“DC MOTOR CONTROL USING PWM ”

A Project Report

Submitted in Partial Fulfillment of the Requirements for

the degree of

BACHELOR OF ENGINEERING

I
N
ELECTRICAL ENGINEERING

B
y
GADHVI DEVENDRA (03)
ACHARYA ANAND (35)
HEMANT MEENA (37)
SHAKYA SANJIV (50)

Department of Electrical Engineering

LALJIBHAI CHATURBHAI INSTITUTE OF

TEHCHNOLOGY, BHANDU.

Dist: Mehsana – 384 120

I
 ACKNOWLEDGEMENT

I express my gratitude to those who have helped me throughout my

project. It is not possible to construct anything of the magnitude of a final year
electrical project without any help. First of all we would like to take the opportunity to
convey our heartiest thank to the fine people at our institute and its associated units which are
interacted by us during the course of our project. We would like to acknowledge our
indeptedness and sincere gratitude to our guide MR. D .R. Vyas, who allowed taking up the
work in his company, guided with great zeal and interest.
We acknowledge with sincere thanks to all the lecturers of EE
department for excellent guidance and entirely selfless efforts. Without their
Co-operative attitude, constant inspiration, and dedicated at each and every
stage of this project, it would not possible to make this project complete.
Our cordial thanks to all other persons who helped us in our projects
directly or indirectly.
We would also like to express our gratitude & thanks towards the staff of
Electrical Department of L.C.I.T for their continuous support and to
encouraging undertaking the project.

NAME ROLL NO.

GADHVI DEVENDRA
(03)
ACHARYA ANAND
(35)

II
 HEMANT MEENA
(37)
SHAKYA SANJIV
(50)

III
 ABSTRACT

This project is to carry out to control the speed of DC motor. As we know that
the speed of any type of dc motor depends on the supply voltage and by
varying the supply voltage using the small dc pulses found be very efficient as
compare to other methods for varying the supply voltage.
In this method of PWM the output voltage generated always depends on
the duty cycle which means by varying the turn on time of the pulse. This
variation of pulse can be done using the variable port connected in the circuit.
The use of PWM also reduces the loss of power during the turn on and turn off
time of dc motor which is advantageous which results in increase of overall
efficiency.

Keywords: DC MOTOR CONTROL USING PWM, SPEED CONTROL OF DC

MOTOR, EFFICIENT CONTROL USE OF MOTOR, FINAL YEAR PROJECT

IV
 LIST OF FIGURES

FIG.NO. DESCRIPTION PAGE NO.

2.1. Principle of motor 02

2.2. 03
Multipolar d.c motor

2.3. 05
Ward-Leonard system

2.4. 07
Resistance in series

4.1. Block diagram of project 12

4.2. PCB View of dc motor controller 13

4.3. Schematic diagram of project 14

4.4. Block diagram of power supply 15

4.5. output waveform when r = 2.8 kΩ 19

4.6. output waveform when r = 6.2 kΩ 20

V
 LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO.

1
4.1. Observation table 8

VI
 CONTENTS

Acknowledgement…………………………………………………………....... I
Abstract…………………………………………………………...................... II
List of Figures………….……………………………………………………….. III
List of Tables……………………………………………………………………. IV
Contents…………………………………………………………………………. V

Chapter 01: Introduction ……………………………………………………… 01

Chapter 02: Theory of dc motor ………………………………………………. 02

Chapter 03: Description of pulse width modulation (PWM)………………… 08

Chapter 04: Working of project ………………………………………………. 12

4.1 PCB View of Motor Controller………………………………………….. 13
4.2 Schematic Diagram of Project…………………………………………… 14
4.3 Component Description………………………………………………….. 15
4.4 Output waveform of PWM………………………………………………. 18

Chapter 05: Datasheets of different components……………………………… 21

5.1 Timer IC-555…………………………………………………………….. 22
5.2 IRG4PH30K……………………………………………………………… 28
5.3 78XX Series……………………………………………………………… 34
5.4 CD4093…………………………………………………………………... 44
5.5 LM393……………………………………………………………………. 51
5.6 LM358……………………………………………………………………. 55

VII
Bibliography………………………………………………………………………. 63
Conclusion………………………………………………………………………… 64

VIII
 CHAPTER 01: INTRODUCTION

This project is to carry out to control the speed of DC motor. As we know that the speed of
any type of dc motor depends on the supply voltage and by varying the supply voltage
using the small dc pulses found be very efficient as compare to other methods for varying
the supply voltage.

The circuit converts a DC voltage into series of pulses, such that the pulse duration
is directly proportion to the value of the DC voltage. The output voltage at the motor
terminals will be dependent on only two main factors that is supply voltage and percentage
duty cycle. By keeping the supply voltage constant and varying duty cycle the required
output voltage can be achieved. In this method of PWM the output voltage generated
always depends on the duty cycle which means by varying the turn on time of the dc pulse.
This variation of pulse can be done using the variable port connected in the circuit. The use
of PWM also reduces the loss of power during the turn on and turn off time of dc motor
which is advantageous which results in increase of overall efficiency.

The purpose of a motor speed controller is to take a signal representing the

demanded speed, and to drive a motor at that speed. The controller may or may not
actually measure the speed of the motor. This control circuit is ideal for the accurate
control of DC motors as well as other applications like lighting levels and small heaters
etc. These pulses vary in duration to change the speed of the motor. The longer the pulses,
the faster the motor turns, and vice versa.

Benefits and product features:

• Low power, will require minimal power from 12V lead acid battery
• Output range of 0-15V DC
• Output power of up to 250W continuous and 500W up to one minute
• High current rating
• Speed control
• Minimal cost
• Control aspect providing compensation and maintaining desired output

9
 CHAPTER 02: THEORY OF DC MOTOR

MOTOR PRINCIPLE:

An electrical motor is a machine which converts electrical energy in to mechanical

energy Its action is based on the principle that ‘When a current-carrying conductor is
placed in a magnetic field, it experiences a mechanical force whose direction is given by
Fleming’s Left-hand rule and whose magnitude is given by F=BIL Newton.
Constructionally, there is a no basic difference between a d.c. generator and d.c. motor. In
fact same machine can be used interchangeably as a generator or as a motor.

Fig 2.1: Principle of motor

D.C. motors are classified as shunt-wound, series-wound and compound-wound. In fig.

2.2, a part of a multipolar d.c. motor is shown. When its field magnets are excited and its
armature conductors are supplied with current from the supply mains, they experience a
force tending to rotate the armature.
1. Armature conductors under N-pole are assumed to carry current downwards shown
by crosses.
2. Armature conductors under S-pole are assumed to carry current upwards shown by
dots.
10
 Fig 2.2: Multipolar d.c motor
In fig. 2.2, by applying Fleming’s Left-hand rule, the direction of the force on each
conductor can be found.
 It is shown by small arrows placed above each conductor.
 It will be seen that each conductor can be found.
 It will be seen that each conductor experiences a force F which tend to rotate the
armature in anticlockwise direction.
 These forces collectively produce a driving torque which sets the armature rotating.
It should be noted that the function of a commutator in the motor is the same as in a
generator. By reversing current in each conductor as it passes from one pole to another, it
helps to develop a continuous and unidirectional torque.

11
FACTORS CONTROLLING MOTOR SPEED:

Speed of a motor is given by the relation, N = [A (V- I a Ra)] / [PZΦ]

= [K (V- I a Ra)] / [Φ]

Where,
N = speed of a motor in r.p.s
V = applied voltage in volt
I a = armature current in ampere
Ra = armature circuit resistance
I a Ra = armature ohmic drop in volt
Φ = flux / pole in Weber
Z = total number of armature conductors
= No. of slots × No. of conductors / slots
P = No. of motor poles
A = No. of parallel paths in armature
K= Constant = [A/(PZ)]

It is obvious that the speed can be controlled by varying

1. Flux control method: By varying flux / pole i.e. Φ
2. Rheostat control method: By varying armature circuit resistance i.e. Ra
3. Voltage control method: By varying applied voltage i.e. V
These three methods are applied to shunt, compound and series motors.

12
VOLTAGE CONTROL METHOD IN DC SHUNT MOTOR:
METHOD 1:- MULTIPLE VOLTAGE CONTROL
• In this method, the shunt field of the motor is connected permanently to a
fixed exciting voltage, but the armature is supplied with different voltages by
connecting it across one of the several different voltages by means of suitable
switchgear.

• The armature speed will be approximately proportional to these different

voltages.

• The intermediate speeds can be obtain by adjusting the shunt field regulator

• However the method is not much used.

METHOD 2:- WARD-LEONARD SYSTEM

• This system is used where an usually wide (up to 10:1) and very sensitive
speed control is required as for colliery winders, electric elevators and the main
drives in steel mills and blooming and paper mills.

Fig 2.3: Ward-Leonard system

• The arrangement is illustrated in fig.

 M1 is the main motor whose speed control is required. The field of

this motor is permanently connected across the d.c. supply lines. By varying a
variable voltage across its armature, any desired speed can be obtained.

 The variable voltage is supplied by a motor-generator set which

13
 consists of either a d.c. or an a.c. motor M2 directly coupled to the generator.

 The motor M2 runs at an approximately constant speed.

 The output voltage of G is directly fed to the main motor M1.

 The voltage of a generator can be varied from zero up to its

maximum value by means of its field regulator.

 By reversing the switch RS, generated voltage can be reversed and

hence the direction of rotation of direction main motor M1.

 It should be remember that motor generator set always runs in the

same direction.

• Despite the fact that capital outlay involved in this system is high because
1. A large output machine must be used for the motor generator set.
2. Two extra machine employed, still it is used extensively for elevators, hoist
control and for main drive in steel mills where motors ratings 750 KW to 3750
KW are required.

• The reason for this is that the almost unlimited speed control in either
direction of rotation can be achieved entirely by field control of the generator and
the resultant economics in steel production outweigh the extra expenditure on the
motor generator set.

WARD-LEONARD-ILGER SYSTEM
• A modification of the Ward-Leonard system is known as Ward-Leonard-
Ilger system which uses a smaller motor-generator set with the addition of a
flywheel whose function is to reduce fluctuations in the power demand from the
supply circuit

• When the main motor M1 becomes suddenly overloaded, the driving motor
M2 of the motor-generator set slows down, thus allowing the inertia of the
flywheel to supply a part of the overload.

• However, when the load is suddenly thrown off the main motor M1, then the
driving motor M2 speeds up, thereby again storing energy in the flywheel.
When the Ilger system is driven by means of an a.c. motor another refinement
in the form of a ‘slip regulator’ can be usefully employed, thus giving an
additional control.

14
DEMERITS
• Low overall efficiency especially at light loads

MERITS
• Wide range of speed control from maximum in one direction through zero
to the maximum in the opposite direction

• Giving smooth acceleration

VARIBLE RESISTOR IN SERIES WITH MOTOR:

• By increasing the variable resistor in series with the armature the voltage applied
across the armature terminals can be decreased.
• With reduced voltage across the armature, the speed is reduced.

• However, it will be noted that since full motor current passes through this
resistance, there is a considerable loss of power in it.

Fig 2.4: Resistance in series

15
 CHAPTER 03: PULSE WIDTH MODULATION (PWM)

WHAT IS PWM?

PWM is a common technique for speed control. Usually the PWM signal will be generated
using analog ICs and operates at low frequency. Hence the accuracy of this type of PWM
will be moderate. But here we use digital logic device to generate high frequency PWM
control signal, which is more accurate and gives very smooth and minute control.

HOW IT WORKS?

An oscillator is used to generate a triangle or sawtooth waveform (green line). At low

frequencies the motor speed tends to be jerky, at high frequencies the motor's inductance
becomes significant and power is lost. Frequencies of 30-200Hz are commonly used. A
potentiometer is used to set a steady reference voltage (blue line). A comparator compares
the sawtooth voltage with the reference voltage. When the sawtooth voltage rises above the
reference voltage, a power transistor is switched on. As it falls below the reference, it is
switched off. This gives a square wave output to the fan motor. If the potentiometer is
adjusted to give a high reference voltage (raising the blue line), the sawtooth never reaches
it, so output is zero. With a low reference, the comparator is always on, giving full power.
16
The higher the switching frequency, the more stable is the current waveform in the motors.
This waveform will be a spiky switching waveform at low frequencies, but at high
frequencies the inductance of the motor will smooth this out to an average DC current level
proportional to the PWM demand. This spikyness will cause greater power loss in the
resistances of the wires, IGBTs, and motor windings than a steady DC current waveform.

This on-off switching is performed by power IGBTs. A IGBTs (insulated gate bipolar
junction transistor) is a device that can turn very large currents on and off under the control
of a low signal level voltage. The time that it takes a motor to speed up and slow down
under switching conditions is dependent on the inertia of the rotor (basically how heavy it
is), and how much friction and load torque there is.

17
In the above diagrams, V is the voltage across the motor and t is time. By switching
quickly, we can create an average voltage across the motor. The speed of the motor can be
adjusted by changing the pulse-width ratio:

Pulse-Width Ratio = t(on) / t(period)

of the voltage applied across its terminals. The voltage across the output terminals will be

Vout = Vs x pulse width ratio

Where, Vs = supply voltage to the motor,

PWR = %duty cycle.

The maximum value of output voltage will be equal to the supply voltage and that can be
achieved when duty cycle will be 1.

One additional advantage of pulse width modulation is that the pulses reach the full supply
voltage and will produce more torque in a motor by being able to overcome the internal
motor resistances more easily. Finally, in a PWM circuit, common small potentiometers
may be used to control a wide variety of loads whereas large and expensive high power
variable resistors are needed for resistive controllers.

The main Disadvantages of PWM circuits are the added complexity and the possibility of
generating radio frequency interference (RFI). RFI may be minimized by locating the
controller near the load, using short leads, and in some cases, using additional filtering on
the power supply leads.
A good analogy is bicycle riding. You peddle (exert energy) and then coast (relax)
using your momentum to carry you forward. As you slow down (due to wind resistance,
friction, road shape) you peddle to speed up and then coast again. The duty cycle is the
ratio of peddling time to the total time (peddle + coast time). A 100% duty cycle means
you are peddling all the time, and 50% only half the time.

PWM for motor speed control works in a very similar way. Instead of peddling, your
motor is given a fixed voltage value (say +5 V) and starts spinning. The voltage is then
removed and the motor "coasts". By continuing this voltage on-off duty cycle, motor speed

18
is controlled. The concept of PWM inherently requires timing. The classic 555 timer chip
and some potentiometers can be used to generate PWM. The pots are manually adjusted
for the desired duty cycle.

EXAMPLE:-

The Pulse Width Modulation (PWM) is a method of controlling the amount of power to a
load without having to dissipate any power in the load driver. Imagine a 10W DC motor
load supplied from a battery. In this case the battery supplies 10W of power, and the motor
converts this 10W into mechanical energy. No power is lost anywhere else in the circuit. If
we wanted to reduce the speed, so it only absorbed 5W of power, we could place a resistor
in series, which absorbed 5W, then the DC motor could absorb the other 5W. This would
work, but the power dissipated in the resistor is not only makes it get very hot, but also
wastes power. The battery is still supplying 10W.

An alternative way is to switch the motor on and off very quickly (at higher
frequency), so that it is only on for half of the time. Then the average power taken by the
light bulb is still only 5W, and the average power supplied by the battery is only supplying
5W. If we wanted the bulb to take 6W, we could leave the switch on for a little longer than
the time it was off, then a little more average power will be delivered to the bulb. This on-
off switching is called PWM. The amount of power delivered to the load is proportional to
the percentage of time that the load is switched on.

19
 CHAPTER 04: WORKING OF PROJECT

Fig 4.1: Block diagram of project

20
Power supply is derived from step down transformer, rectifier, filter and regulator IC 7805
which gives 10 v dc regulated. Ne555 IC generates ramp signal which will act as carrier
frequency. This is buffered by operational amplifier IC lm358. DC voltage is controlled by
variable resistance this voltage is compared with ramp signal and PWM output is
generated. This is buffered by cd 4093 and given as driver to the IGBT IRg4ph30k. Bridge
rectifier gives dc output from ac line voltage. IRg4ph30k which use to control the dc
power as width of pulse change according to the pot variation.

4.1 PCB View of Motor Controller

21
Fig 4.2: PCB View of dc motor controller

4.2 Schematic Diagram of Project

22
Fig 4.3: Schematic diagram of project

4.3 Component Description

23
1) POWER SUPPLY: The function of this is to give power to different components.

Fig 4.4: Block diagram of power supply

The main function of transformer is to steps down high voltage ac mains to low voltage ac.
The supply is given through single phase ac supply which is fed to 230/12V step down
transformer. The low voltage ac output is suitable for lamps, heaters and special ac motors.
It is not suitable for electronic circuits unless they include a rectifier and a smoothing
capacitor.

The transformer used is further center-tapped which can be used to convert low voltage ac
to dc using two diodes. This process is known as rectification. The varying dc output is
suitable for lamps, heaters and standard motors. It is not suitable for electronic circuits
unless they include a smoothing capacitor.

24
 The output of the dc will be pulsating dc which can be made pure dc using by using
capacitor. This process is known as smoothing. The output at capacitor terminals will be
12V. The smooth dc output has a small ripple. It is suitable for most electronic circuits.

The 12V dc supply is given to regulator IC7805 whose function is to give constant output
of 5V and another 5V is provided from zener diode. Hence 10V is available at the output
terminals of 7805. This process is known as regulator. The regulated DC output is very
smooth with no ripple. It is suitable for all electronic circuits. The output 10V is used to
drive many ICs in the project.

2) RAMP GENERATOR: To generate any PWM we need to compare any two type
of signals or waveform, out of which one is ramp generator known as carrier frequency
which can be developed using 555 timer IC. In this 555 is used as an astable multivibrator
to generate ramp signal. The supply voltage given to IC is taken from the output voltage of
7805 IC. The output of the 555 is fed to IC named as LM358 which will act as op-amp and
thus generate the desired waveform.

25
3) COMPARATOR: The oscillator's ramp is internally connected to a comparator
which compares it to the speed control signal. The output of this comparator is the pwm
signal. The output waveform generated with the help of timer and op-amp that is ramp is
compared with the dc signal of constant amplitude LM393 will be used as comparator IC.
The dc signal is provided through the 10K variable port. Thus the output of comparator can
be easily varied from 0 to 10K. this indicates the variation of the speed of motor as the
variable port is varied from initial to final value. In this the initial value indicates the
minimum speed and as the port is varied the speed also changes. The output waveform is
buffered using CD4093 IC, one terminal is given to the transistor which check the input
current to any device. Depending upon the input current required by the device can be
adjusted using 10K variable port.
4) SWITCHING DEVICE: IGBT is used as switching device to control the speed of
dc motor depending on the turn on time of PWM. An IGBT combines the advantages of
BJTs and MOSFETs. The use of IGBT is due to its high input impedance like MOSFETs
and low on state conduction losses like BJTs. IGBT is connected with a current set limiter
which will limit the maximum input current to the device connected in the circuit for eg.,
the motor input current is 8A, thus by using the variable port we can easily adjust the
current limit.

4.4 Output waveform of PWM

26
The output waveform is taken on digital oscilloscope to show the variation with respect to
potentiometer and thus can easily be relate with the speed of motor. As the value of
potentiometer increases the turn on time increases which result in increase in duty cycle,
thus output voltage increases by the following equation:

Vout = Vs x pulse width ratio

Where, Vs = supply voltage to the motor,

Pulse-Width Ratio = t(on) / t(period)

PWR = %duty cycle.

The maximum value of output voltage will be equal to the supply voltage and that can be
achieved when duty cycle will be 1.

Table 4.1.: Observation table

SR NO. VALUE TURN ON TOTAL % DUTY FIG.
OF R (KΩ) TIME TIME (T) CYCLE
(TON) (µS) (µS) (TON/T) NO.
01. 2.8 24 108 0.22 4.5
02. 4.7 40 108 0.37
03. 6.2 66 108 0.61 4.6

27
Fig 4.5: output waveform when r = 2.8 kΩ

28
Fig 4.6.: output waveform when r = 6.2 kΩ

29
 CHAPTER 05: DATASHEETS OF DIFFERENT COMPONENTS

Manufacturers supply data sheets for the ICs they produce. Datasheet provide a
wealth of information:
1. Absolute maximum ratings
2. Intended applications
3. Electrical characteristics
4. Performance limitations
5. Pin diagrams
6. Equivalent circuits of the devices & more

The most use out of these data sheets , we must be able to interpret properly the
information presented in them. The lack of standardization of IC Specifications ,
which include package type designations, device nomenclature, pin configuration,
and ordering information, also make it imperative to refer to the datasheet.

30
 5.1 Timer IC-555

The 555 is an integrated circuit (chip) implementing a variety of timer and multivibrator
applications. The IC was designed and invented by Hans R. Camenzind. It was designed in 1970
and introduced in 1971 by Signetics (later acquired by Philips). The original name was the
SE555/NE555 and was called "The IC Time Machine". The 555 gets its name from the three 5-
kOhm resistors used in typical early implementations (Reference 1). It is still in wide use, thanks
to its ease of use, low price and good stability. As of 2003[update], 1 billion units are
manufactured every year.
The 555 timer is one of the most popular and versatile integrated circuits ever produced. It
includes 23 transistors, 2 diodes and 16 resistors on a silicon chip installed in an 8-pin mini dual-
in-line package (DIP-8). The 556 is a 14-pin DIP that combines two 555s on a single chip. The
558 is a 16-pin DIP that combines four slightly modified 555s on a single chip (DIS & THR are
connected internally, TR is falling edge sensitive instead of level sensitive). Also available are
ultra-low power versions of the 555 such as the 7555 and TLC555. The 7555 requires slightly
different wiring using fewer external components and less power.
The 555 has three operating modes:
Monostable mode:
In this mode, the 555 functions as a "one-shot". Applications include timers, missing pulse
detection, bouncefree switches, touch switches, Frequency Divider,Capacitance Measurement,
Pulse Width Modulation (PWM) etc
Astable/ Free Running mode: :
In this mode 555 can operate as an oscillator. Uses include LED and lamp flashers, pulse
generation, logic clocks, tone generation, security alarms, pulse position modulation, etc.
Bistable mode or Schmitt trigger:
In this mode 555 can operate as a flip-flop, if the DIS pin is not connected and no capacitor is
used. Uses include bouncefree latched switches, etc.

31
32
33
34
35
36
 5.2 IRG4PH30K

37
38
39
40
41
42
 5.3 78XX Series

43
44
45
46
47
48
49
50
51
52
53
 5.4 CD4093

54
55
56
57
58
59
 5.5 LM393

60
61
62
63
 5.6 LM358

64
65
66
67
68
69
70
71
 BIBLIOGRAPHY

• Google
• Lecturers of electical department
• Friends to give their views about the project
• www.alldatasheets.com
• www.adhsproject.wetpaint.com
• www.electronics-lab.com
• Power electronics-circuits, devices, and application, 3rded. By Muhammad h.
Rashid
• E-book on a textbook on electrical technology (vol.2)

72
 CONCLUSION

In this method of PWM the output voltage generated always depends on the duty cycle
which means by varying the turn on time of the dc pulse. This variation of pulse can be
done using the variable port connected in the circuit. The use of PWM also reduces the loss
of power during the turn on and turn off time of dc motor which is advantageous which
results in increase of overall efficiency.
Thus by changing the value of port in the circuit, we get the required output and
finally control the speed of DC motor. This project can be used for various other
application.

73