Electric Motor Selection
DC motors are typically used when
Two basic decisions to make:
Ø What type of motor is needed?
• DC “brush” motor?
• DC brushless motor?
• Stepper motor?
Ø Once type of motor is selected, what
size motor is required?
Type Selection - Stepper Motor
Stepper motors are typically used when
• low--cost, open-
low open-loop positioning required
§ no feedback sensors required to monitor
position if max torque not exceeded
§ noncumulative nature of positioning errors
gives good accuracy over long motions
• reasonably high torques at low speeds
§ not able to handle large inertial loads due to
low acceleration requirements
• energy efficiency not important
Type Selection - DC Motor
• low--cost, variable speed is advantageous
low
§ but precise speed regulation not required
• starting torque required up to 5-
5-10 times
more than running torque
§ brief overloads OK, since motor has time to
cool
• frequent start/stop cycles, reversing, or
closed--loop positioning required
closed
See Parker-Compumotor notes (p. A3) for additional details
DC Motor Ratings
Ø DC motors are “rated” at a single speed
and torque
Ø In most cases, the motor can operate at
this point continuously
• temperature rating will not be exceeded
• DC motors rated with form factor of 1
Ø DC motors are “typically” used at
• about 90% of rated speed
• about 10 to 40% of rated torque
1
 Circuit Model for Permanent
PMDC Motor Equations #1
Magnet DC Motor

di a
+
ia
+ Va = R a i a + La + Vb from circuit
Ra La dt
Va Vb
- - Vb = k bω from dV= B v dL and v = rω

Va= applied armature voltage Vb= back EMF τ = k ai a from df = ia dL X B and τ = rf

Ra= armature resistance ia= armature current
La= armature inductance

PMDC Motor Equations #2 Motor Sizing #1

Va = Ra ia + Vb Vb = k bω τ = k ai a
Ø The major constraint on all motor
operation is thermal in nature.
Va = R a ia + k bω k b = k a →τ = k bi a
Multiply both sides by ia Electrical Power = Power Dissipated + Mechanical Power
(Input) (as heat) (useful output)
Va i a = R a ia2 + k b iaω
Ø The heat a DC motor must dissipate
Va i a = R ai 2a + τω
can be calculated:
Electrical Power = Power Dissipated + Mechanical Power Va i a = R ai 2a + τω
(Input) (as heat) (useful output)

2
 Manufacturer’s Data DC Motor Commutation

Ø DC motors require periodic switching of

currents to maintain rotation
(“commutation”)
This axis is
proportional • conventional DC motors use brushes to
to current provide commutation, but
• "brushless" DC motors which use
Constant
electronic commutation have been
i2R power
developed.

DC Brushed Motor
DC Brushed Motor Advantages
Disadvantages

Ø operation, requiring only a

Simple operation,
voltage source, power transistor, and
analog control input for variable speed
or servo operation
Ø Dynamic braking capability without
additional power input (short the leads)
Ø Heat is generated in the rotor windings which
is primarily conducted away through the rotor
shaft
• Harder to keep cool
Ø The brushes wear,
wear , the wear producing small
particles which can affect the cleanliness of
surrounding operations.
Ø High current through the brushes can cause
them to burn out rapidly

3
 DC Brushless Motor DC Brushless Motor Advantages

Ø The magnetic field in the rotor is provided by
permanent magnets on the rotor
Ø Need to signal a motor driver when to switch
the current in the stator’s windings
• Hall effect sensors,
• optical encoders, or
• resolver
Ø Motor driver depends on the controller to set
desired torque output
Ø No appreciable heat is generated in the rotor
and hence the heat conducted to the shaft is
minimized.
Ø Due to the lack of brushes, motors can be
operated at high torque and zero rpm
indefinitely as long as the winding
temperature does not exceed the limit.
Ø No brushes to wear out or contaminate the
surroundings

DC Brushless Motor
Disadvantages
Ø Motor operation requires the purchase of a
complicated electronic motor driver
Ø Most motor drivers brake DC brushless
motors by applying reverse current, in which
almost as much power is expended to stop
the motor as was required to start it moving