DC Motors Information

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DC motors are electric motors that are powered by direct current (DC), such as
from a battery or DC power supply. Their commutation can be brushed or
brushless. The speed of a brushed DC motor can be controlled by changing the
voltage alone. By contrast, an AC motor is powered by alternating current (AC)
which is defined by both a voltage and a frequency. Consequently, motors that
are powered by AC require a change in frequency to change speed, involving
more complex and costly speed control. This makes DC motors better suited for
equipment ranging from 12VDC systems in automobiles to conveyor motors, both
which require fine speed control for a range of speeds above and below the rated
speeds.

When selecting DC motors, industrial buyers need to identify the key performance
specifications, determine design and size requirements, and consider the
environmental requirements of their application. This selection guide is designed
to help with this process.

Performance Specifications

Speed, torque, and operating voltage are the most important performance
parameters for DC motors. Supplier datasheets list these specifications as
numerical values.

Application Requirements
 Buyers should compare what's listed on a DC motor's datasheet to their own
application requirements. Because the motor's output parameters are
interdependent, a GlobalSpec user may define one or two specifications. The
other specifications depend upon these selections.

 Shaft speed: A DC motor applies a voltage (V) to rotate a shaft at a

proportional rotational speed (ω). Shaft speed specs generally refer to the
no-load speed, which is the maximum speed the motor can reach when no
torque is applied. Typically, shaft speed is given in rotations or revolutions per
minute (rpm). These rotations or revolutions can be related to the number of
radians to express the motor speed in radians per second (rad/s). For
numerical calculations, this unit of rotational speed is more convenient. The
following formula describes the relationship between radians per second and
rotations or revolutions per minute.

ωrad/s = ωrpm · (2π/60)

For an ideal DC motor, the rotational speed is proportional to the supplied voltage,
or
ω=j·V
where j is the constant of proportionality, with units rad/(s-V).

Design Tip: For optimal continuous performance, DC motors typically operate

at 70-90% of its no-load speed.

 Output torque: Shaft rotation generates a rotational force called torque (τ)
in the motor. This is the load the motor can generate or handle. Torque is
given in force-distance units (lb-ft, oz-in, N-m, etc.). Torque specs generally
refer to the stall torque and the continuous torque. Stall torque is the τ at which
the shaft speed is zero, or the motor stalls. Continuous torque is the maximum
τ at normal running conditions. Note that the torque (τ) of a DC motor is
proportional to the armature current (I), and the constant of proportionality is
the torque constant (k). The following equation describes the relationships
between torque and current.
τ=k·I
or
I = τ/k
The importance of the torque constant is evident from the above equation. For a
given torque, a high value of k limits the current to a low value. This is a measure
of efficiency, since lower current consumption means lower power (heat)
dissipation. The torque constant and the torque produced by the rotor allow us to
calculate the current through the armature, which is used to calculate temperature
ratings (as shown later).

Design Tip: DC micromotors generally operate at 10-30% of their stall torque

(the torque at which the shaft speed is zero or the motor stalls). Motors that are

subjected continuously to higher loads are more prone to mechanical failure or

heat-related degradation.
 Figure 1 - This graph illustrates the relationship between torque and speed,
indicating highest (stall) torque at 0 speed and highest (no-load) speed at 0
torque.

 Available voltage: DC motors may be designed to operate at a specified

voltage if only a small or specific range of power supplies is available. The
specified voltage determines the motor's rated speed. Generally, voltage is
given in volts (V).
Derived Specifications

DC motor datasheets also contain parameters that are derived from or related to
the essential requirements.

 Output power: A regular and important specification, the rated output

power (PO) is the product of the motor's rated torque and speed. In equation
form, the output power is given by
PO = τ · ω
Maximum output power occurs at 50% of the no-load speed and 50% of the stall
torqueMany suppliers specify the output power in terms of horsepower (hp). To
convert a calculated value of power from units of watts (W) to units of hp, divide
the power in watts by 746.

Design Tip: The motor's rated power should be at least twice the required
(calculated) power. This ensures sufficient power for the operation so that the
motor is not overworked.

 Power dissipation: The current produced in a DC motor

dissipates power (Pdis) and heats the motor. Total power dissipation is related
to total system resistance (RT), which is the resistance of the entire motor
system including friction losses in the stator (Rstator) and rotor (Rrotor). The
motor's current allows us to calculate the power dissipation and, in turn, the
increase in rotor temperature (ΔT) due to the rotation. From ΔT, the total
 motor temperature (TM) is calculated by adding the environmental
temperature (Tenv). The following equations illustrate the steps used to
calculate the final motor temperature

Pdis = I2RT
RT = Rrotor + Rstator (except for permanent magnet motors)
ΔT = Pdis(Rtot)
TM = Tenv + ΔT

Design Tip: To extend product life and performance, select a motor with a larger
difference between maximum operating temperature and total motor
temperature. A rule of thumb is that for every 10°C that the motor temperature
exceeds its rated temperature, insulation life is reduced by half. For every 10°C
cooler, insulation life is doubled.

Motor Construction

The suitability of a DC motor for an application also depends on its construction,

another aspect of the selection process.

Types of DC Motors

There are several different types of DC motors, each of which offers advantages

based upon the motor construction.

 Shunt wound motors exhibit minimum speed variation through load range
and can be configured for constant horsepower over an adjustable speed
range. They are used for applications where precise control of speed and
torque are required.
 Figure 2 - Typical torque speed curve for a shunt wound motor, with
relatively constant torque over a large speed range. Graph Credit: Baldor
Electric Company

 Series wound motors exhibit high starting torques for permanently attached
loads which are required to prevent damage from high speed conditions.
These motors develop a large torque and can be operated at low speeds.
They are best suited for heavy industrial applications that require heavy loads
to move slowly and lighter loads to move quickly.

Figure 3 - Typical torque speed curve for series wound motors, with high
torque at low speed.
Graph Credit: Baldor Electric Company

 Compound wound motors are designed with both series and shunt winding
for constant-speed applications requiring higher torque. They are often used
where the primary load requirement is a heavy starting torque, and adjustable
speed is not required. Applications include elevators, hoists, and industrial
shop equipment.
 Figure 4 - Typical torque speed for compound wound motors, combining
characteristics of shunt wound and series wound. Graph Credit: Baldor
Electric Company

 Permanent magnet motors have a magnet permanently embedded into the

assembly and no wound field. They offer constant speed with varying load
(zero slip) and excellent starting torque. Compared to wound types,
permanent magnet construction provides higher efficiency but less speed
regulation.

Figure 5 - Typical speed curve for permanent magnet motors, with linear
torque-speed proportionality.
Graph Credit: Baldor Electric Company

 Disc armature motors, also called "pancake" or "printed armature" motors,

use flat rotors driven by an axially-aligned magnetic field. Their thin
construction allows for low inertia, resulting in high acceleration. These motors
are good for applications requiring a quick startup and shutdown while bearing
a constant load, such as in an electric vehicle.
 Coreless and slotless motors incorporate cylindrical winding that is
physically outside of a set of permanent magnets. Because the winding is
laminated and excludes an iron cage, these designs have much lower inertia.
They boast high acceleration, high efficiency, excellent speed control, and
little to no vibration. They are commonly used as servomotors for process
control applications.
Commutation

DC motor commutation can be either brushed or brushless, both of which offer

specific advantages.

 Brushed motors use contact brushes that connect with the commutator to
alter current direction. Brushed construction is less costly than brushless, and
control of brushed motors is simple and inexpensive. Brushed motors require
periodic maintenance to replace worn out brushes, but can operate in extreme
environments due to their lack of electronics.

 Brushless motors use a permanent magnet embedded in the rotor

assembly. They may use one or more Hall Effect devices to sense rotor
position, and the associated drive electronics control the shaft rotation
(speed). Brushless motors are similar to AC motors, but are electronically
commutated (ESM) so that they can be powered by DC. Brushless
commutation is more efficient, requires less maintenance, generates less
noise, and has a higher power density and speed range than brushed
commutation. However, the electronics of brushless motors generally
contribute to their higher capital cost, complexity, and environmental
limitations.
Sizing and Environmental Considerations

When selecting DC motors, buyers should also consider the design area and
environmental factors.

Sizing Considerations
 If a DC motor must fit a space or meet a weight requirement, then physical
characteristics may be important selection factors. Shaft configuration and
incorporated gearing are also important considerations.

 Shaft configuration determines how the motor is mounted and connected to

the system it powers. Shaft selection is essential for system compatibility.
Optimum selection boosts effectiveness and can save time and cost during
assembly. Configurations may include concave, round, square, hexagonal,
splined, grooved, stepped, and screw types.

 Gearing is used in motors to increase or reduce shaft speed. It tends to

decrease motor volume or weight. The types of gears that are used in DC
motors may include spur, planetary, harmonic, worm, or bevel gears.
Environmental Considerations

Finally, buyers of DC motors may need to consider environmental conditions or

application requirements when sourcing products.

 Operating temperature should be considered when using sensitive

electronic equipment, when the environment is not at the standard 40°C, or
when the environment may be sensitive to a motor's heat dissipation. Additive
cooling mechanisms can be installed to counteract excessive heating of the
motor or the surrounding environment.

 Corrosion protection should be considered in environments where the

motor is exposed to radiation, dust, or hazardous substances that could
degrade the motor. Proper motor enclosure and materials can be selected to
ensure protection against contamination.

 Water protection should be considered when a motor must operate while

exposed to water. Protection levels range from protection against minimal
vertical dripping to full submersion under pressure.