Collector speed regulator with feedback. Speed ​​controller for commutator motor: design and DIY production. How to make a homemade engine speed controller

65 rub.

Description:

More details:

The module is a small board with all the necessary elements for wiring and built on a microcircuit TDA1085c. A necessary condition for connection is the presence of a tachometer (tachogenerator), which allows you to provide feedback from the electric motor to the microcircuit. When the engine is loaded, the speed begins to drop, which is detected by the tachometer, which commands the microcircuit to increase the voltage and vice versa, when the load weakens, the voltage to the engine drops. Thus, this design allows maintain constant power commutator motor when the rotor speed changes.

The The module is well suited to the electric motor from washing machine machine. In combination of two devices, you can easily make it yourself: Wood lathe, Milling machine, Honey extractor, Lawn mower, Potter's wheel, Wood splitter, Emery, Drilling machine, Feed cutter and other devices where rotation of mechanisms is necessary.

There is an option for capacitor power supply:

The cost of this board 55.00 BYN.

Connection

To connect the commutator motor to the control board, you mustUnderstand the pinout of wires. A standard commutator motor has 3 groups of contacts: tachometer, brushes and stator winding. Rarely, there may also be a 4th group of thermal protection contacts (the wires are usually white).

Tachometer: located at the rear of the engine with wires coming out (smaller in cross-section than the others). The wires can be probed with a multimeter and may have a slight resistance.

Brushes: the wires communicate with each other and the engine commutator.

Winding: Wires have 2 or 3 terminals (with a middle point). The wires communicate with each other.

When connecting the commutator motor to a 220 Volt network:

We short-circuit one end of the brush and winding wires (or put a jumper in the terminal block), connect the other end of the wires to a 220V network. The direction of rotation of the motor will depend on which of the winding wires will be connected to the 220V network. If you need to change the direction of movement of the motor, place a jumper on another pair of winding-brush wires.

When connecting a brushed motor to the speed controller board:

We connect the wires with which the engine was connected to the 220V network to the terminal " M". To terminal " Taho" connect the tachometer. To terminal "L N" connect the mains power 220 Volts. Polarity doesn't matter.

The kit includes a switch (terminal S.A.). If a switch is not needed, install a jumper.

Settings

The board provides 3 types of settings:

Setting the speed smoothness;

Setting up the tachometer;

Setting the speed control range.

For operational reliability and correct setup, it is recommended to perform the setup in the following sequence:

1) Nadjusting the speed smoothness R1, which is responsible for the smooth speed of the commutator engine.

2) Setting up the tachometer performed by a trimming resistor R3, which allows you to eliminate jerking and jerking in engine operation when adjusting the rotation speed.

3) Setting the speed control range performed by a trimming resistor R2. The setting allows you to limit or increase the minimum speed of the commutator motor, even with the potentiometer turned down to the minimum.

Reverse connection

To connect the reverse switch, you need to remove the jumper in the motor (winding and brushes). The wires in the switch are separated by three pairs of wires, one of which has tinned ends. The pair with tinned ends is connected to terminal M. The remaining two pairs are connected to the winding and brushes. Which pair will be connected to the winding or brushes does not matter. The polarity of the connection does not matter.

A pair of wires for connecting to the engine tach sensor is green or black.

The reverse switch is not included in the standard package of the board and must be purchased separately.

Scheme for connecting the reverse to the board:

Board is customized and tested before sale!

Specifications

Contents of delivery

Power regulator board for TDA1085 - 1 pc.

Potentiometer with knob - 1 pc.

Switch - 1 pc.

Packaging with instructions - 1 pc.

Additional equipment

Set of wires with terminals - 5 pcs. +4 rub.

Reverse switch with wires on terminals - 1 set. +8 RUR

Installing the board into the case with all switches and wires (only connect to the motor) +35 rub.

Advantages:

1. The transformer power circuit ensures safe and reliable operation.
2. Before sale, all boards are configured and tested in operation.
3. The board's compact size allows it to be installed in any case.
4. High-quality installation of radio elements.
5. A factory-made board with a mask will provide protection from dust and corrosion.

Download description of the speed controller on the chip TDA1085CG

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A high-quality and reliable rotation speed controller for single-phase commutator electric motors can be made using common parts in literally 1 evening. This circuit has a built-in overload detection module, provides a soft start of the controlled motor and a motor rotation speed stabilizer. This unit operates with voltages of both 220 and 110 volts.

Regulator technical parameters

• Supply voltage: 230 volts AC
• regulation range: 5…99%
• load voltage: 230 V / 12 A (2.5 kW with radiator)
• maximum power without radiator 300 W
• low noise level
• speed stabilization
• soft start
• board dimensions: 50×60 mm

Schematic diagram

The control system module circuit is based on a PWM pulse generator and a motor control triac - a classic circuit design for such devices. Elements D1 and R1 ensure that the supply voltage is limited to a value that is safe for powering the generator microcircuit. Capacitor C1 is responsible for filtering the supply voltage. Elements R3, R5 and P1 are a voltage divider with the ability to regulate it, which is used to set the amount of power supplied to the load. Thanks to the use of resistor R2, which is directly included in the input circuit to the m/s phase, the internal units are synchronized with the VT139 triac.

The following figure shows the arrangement of elements on a printed circuit board. During installation and startup, attention should be paid to ensuring safe operating conditions - the regulator is powered by a 220V network and its elements are directly connected to the phase.

Increasing regulator power

In the test version, a BT138/800 triac with a maximum current of 12 A was used, which makes it possible to control a load of more than 2 kW. If you need to control even larger load currents, we recommend installing the thyristor outside the board on a large heatsink. You should also remember about making the right choice fuse FUSE depending on the load.

In addition to controlling the speed of electric motors, you can use the circuit to adjust the brightness of lamps without any modifications.

The regulator circuit, which is used to change the speed of rotation of the engine or fan, is designed to operate from an alternating current network at a voltage of 220 volts.

The motor, together with the power thyristor VS2, is connected to the diagonal of the diode bridge VD3, and the other receives mains voltage AC 220 volts. In addition, this thyristor carries out control with sufficiently wide pulses, due to which short circuit breaks, with which all commutator motors operate, do not affect the stable operation of the circuit.

The first thyristor is controlled by transistor VT1, connected according to a pulse generator circuit. As soon as the voltage on the capacitor becomes sufficient to open the first transistor, a positive pulse will be sent to the control terminal of the thyristor. The thyristor will open and now a long control pulse will appear on the second thyristor. And from it the voltage, which actually affects the speed, goes to the engine.

The rotational speed of the electric motor is adjusted by variable resistance R1. Since the second thyristor is connected to the circuit inductive load, then spontaneous opening of the thyristor is possible, even in the absence of a control signal. Therefore, to block this, a diode VD2 is included in the circuit, which is connected in parallel to the L1 winding of the motor.

When setting up the engine speed controller circuit, it is advisable to use one, which can be used to measure the rotational speed of the electric motor, or a regular pointer voltmeter for alternating current, which is connected in parallel with the engine.

By selecting resistance R3, the voltage range is set from 90 to 220 volts. If the engine does not operate correctly at minimum speed, then it is necessary to reduce the value of resistor R2.

This circuit is well suited for adjusting fan speed depending on temperature.

It is used as a sensitive element. As a result of its heating, its resistance decreases, and therefore at the output operational amplifier, on the contrary, the voltage increases and controls the fan speed through a field-effect transistor.

With variable resistance P1, you can set the lowest fan rotation speed at the lowest temperature, and with variable resistance P2, you can control the highest rotation speed at maximum temperature.

IN normal conditions We set resistor P1 to the minimum engine speed. Then the sensor is heated and the desired fan speed is set with resistance P2.

The circuit controls the fan speed depending on the temperature readings, using a conventional negative temperature coefficient.

The circuit is so simple that there are only three radio components: adjustable stabilizer voltage LM317T and two resistances forming a voltage divider. One of the resistances is a negative TCR thermistor, and the other is a regular resistor. To simplify assembly, drawing printed circuit board I quote below.

In order to save money, you can equip a standard angle grinder with a speed controller. Such a regulator for grinding housings of various electronic equipment is an indispensable tool in the arsenal of a radio amateur.

The U2008B microcircuit is a PWM speed controller for commutator electric motors AC voltage. Manufactured by TELEFUNKEN, it can most often be seen in the control circuit of an electric drill, step saw, jigsaw, etc., and also works with motors from vacuum cleaners, allowing you to adjust the traction. The built-in soft start circuit significantly extends the life of the engines. Control circuits based on this chip can also be used to regulate power, for example, heaters.

All modern drills are produced with engine speed regulators built into them, but for sure, in the arsenal of every radio amateur there is an old Soviet drill, in which the change in speed was not intended, which sharply reduces the performance characteristics.

You can regulate the rotation speed of an asynchronous brushless motor by adjusting the frequency of the AC supply voltage. This scheme allows you to adjust the rotation speed in a fairly wide range - from 1000 to 4000 rpm.

Another review on the topic of all sorts of things for homemade products. This time I'll talk about digital controller rpm The thing is interesting in its own way, but I wanted more.
For those interested, read on :)

Having on the farm some low-voltage devices such as a small grinder, etc. I wanted to increase their functional and aesthetic appearance a little. True, it didn’t work out, although I still hope to achieve my goal, perhaps another time, but I’ll tell you about the little thing itself today.
The manufacturer of this regulator is Maitech, or rather this name is often found on all sorts of scarves and blocks for homemade products, although for some reason I did not come across the website of this company.

Due to the fact that I didn’t end up doing what I wanted, the review will be shorter than usual, but I’ll start, as always, with how it is sold and sent.
The envelope contained a regular zip-lock bag.

The kit includes only a regulator with a variable resistor and a button, there is no hard packaging or instructions, but everything arrived intact and without damage.

There is a sticker on the back that replaces the instructions. In principle, nothing more is required for such a device.
The operating voltage range is 6-30 Volts and the maximum current is 8 Amps.

The appearance is quite good, dark “glass”, dark gray plastic of the case, when turned off it seems completely black. By appearance cool, nothing to complain about. Shipping film was glued to the front.
Installation dimensions of the device:
Length 72mm (minimum hole in case 75mm), width 40mm, depth excluding front panel 23mm (with front panel 24mm).
Front panel dimensions:
Length 42.5, mm width 80mm

A variable resistor is included with the handle; the handle is certainly rough, but it’s fine for use.
The resistor resistance is 100KOhm, the adjustment dependence is linear.
As it turned out later, 100KOhm resistance gives a glitch. When powered from a switching power supply, it is impossible to set stable readings, the interference on the wires to the variable resistor affects, which is why the readings jump +\- 2 digits, but it would be fine if they jumped, and at the same time the engine speed jumps.
The resistance of the resistor is high, the current is small and the wires collect all the noise around.
When powered from a linear power supply, this problem is completely absent.
The length of the wires to the resistor and button is about 180mm.

Button, well, nothing special here. Contacts are normally open, installation diameter 16mm, length 24mm, no backlight.
The button turns off the engine.
Those. When power is applied, the indicator turns on, the engine starts, pressing the button turns it off, a second press turns it on again.
When the engine is turned off, the indicator also does not light up.

Under the cover there is a device board.
The terminals contain power supply and motor connection contacts.
The positive contacts of the connector are connected together, the power switch switches the negative wire of the engine.
The connection of the variable resistor and the button is detachable.
Everything looks neat. The capacitor leads are a little crooked, but I think that can be forgiven :)

I will hide further disassembly under a spoiler.

More details

The indicator is quite large, the height of the digit is 14mm.
Board dimensions 69x37mm.

The board is assembled neatly, there are traces of flux near the indicator contacts, but overall the board is clean.
The board contains: a diode for protection against polarity reversal, a 5 Volt stabilizer, a microcontroller, a 470 uF 35 Volt capacitor, power elements under a small radiator.
Places for installing additional connectors are also visible, their purpose is unclear.

I sketched out a small block diagram, just for a rough understanding of what is switched and how it is connected. The variable resistor is connected with one leg to 5 Volts, the other to the ground. therefore, it can be safely replaced with a lower denomination. The diagram does not show connections to an unsoldered connector.

The device uses a microcontroller manufactured by STMicroelectronics.
As far as I know, this microcontroller is used in quite a lot of different devices, such as ampere-voltmeters.

The power stabilizer heats up when operating at maximum input voltage, but not very much.

Part of the heat from the power elements is transferred to the copper polygons of the board, visible on the left a large number of transitions from one side of the board to the other, which helps dissipate heat.
Heat is also removed using a small radiator, which is pressed to the power elements from above. This placement of the radiator seems somewhat questionable to me, since heat is dissipated through the plastic of the case and such a radiator does not help much.
There is no paste between the power elements and the radiator, I recommend removing the radiator and coating it with paste, at least a little bit will improve.

A transistor is used in the power section, the channel resistance is 3.3 mOhm, the maximum current is 161 Amps, but the maximum voltage is only 30 Volts, so I would recommend limiting the input at 25-27 Volts. When operating at near-maximum currents, there is slight heating.
There is also a diode nearby that dampens current surges from the motor’s self-induction.
10 Amperes, 45 Volts are used here. There are no questions about the diode.

First start. It so happened that I carried out the tests even before removing the protective film, which is why it is still there in these photos.
The indicator is contrasty, moderately bright, and perfectly readable.

At first I decided to try it on small loads and received the first disappointment.
No, I have no complaints against the manufacturer or the store, I just hoped that such a relatively expensive device would have stabilization of engine speed.
Alas, this is just an adjustable PWM, the indicator displays % fill from 0 to 100%.
The regulator didn’t even notice the small motor, it’s a completely ridiculous load current :)

Attentive readers probably noticed the cross-section of the wires with which I connected the power to the regulator.
Yes, then I decided to approach the issue more globally and connected a more powerful engine.
Of course he's noticeable more powerful than the regulator, but at idle its current is about 5 Amperes, which made it possible to test the regulator in modes closer to the maximum.
The regulator behaved perfectly, by the way, I forgot to point out that when turned on, the regulator smoothly increases the PWM filling from zero to the set value, ensuring smooth acceleration, while the indicator immediately shows the set value, and not like on frequency drives, where the real current one is displayed.
The regulator did not fail, it warmed up a little, but not critically.

Since the regulator is pulse, I decided, just for fun, to poke around with an oscilloscope and see what happens at the gate of the power transistor in different modes.
The PWM operating frequency is about 15 KHz and does not change during operation. The engine starts at approximately 10% fill.

Initially, I planned to install a regulator in my old (most likely ancient) power supply for a small power tool (more on that another time). In theory, it should have been installed instead of the front panel, and the speed controller should have been located on the back; I didn’t plan to install a button (fortunately, when turned on, the device immediately goes into on mode).
It had to turn out beautiful and neat.

But then some disappointment awaited me.
1. Although the indicator was slightly smaller in size than the front panel insert, the worse thing was that it did not fit in depth, resting against the racks for connecting the halves of the case.
and even if the plastic of the indicator housing could have been cut off, I wouldn’t have done it anyway, since the regulator board was in the way.
2. But even if I had solved the first question, there was a second problem: I completely forgot how my power supply was made. The fact is that the regulator breaks the minus power supply, and further along the circuit I have a relay for reverse, turning on and forcing the engine to stop, and a control circuit for all this. And remaking them turned out to be much more complicated :(

If the regulator were with speed stabilization, then I would still get confused and redo the control and reverse circuit, or remake the regulator for + power switching. Otherwise, I can and will redo it, but without enthusiasm and now I don’t know when.
Maybe someone is interested, a photo of the insides of my power supply, it was assembled like this about 13-15 years ago, it worked almost all the time without problems, once I had to replace the relay.

Summary.
pros
The device is fully operational.
Neat appearance.
High quality build
The kit includes everything you need.

Minuses.
Incorrect operation from switching power supplies.
Power transistor without voltage reserve
With such modest functionality, the price is too high (but everything is relative here).

My opinion. If you close your eyes to the price of the device, then in itself it is quite good, it looks neat and works fine. Yes, there is a problem of not very good noise immunity, I think it’s not difficult to solve, but it’s a little frustrating. In addition, I recommend not to exceed the input voltage above 25-27 Volts.
What’s more frustrating is that I’ve looked quite a lot at options for all sorts of ready-made regulators, but nowhere do they offer a solution with speed stabilization. Perhaps someone will ask why I need this. I’ll explain how I came across a grinding machine with stabilization; it’s much more pleasant to work with than a regular one.

That's all, I hope it was interesting :)

The product was provided for writing a review by the store. The review was published in accordance with clause 18 of the Site Rules.

I'm planning to buy +23 Add to favorites I liked the review +38 +64

Many types of work on processing wood, metal or other types of materials require no high speeds, and good traction. It would be more correct to say - the moment. It is thanks to him that the planned work can be completed efficiently and with minimal power losses. For this purpose, motors are used as a driving device. direct current(or collector), in which the supply voltage is rectified by the unit itself. Then, to achieve the required performance characteristics, it is necessary to adjust the speed of the commutator motor without loss of power.

Features of speed control

It is important to know, what each engine consumes when rotating not only active, but also reactive power. In this case, the level of reactive power will be higher, which is due to the nature of the load. In this case, the task of designing devices for regulating the rotation speed of commutator motors is to reduce the difference between the active and reactive power. Therefore, such converters will be quite complex, and it is not easy to make them yourself.

You can construct only some semblance of a regulator with your own hands, but there is no point in talking about saving power. What is power? In electrical terms, it is the current drawn multiplied by the voltage. The result will give a certain value that includes active and reactive components. To isolate only the active one, that is, to reduce losses to zero, it is necessary to change the nature of the load to active. Only semiconductor resistors have these characteristics.

Hence, it is necessary to replace the inductance with a resistor, but this is impossible, because the engine will turn into something else and obviously will not set anything in motion. The goal of lossless regulation is to maintain torque, not power: it will still change. Only a converter can cope with such a task, which will control the speed by changing the duration of the opening pulse of thyristors or power transistors.

Generalized controller circuit

An example of a controller that implements the principle of controlling a motor without power loss is a thyristor converter. These are proportional integral circuits with feedback that provide strict regulation characteristics, ranging from acceleration and braking to reverse. The most effective is pulse-phase control: the repetition rate of the unlocking pulses is synchronized with the network frequency. This allows you to maintain torque without increasing losses in the reactive component. The generalized diagram can be represented in several blocks:

• power controlled rectifier;
• rectifier control unit or pulse-phase control circuit;
• tachogenerator feedback;
• current control unit in the motor windings.

Before delving into a more precise device and principle of regulation, it is necessary to decide on the type of commutator motor. The control scheme for its performance characteristics will depend on this.

Types of commutator motors

At least two types of commutator motors are known. The first includes devices with an armature and an excitation winding on the stator. The second includes devices with an armature and permanent magnets. It is also necessary to decide, for what purpose is it necessary to design a regulator:

Motor design

Structurally, the engine from the Indesit washing machine is simple, but when designing a controller to control its speed, it is necessary to take into account the parameters. Motors may have different characteristics, which is why the control will also change. The operating mode is also taken into account, which will determine the design of the converter. Structurally, the commutator motor consists from the following components:

• An armature, it has a winding laid in the grooves of the core.
• Collector, a mechanical rectifier of alternating mains voltage, through which it is transmitted to the winding.
• Stator with field winding. It is necessary to create a permanent magnetic field, in which the anchor will rotate.

When the current in the motor circuit, connected according to the standard circuit, increases, the field winding is connected in series with the armature. With this inclusion, we also increase the magnetic field acting on the armature, which allows us to achieve linearity of characteristics. If the field remains unchanged, then it will be more difficult to obtain good dynamics, not to mention large power losses. Such engines are best used on low speeds, since they are more convenient to control at small discrete movements.

By organizing separate control of the excitation and armature, it is possible to achieve high positioning accuracy of the motor shaft, but the control circuit will then become significantly more complicated. Therefore, we will take a closer look at the controller, which allows you to change the rotation speed from 0 to the maximum value, but without positioning. This might come in handy, if a full-fledged drilling machine with the ability to cut threads will be made from a washing machine engine.

Scheme selection

Having found out all the conditions under which the motor will be used, you can begin to manufacture a speed controller for the commutator motor. You should start by choosing a suitable scheme that will provide you with all the necessary characteristics and capabilities. You should remember them:

• Speed ​​regulation from 0 to maximum.
• Providing good torque at low speeds.
• Smooth speed control.

Looking at many schemes on the Internet, we can conclude that few people are creating such “units”. This is due to the complexity of the control principle, since it is necessary to organize the regulation of many parameters. Thyristor opening angle, control pulse duration, acceleration-deceleration time, torque rise rate. These functions are handled by a circuit on the controller that performs complex integral calculations and transformations. Let's consider one of the schemes that is popular among self-taught craftsmen or those who simply want to put it to good use. old engine from the washing machine.

All our criteria are met by the circuit for controlling the rotation speed of a commutator motor, assembled on specialized chip TDA 1085. This is a completely ready driver for controlling motors that allow you to adjust the speed from 0 to the maximum value, maintaining torque through the use of a tachogenerator.

Design Features

The microcircuit is equipped with everything necessary for high-quality engine control in various speed modes, from braking to acceleration and rotation with maximum speed. Therefore, its use greatly simplifies the design, while simultaneously doing all universal drive, since you can choose any speed with a constant torque on the shaft and use it not only as a drive for a conveyor belt or drilling machine, but also for moving the table.

The characteristics of the microcircuit can be found on the official website. We will indicate the main features that will be required to construct the converter. These include: an integrated frequency-to-voltage conversion circuit, an acceleration generator, a device soft start, Tacho signal processing unit, current limiting module, etc. As you can see, the circuit is equipped with a number of protections that will ensure stable operation of the regulator in different modes.

The figure below shows a typical circuit diagram for connecting a microcircuit.

The scheme is simple, so it is quite reproducible with your own hands. There are some features that include limit values ​​and speed control method:

If you need to organize a motor reverse, then for this you will have to supplement the circuit with a starter that will switch the direction of the excitation winding. You will also need a zero speed control circuit to give permission for reverse. Not shown in the picture.

Control principle

When the rotation speed of the motor shaft is set by a resistor in output circuit 5, a sequence of pulses is formed at the output to unlock the triac by a certain angle. The speed of rotation is monitored by a tachogenerator, which occurs in digital format. The driver converts the received pulses into an analog voltage, which is why the shaft speed is stabilized at a single value, regardless of the load. If the voltage from the tachogenerator changes, the internal regulator will increase the level of the output control signal of the triac, which will lead to an increase in speed.

The microcircuit can control two linear accelerations, allowing you to achieve the dynamics required from the engine. One of them is installed on the Ramp 6 pin of the circuit. This regulator is used by washing machine manufacturers themselves, so it has all the advantages to be used for domestic purposes. This is ensured by the presence of the following blocks:

Usage similar scheme provides full control of the commutator motor in any mode. Thanks to forced acceleration control, it is possible to achieve the required acceleration speed to a given rotation speed. Such a regulator can be used for all modern washing machine motors used for other purposes.