Experiment No.

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LAYOUT DESIGN 3 – DC MOTOR CONTROLLER CIRCUIT

OBJECTIVES:
The activity aims to:
1) Create a DC Motor Controller circuits for interfacing purposes.
2) Use ExpressSCH and ExpressPCB software and apply the port command to
show direction.

LEARNING OUTCOMES (LOs) COURSE LEARNING

At the end of the activity, the students should be able OUTCOMES (CLOs)
to: 1 2 3 4
1. Create a PCB artwork of DC Motor Controller
● ● ●
Circuit using ExpressPCB.
2. Design a schematic diagram of DC Motor
● ● ●
Controller Circuit using ExpressSCH.

COURSE LEARNING OUTCOMES (CLOs)

1. Analyze the electronic symbols, components diagrams, flowcharts, system

structures; electro-mechanical packaging and Printed circuit board layouts.
2. Create detailed drawing / schematic of electronic circuit.
3. Demonstrate the use of PCB express software to the extent that is conducive
to a work environment together with all fundamental operations of the PCB
design and layout tools.
4. Design, layout, and manufacture of PCB.

MATERIALS:
Personal Computer with PCB Express Software

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DISCUSSION:

Every electric motor has to have some sort of controller. The motor controller
will have differing features and complexity depending on the task that the motor will
be performing.

The simplest case is a switch to connect a motor to a power source, such as

in small appliances or power tools. The switch may be manually operated or may be
a relay or contactor connected to some form of sensor to automatically start and stop
the motor. The switch may have several positions to select different connections of
the motor. This may allow reduced-voltage starting of the motor, reversing control or
selection of multiple speeds. Overload and over current protection may be omitted in
very small motor controllers, which rely on the supplying circuit to have over current
protection. Small motors may have built-in overload devices to automatically open
the circuit on overload. Larger motors have a protective overload relay or
temperature sensing relay included in the controller and fuses or circuit breakers for
over current protection. An automatic motor controller may also include limit switches
or other devices to protect the driven machinery.

More complex motor controllers may be used to accurately control the speed
and torque of the connected motor (or motors) and may be part of closed loop
control systems for precise positioning of a driven machine. For example, a
numerically controlled lathe will accurately position the cutting tool according to a
pre-programmed profile and compensate for varying load conditions and perturbing
forces to maintain tool position.

PROCEDURE:

Start ExpressSCH Software

 Click Start->Programs->ExpressPCB->ExpressSCH or double click the

icon on the desktop
 Select New from the File menu and then choose the desired page size,
typically Letter – 8.5" x 11" is used. It is best to set the page size to the same

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 dimensions as the paper in your printer. By doing this, your schematic will be
printed one-to-one. If you create a schematic with a larger page size than
your printer can handle, the printed schematic is compressed to fit the printer.

Document your project by filling in the title block located on the lower right corner of
the page.

EXERCISES:
1. Draw the given schematic diagram applying the different symbols.

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 For SIGNAL PINS go to component and symbol manager, select Library Symbol and use Port (4-Letter Wide)

2. Save the file, export to image, close the program.

 Click File->Check Schematic for netlist error.
 Click File->Save and type your desired filename.
 Click File->Export Schematic image... then select Bitmap, 300 pixels/inch
and press OK.
 Click File->Exit to close the software.

3. Create the PCB artwork of the above schematic diagram.

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OBSERVATION:
Motor controllers can vary significantly in their complexity, from basic on/off switches to advanced
systems that precisely control motor speed and torque. The complexity is influenced by the specific
needs of the application. Common features in motor controllers include protection mechanisms like
overload and overcurrent protection. Smaller systems may use built-in protection, while larger
systems utilize dedicated relays and circuit breakers. Advanced controllers often have features such
as limit switches, sensors, and feedback loops to ensure precise control and protect both the motor
and the machinery it drives. This precision and adaptability are crucial for applications that require
exact positioning and responsiveness to varying loads. Additionally, the design and documentation of
motor controller systems involve using software like ExpressSCH to create schematics, ensuring
accurate scaling and thorough documentation for practical implementation.
CONCLUSION:
Motor controllers play a crucial role in the functioning of electric motors, acting as the intermediary
between the motor and its power source. The complexity of these controllers can range from basic
switches to sophisticated closed-loop control systems, depending on the application's requirements.
Simple controllers may only turn the motor on and off manually or with basic sensors, while advanced
controllers can handle multiple speeds, provide overload protection, and precisely regulate motor
speed and torque. The specific demands of the application, whether for basic tools or advanced
machinery like numerically controlled lathes, determine the complexity and features of the motor
controller.

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