Selecting Motors and Motor Controllers

We have extensive experience in selecting COTS motors and motor controllers for a wide range of applications. If you have an open task to add a motor to your system, or would like to improve the efficiency of your system, we can help with:

• Specifying motor requirements such as torque, speed, power, voltage. This includes whether the motor will operate in one direction or must reverse direction, and if it must be capable of regenerating energy.

• Determining the optimal motor feedback approach for your application such as hall sensors, encoders/resolvers, or sensorless motor control. Factors include the environment where the motor and controller will be operated, the distance required between the motor and controller, the speed the motor will operate, and if a homing method is required.

• Determining the optimal control strategy for the motor whether it be torque, speed, or position control modes. This is based on the operating requirements. Often multiple control modes will be needed.

• Selecting and sourcing a COTS motor and motor controller for your application. The motor needs to meet your requirements with a safety factor, without being too large or too expensive for your project. The motor may require a gearbox to provide the required speed or torque. The controller must provide both the desired control method for your application but also the required voltage and current.

• For applications that require control or feedback of position, a homing strategy will be developed based on the motor technology, position feedback method, and controller capabilities. Homing is the process of telling the motor controller where the starting position of the motor is. This could include the recommendation for using homing switches, or absolute encoders that do not require homing.

• Selecting and implementing a communication interface between your system and the motor controller. Common options include analog/digital commands, UART, CAN, and Ethercat.

• Assisting with motor and motor controller tuning, which is the process of setting control parameters to enable efficient and safe operation of the motor in all operating modes.

• Assisting with integrating the motor and motor controller into simulations, whether it be PSICE level, Simulink, or physics based simulators such as Gazebo.

Example systems we’ve used recently:

ClearPath Motor with Integrated Controller

Elmo Gold Drum 360

ODrive Dual Shaft Motor

UQM PowerPhase HD-220 Inverter and Motor

Copley Xenus XPL-230-36