Controlling a Brushed DC Motor with a BLDC Motor Controller: Impossible or Affordable?

Can We Control a Brushed DC Motor with a BLDC Motor Controller?

Introduction to Motor Controllers

The quest to control a brushed DC motor with a three-phase BLDC motor controller can be a common query among hobbyists and professionals alike. However, the reality is that these two types of controllers are designed for different motors and typically do not work interchangeably. This article aims to clarify the feasibility and practicality of such an endeavor.

Understanding Brushed and Brushless DC Motors

A brushed DC motor (also known as a commutator motor) has a mechanical commutator, which switches the current direction in the rotor windings. A brushless DC motor (BLDC) uses a sensor-based electronic commutator to control the current

Why a BLDC Motor Controller Can't Control a Brushed DC Motor

No Hall Sensors: A typical BLDC motor controller requires Hall sensors to determine the rotor position. These sensors are not present in a brushed motor, making the controller unable to function correctly. No Commutation Needed: A brushed motor’s commutator already handles the switching of the current, so additional electronics would be redundant and often unnecessary. Cost and Complexity: For a brushed motor, a simple H-bridge driver and a microcontroller can control the speed and direction more efficiently and at a lower cost.

Blending Compatibility: Brushed DC Motor Control Without a BLDC Controller

If the goal is to control a brushed DC motor, a cost-effective solution would be an H-bridge motor controller driver paired with a microcontroller. This setup can be considerably cheaper and more straightforward than using a BLDC controller. Here are some advantages:

Cost-Efficiency: Using an H-bridge and microcontroller is often more affordable than a BLDC controller, which can be quite expensive. Flexibility: An H-bridge setup offers more flexibility in terms of controlling various motors and can be easily customized for specific needs. Reliability: The simplicity and robust design of H-bridge controllers can lead to better reliability over time.

Conclusion

While it is technically not feasible to directly control a brushed DC motor using a BLDC motor controller, there are affordable and efficient alternatives. An H-bridge and microcontroller setup is a practical solution that can provide reliable and cost-effective control of a brushed DC motor. This approach not only aligns with the core principles of motor control but also offers a more appropriate solution for the application.