Among the most popular electric motors in a variety of sectors, such as consumer appliances, industrial, and automotive, are brushed DC motors. They are particularly favored for their simple design, cost-effectiveness, and ability to provide high starting torque.

There are several methods for controlling brushed DC motors, each offering distinct advantages, and the choice of control method depends on factors such as application requirements, cost, complexity, and performance needs. This article explores four common control methods for brushed DC motors, discusses their advantages and disadvantages, and provides guidance on how to select the right one for your application.

Introduction to Brushed DC Motors

A brushed DC motor (BDC) consists of a stator, rotor (armature), commutator, and brushes. The motor’s operation relies on the mechanical contact between brushes and the commutator, which reverses the current in the rotor windings, generating a rotating magnetic field. This simplicity makes BDC motors suitable for various applications, but it also means that they require specific control strategies to ensure optimal performance, especially in terms of speed, torque, and direction.

Four Common Control Methods for Brushed DC Motors

The control of brushed DC motors typically involves regulating the voltage applied to the motor, which in turn controls the motor’s speed, torque, and direction. The following are four widely used methods of controlling these motors:

• On/Off Control (Switching Control)
• Pulse Width Modulation (PWM) Control
• Analog Control
• Closed-Loop Control (Feedback Control)

On/Off Control (Switching Control)

On/off control, also known as binary or switching control, is the most basic method of controlling a brushed DC motor. It involves applying either a full voltage to the motor or disconnecting it completely from the power supply. This method is typically used in simple applications where precise control over the motor’s speed and direction is not required.

How it Works:

• The motor is either on (with full voltage) or off (no voltage).
• The motor’s operation is controlled by a simple switch or relay, which toggles the power supply to the motor.
• No feedback or modulation of the motor speed is involved.

Advantages:

• Simplicity: On/off control is the simplest and least expensive method, requiring minimal components.
• Cost-Effective: This method requires very little circuitry, making it highly affordable.
• Suitable for Simple Applications: Ideal for tasks that require the motor to be either fully on or off, such as in toys, basic fans, or small appliances.

Disadvantages:

• Lack of Precision: It does not offer any control over speed or torque.
• High Wear and Tear: The motor is either running at full speed or not at all, which can result in stress on the motor and higher wear rates.

Applications:

• Basic toys and gadgets.
• Simple appliances with no variable speed requirements.

Pulse Width Modulation (PWM) Control

By quickly turning the motor’s power source on and off, PWM regulates the average voltage delivered to the motor. The average voltage and, consequently, the motor’s speed and torque are determined by the duty cycle, or the ratio of on-time to off-time.

How it Works:

• The motor power is pulsed at a fixed frequency, and the proportion of time the power is on is varied to control the motor’s speed.
• The pulse’s duty cycle determines the effective voltage. For example, a 50% duty cycle applies 50% of the maximum voltage to the motor.
• The frequency of the PWM signal remains constant, and the motor’s speed is determined by adjusting the duty cycle.

Advantages:

• Efficient Speed Control: PWM allows for efficient control of motor speed without wasting power in resistive losses.
• Improved Torque Control: By adjusting the duty cycle, it is possible to control the motor’s torque output more effectively.
• Reduced Heating: The high switching speed of PWM reduces the heating issues typically caused by resistive losses.
• Low Power Losses: Since the motor is only supplied with the necessary amount of power, PWM reduces power wastage.

Disadvantages:

Complexity: PWM requires additional components like pulse generators and controllers, which adds complexity compared to on/off control.
Electromagnetic Interference (EMI): High-frequency switching may lead to EMI, which could interfere with sensitive electronics.

Applications:

• Robotics and automation.
• DC fans and motors with variable speed control.
• Electric vehicles (EVs) and electric scooters.
• Adjustable-speed pumps and conveyors.

Analog Control

A variable voltage is used in analog control to regulate the brushed DC motor’s speed. By altering the input voltage, the motor’s speed can be changed. This method provides a simple way to control the motor, although it has limitations when compared to PWM control.

How it Works:

• A variable resistor, potentiometer, or voltage regulator is used to adjust the voltage supplied to the motor.
• As the input voltage increases, the motor speed increases proportionally, and vice versa.
• This method is less efficient than PWM because the motor may operate at less than optimal voltage levels for certain tasks.

Advantages:

• Simple Implementation: Analog control circuits are relatively simple and cost-effective.
• Smooth Control: Analog control allows for smooth, continuous speed adjustments without the abrupt transitions of on/off control.

Disadvantages:

• Less Efficient: This method involves wasting power as heat due to resistive losses.
• Limited Control: Analog control doesn’t provide precise, fine-grained speed adjustments or torque control.
• Voltage Dependency: A stable power supply is required to achieve accurate motor control.

Applications:

• Simple speed control applications like electric fans and small electric pumps.
• Applications in which energy efficiency is not a top priority.

Closed-Loop Control (Feedback Control)

Closed-loop control, or feedback control, uses sensors to monitor the motor’s performance and adjusts the input signal accordingly to maintain the desired speed or torque. This approach is more sophisticated than the others since it offers ongoing modifications based on data collected in real time, resulting in motor control that is more precise and dependable.

How it Works:

• A feedback device (e.g., encoder, tachometer, or Hall sensor) is used to measure the motor’s speed or position.
• The feedback is fed back into a controller, which compares the actual speed with the desired speed and adjusts the motor’s input accordingly.
• The controller continuously fine-tunes the power supplied to the motor, ensuring consistent speed or torque under varying loads.

Advantages:

• Precision Control: Closed-loop control allows for precise management of speed, torque, and position.
• Adaptability: The motor can respond to changes in load and external conditions, making it ideal for applications requiring constant performance.
• Increased Efficiency: Feedback systems ensure that the motor operates at optimal levels, minimizing energy waste.

Disadvantages:

• Complexity and Cost: This method requires additional sensors and a more sophisticated controller, leading to increased complexity and cost.
• Power Consumption: The need for additional sensors and circuitry can increase power consumption.

Applications:

• Robots and CNC machines where exact speed and placement are necessary.
• Industrial automation and high-performance applications.
• Automotive applications like power steering and window motors.

Comparison of the Four Control Methods

Feature	Voltage Control	PWM Control	Armature Resistance Control	Field Control
Complexity	Simple	Moderate	Simple	High
Efficiency	Low	High	Low	Moderate
Cost	Low	Moderate	Low	High
Precision	Low	High	Moderate	High
Maintenance	Low	Moderate	Low	High
Speed Control Range	Limited	Wide	Limited	Wide
Heat Generation	High	Low	High	Moderate

How to Pick the Best Control Technique for Your Use Case

It is crucial to take into account the following elements when choosing the best control strategy for a brushed DC motor:

Application Requirements:

• If your application requires simple on/off control, such as in toys or basic appliances, on/off control may be sufficient.
• PWM control is usually the best option for applications that need precise speed control, like fans or robotics.
• If simplicity and low cost are crucial factors, analog control might be the most straightforward option.
• Closed-loop control is the ideal option for applications requiring a high degree of precision, like industrial robots or CNC machines.

Efficiency Needs:

For applications where energy efficiency is important, PWM control and closed-loop control are preferable, as they provide precise and optimized motor performance.

Complexity and Cost:

For budget-conscious applications where complexity is a concern, on/off control or analog control are cost-effective solutions.
For high-performance applications, closed-loop control is worth the additional investment.

Speed and Torque Control:

PWM control and closed-loop control are ideal for achieving both fine speed and torque control in dynamic environments.

Maintenance and Longevity:

PWM control and closed-loop control are better for applications where the motor will be used continuously, as they improve the lifespan and reduce wear.

Summary

Choosing the right control method for your brushed DC motor depends on the application’s requirements, including the need for efficiency, precision, cost, and complexity. While on/off control is simple and cost-effective, more advanced methods like PWM, analog, and closed-loop control provide finer control over motor speed, torque, and overall performance. By carefully considering the application’s specific needs, you can select the control method that will ensure optimal motor performance and longevity.

In recent years, the advancements in motion control systems have led to the development of two crucial types of motors: the hybrid synchronous stepper motor and the hybrid servo stepper motor.

Both types have distinct characteristics and applications, but understanding their key differences can help engineers and designers select the right motor for specific applications. This detailed comparison explores the differences in performance, efficiency, and applications, and provides a clear guide to choosing between the two.

What is a Hybrid Synchronous Stepper Motor?

Stepper motors that combine the features of variable reluctance and permanent magnet stepper motors are known as hybrid synchronous stepper motors. It operates using a fixed magnetic field generated by the stator, which interacts with the rotor’s magnetic field to produce precise incremental movements. The motor’s step angle is fixed, meaning the rotor moves in small, discrete steps.

Generally speaking, hybrid synchronous stepper motors are made for uses requiring precise placement and dependable operation. Common uses include CNC machines, robotics, and various precision tools. These motors are widely used because they offer high torque at low speeds, making them ideal for tasks requiring constant movement without slippage.

What is a Hybrid Servo Stepper Motor?

On the other hand, a hybrid servo stepper motor integrates a stepper motor with a servo control system, offering both precision and continuous feedback to control motion more accurately than traditional stepper motors. This hybrid motor has the benefits of closed-loop feedback systems, making it a more efficient choice for high-performance applications.

A hybrid servo stepper motor uses a combination of a stepper motor’s fixed steps and the servo’s dynamic control to ensure smooth operation with minimal errors. Usually, these motors are employed in situations where power efficiency, speed control, and dynamic performance are essential. Examples include automated assembly lines, packaging machines, and advanced robotics.

Important Distinctions Between Hybrid Servo Stepper Motors and Hybrid Synchronous Stepper Motors

Feature	Hybrid Synchronous Stepper Motor	Hybrid Servo Stepper Motor
Control Type	Open-loop or closed-loop	Closed-loop
Precision	Fixed step angles	Dynamic, continuous feedback
Efficiency	Moderate, may have more heat generation	Higher efficiency, lower heat loss
Torque	High torque at low speeds	High torque with smooth control at all speeds
Speed	Limited by step angle and driver	Faster response with smooth motion
Power Consumption	Can be higher at low speeds	Generally more efficient with power
Applications	CNC machines, 3D printers, robotics	Packaging machines, conveyors, advanced robotics
Cost	Less expensive	Higher cost due to integrated control system

Advantages of Hybrid Synchronous Stepper Motors

• Cost-Effective:  Hybrid synchronous stepper motors are less expensive compared to their hybrid servo counterparts. Their simple design and open-loop control make them a more budget-friendly option for standard applications.
• Reliable Torque at Low Speeds: These motors have exceptional torque at low speeds, which is crucial for applications like CNC or 3D printing systems that need steady power with little variation.
• Simplicity: The open-loop system design allows for ease of use and less complexity, making it easier to set up and troubleshoot.

Advantages of Hybrid Servo Stepper Motors

• Higher Efficiency:  Hybrid servo stepper motors feature closed-loop control, which allows them to adjust dynamically to load conditions, improving efficiency and reducing power consumption.
• Precise Speed Control: These motors provide precise and smooth speed regulation, which is crucial in applications where variable speeds and load conditions are involved.
• Better Heat Management: Due to the feedback system, hybrid servo motors tend to produce less heat during operation, making them ideal for high-performance, continuous use applications.
• Improved Performance: The continuous feedback of a hybrid servo stepper motor ensures more accurate and stable motion, making it suitable for highly sensitive applications where precision is critical.

Applications of Hybrid Synchronous Stepper Motors

• CNC Machines: Hybrid synchronous stepper motors are widely used in CNC machining applications due to their ability to handle precise movements and work at low speeds.
• 3D Printers: These motors provide the precise control required for 3D printing applications, where accuracy in layer deposition is paramount.
• Robotics: When precise incremental movements are necessary for tasks such as robotic arm control, hybrid synchronous stepper motors offer a reliable solution.

Applications of Hybrid Servo Stepper Motors

• Packaging Machinery: The hybrid servo stepper motor is ideal for applications such as high-speed packaging systems where speed and accuracy are essential.
• Conveyor Systems: These motors are ideal for factory conveyor belt systems because they offer precise torque and speed control.
• Advanced Robotics: Hybrid servo stepper motors excel in robotics where precise, continuous motion is necessary for high-performance tasks.

Conclusion

Both hybrid synchronous stepper motors and hybrid servo stepper motors bring unique benefits to different types of applications. Hybrid synchronous stepper motors are ideal for cost-effective, low-speed precision tasks, while hybrid servo stepper motors excel in high-performance, dynamic systems requiring constant feedback and efficiency.

The final decision between these two motor types is based on the particular needs of the application, including budgetary restrictions, speed, accuracy, and power efficiency. Comprehending these distinctions guarantees that engineers can choose the best motor for their system with knowledge.

In many systems that need precise and regulated motion, stepper motors are essential parts. Numerous devices, including robotics, CNC machines, and 3D printers, employ these motors.

Based on the operating voltage, stepper motors are generally divided into two primary types: low voltage and high voltage. Knowing the distinctions between these two motor types will enable you to choose the one that best meets your unique requirements.

Low Voltage Stepper Motors

Low voltage stepper motors are commonly used in systems where low power consumption, compactness, and energy efficiency are prioritized. These motors are perfect for smaller, less demanding applications and usually run between 3 to 24 volts.

Advantages of Low Voltage Stepper Motors

• Energy Efficiency: When compared to their high voltage counterparts, low voltage motors use less energy. Applications requiring minimal power consumption and battery-operated devices are ideal for them.
• Compact Design: Low voltage motors are generally smaller and lighter, making them suitable for compact systems or devices with limited space.
• Simple Control: These motors are relatively easier to control with simple drive electronics, making them a good choice for projects with basic control needs.
• Lower Heat Generation: Due to their lower operating voltage, these motors produce less heat, reducing the need for complex cooling systems in most applications.

Disadvantages of Low Voltage Stepper Motors

• Lower Torque: Low voltage stepper motors produce less torque compared to high voltage motors, which limits their suitability for high-load applications.
• Limited Speed: These motors tend to have lower maximum speeds and are not ideal for applications that require high-speed motion.
• Not Suitable for Heavy-Duty Applications: Low voltage stepper motors may struggle to perform efficiently in heavy-duty applications or those requiring high torque at higher speeds.

High Voltage Stepper Motors

High voltage stepper motors are designed for applications that demand more power, higher speed, and greater torque. These motors typically operate at voltages of 48V and above, making them suitable for industrial and high-performance applications.

Advantages of High Voltage Stepper Motors

• Higher Torque: High voltage stepper motors can produce more torque, making them ideal for applications where high power is needed, such as CNC machines and industrial robots.
• Faster Speeds: These motors can operate at higher speeds, making them suitable for systems where quick, precise movement is required.
• Better Performance at High Speeds: High voltage motors perform better at high speeds, maintaining efficiency and performance over extended periods of use.
• Improved Heat Dissipation: These motors are designed to handle higher levels of heat and can maintain operational efficiency even under heavy-duty conditions.

Disadvantages of High Voltage Stepper Motors

• Higher Power Consumption: High voltage motors consume more energy, which may lead to higher operational costs, especially in long-running applications.
• Greater Size: Because of their increased power capacity, these motors are typically bigger and more cumbersome, necessitating greater installation space.
• Complex Control Systems: High voltage stepper motors require more advanced and complex control systems, which can increase both the cost and complexity of the setup.
• Increased Heat Generation: While they can handle higher heat, these motors tend to generate more heat than low voltage motors, requiring effective cooling solutions to avoid overheating.

Low Voltage vs. High Voltage Stepper Motors: A Comparative Overview

The following table provides a summary of the primary distinctions between stepper motors with low voltage and high voltage:

Feature	Low Voltage Stepper Motors	High Voltage Stepper Motors
Operating Voltage	3V, 5V, 6V, etc., below 24V	48V and higher
Torque Output	Lower torque	Higher torque
Speed Capabilities	Lower speed range	Higher speed capabilities
Efficiency	Energy-efficient at low speeds	High efficiency at high speeds
Size	Smaller and compact	Larger and bulkier
Heat Generation	Lower heat production	Higher heat production
Control Complexity	Simple control systems	More complex control systems
Best Suited For	Low power, compact systems	High-performance, industrial systems
Cost	Generally lower cost	Higher initial cost

Choosing the Right Motor for Your Application

A number of things need to be taken into account when choosing between stepper motors with low voltage and high voltage. The decision should be based on the specific demands of your system, such as power requirements, speed, torque, size constraints, and cost.

• Energy Efficiency: If your application is energy-sensitive, such as a portable battery-operated device, low voltage stepper motors are the preferred choice due to their lower power consumption.
• Torque and Speed Requirements: If your application demands high torque and speed, such as in CNC machines or industrial automation, high voltage stepper motors will provide the necessary power.
• Size and Space Constraints: For systems with limited space, low voltage stepper motors are typically smaller and easier to integrate into tight spaces.
• Control Requirements: Low voltage stepper motors are easier to control, while high voltage motors may require more advanced electronics and drivers, adding complexity to the system.

Applications of Low Voltage Stepper Motors

Low voltage stepper motors are frequently employed in settings where small size and energy efficiency are essential. Some typical use cases include:

• 3D Printers: These motors are ideal for 3D printers, providing accurate motion control without consuming excessive power.
• Robotics: Low voltage stepper motors are used in small robots and automated systems that require efficient, precise movements.
• Medical Devices: Low voltage motors are used in medical equipment such as pumps, actuators, and robotic surgical tools, where compact design and energy efficiency are essential.
• Consumer electronics: Low voltage motors are used in printers, scanners, and other household gadgets that need to be precisely controlled without using a lot of energy.

Applications of High Voltage Stepper Motors

High voltage stepper motors are often used in applications that require more torque, speed, and power. Common use cases include:

• Industrial Automation: These motors are essential for industrial machinery, such as CNC machines, robotic arms, and automated assembly lines, where higher torque and speed are required.
• Robotics: High voltage stepper motors are used in industrial robots and robotic arms that need to handle heavy loads and perform tasks at high speeds.
• Conveyor Systems: High voltage motors are used to power conveyor systems that move heavy items quickly and efficiently in manufacturing facilities and warehouses.
• Electric Vehicles: To provide the power required for accurate motion control, electric vehicle systems employ high voltage stepper motors.

Conclusion

In conclusion, low voltage and high voltage stepper motors both have distinct advantages depending on the application. Low voltage stepper motors are energy-efficient, compact, and easier to control, making them ideal for small, battery-powered systems. On the other hand, high voltage stepper motors are more powerful and capable of delivering higher torque and speed, making them the better choice for industrial and high-performance applications.

By carefully considering the requirements of your system, including power, space, and performance, you can choose the right stepper motor to meet your needs.