The speed controllers from FAULHABER are developed specifically for optimum operation of our DC-motors and BLDC-motors. Matched to the drives, they are characterized by their compact design and easy operation. They enable precise as well as efficient speed control that is optimally suited to the application.
In the context of electric motors, the term "speed control" refers to the regulation of rotational speed. A speed controller is a control unit used to change the speed of a motor as required or, with varying load, to maintain the speed constantly at a predefined value.
The three most important elements of a motor speed controller are the processor, the control electronics and the output stage. From the specified set-point and the data of the feedback channel, the microprocessor calculates the control variable used to reach the appropriate speed. The control electronics process the relevant signals; the output stage is responsible for supplying power to the motor.
The speed controllers from FAULHABER have separate I/O inputs and outputs. An analog input is used for specifying the speed via pulse width modulation (PWM) or via an analog voltage value. A digital switching input allows selection of the direction of rotation; a digital output can be programmed either as a frequency output or a fault output.
With most devices, the power supply for the electronics can be separated from that of the motor. The speed controllers are available with or without housing. Devices with housing are connected using screw terminals; the unhoused variants are plugged directly into a master board. Using a USB programming adapter, it is possible to configure the operating mode, the controller parameters as well as the type and scaling of the set-point specification.
The speed controller specifies the set-point, i.e. the desired speed of the motor. This is done by changing the power supply voltage (analog value) or by means of pulse width modulation (PWM).
At the same time, the motor speed controller receives the actual speed, which is influenced by the load of the application and by other variables, via the feedback channel and adapts speed control to the current conditions. Depending on the motor variant, the actual motor speed is determined using a connected sensor system or, if there are no sensors, from the motor current.
A separate switching input is provided for switching the direction of rotation. The frequency output is used for reading out the speed signal. Speed control appropriate for the application can be set up easily on a computer using the free software FAULHABER Motion Manager.
Speed controllers from FAULHABER determine the temperature of the motor winding from the motor load characteristic. With continuous operation in the limit range, the current is limited to the permissible continuous current in order to prevent overloading. In the case of dynamically varying operation, a 2-times higher peak current is temporarily available. In the case of frequent reversing operation with large connected masses, it is recommended to use a motion controller.
The performance data of the speed controller (voltage and current) must always match the connected motor. Further criteria are size, compatibility with the ambient conditions as well as the available EMC filters to ensure electromagnetic compatibility within the application. The FAULHABER product range for speed control in combination with the offered accessories means that a device matching the motor and application is available in practically all cases.
Motor speed controllers from FAULHABER are designed for actuating the following drive combinations: DC-motors with and without incremental encoders, brushless motors with analog or digital Hall sensors, brushless motors with AES absolute encoders as well as brushless motors with digital Hall sensors and incremental encoders. Depending on the size and delivery state, different motor and sensor combinations can be operated with the speed controller. The different sizes and flexible connection options open up many potential uses for most applications in which the motors are used.
In the configuration for brushless motors with hall sensors, the motors are operated with speed control, whereby the signals from the Hall sensors are used for commutation and determination of the actual speed for the Speed Controllers.
In this combination of BL motor and speed controller, no hall sensors are used. Instead, the back-EMF of the motor is used for commutation and speed control.
This configuration of the Speed Controllers can only be selected in combination with the appropriate hardware. In this configuration, the encoder outputs an absolute position. This is used for commutation as well as for speed control. Due to the high resolution of the encoder, (absolute encoders) can achieve low speeds in this mode.
In this configuration, the motors, in combination with a speed controller, are operated speed-controlled and offer the additional brake and enable inputs. Through these inputs easier connection of the control to e.g. PLCs or safety circuits is possible.
In the configuration, consisting of DC motors with encoder and Speed Controller, the motors are operated with speed control by means of an incremental encoder. The incremental encoder is needed here as an actual value encoder for speed control.
In a DC motors configuration without encoder, the speed-controlled motors are operated without a sensor with the use of a Speed Controller. Depending on the given load condition, either the back electromotive force (EMF) or IxR compensation is used for speed actual value acquisition. Matching to the respective motor type is required for this type of speed control.
