ECEA 5341 Motors and Motor Control Circuits

2nd course in the Embedding Sensors and Motors Specialization.

Instructors: Jay Mendelson, MSME, Lecturer​ & James Zweighaft, MSME

Note: This specialization requires purchase of a hardware kit in order to apply your knowledge and skill with real world tools. The hardware will be used to complete the lab exercises across the four courses of this specialization. Please allow adequate time to receive the hardware. It is highly suggested that you receive the hardware by the end of the first week of the session.

Prior knowledge needed: ECEA 5340 Sensors and Sensor Circuit Design.

Learning Outcomes

  • Understand how to specify the proper AC or DC motor for a machine design.
  • Integrate the motor to a machine, based on analysis of motor equations for voltage, current, torque and speed.
  • Implement the motor and accompanying rotary sensor into a motor control circuit in both hardware and software.
  • Add a motor and motor control circuit into a microprocessor based development kit.
  • Create hardware and firmware to process motor feedback data to a microprocessor for further evaluation.

Syllabus

Duration: 5 hours

In module 1 you will learn principles of operation of AC induction motors, both single and 3-phase types. You well then learn how to interpret data from torque speed curves, and how to optimize data in these curves based on electrical resistance, inductance, and capacitance. Then you will learn about different types of single phase motors, featuring a video analysis of a split phase motor used in a clothing dryer. You will also learn about typical applications for single phase motors, which will assist you in picking the right one for an application.

Duration: 6 hours

In module 2 you will learn the details of AC motor specifications and enclosures, as well as how these details are governed by national and international design standards. Then you will learn a detailed methodology for researching design requirements for AC motors, and how to use these requirements to pick the right motor for your needs. Afterwards, you will have lessons on AC motor control components and systems, both manual and automatic. This will culminate in training for you on AC variable speed drives.

Duration: 6 hours

In module 3 you will learn principles of DC motors, traditional brushed motors, as well as electronically driven brushless motors. We will discuss shunt wound, series wound, compound wound, servo, stepper, and torque motors, with a detailed explanation of how commutation and control are implemented in these designs. We will have a lab exercise for you on DC motor speed measurement. We will have another video analysis for you, this time featuring teardown of a paper shredder. Then you will learn a detailed methodology for researching design requirements for DC motors, and how to use these requirements to pick the right motor for your needs.

Week 4 | 6 hours

In module 4 you will start off with another lab exercise, this time gaining hands-on experience with DC motor control. Then we will illustrate a simplified stepper motor drive, so you will understand the basic principles involved in stepper motor control. Next, you will do a deep dive into stepper motor specs, operation, and commercial driver chips and packages. You will then do another lab exercise, this time on actuating a rotary sensor. We end the module with a comparison of DC vs. AC motors, so you take away a core understanding of their pros and cons.

Duration: 13 hours

In this module you will perform your lab work for the course. There will be two labs.

Duration: 2 hours

Final Exam for this course.

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Grading

Assignment
Percentage of Grade
Assignment for Week 1: AC Motor Designs12.5%
Week 1: Quiz 1.25%
Assignment for Week 2: AC Motor Control12.5%
Week 2: Quiz1.25%
Assignment for Week 3: DC Motors12.5%
Week 3: Quiz1.25%
Assignment for Week 4: Stepper Motors12.5%
Week 4: Quiz1.25%
Week 5: Course Project 12.5%
Week 5: Course Project 22.5%
Week 5: Final Exam40%

Letter Grade Rubric

Letter Grade 
Minimum Percentage
A90%
B80%
C70%
D60%
F50%

Component List

You will need to buy the following components to do the two-course projects based on the videos in this module. Note that if you have already purchased the PSOC 5LP PROTOTYPING KIT, you do not need to buy it again. These parts may be purchased off the Digikey website at www.digikey.com. Or, you may obtain the specs from the site, and purchase them elsewhere.

These are the part numbers for the lab on Motor Voltage and Current Measurement. You can copy and paste them into the search engine on the Digikey website. You need one of each except for the AA batteries (N107-ND), which you would need 3.

  • 428-3390-ND
  • 942-PPN7PA12C1-ND
  • IRLU120NPBF-ND
  • N107-ND
  • 1N5393-E3/54GICT-ND
  • RNF14FTD1K00CT-ND
  • P0.62W-1BK-ND

Additionally, for the lab on rotary sensors, you will need one of these. You can copy and paste them into the search engine on the Digikey web site.

  • 987-1188-ND