1.

INTRODUCTION

Generally, a motor is directly connected to battery. But there is no regulation of voltage

and current. To control the speed of the motor, we have to change the battery voltage. However,
in many applications changing the batter voltage is impractical.

So our project uses a regulator circuit to regulate the voltage supply to the motor. So, now
to change the speed of the motor, only a potentiometer needs to changed. No need to change the
battery voltage itself.

Also, generally the current handling capacity of a motor controller is very less. In our
project, the current rating of the regulator is 30 Amps which is very high. Hence the circuit can
be used to drive a large number of motors safely ie without the fear of burnout of components.

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 2. HOW IT WORKS

In the circuit VR1 is used as voltage divider to drive Q7. This Q7 drives Q1 to Q6 transistor. As
VR1 is turned clockwise the voltage increases on the base of Q7. Transistor Q7 will increases the
voltage on the base of Q1 to Q6. As the base voltage to Q1 to Q7 transistor increases, the voltage
supplied to the motor also increases because Q1, Q2, Q3 and Q4 are connected in parallel. 1
ohm resistors are placed on the output of the 3055s to make an attempt to balance the load
between them. The 12 volt regulator is used to supply a constant 12 volts to the fan when using
voltage above 12.

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 3. COMPONENTS

3.1 Transistor:

In this circuit we require high power handling

transistors. So we are using MJE3055T. The
MJE3055T is a silicon epitaxial-base NPN transistor.
It is intended for power switching circuits and general-
purpose amplifiers. The complementary PNP type is
MJE2955T.

Features of MJEXX55T:
Power Dissipation – PD = 75W @ Tc = 250C
DC Current Gain hFE = 20~100 @ Ic = 4.0A
VCE (sat) = 1.1(Max.) @ IC = 4.0A, IB = 400mA

I project, we are using transistor for heavy load.

Due to which heat dissipation is more. So it is necessary
to attach heat sink.

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3.2 Heat Sink
A heat sink is a term for a component
or assembly that transfers heat generated
within a solid material to a fluid medium,
such as air or a liquid. There are various type
of package available. A heat sink uses its
extended surfaces to increase the surface
area in contact with the cooling fluid, the air
for example. The term is not meant literally,
as a heat sink does not have a "magical
ability to absorb heat like a sponge and send
it off to a parallel universe. Heat transfer theory helps explain practical aspects of how heat sinks
work, and can also help to clear up common misconceptions and design mistakes. Approach air
velocity, choice of material, fin (or other protrusion) design and surface treatment are some of
the design factors which influence the thermal resistance, i.e. thermal performance, of a heat
sink.
In our project we are using a basic clip type heat sink used for transistor. Image shown below is
of clip type transistor.

The most common heat sink material is aluminium. Chemically pure aluminium is not
used in the manufacture of heat sink, but rather aluminium alloys. Aluminium alloy 1050A has
one of the higher thermal conductivity values at 229 W/m•K. However, it is not recommended
for machining, since it is relatively soft material. Aluminium alloys 6061 and 6063 are the more
commonly used aluminium alloys, with thermal conductivity values of 166 and 201 W/m•K,
respectively. The aforementioned values are dependent on the temper of the alloy.
Copper is also used since it has around twice the conductivity of aluminium, but is three times as
heavy as aluminium. Copper is also around four to six times more expensive as aluminium.

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3.3 Voltage regulator:

In this project we require fan for cooling of heat sink feted to

transistor. So we require fix regulated voltage source to run fan. This
work is done buy L7800 voltage regulator ic. The L7800 series of
three-terminal positive regulators is available in TO-220, TO-220FP,
TO-3 and D2PAK packages and several fixed output voltages,
making it useful in a wide range of applications. These regulators can
provide local
on-card regulation, eliminating the distribution problems associated
with single point regulation. Each type employs internal current
limiting, thermal shut-down and safe area protection, making it
essentially indestructible. If adequate heat sinking is provided, they
can deliver over 1A output current. Although designed primarily as
fixed voltage regulators, these devices can be used with external
components to obtain adjustable voltage and currents.

Features of L7800 voltage regulator:

 OUTPUT CURRENT TO 1.5A
 OUTPUT VOLTAGES OF 5; 5.2; 6; 8; 8.5;
9;12; 15; 18; 24V
 THERMAL OVERLOAD PROTECTION
 SHORT CIRCUIT PROTECTION
 OUTPUT TRANSITION SOA
PROTECTION

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4. PCB LAYOUT

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 5. CONCLUSION
Generally, DC motors are controlled by simple circuits using a Potentiometer. These circuits
waste a lot of power. Also the torque of the motor is low at lower speeds. To avoid this problem
transistor are used, which control voltage across motor resulting in to speed control. As transistor
is used in parallel to control voltage, no loading effect will occur. Hence circuit can be used up to
30Amps of load.

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 6. FUTURE DEVELOPMENTS

 Circuit can be interfaced with analog to digital converter to display regulator voltage
 \As per requirement no of parallel y connected transistors can be increased for higher
load value.

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REFERENCE

Websites
http://www.discovercircuits.com/M/motor-cont.htm
http://www.zen22142.zen.co.uk/Circuits/Power/1230psu.htm
http://en.wikipedia.org/wiki/Dc_motor
http://en.wikipedia.org/wiki/Motor_controller#Adjustable-speed_drives
http://www.scienceprog.com/control-motor-pwm-schematic/

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