROTOR
Where Are
Electric Motors Used?
Electric motors are used in many different automotive applications:

Power windows
Power seats
Power mirrors
Fans
Windshield wipers
Windshield washer pumps
Starter motor
Electric radio antennae
Door locks
Information gauges
Sunroof
Brakes
Power steering
Fuel pump
Water pump
Hybrid and electric vehicles
Cruise control
Throttle plate control
Air vents
Others
Agenda
Introduction to Electromagnets and Electric Motors

Stepper Motors
Brushless DC Motors

The controlled application of electrical energy to a motor to
elicit a desired mechanical response

Start / Stop
Speed
Torque
Position

Significant amount of electronics may be required to
control the operation of some electric motors
What Is Motor Control ?
Control of Electromagnetics
Much of the physical design of an electric motor and its control
system are related to the switching of the electromagnetic field

There is a mechanical force which acts on a current carrying wire
within a magnetic field

The mechanical force is perpendicular to the wire and the magnetic
field

The relative magnetic fields between the rotor and stator are
arranged so that a torque is created, causing the rotor to rotate
about its axis
Agenda

Stepper Motors
Brushless DC Motors

There are many different types and classifications of electric
motors:
Permanent magnet DC motor
Stepper motor
Brushless DC motor
Wound field motor
Universal motors
Three phase induction motor
Three-phase AC synchronous motors
Two-phase AC Servo motors
torque motors
Shaded-pole motor
split-phase induction motor
capacitor start motor
Permanent Split-Capacitor (PSC) motor
Repulsion-start induction-run (RS-IR) motor

Repulsion motor
Linear motor
Variable reluctance motor
Unipolar stepper motor
Bipolar stepper
Full step stepper motor
Half step stepper motor
Micro step stepper motor
Switched reluctance motor
Shaded-pole synchronous motor
Induction motor
Coreless DC motor
Others......

Types of Electric Motors
Permanent Magnet DC Motor
Similar in construction to the introductory example
Metallic contacts (brushes) are used to deliver electrical energy
Rotational speed proportional to the applied voltage
Torque proportional to the current flowing through the motor
Advantages:
+ Low cost (high volume demand)
+ Simple operation
Disadvantages:
Medium efficiency
Poor reliability (brush, commutator wear out)
Strong potential source of electromagnetic interference
Stepper Motor
Full rotation of electric motor divided into a number of "steps"
For example, 200 steps provides a 1.8
o
step angle
A stepper motor controller can move the electric motor one step (in
either direction) by applying a voltage pulse
Rotational speed is controlled by changing the frequency of the
voltage pulses
Advantages:
+ Low cost position control (instrument gauges)
+ Easy to hold position
Disadvantages:
Poor efficiency
Requires digital control interface
High motor cost
Brushless DC Motor
Similar to a permanent magnet DC motor
Rotor is always the permanent magnet (internal or external)
Design eliminates the need for brushes by using a more
complex drive circuit
Advantages:
+ High efficiency
+ High reliability
+ Low EMI
+ Good speed control
Disadvantages:
May be more expensive than "brushed" DC motors
More complex and expensive drive circuit than
"brushed" DC motors
Agenda

Stepper Motors
Brushless DC Motors

How Does a Permanent Magnet
DC Motor Work?
"DC Motors" use magnets to produce motion
Permanent magnets
NORTH SOUTH
"DC Motors" use magnets to produce motion
Permanent magnets
An electromagnet armature

How Does a Permanent Magnet
DC Motor Work?
NORTH SOUTH
NORTH SOUTH
Electromagnet armature is mounted on axle so that
it can rotate
Rotating Armature
NORTH SOUTH
Electromagnet armature is mounted on axle so that
it can rotate
A commutator makes an electrical contact with the
motor's brushes
Commutator and Brushes
Commutator Structure
Commutator is comprised of two "near-
halves" of a ring
Commutator is comprised of two "near-halves" of a ring
Mounted on the armature's axle to rotate with the rotor
Armature
Armature's windings are connected to the
commutator
Commutator and Brushes
Armature's windings are connected to the commutator
Brushes connect the commutator to the battery
NORTH SOUTH
Current flows through the armature's windings,
which polarizes the electromagnet
+
-
Electromagnet Polarization
NORTH SOUTH
The like magnets (NORTH-NORTH and SOUTH-SOUTH) repel
As the like magnets repel, the armature rotates, creating mechanical
motion
+
-
Rotation
NORTH SOUTH
What direction will the armature spin?
Clockwise? Counterclockwise?
Clockwise ?
Counterclockwise ?
Rotation Direction?
+
-
To determine the direction of the motor's rotation, we need
to use the "Left Hand Rule"
Rotation Direction?
Left Hand Rule
Start with two opposite
ends of a magnet
NORTH
SOUTH
Left Hand Rule:
Magnetic Field
NORTH
SOUTH
The magnetic field (B) is from
the NORTH pole to the
opposite SOUTH pole

The pointing finger
follows B into
screen
B
Left Hand Rule:
Current Flow
NORTH
SOUTH
Current flows in a wire through
the magnetic field from left to
right

The middle finger follows I
1

right, or I
2
left
I
1
I
2
Left Hand Rule:
Force
NORTH
SOUTH
The force, F, acting on each wire
is in the direction of the
thumb

The wire with I
1

is pushed up,
I
2
down
I
1
I
2
F
1
F
2
Left Hand Rule:
Force
NORTH
SOUTH
The magnitude of F is give by:

| F | = | I | * * | B |

where is the length of the
wire in B
I
1
I
2
F
1
F
2

Left Hand Rule:
Current Loop
NORTH
SOUTH
If the current flows in a loop,
the force(s) will cause the
loop to rotate

I

F

F

NORTH SOUTH
Magnetic field is from right to left
Imagine current flows out of the screen in this cross
section

+
-
Rotation
NORTH SOUTH
Imagine current flows out of the screen in this cross section
The force causes the armature to rotate clockwise
+
-
Rotation
NORTH SOUTH
+
-
Rotation
At some point, the commutator halves will rotate away
from the brushes
Momentum keeps the electromagnet and the commutator
ring rotating
NORTH SOUTH
+
-
Rotation
When the commutator halves reconnect with the
other brush, the current in the windings is reversed
NORTH SOUTH
+
-
Rotation
When the commutator halves reconnect with the
other brush, the current in the windings is reversed
The polarity is reversed and the armature continues
to rotate
+
-
NORTH SOUTH
Imagine current flows out of the screen in this cross section
The force causes the armature to rotate clockwise
+
-
Rotation
Controlling a Permanent Magnet
DC (PMDC) Motor
Bi-directional PM DC motors are controlled with an "H-Bridge"
circuit consisting of the motor and four power switches
Current
Turning On a PMDC Motor
One switch is closed in each leg of the "H"
One switch is open in each leg of the "H"

Current
One switch is closed in each leg of the "H"
One switch is open in each leg of the "H

Turning On a PMDC Motor
in the Other Direction
Current
Unidirectional motors are controlled by a half-H
bridge circuit
Controlling a Permanent Magnet
DC (PMDC) Motor
Controlling a PMDC Motor
Options
DC operation
Rotational speed of the DC motor is fixed at a given voltage
and load

PWM Operation
Average voltage (and rotational speed) can be controlled
by opening/closing the switches quickly

Braking
Shorting the terminals or momentarily reversing the drive

Others

Agenda

Stepper Motors
Brushless DC Motors

Why a Stepper Motor ?
Unlike the permanent magnet DC motor, stepper
motors move in discrete steps as commanded by the
stepper motor controller

Because of their discrete step operation, stepper
motors can easily be rotated a finite fraction of a
rotation

Another key feature of stepper motors is their ability
to hold their load steady once the require position is
achieved

An example application for stepper motors is for
implementing traditional "analog" instrumentation
gauges on a dashboard
How Does a
Stepper Motor Work ?
A stepper motor often has an internal rotor with a large number of
permanent magnet teeth

A large number of electromagnet "teeth" are mounted on an
external stator

Electromagnets are polarized and depolarized sequentially, causing
the rotor to spin one "step"

Full step motors spin 360
o
/(# of teeth) in each step

Half step motors spin 180
o
/(# of teeth) in each step

Microstep motors further decrease the rotation in each step
Full Step Motor Operation
`
Half Rotate
and Hold
`
Half Step Motor Operation
Half Rotate
and Hold
Stepper Motor Control
The stepper motor driver receives square wave pulse
train signals from a controller and converts the
signals into the electrical pulses to step the motor

This simple operation leads stepper motors to
sometimes be called "digital motors"

To achieve microstepping, however, the stepper
motor must be driven by a (quasi) sinusoidal current
that is expensive to implement
Agenda

Stepper Motors
Brushless DC Motors

Many of the limitations of the classic permanent magnet "brushed"
DC motor are caused by the brushes pressing against the rotating
commutator creating friction
As the motor speed is increased, brushes may not remain in
contact with the rotating commutator
At higher speeds, brushes have increasing difficulty in maintaining
contact
Sparks and electric noise may be created as the brushes
encounter flaws in the commutator surface or as the commutator
is moving away from the just energized rotor segment
Brushes eventually wear out and require replacement, and the
commutator itself is subject to wear and maintenance
Brushless DC motors avoid these problems with a modified design,
but require a more complex control system
Why a Brushless DC Motor ?
How Does a Brushless DC Motor
Work ?
A brushless DC motor uses electronic sensors to detect the
position of the rotor without using a metallic contact

Using the sensor's signals, the polarity of the electromagnets
is switched by the motor control drive circuitry

The motor can be easily synchronized to a clock signal,
providing precise speed control

Brushless DC motors may have:
An external PM rotor and internal electromagnet stator
An internal PM rotor and external electromagnet stator
This example brushless DC motor has:
An internal, permanent magnet rotor
Example Brushless DC Motor
Operation
An external, electromagnet stator
Operation
An external, electromagnet stator, with magnetic
field sensors
Operation
Brushless DC Motor
Construction
A
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Brushless DC Motor Operation
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2
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3
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4
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5
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6
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com
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
1
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
2
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
3
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
4
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
5
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
6
A1 B1 C1
A2 B2 C2
Brushless DC Motor
Control Circuit
Brushless DC Motor
Control Circuit
A
a
b
B
c
C
com
1
A1 B1 C1
A2 B2 C2
Agenda

Stepper Motors
Brushless DC Motors

+
An electric motor converts electric energy into
mechanical motion
Electric Motor
12V
-
Electric
Energy
Electric motors are used to
perform a mechanical task by
using electricity
Open a sunroof
Lift a power antenna
Control windshield wiper

Permanent Magnet Stepper Brushless DC
DC Motor Motor Motor

Advantages: + Low cost + Position control + High efficiency
(high volume) (low cost + High reliability
+ Simple operation control circuits) + Low EMI
+ Speed control
Disadvantages: - Medium efficiency - Poor efficiency - Maybe higher cost
- Poor reliability - Digital interface - Complex control
- Bad EMI - High cost
Types of Electric Motors
Agenda

Stepper Motors
Brushless DC Motors

Thank you!
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Ch14 Intro To Motor Controls

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Ch14 Intro To Motor Controls

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Bridging Theory in Practice

Transferring Technical Knowledge

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