DC Motor Controller Explained
In an industrial production setting, such as in paper or rolling mills, speed control is necessary to keep motors running smoothly. Factories that use DC motors usually have to purchase a DC motor controller to keep both speed and torque under control during operation. The controller is necessary because motors rotate at such high speeds.
There are a number of direct and indirect benefits of using a speed control drive. It allows for the control of acceleration and stopping, which reduces product loss that usually results because of mechanical wear and tear or breakage of the product. Some provide energy savings due to less horsepower being used during operation. Other benefits include an adjustable operating speed and torque limit, lower power needed to start, and savings realized because the need for expensive mechanical drive components might be eliminated.
Speed controllers or drives work by detecting a signal that represents the needed speed. Drives that measure the actual speed of the motor are called feedback or closed loop speed controllers. Because motors often differ in design and size, DC motor controllers are available with various drive outputs.
Switching the Voltage
A controller can vary the motor's average voltage by quickly switching the motor's supply on and off. This switch occurs very quickly so the motor will not actually be affected by the change, but only the speed will be affected. A DC motor's speed is directly related to its supply voltage. So simply reducing the voltage to half the volts will also cut its speed in half. This simple voltage switching process can extend the life of a motor as well as help prevent mishaps when operating heavy-duty machinery.
There are several key elements that a controller needs to operate correctly. It needs a means to alter the motor's voltage and to measure the absolute speed of the shaft. It also needs software to help keep the motor's speed constant despite any type of interference.
How to Find the Appropriate Controller
The key to understanding what type of DC motor controller to use is to learn about the types of motors and what they require. The main types of motors include brushed, brushless, uncommulated (homopolar and ball bearing) and synchronous. It's also important to get to know what types of drives are available. There are nonregenerative and regenerative drives that support varying ranges of horsepower. One DC drive might have several models for flexibility to meet the end user's needs.
Look for a DC motor controller that's affordable and offers multiple options. If you need assistance, some distributors and manufacturers provide one-on-one technical assistance to help determine the best product for your application. You can also browse brochures, manuals, etc. online to get ideas.
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