DC Motor Speed Control

Controlling a DC motor's speed is achieved simply by controlling the voltage of the supply
power (within the safe operating range for the motor) using a potentiometer. DC motors maintain
consistent torque across the entire speed range without the need for additional components. This
makes controlling their speed considerably easier than AC motors, and they are well suited to
applications requiring precise control at any speed.
However, further considerations are depending on the requirements of the speed controller. DC
controllers operating on AC power require conversion of the supply using a rectifier. Unlike AC
motors, braking or reversing a DC motor requires additional components, typically a power
resistor for braking and a relay for switching the polarity of the supply power to reverse the
motor. It is also necessary to ensure that the motor has stopped before reversing the polarity of
the supply, which requires a means of sensing when the motor is at a standstill. This can add up
to a significant additional cost, especially for larger applications.
AC Motor Control Basics
An AC motor controller is known as the device that controls the speed of the AC motor. An AC
controller can also be referred to as a variable frequency drive, adjustable speed drive, frequency
converter and more. The AC motor receives power, which is converted by the AC motor
controller into an adjustable frequency. This adjustable output allows the motor speed to be
precisely controlled.
Typically, an AC motor controller consists of three basic parts: the rectifier, inverter, and the DC
link to connect the rectifier and inverter. The rectifier converts AC input into DC (direct current),
while the inverter switches the DC voltage to an adjustable frequency AC output voltage. The
inverter can also be used to control output current flow if needed. Both the rectifier and inverter
are directed by a set of controls to generate a specific amount of AC voltage and frequency to
match the AC motor system at any given point in time.

Typical industrial AC motor

An AC controller can be used in many different industrial and commercial applications. Most
often motor controls used to control fans in air conditioning and heating systems, the AC
controller allows for more control of the airflow. The AC controller also aids in adjusting the
speed of pumps and blowers. Other applications include conveyors, cranes and hoists, machine
tools, extruders, film lines, and textile-fiber spinning machines and more.
AC Motor Speed Control
An AC motor's speed is effectively determined by the frequency of the AC power supply, speed
control is achieved by modifying this frequency. A device that does this is known as a Variable
Frequency Drive or VFD. VFDs first convert the AC power supply to DC using a rectifier, and
then back to AC at the desired frequency, using an inverter.
There are two main types of VFDs. The most common is referred to as a ‘V/Hz’ drive and
operates by maintaining a consistent voltage to frequency (V/Hz) ratio to ensure consistent
torque across a wide speed range. This type of controller provides good speed control above 5
Hz. Below this speed, because of the relationship between voltage, frequency and torque
changes, simply keeping the V/Hz ratio consistent is not enough to control the motor, which
typically begins to overheat due to inefficient conversion of power to torque. Therefore, this type
of control is great for medium to high-speed applications requiring a narrow band of speed
adjustment and is not sufficient for very low speed or no speed (holding torque) applications
such as servo motors.
The second type of VFD is known as a ‘vector drive’ and enables control of an AC motor's speed
and torque even at very low speeds. It achieves this by separately controlling two different types
of current within the motor, the magnetizing current and the torque-producing current. Using a
complex algorithm, vector drives manipulate these currents to maintain optimum conversion of
power to torque at very low speeds and reduce heat losses at low speeds. This means that vector
drives typically provide higher starting torque and precise control across the full speed range and
are ideal for low speed, reversing, and holding torque applications.
AC Motors vs DC Motors
There are many differences between AC and DC motors. The most obvious difference is the type
of current each motor turns into energy, alternating current in the case of AC motors, and direct
current in the case of DC motors. AC motors are known for their increased power output and
efficiency, while DC motors are prized for their speed control and output range. AC motors are
available in single- or three-phase configurations, while DC motors are always single-phase.
In an AC motor, energy comes from magnetic fields generated through coils wrapped around the
output shaft. AC motors consist of several parts, including a stator and rotor. AC motors are
efficient, durable, quiet, and flexible, making them a viable solution for many power generation
needs.
The two types of AC motors include:
• Synchronous: The synchronous motor rotates at the same rate as the frequency of the
supply current, a fact that gives the motor its name. Synchronous motors are constructed
of a stator, rotor and Synchronous motors are used in a wide range of applications.
• Induction: Induction motors are the simplest and most rugged electric motor available.
These AC electric motors consist of two electrical assemblies: the wound stator and the
rotor assembly. The electric current needed to turn the rotor is created by electromagnetic
 induction created by the stator winding. Induction motors are among the most commonly
used type of motor in the world.
AC motors are used in a number of applications, including food service pumps, water
heaters, lawn and garden equipment and more.
More About DC Motors
The energy used by a DC motor comes from batteries or another generated power source that
offers constant voltage. DC motors are made up of several parts, the most notable of which
include bearings, shafts and a gearbox or gears. DC motors offer better speed variation and
control and produce more torque than AC motors.
The two types of DC motors include:
• Brushed: One of the oldest types of motor, brushed motors are internally commutated
electric motors powered by direct current. Brushed motors are constructed of a rotor,
brushes, an axle and the charge and polarity of the brushes control the direction and speed
of the motor.
• Brushless: In recent years, brushless motors have gained in popularity for many uses,
largely due to their efficiency. Brushless motors are constructed in the same fashion as
brushed motors, minus, of course, the brushes. Brushless motors also include specialized
circuitry to control speed and direction. In brushless motors, magnets are mounted around
the rotor, a configuration that improves efficiency.
DC motors are used in a wide range of applications, including electric wheelchairs,
handheld sprayers and pumps, coffee machines, off-road equipment and many more.
What is the control method for synchronous motor?
The synchronous motors can be controlled by various methods, including zero d‐axis current
(ZDC) control, maximum torque per ampere (MTPA) control, direct torque control (DTC), and
power factor control (PFC). The chapter introduces the dynamic and steady‐state models of the
synchronous motor.
Speed control of a synchronous motor: Methods & applications
A synchronous motor is a type of AC motor that runs at a constant speed. And before discussing
the speed control methods of a Synchronous motor, let us see how to find the speed of a
synchronous motor.
Using this simple formula: Ns = (120xf) / p , we can calculate the synchronous speed of any
synchronous motor.
Ns here stands for synchronous motor speed and as evident by the formula, it depends on two
factors:
Frequency (f)
We know that an AC supply system has a particular frequency. The frequency indicates the
number of times the rotating magnetic field rotates inside the armature. In the US, this frequency
is 60Hz, while in India / UK, this frequency is 50 Hz. So, the (f) in the formula represents the
frequency of the AC supply connected to the synchronous motor.
Number of stator poles (p)
Every AC motor consists of a Stator (the stationary part of the motor). The inner periphery of the
stator contains slots for the windings. So, according to the winding distribution inside these slots,
we can create the desired number of Stator poles. The (p) in the formula represents the number of
stator poles.
So, from the formula given above, it is clear that we can achieve the speed control of
synchronous motor by either of the two methods:
• Changing the number of Stator poles
• Changing the frequency of AC supply
Why do we require speed control of synchronous motor?
We know that a Synchronous motor is a constant speed motor. Its speed does not alter despite the
load variations. So, why do we need speed control of synchronous motor?
It is because some industries prefer Synchronous motors over induction motors for speed control.
Synchronous motors are more efficient and have fewer losses than induction motors. So, using
them improves reliability.
What parameters can we vary for speed control of Synchronous motor?
After designing an AC motor, it is difficult to change the speed by changing the stator poles.
Because to make it happen, for every speed variation that we require, we have to open the motor
and rearrange the windings to modify the number of Stator poles. This method doesn’t look
practical, agree? So, the only option that remains is to vary the frequency of incoming AC supply
to control the motor speed.
To vary the frequency, we use a combination of rectifiers and inverters and use them in either of
the following modes:
• Separate control or Open loop mode
• Self-control or Closed-loop mode
Separate control or Open loop mode
This method uses an open-loop system that does not have any feedback. The following figure
shows the block diagram of the separate control synchronous motor system.
 Block diagram of Separate-control or Open-loop control method

Working
A rectifier unit first converts the Alternating current to pulsating Direct current. The inductor and
capacitor in the circuit act as a filter and refine the DC waveform.
We can easily set the new frequency for the AC waveform using the frequency circuit. The
inverter uses the Pulse Width Modulation (PWM) technique to convert the DC to AC. The AC
obtained now has a different frequency as compared to the original AC supply.
Hence in this way, we can vary the frequency to control the speed of the synchronous motor.
Drawbacks
As said earlier, this is an open-loop system, i.e., once we set the frequency in the circuit, the
system does not know about the output condition. If somehow the speed of the motors changes,
the system can’t take any actions to regulate the speed of the motors. Thus, to reduce the chances
of speed error, we require a better speed control method.
Applications
• This method finds applications where slight changes in motor speed do not vary the load
connected to the motor.
• The open-loop control is a suitable way to control parallel-connected synchronous
motors. By setting the frequency in the circuit, the speed of all the motors changes
simultaneously.
Self-control or closed-loop Mode
The closed-loop method uses a feedback system to monitor the speed of the motor. The
following figure shows the block diagram of the closed-loop speed control system.
 Block diagram of Self-control or Closed-loop control method
Working
The working procedure of this system is similar to the above-discussed method. Here also, we
can easily vary the frequency of the output AC wave using the frequency circuit.
But here, a sensor continuously monitors the rotor speed. An error detector compares the preset
speed and the actual speed of the rotor and sends the difference value to the rectifier circuit. The
rectifier circuit suitably adjusts the firing angle to control the magnitude of the output DC wave.
Thus, this method reduces the chances of speed error and is more reliable than the open-loop
speed control method.
Applications
• We use the closed-loop speed control method where accurate speed control is required.
• This method is suitable for large gearless drives, viz. mine hoists, drives for mills, etc.
What is speed regulation in AC motor?
The speed of the rotating magnetic field is referred to as synchronous speed. The synchronous
speed (S) of a motor is defined as S = 120(F) ÷ P, where (F) is the incoming line frequency, and
(P) is the number of poles in the motor.
What is the speed regulation of a DC motor?
The permanent magnet DC motor has speed regulation between 10 to 15 %. A speed regulation
below 10 % is considered bad speed regulation. The compound dc motor has a speed regulation
range of 25%, and the differential compound motor has a speed regulation range of 5%.