Simple Two Speed Contactor DC Motor Controller


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The simplest of all motor controllers (besides a straight on/off switch) is the contactor controller. I designed this contactor controller for use in my electric scooter project. It is based around three 12V relays, two 12V batteries, two switches and of course a motor. Having no silicon to "fry", it is quite reliable and robust. A contactor controller works by rearranging the two (or more) supply batteries between series and parallel. This gives the motor a slow speed (batteries in parallel, current adds) and a fast speed (batteries in series, voltage adds). This assures that both batteries are discharged equally. When the circuit is "at rest", the batteries are connected in parallel, which allows easy recharging.

Schematic

This is the schematic of the contactor motor controller

Parts

Part
Total Qty.
Description
Substitutions
K1, K2, K3312V 30A SPDT Relay (See Notes)
S1, S22SPST Switch or Button
B1, B2212V Battery (See Notes)
M1112V or 24V Motor (See Notes)
MISC1Case, Wire, etc.

Notes

  1. S1 closes K3 and thus causes M1 to operate. S2 activates K1 and K2, reconfiguring the batteries for series operation and thus causes M1 to operate at "fast" speed.
  2. B1 and B2 should be chosen based on the current requirements of M1. Often, sealed lead-acid type batteries are available at local suppliers for surprisingly low prices. These batteries are ideal for things such as scooters, go-karts, etc.
  3. The relays are standard automotive type relays, available cheaply from any auto parts store.
  4. Your motor will depend on your requirements. 12V motors will normally run fine at 24V, and vice versa.
  5. You will notice that in series mode, all three relays only pull power from B2. This is because the relays have 12V coils, and it is impossible to switch the batteries from series to parallel and keep power to the coils at the same time. This does, however, mean that B2 is discharged slighty before B1. This should normally not be an issue unless the batteries are being drained completely "dead". Draining a battery dead is not good for it in any situation, and should be avoided. If you wish, you can use a small 12V battery to run the relays separately.
  6. You can add two more speeds to this controller using the schematic below. It connects at points A and B shown above on the controller schematic.

    Adding more speeds

    K1 is simply another of the same relay as used in the controller. S1 is another switch. R1 needs to be chosen based on your motor, but it will be of low value (under 10 Ohm) and high wattage (normally at least 100W). It must be capable of handling the full current drawn by the motor. This is not exactly an efficient way to limit current to the motor as excess current is dissipated as heat by the resistor, so it is normally only used for a "starter" speed.

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Comments

anonymous Tommi
Simple Two Speed Contactor DC Motor Controller
Sunday, October 14, 2007 8:13:27 PM
Thank you for your time in this presentation of a simple controller, greatly appriciated, will gather thses parts and test out.
rakesh r makwananymous
solution for make low watts in contorller in electric bike
Sunday, September 09, 2007 5:03:22 AM
hi , dear, i need solution for make out put watts low, can it posible in my recent controller of my electric bike ? my cotroller right now is 250w for use of 48 v battery. right now i need solution of want low output watts from controller with loading one person. i hope reply me promptly.
shittu oluwole johnson
Building of feedback motor
Saturday, August 04, 2007 3:53:15 PM
I've been trying for the past couples of days now to build a simple 12V DC motor using FDN and PFN circuit but is not working out because anytime i apply the power; it just scooting on without any control and if their is any barrier on the way it will be put to stop instead of getting power from the feedback circuit.Is their anything i could do to make it work properly.
bala_udhaya
Simple Two Speed Contactor DC Motor Controller
Sunday, July 29, 2007 1:36:08 AM
the cost of this circuit ?..
senthilkumar
dc motor used in bike(low volt high speed with high ampere
Friday, July 20, 2007 8:18:10 AM
hi, i need the details of the dc series motor used in motor bike (for electric bike).
cosmas c.
Simple Two Speed Contactor DC Motor Controller
Thursday, July 19, 2007 4:32:39 AM
can i get that of AC motors
Steve
Simple Two Speed Contactor DC Motor Controller
Sunday, July 15, 2007 12:40:54 AM
Two graduate projects and one project "to the faculty"...wow...is there a way to chip these people so they can be tracked? I don't want to buy anything from the companies they end up working for.
Firdausnonymous
DC motor speed control using PIC microcontroller
Wednesday, June 13, 2007 9:16:16 PM
Hello.. I need articles and circuit diagram with source code for "DC motor speed control using PIC microcontroller" for my graduate project.. I am waiting for your reply.. Thank you..
Nick
Simple Two Speed Contactor DC Motor Controller
Wednesday, June 13, 2007 8:07:03 AM
Can anyone show me how to make a one speed motor into a two speed motor? I have a 7.5 HP Pool pump but i need only half the amount of horse power. 7.5 is too much. It runs on 220 Volts. Thanks
Alan Jackson
Simple Two Speed Contactor DC Motor Controller
Tuesday, May 29, 2007 12:04:55 AM
I have been hunting for a controller circuit that I can build and this is it. I have a stern wheel paddle boat I built that runs on 12vdc and so far it has been running wide open both in forward and reverse. Obviuosly this is hard on the drive train. The second circuit is what I need as I run two seperate motors. (one for each side as the paddles are split for stearing purposes along with the rudder) They draw 8-12 amps under load so the 30 amp relays are plenty enough. I will let you know how it turns out.
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