How to Match DC Voltage and Current to Brush Motors

Inhaltsübersicht

Matching DC voltage and current to brushed motors helps them work well and ensures their safety during operation. If the DC power requirements are not met, issues can arise, including overheating, reduced lifespan, or erratic movements. For instance, a motor operating at 347 rpm with 40 mNm torque typically requires about 6 volts and 465 mA. However, during start-up or when stopping, the voltage and current fluctuate. Careful adjustments are necessary to maintain stability. Understanding DC power requirements is crucial to prevent problems and enhance motor performance in demanding applications.

Wichtigste Erkenntnisse

  • Using the correct DC voltage and current stops motors from overheating and helps them last longer.

  • Knowing voltage limits is important; too much or too little can harm the motor or make it work poorly.

  • Check and care for your motor often to keep it working well within its power limits.

  • Use tools like multimeters to check voltage and current, making sure they fit the motor’s needs.

  • Pick the right power source and use voltage regulators to keep the motor safe and running well.

Basics of Brushed DC Motors

Key Parts and Their Jobs

Brushed DC motors have important parts that work together. They change electricity into movement. The Armatur is the spinning part with wire coils. When electricity flows, it makes a magnetic field. The stator stays still and creates a magnetic field that pushes the armature to spin. The Kommutator switches the direction of electricity in the armature. This keeps the armature spinning smoothly. Carbon brushes touch the commutator and send electricity to the armature. Magnets make the magnetic field needed for the motor to work.

Part

Job in the Motor

Armatur

Makes a magnetic field when electricity flows through its wires.

Kommutator

Changes electricity direction for smooth spinning.

Carbon Brushes

Send electricity to the armature by touching the commutator.

Magnets

Create the magnetic field that works with the armature’s field.

These parts help the motor work well. But, the brushes rubbing on the commutator can cause wear and lower efficiency over time.

How Brushed Motors Work

Brushed DC motors turn electric energy into movement using magnetic fields. When electricity flows in the armature, it makes a magnetic field. This field works with the stator’s field to create spinning force. The armature spins because of this force. The commutator changes the electricity direction at the right time. This keeps the armature spinning instead of moving back and forth. Carbon brushes send electricity to the armature by staying in contact with the commutator.

To keep your motor working well, take care of it regularly. Check for damage to avoid problems. Use the right size motor to save energy and improve performance. Good brushes and cooling systems make the motor last longer and work better.

Uses in Industries and Devices

Brushed DC motors are used in many industries because they are simple and cheap. In cars, they power wipers, seat adjusters, and small fans. Factories use them for conveyor belts and robotic arms. Home gadgets like toys, hair dryers, and small machines also use these motors. In medical tools, they help run precise instruments like surgical devices. The aerospace field uses them in control systems and actuators.

Industrie

2023 Value (USD Billion)

2032 Expected Value (USD Billion)

Autos

2.5

3.5

Factories

1.5

2.0

Home Gadgets

1.8

2.4

Medical Tools

0.8

1.2

Luft- und Raumfahrt

0.82

1.0

Bar chart showing 2023 and 2032 values for brushed motor uses in different industries.

These motors are great for jobs needing simple speed control and steady performance. Knowing their DC power needs helps them work best in your projects.

Understanding DC Power Needs for Brushed Motors

Why Voltage Ratings Matter

Voltage ratings show how much electrical pressure a motor needs. Each brushed motor works best within a specific voltage range. Staying in this range keeps the motor from overheating or losing power. For example, a motor rated for 6 volts works best with exactly 6 volts. Too little voltage makes it weak, while too much can break its parts.

When using Pulse Width Modulation (PWM) to control speed, be careful. You need to adjust the duty cycle and frequency properly. At medium speeds, Back EMF (Electromotive Force) becomes important. It affects how the circuit works. This makes PWM control harder, so knowing how the motor handles voltage is key.

Current Ratings: Stall, No-Load, and Operating Current

Brushed motors have three main current ratings: stall, no-load, and operating current. Stall current is the highest current when the motor starts or gets stuck. No-load current is the smallest current when the motor runs without a load. Operating current is the average current during normal use.

Knowing these ratings helps you pick the right motor. If your motor often runs near its stall current, it might overheat or wear out faster.

Problems with Wrong Power Supply

Giving a motor the wrong power can cause big problems. Too much voltage makes it hot and damages its parts. Too little voltage makes it weak and less efficient. Wrong current levels are also bad. Too much current can burn the motor, while too little might stop it from working.

For example, the Portescap 16C18 motor with a 205P coil has a back EMF of 0.70 mV/rpm. At 10,000 rpm, its output voltage is 7.0 V. If the power supply doesn’t match, the motor’s efficiency, which is about 50% at full power, will drop a lot.

To avoid these issues, always match the motor’s power needs to its specs. This keeps the motor working well and lasting longer.

Determining Voltage Needs for Your Motor

Understanding Motor Details

To find the right voltage for your brushed motor, start by checking its details. These details explain how the motor works and what it needs to run well. Look for this information in the motor’s datasheet or manual. Pay attention to these key points:

Aspekt

Was es bedeutet

Voltage Needs

Shows the power supply needed for the motor to work well.

Torque Strength

Tells how much spinning force the motor can make.

Power Compatibility

Makes sure the motor’s voltage matches the power source to avoid damage.

Voltage Range

Helps prevent overheating and makes the motor last longer.

Focus on the voltage range when reading these details. This range helps the motor run smoothly without overheating or losing power. For example, if a motor’s range is 6-12 volts, giving it less than 6 volts makes it weak. Giving it more than 12 volts can break its parts.

Picking Voltage for Your Needs

The right voltage depends on how you’ll use the motor. Different devices need different voltages to work their best. For example, a motor in a medical tool needs precise voltage for accuracy. A motor in a toy might focus on being simple and cheap.

Here’s a table comparing voltage needs for different uses:

Gerätetyp

Voltage Range

Current Range

Switching Speed

Wesentliche Merkmale

MOSFET

Lower voltages

Higher currents

Faster switching

Low resistance, quick operation

IGBT

Higher voltages

Up to 10 A

Slower switching

Handles high voltage, durable

When choosing a motor, check the power source in your device. If your device uses a 12V battery, pick a motor with a voltage rating close to 12V. This match avoids wasting energy and helps the motor work properly.

Problems with Wrong Voltage

Giving the motor the wrong voltage can cause big issues. Too much voltage, called overvoltage, can damage the motor’s parts. It can break the insulation and make the motor fail early. Too little voltage, called undervoltage, makes the motor weak and less efficient.

Here are some effects of voltage problems:

For example, sudden voltage spikes can harm the motor’s insulation. Uneven voltage can also hurt its performance. Always check the voltage to keep it within the motor’s range. This helps the motor last longer and work better.

Tipp: Use a voltage regulator to keep the voltage steady. It protects the motor from changes and keeps it running smoothly.

Calculating Current Needs for Best Performance

Figuring Out Current Based on Load and Use

To know how much current your motor needs, start by looking at the load and how it’s used. Motors work differently depending on the weight they move, their speed, and where they operate. You can use these methods to estimate current needs:

Method/Technique

Was es bewirkt

Torque-Speed Curves

Shows how speed, current, power, and efficiency change with torque.

Basic Parameter Measurement

Measures voltage, current, and speed for detailed motor data.

Load Testing

Tests the motor under different loads to see how it performs.

Smart Meters for Monitoring

Tracks motor performance and power use over time.

For example, if your motor runs a conveyor belt in a factory, think about the weight of the items and how fast the belt moves. Heavier loads or faster speeds need more current. Tools like torque-speed curves and load tests help you figure this out.

Looking at performance curves also helps you understand how your motor behaves in different situations. Here are some features that help with current estimates:

Feature/Tool

What It Helps With

Machine Circuit Parameters

Calculates details needed to estimate motor load.

Locked-Rotor Current and Torque

Gives key inputs for motor performance analysis.

Generator Characteristic Curves

Shows torque-slip, current-slip, and power factor-slip for evaluation.

Auto-Update to Machine Editor

Updates motor settings for real-time analysis.

Using these methods ensures your motor gets the right current for smooth operation.

Tools for Checking Current Use

Measuring your motor’s current is important to keep it efficient and safe. Tools like multimeters, clamp meters, and advanced sensors make this easy. Magnetic current sensors are especially useful because they:

  • Measure current accurately without touching the motor, reducing wear.

  • Help manage heat, making the motor last longer.

  • Save space on circuit boards, simplifying designs.

Smart meters are great for real-time tracking. They monitor runtime and performance, helping you spot problems early. For example, tracking runtime lets you calculate how often your motor is available for use.

Always measure current in real-world conditions. If your motor powers a robotic arm, test it while the arm does its usual tasks. This gives you accurate readings based on actual use.

Problems with Too Much or Too Little Current

Giving your motor the right current is key to keeping it healthy. Too little current makes it weak, while too much can cause overheating or damage. Common problems from incorrect current include:

  1. Overheating: Too much current makes parts too hot and can break them.

  2. Lower Efficiency: High current wastes energy and wears out parts faster.

  3. Battery Strain: Overloading the motor can damage batteries or cause fires.

  4. Damaged Parts: Long-term high current can ruin motors and controllers.

  5. Safety Risks: Extreme current levels can even cause fire hazards.

Other issues, like stuck parts or bad gear ratios, can also raise current use. For example, worn-out parts make the motor work harder, using more current. Overloading the motor or using the wrong gears can also waste energy.

To avoid these problems, follow these tips:

  • Use sensors to check and control current levels.

  • Make sure your motor and controller match.

  • Inspect your motor often for damage or wear.

  • Pick good-quality parts to reduce resistance.

By managing current properly, you protect your motor and help it work better. Calculating and controlling current needs will make your motor last longer and perform well.

Tipp: Always check your motor’s datasheet for its power needs. This ensures you give it the right voltage and current for the best results.

Testing and Verifying DC Power Compatibility

Using a Multimeter for Voltage and Current Testing

A multimeter is a helpful tool to check voltage and current. It ensures the motor gets the right power supply. Follow these steps to use it:

  1. Check if the motor needs AC oder DC voltage.

  2. Set the multimeter to the correct voltage type.

  3. Choose a range higher than the expected measurement. If unsure, pick the maximum.

  4. Connect the red lead to the voltage terminal and the black lead to the common terminal.

  5. Place the leads on the motor’s circuit and wait for the reading.

Digital multimeters are better for testing motors. They give accurate results and avoid errors like parallax. Auto-ranging makes them easier to use. High input impedance ensures reliable readings. These features make digital multimeters great for testing brushed motors.

Tipp: Always check the multimeter settings before testing to avoid wrong readings or damage.

Testing Under Real-World Load Conditions

Testing motors in real-world conditions shows how they work during use. Load testing helps you see how heat and resistance affect performance. For example, when the motor gets hot, its resistance increases. This lowers torque and changes voltage constants, affecting how it works.

Data shows temperature impacts motor operation. At 100°C, resistance rises, and magnetic flux density drops compared to 25°C. This reduces locked-rotor torque and slows no-load speed. Testing in realistic conditions ensures the motor can handle its job without overheating or losing efficiency.

Hinweis: Do load tests in safe environments to avoid damage from extreme conditions.

Safety Tips for Testing Motors

Safety is important when testing brushed motors. Follow these tips to stay safe:

  • Train workers on safe testing steps before starting.

  • Keep test areas secure to avoid contact with live parts.

  • Ground high-voltage circuits visibly before working on them.

  • Use proper grounding methods to protect people during tests.

  • Make sure all tools meet safety standards to lower risks.

These steps help prevent shocks and fires. Training and safety measures create a safer testing environment.

Alert: Never test motors without safety gear and rules in place.

Practical Tips for Matching Power Supply to Brushed Motors

Picking the Right Power Supply for INEED Motors

Choosing the right power supply helps your brushed motor work well. Think about power needs, stability, and size when selecting a power supply for INEED motors. The table below shows important factors to consider:

Kriterien

Beschreibung

Peak and Average Power

Match the motor’s highest and usual power needs.

Load Regulation

Keep voltage steady even if the load changes.

Line Regulation

Ensure stable DC voltage even with AC power changes.

Physical Volume

Make sure the size fits your device’s design.

Gewicht

Check the weight for easier shipping and mounting.

Kosten

Compare cost per watt for peak and regular power output.

Regen Control

Handle energy returned when the motor slows down.

Additional Features

Look for helpful extras like diagnostic LEDs or fast discharge.

In-Rush Current Limiting

Avoid high current draw when turning on the motor.

Protection Features

Protect against overheating, short circuits, and wrong connections.

DC Output Voltage Level

Pick a voltage range that makes the motor run efficiently.

By following these tips, you can give your motor the right power supply. This improves how it works and makes it last longer.

Using Voltage Regulators and Current Limiters

Voltage regulators and current limiters keep your motor stable. A voltage regulator gives steady voltage, even if the input changes. For example, the LM3480 regulator turns 5V into a stable 3.3V output. This is great for small systems and keeps sensitive parts working smoothly.

Current limiters stop the motor from drawing too much current, which can cause damage. Adding extra capacitance helps keep voltage steady and provides quick bursts of power when needed. This is useful during start-up or sudden changes. The LM3480 regulator also reduces power loss and lowers the need for extra parts, making the motor system more efficient.

Tipp: Use both voltage regulators and current limiters to protect your motor and make it more reliable.

Checking Motor Performance Over Time

Regular checks help you find problems early. Use tools like smart meters or magnetic current sensors to monitor your motor. These tools measure voltage and current in real-time, showing how well your motor is working.

For example, tracking runtime can show if the motor is using too much current. This might mean parts are worn out or the load is too heavy. Magnetic current sensors are helpful because they measure current without touching the motor. This reduces wear and helps control heat, making the motor last longer.

Hinweis: Check your motor regularly to keep it within safe voltage and current levels. This prevents breakdowns and keeps it running smoothly.

Matching DC voltage and current to brushed motors helps them work well, stay safe, and last longer. To do this, learn about motor details, figure out power needs, and test setups in real-world situations.

Tipp: Check the datasheet for voltage and current details. Use tools like multimeters and smart meters to confirm they match.

Bürstenloser DC-Motor

INEED Motors offers dependable brushed and brushless DC motors. Their compact Bürstenloser DC-Motor is efficient and strong for many uses. Visit INEED-Motoren to see their advanced motor options.

FAQ

How can I tell if my brushed motor is too hot?

Feel for unusual heat or notice burning smells while it runs. Use a temperature sensor to check the motor’s surface. If the temperature goes above the motor’s limit, reduce the load or improve cooling.

Tipp: Regular care stops overheating and helps the motor last longer.

Can I use a stronger power supply for better results?

No, using more voltage than needed can harm the motor. Always match the voltage to what the motor needs. Too much voltage causes extra heat and lowers efficiency.

Alert: Too much voltage can break insulation and damage the motor early.

What tools can measure motor current correctly?

Use a digital multimeter or clamp meter for accurate readings. Magnetic current sensors are great for checking current without touching the motor. These tools help monitor current safely and precisely.

Why does my motor stop working with heavy loads?

Heavy loads make the motor draw more current, causing heat or strain. Check the motor’s torque and current limits. Lower the load or use a motor with more capacity.

Hinweis: Heavy loads wear out motors faster and waste energy.

How often should I check my motor’s power setup?

Check the motor’s voltage and current when installing or after big changes. Regular tests keep it running well and prevent damage.

Tipp: Use smart meters to track performance and catch problems early.

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