working principles of motor control

Posted on Feb 7, 2014

After dismantling chinese copy of segway I wanted to check how the controller is made. After a couple of hours of work with multimeter, pen, a sheet of paper and Kicad I came up with a block diagram and schematic of motor controller. This motor controller is made in a cheap and a very simple way. Reverse engineering and analysing this unit is a ve

working principles of motor control
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ry good way to learn the basics of motor control. Here are some pictures of dismantled motor controller: Motor controller consists of three parts - motor controller board, motor direction control board and main power relay. You can see those parts in the first picture (main power relay was removed, thus there is empty space between boards). Main power relay and motor direction control board were fixed to the botton of the box by double sided duct tape. Motor controller board was fixed properly. PCB was pushed in the grooves of the walls of a box. Power transistors were fixed by a metal plate which was screwed to the wall. Because this controller had burned, I changed power mosfets and had to modify this part a little bit. Originally there were two mosfets and one freewheeling diode in TO-220 case. I did not have appropriate diodes by hand, so I replaced it with two mosfets. Original metal mounting plate was too short to hold four TO-220 devices. I had to make a longer aluminium plate and drill one extra hole to fix it properly to the wall (picture 2). As it is visible from the third picture, there were some modifications (at the bottom part of the board) done after the board was manufactured. One modification, voltage delay circuit (transistor, electrolytic capacitor and resistor in picture 4) was made by assemblers of this device, and the other (blue multi-turn potentiometer) was made by me - it allows to change...

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