Zikodrive Motor Controllers - stepper motor drivers, brushless ESCs, bldc motor drivers, stepper motor controllers

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Zikodrive Motor Controllers - stepper motor drivers, brushless ESCs, bldc motor drivers, stepper motor controllers

+44 (0) 333 123 7130

Zikodrive Motor Controllers is a trading name of Round Bank Engineering ltd. Registed Company Number 08288866. VAT Number: GB226504428

Can I replace a brushed DC motor with a stepper motor and controller?



REPLACING BRUSHED DC MOTORS WITH STEPPER MOTORS - THE QUICK ANSWER


Yes but you must be careful to make sure that the specifications of the original motor you have and the new motor and controller you install match. If in doubt at all you can CONTACT US to discuss your application.


AN EMERGING TREND IN THE MOTION CONTROL INDUSTRY


Many companies are increasingly replacing DC motors with brushless DC motors and brushless motor controllers in a wide range of systems.


You can find out more about this by reading our article on replacing brushed DC motors with brushless motors.


However, swapping DC motors to stepper motors and controllers is less common. That said, as with lots of things in life and in engineering, just because something is not common, does not necessarily make it a bad idea. There are a number of specific applications in which replacing a brushed DC system, (particularly a geared DC system) with a stepper motor and controller can be a very sensible choice.


WHY SHOULD I REPLACE A BRUSHED DC MOTOR WITH A STEPPER MOTOR?


The simple benefits of doing so are that you will improve the lifespan of the system you have (stepper motors only have bearings as parts that can wear out as opposed to brushes).


Stepper motors also improve the range of performance options available (they can turn a fixed number of degrees easily).


Stepper motors can also be used to increase the


REPLACING GEARED DC MOTORS WITH STEPPER MOTORS AND CONTROLLERS IN DOSING APPLICATIONS


What is more common is to replace geared brushed DC motors with a stepper motor in applications such as pumps, lab equipment and similar applications where positional accuracy can be improved vastly by using a stepper motor and stepper motor controller.


Many applications were addressed in years gone by by using a geared DC motor and timing as a means of dosing and measuring - however developments in stepper motor controller technology such as on the ZD4 Stepper Motor Controller means that huge advances have been made in the accuracy, flexibility and performance of suhc systems.


Of equal importance, the cost of such technology has dropped considerably in recent years, making advanced performance options affordable to a broad range of applications.


Whereas 10 or 20 years ago a programmable stepper motor controller would have cost a fortune, these days it is much less.


The result of this trend is that many people and companies have started to look at replacing geared brushed DC motors with stepper motor controllers as a means of improving the performance of the system and also as a way of adding more features.


DON’T FORGET TO DO YOUR HOMEWORK


The key to making the transition between the two units successful is making sure you know the performance characteristics and key specifications of the motor that you are wanting to replace and then being able to make an appropriate match with a stepper motor and controller. If you are not sure how to find out the performance characteristics of the motor (and gearbox) that you have you can start with the part number of the motor and research that. Key characteristics to look for are max and nominal RPM and torque.


Once you have these details you then need to source an appropriate stepper motor with the right performance characteristics. Don’t forget to check the torque speed curve of the motor to make sure it will deliver the torque you need at the speed you want (if you are not sure about this you can find out more about this by reading our guide to understanding torque speed curves). If you have any questions at all about implementing this system then you can always CONTACT US and talk to one of our engineers about your specific project or application.


WHAT NEXT?


If you have an existing project where you are looking to replace a DC motor with a stepper motor and controller you could start by having a look at our main STEPPER MOTOR page. This page has links to case studies, applications, stepper motors with controllers and much more…


If you have any questions about anything that you have read above please feel free to CONTACT US to discuss.

Return to FAQsTech Support Forum

Why not start by browsing some of the stepper motor and stepper motor driver packages that we have and see what simple alternatives to brushed Dc motors are out there. If there is nothing that looks to meet your needs we can put a custom package together which will deliver exacting performance and value for money.

Stepper Motors & DriversContact UsStepper motors with integrated stepper motor drivers and controllers - NEMA 17 and NEMA 23

Frequently Asked Questions

Can I replace a DC motor with a brushless DC motor and controller?

How fast can a stepper motor go?

How complex can the programming on the Zikodrive stock range of motor controllers be?

Can sensorless brushless motor controllers be used in dosing applications?

Can a sensorless brushless motor be started efficiently under load?

Can I purchase the IP rights to a bespoke designed controller?

Do you offer on site support and assistance setting up a new controller?

What are the typical costs associated with modifying an existing stock stepper motor controller or brushless motor driver?

Can I run a motor at a fixed speed under a variable or changing load?


Contact us to discuss your DC replacement system today