Birla Institute of Technology & Science, Pilani

Work Integrated Learning Program

Lab Manual: Fundamentals of

Mechatronic Actuators
Using the Quanser Mechatronic Actuators Board for NI ELVIS III
Section 3: DC Motor Design Considerations

3.1 Theory and Background

Common Specifications

When selecting a DC motor, there are several pieces of specification data which will be
of particular interest. Figure 3-1 shows an excerpt from the datasheet for the RF-
370CHV brushed DC motor on the Mechatronic Actuators board.

Figure 3-1: Brushed DC motor specifications

This is a fairly standard set of specifications for a motor, and is more complete than you
will find on several data sheets. For comparison, Figure 3-1 shows the same data from
the datasheet for the BLWR092S-24V brushless DC motor on the board.

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 Figure 3-2: Brushless DC motor specifications

Key information which should be provided for any DC motor will be:
1. Rated voltage
2. Max torque
3. Max speed
4. Max current

There will also be mechanical information about the motor, usually in the form of a
mechanical drawing like that shown in Figure 3-3. This information is important for
deciding if a motor will physically fit in a required space, or mount effectively.

Figure 3-3: Motor mechanical drawing

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There may also be electromechanical specifications which may be important for the
specific type of motor, examples of this include the coil wiring and hall-effect sensor
specifications for the brushless DC motor shown in Figure 3-4.

Figure 3-4: Additional brushless DC motor specifications

Major Design Criteria

Given the specification data discussed above, there are several design criteria which
will likely be important for deciding whether or not a motor is appropriate for your
application.

Rated Voltage
This is the voltage at which the motor is designed to run, and at which the motor will
have been tested for other specifications. If the motor voltage is significantly greater
than that of the power supply driving it, the system will be unable to produce the rated
torque. If the supply voltage exceeds the rated voltage, there is risk of damage to the
motor hardware.

Peak/Stall Current
This is the current which the motor will draw when exerting maximum torque, that is,
when the motor is stalled. This is important, since a peak current which exceeds the
rated current of the power supply may cause damage to the supply.

Rated/Max Torque
Most applications will have a torque requirement either to supply a required acceleration
or to overcome resistance in the mechanical system, such as friction. If the required

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torque exceeds the rated torque for the motor, there is risk of overheating the motor
during operation. If the peak torque of the motor is insufficient, the motor will stall.

Motor Speed
In many cases, the rated no-load maximum speed of the motor will be less useful than
the torque-speed curve. An example plot for the brushless DC motor on the board is
shown in Figure 3-5.

Figure 3-5: Torque-speed curve plot for a brushless DC motor

This plot shows the maximum speed the motor is capable of achieving under a given
torque load. If the desired speed lies under the curve at the required load torque, then
the motor will be capable of meeting the required performance.

Common Design Decisions

Cost
Cost will often be the principal driver in a design. The final cost of a motor will depend
on a large number of variables, including volume of production and the location of the

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manufacturer. However, in general, brushed DC motors have an advantage as they
have fewer components. The lack of hall-effect sensors and the simpler coil wiring
means that if cost is the principal design limitation, then brushless DC motors will likely
not be applicable.

Efficiency
The efficiency of a motor is the ratio of the electrical power supplied to the motor (1 watt
= 1 volt * 1 amp) to the mechanical power supplied by the motor (1 watt = 1 Nm * 1
rad/s). This relationship is likely non-linear, however, the efficiency of a motor at a given
speed and torque can usually be inferred from the torque-speed plot like that shown in
Figure 3-5. Since this plot shows the current draw and the test is at a constant voltage,
all the information required to calculate the motor efficiency is available. However, if one
is looking for a general rule, brushless DC motors do not have to overcome the friction
caused by the brushes and as such are usually slightly more efficient.

Ease of Use
This is harder to quantify based on technical documentation, however, the overriding
factor in ease of use for DC motors is the complexity of the motor control circuitry. Due
to the complex excitation signals required to drive a brushless DC motor, the brushed
motor will almost always be easier to use. In some cases, this gap can be narrowed
through the use of an off-the-shelf brushless DC motor driver; however, this will have an
effect on the overall cost of the solution.

Lifespan
The lifespan of the motor will often be given in the datasheet either in term of hours of
operation or number of rotations. Generally, because brushes are subject to friction
wear, the lifespan of a brushed DC motor will almost always be less than that of a
comparable brushless DC motor.

Power-to-Weight Ratio
This is the other factor where the complexity of the brushless DC motor is offset.
Because there is more flexibility in the design of the rotor/stator combination for the
brushless DC motor, they generally achieve greater power for a similar weight and size
than the brushed DC motor.

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3.2 Analyze

3-1 Would you use a brushed DC motor to build a 3D printer? Explain.

3-2 How would you choose whether to use a brushed vs. brushless DC motor to build a
Quadcopter? Which motor would you choose?

3-3 How would you choose whether to use a brushed vs. brushless DC motor to build a
cordless drill? Which motor would you choose?

3-4 You are designing a Robot Arm. What are your main design considerations?

3-5 You are designing an RC car. What are your main design considerations?