A DC motor controller is a special type of electrical device that converts electrical energy into mechanical energy. DC motors use DC electricity to receive electrical energy and then convert this energy into automatic rotation of the motor. DC motors are almost everywhere. They use the magnetic field generated by the electric current to drive the rotor fixed to the output shaft. Speed and output torque depend on motor design and electrical input.

　　How does a DC motor controller work?

　　DC motors vary in power and size and can be used in electric hoists, elevators, electric cars and toys. A DC motor consists of two basic parts: the armature and the stator. The stator is the stationary part of the motor and the armature is the rotating part. In addition to using coils, a DC motor uses a set of stationary magnets in the stator through which current flows in the circuit, creating an aligned electromagnetic field. One or more coil windings of insulated wire are wrapped around the iron core of the motor to concentrate the magnetic field. The windings of the insulated wire are connected to a rotary electrical switch (commutator) that continues to apply current to the coil windings. A rotary electrical switch allows each armature coil to be energized, producing torque or a steady rotational force. When the coils are opened and closed sequentially, a magnetic field is created that interacts with different areas of the stationary magnet, creating torque. These basic working principles allow DC motors to convert electrical energy from DC electricity to mechanical energy that can be used to facilitate equipment, all through rotational motion.

　　Who Invented the DC Motor Controller?

　　The DC motor is an excellent electrical device that has completely changed people's lives in many different ways, but who is the inventor of the DC motor? Like all other innovations, many have made a difference by developing other devices. Thomas in Davenport, USA, where he was the inventor of the first electric motor. In 1837, Davenport was the first to file a patent for a usable motor. Davenport wasn't the first to build a motor in this way, however, as other inventors in Europe had earlier developed more powerful motors. He credits Davenport as the original inventor because he filed a patent early. In 1834, Jacobi Moritz had already proposed a higher power motor than Davenport's (three times as powerful). A year later, SibrandusStratingh and Christopher Becker showed the motor in action.

　　Types of DC Motor Controllers and DC Motor Controls

　　Brushless DC Motor

　　It is also known as a synchronous DC motor or an electronically commutated motor. The main difference between these motors is the lack of a commutator, replaced by a servo that can detect and adjust the angle of the rotor. Brushless DC motors are robust, durable and safe.

　　Brushed DC Motor

　　These are the earliest DC motors, dating back to the original design of the motor. While they are still popular in paper machines, cranes and rolling mills, they have been slowly disappearing recently.

　　Parallel DC Motor

　　This is a brush motor with the field winding in parallel with the armature. Due to their low current flow due to the parallel windings, parallel motors find many uses in a variety of applications requiring constant torque. Mixers, conveyors and cranes rely the most on them.

　　Series DC Motors

　　These are the ultimate varieties. The series field winding distinguishes it from a parallel motor, which means that the armature current does flow faster through the field winding. Series DC motors are ideal for high starting torque tasks.

　　Here are the most commonly used methods when it comes to DC motor control:

　　Direction controller: H-bridge

　　H-bridge circuits are one of the easiest ways to control a DC motor. Four pairs of control switches can be found in this motor. When either of the two pairs is turned off, they immediately complete the circuit and then power the motors. The H-bridge can also control the speed.

　　Speed Controller: Pulse Width Modulation (PWM)

　　The PWM circuit changes the speed of the motor by simulating the increase or decrease of the power supply. PWM is easy to apply and low cost, and it is one aspect of continuously controlling the speed of the motor. These controllers work by sending periodic pulses to the motor. When using the coil inductance of regular pulses with a certain restrained smoothing effect, the motor is like being powered by high or low voltage.

　　Armature Controller: Variable Resistor

　　This is another way to affect the speed of a DC motor, where the current entering through the armature or field coil changes. When the coil current changes, so does the speed of the output shaft, and the variable resistor can change the current, increasing the speed.

　　What to Know When Buying a DC Motor

　　Before buying a DC motor, we need to consider some basic things. Here are some key factors: the higher the energy, the higher the torque, the energy keeps the net current flowing in one direction, and check the DC motor pull recommended in the instruction manual. The current powers the motor, and too much current is dangerous because it can damage the motor. Before using a DC motor controller, make sure you know its operating and blocking currents. Speed is a bit complicated in terms of motors, motors operate efficiently at high speeds, but if gearing is required, this cannot be achieved, adding gears does not limit the efficiency of the motor. Therefore, reducing torque and speed also needs to be considered.

　　Why choose a DC motor?

　　When you have the option to use an AC motor, a DC motor is highly recommended as the first choice. Compared with AC motors, DC motors have certain advantages. They are excellent, for example, when high starting torque is required to drive high inertia loads. Unlike AC motors, they are easy to control the speed of DC motors.

　　They are also ideal when DC motors need to be powered from a low voltage DC source such as solar panels or batteries. If you reverse direction quickly, you'll find that a DC motor works great. Unlike AC motors, DC motors can be started and stopped easily and quickly.

　　Fields of application of DC motor controllers

　　There are all kinds of DC motors on the market now, we use them widely, and at home, DC motors can be used in toys, tools and other household appliances. In industry, their needs range from running across carousels to conveyor belts and reversing. The DC motor powers the pump based on its excellent motion responsiveness and ease of shifting. They are the first choice for fans due to their energy saving mechanism. DC motor toys come in a variety of voltages and therefore require different types of movement and speed. DC motors for electric vehicles are preferred because of their durability and energy efficiency. Both the rear and front wheels of the e-bike are equipped with DC motors to achieve the required power level and torque.