Search Results (219)

This paper presents a bench-top occupational power-assist robot aimed at reducing biomechanical effort during repetitive material handling. The prototype adopts a SCARA-like structure with three degrees of freedom and provides assistance on the vertical (z) axis through a three-phase brushless DC (BLDC) motor driven in field-oriented control with inner-loop current regulation. The user interacts with the robot through a single handle-mounted load cell. The measured interaction force is converted, via a calibration-based mapping, into a motor current reference that enforces a prescribed force-sharing ratio. In this way, the drive’s embedded current loop acts as the low-level torque regulator, and the system can share gravitational and inertial loads without additional environment force sensing or explicit high-level impedance/admittance dynamics. A coupled electro-mechanical model is derived and used to select the assistance gain and to verify feasibility in simulation. A pilot experimental campaign with eight participants and two payloads (0.5 kg and 1.5 kg) was carried out on sinusoidal and random tracking tasks. With assistance enabled, the operator contribution was reduced to about 15% of the total load, and the mean bicep brachii EMG amplitude decreased by about 60%, while tracking accuracy was generally preserved and often improved. Full article

Nonlinear energy harvesting systems based on multibody structures constitute a promising solution for autonomous devices powered by ambient vibrations. This paper presents the modeling and control of a nonlinear energy harvester employing a double pendulum configuration and BLDC motors operating as generators. The primary objective of the study was to develop a control strategy that enables the maximization of harvested power while simultaneously improving the energy conversion efficiency during the charging of the battery supplying the target system. The developed model incorporates the mechanical equations of motion of the double pendulum, an electrical model of the BLDC motors, and two independently controlled buck–boost converters, each connected to one joint of the pendulum. In addition, a perturb-and-observe (P&O) maximum power point tracking (MPPT) algorithm was implemented, which utilizes a portion of the computational resources of the target system’s microcontroller and allows for dynamic adjustment of the electrical loads seen by the generators. Simulation results obtained in the Simulink environment confirm that the application of independent power converters combined with local MPPT control leads to an increase in the total harvested power and ensures more stable battery charging under conditions of variable mechanical excitation. The obtained results demonstrate the effectiveness of the proposed approach and indicate its potential applicability in self-powered systems operating in environments characterized by irregular and stochastic vibrations. Full article

Brushless DC (BLDC) motors are widely used in mobile robotics and off-road vehicles due to their high efficiency, reliability, and compactness. However, achieving robust, high-performance speed control in embedded environments remains challenging due to nonlinearities, dead-time effects, parameter uncertainties, and strict real-time constraints. This paper presents a comprehensive experimental study of classical and robust control strategies for BLDC motor speed control, fully implemented on an FPGA platform. Classical PI and PID controllers tuned using Ziegler–Nichols, Cohen–Coon, and Chien–Hrones–Reswick methods are first investigated and discretized using both Zero-Order Hold (ZOH) and Tustin (bilinear) approximations. Model-based approaches, including IMC-based PID controllers, are then introduced to enhance robustness. In addition, a robust two-degree-of-freedom dead-time compensator (DTC) is implemented to explicitly address dead-time uncertainties inherent to inverter-based motor drives. All controllers are implemented using fixed-point arithmetic on a Xilinx Nexys A7 FPGA and validated experimentally on a BLDC motor test bench representative of semi-autonomous robotic applications. Performance is evaluated through time-domain responses and quantitative indices, including ISE, ITAE, I, control effort, and FPGA resource utilization. Experimental tests under controlled DC bus voltage disturbances are conducted to assess disturbance rejection capability and robustness under realistic operating conditions. Experimental results demonstrate that Tustin discretization consistently improves tracking performance, while IMC-PID and DTC strategies provide superior robustness against dead-time and modeling uncertainties, making them particularly suitable for embedded FPGA-based motor control. Full article

This paper presents a new approach to the design of hydraulic pumps, exemplified by a prototype gerotor pump with an integrated direct drive, based on an original concept constituting the basis of the Polish patent PL 236677. One of the objectives of the study is to demonstrate that, despite the long-standing and widespread use of this class of devices, further development potential still exists. To this end, the study focuses on the experimental proof-of-concept validation of the proposed solution, specifically aiming to verify the correctness of the gerotor unit and the BLDC-type magnetic drive circuit design, and to assess the impact of direct integration on the pump’s hydraulic characteristics, thermal behaviour, and control performance. Emphasis is placed on demonstrating the feasibility of the presented solution and its potential for future practical applications. Accordingly, an experimental prototype direct-drive gerotor pump was designed and manufactured, together with a dedicated miniature test stand required for experimental investigations. The research programme comprised preliminary start-up tests, no-load operation, and pump operation under various operating conditions, including different rotational speeds and working pressures. The experimental investigations were successfully carried out, and the obtained results clearly confirmed the correctness of the proposed concept and the proper operation of the prototype. As discussed in the paper, the presented prototype currently exhibits specific limitations, primarily low efficiency and a limited rotational speed range. However, these represent typical early-stage issues that further development can relatively easily eliminate. Full article

To address the performance degradation of the traditional Extended Kalman Filter (EKF) in state estimation for sensorless brushless DC motor (BLDC) control under dynamic operating conditions, such as sudden speed and load changes—a degradation caused primarily by model mismatches—this paper proposes an Adaptive Extended Kalman Filter (AEKF) algorithm. The proposed algorithm incorporates a robust weighting strategy based on the Mahalanobis distance and a dynamically adjusted adaptive forgetting factor. This integration establishes an estimation mechanism capable of online updating of the innovation covariance, thereby enhancing the state observer’s adaptability to system uncertainties and external disturbances. Simulation results demonstrate that, compared to the traditional EKF, the designed AEKF algorithm significantly improves the estimation accuracy of rotor position and speed under various operating conditions, including low-speed start-up, speed step changes, and sudden load applications. Furthermore, it accelerates dynamic response, suppresses overshoot, and enhances the system’s disturbance rejection robustness. This work provides an effective state estimation solution for high-dynamic performance sensorless control of BLDC. Full article

In today’s world, the demand for compact, high-efficiency, and low-cost motors plays a significant role in the design of low-power electric machines. In combi fan applications, single-phase brushless direct current (BLDC) motors are generally preferred. Although these motors offer efficient and compact solutions, the occurrence of dead points at certain rotor positions creates a serious disadvantage that may prevent the motor from initiating motion. In this study, an asymmetric air gap design is proposed for a single-phase BLDC motor to eliminate the dead point problem and increase starting torque. The motor’s performance has been evaluated through analytical calculations and two-dimensional finite element analysis (FEA) conducted using ANSYS Electronics Desktop 2020 R2 (Maxwell) software. The results show that the asymmetric air gap effectively eliminates the dead point and improves the motor’s starting performance. However, torque ripple is still identified as a design parameter that must be considered. The scope of this study is not limited to single-phase BLDC motors; it also provides analytical approaches that can be applied to different electric motor designs, contributing to engineering applications in this field. Full article

This paper presents an open-architecture mechatronic drive platform for operating a three-phase BLDC servomotor in an industrial robotic axis. A sequential and iterative mechatronic design methodology is adopted, integrating electronic design, digital control, mechanical development, and experimental prototyping, with emphasis on open-loop operation. The electronic circuit was designed using schematics and a PCB and validated in Proteus Design Suite 8.15 (Labcenter Electronics Ltd., London, UK) to verify switching sequences and inverter behavior. The power stage is based on a six-switch insulated-gate bipolar transistor (IGBT) inverter module, complemented by an independent snubber protection board and a dedicated digital gate-drive control board. The mechanical enclosure was designed using computer-aided design (CAD), CAD software tools (Shapr3D, version 5.911.0 (9224), Shapr3D Zrt., Budapest, Hungary), and fabricated via 3D printing. Switching behavior was simulated in Octave using parameters from a real industrial BLDC servomotor (Yaskawa SGMAH series) extracted from a Motoman robotic axis. The contribution is design-oriented in a mechatronic engineering sense, emphasizing accessibility, openness, and experimental enablement of industrial drive hardware rather than control-performance optimization. An industrial Yaskawa BLDC servomotor from the Motoman robot is used to determine switching sequences and safe operating parameters. Experimental open-loop tests were conducted by directly commanding the six inverter switching sectors, resulting in the stable synchronous rotation of the motor on the developed electromechanical platform. Full article

While the Internal Model Principle (IMP) and Disturbance Observer (DOB) are fundamental to robust control, their systematic equivalence within a unified framework has received limited attention. IMP-based control achieves robustness through the structural inclusion of signal generators, whereas DOB-based methods rely on extended state representations for disturbance estimation. This paper bridges this gap by designing a state-space Reduced-Order Disturbance Observer (RODOB)-based controller that achieves systematic equivalence with an IMP-based transfer function controller. As a design example, an IMP-based controller is synthesized using a Linear Quadratic Regulator (LQR) for an augmented system in error space, with reference inputs directly integrated into the RODOB structure to eliminate the need for additional filters. Simulations and hardware experiments on a Brushless DC (BLDC) motor verify that both structures exhibit consistent control input and output characteristics, significantly outperforming conventional cascade and PID strategies. Numerical stability during digital implementation is ensured via partial fraction expansion. Furthermore, a method for estimating equivalent disturbances—encompassing both external loads and model uncertainties—is proposed by leveraging RODOB states. These findings suggest significant potential for future applications in fault diagnosis and real-time condition monitoring. Full article

Achieving a balance between rapid adaptation and robustness is a critical yet challenging objective in the design of industrial control systems. Model Reference Adaptive Control (MRAC) is a standard approach for managing system uncertainties; however, it suffers from a fundamental trade-off between adaptation speed and robustness. The high adaptation gains required for fast tracking often lead to parameter bursting or instability in the presence of noise. To resolve this issue, this paper proposes a new Dual-Loop Optimal Feedback Control (OFC) architecture applied to a Brushless DC (BLDC) motor drive. Unlike conventional methods that rely solely on tuning the adaptive mechanism, the proposed architecture introduces a parallel compensation loop designed to decouple disturbance rejection from reference tracking. This structure utilizes a Genetic Algorithm (GA) as an offline optimization engine to identify the Optimal Compensator gains that balance transient recovery with steady-state stability. Experimental validation demonstrates that the proposed Dual-Loop OFC architecture significantly outperforms traditional approaches. Specifically, it achieves an 88.99% reduction in overshoot and a 13.8% reduction in settling time compared to Conventional MRAC (CMRAC). Furthermore, it exhibits an 86.7% faster rise time compared to Self-Tuning Fuzzy PID (STFPID). These results confirm that the proposed Dual-Loop structure effectively mitigates the classic adaptability–robustness trade-off, offering a stable and high-performance solution for industrial actuators under varying operating conditions. Full article

This study presents a comprehensive performance analysis of four different control strategies, Proportional–Integral (PI), classical Sliding Mode Control (SMC), Super-Twisting SMC (ST-SMC), and Exponential Reaching Law SMC (ERL-SMC), applied to the speed regulation of a Hall-effect sensored Brushless DC (BLDC) motor. A mathematically detailed BLDC motor model, three-phase inverter structure with safe commutation logic, and a high-frequency PWM switching scheme were implemented in the MATLAB/Simulink-2024a environment to provide a realistic simulation framework. The control strategies were evaluated under multiple test scenarios, including variations in supply voltage, mechanical load disturbances, reference speed transitions, and steady-state operation. The comparative results reveal that the classical SMC and PI controllers suffer from significant oscillations, overshoot, and limited disturbance rejection capability, especially during voltage and load transients. The ST-SMC algorithm improves robustness and reduces the chattering effect inherent to first-order SMC but still exhibits noticeable oscillations near the sliding surface. In contrast, the proposed ERL-SMC controller demonstrates superior performance across all scenarios, achieving the lowest steady-state ripple, the shortest settling time, and the most stable transition response while significantly mitigating chattering. These results indicate that ERL-SMC is the most effective and reliable control strategy among the evaluated methods for BLDC speed regulation, which requires high dynamic response and disturbance robustness. The findings of this study contribute to the advancement of SMC-based BLDC motor control, providing a solid foundation for future research that integrates observer-based schemes, adaptive tuning, or real-time hardware implementation. Full article

High-precision torque regulation is essential to ensure reaction wheel systems meet the stringent attitude control requirements of modern spacecraft. In three-phase half-bridge brushless DC (BLDC) drives, non-ideal back-electromotive force (back-EMF) waveforms cause pronounced conduction interval torque ripple, leading to inaccurate and unstable output torque. To address this problem, this article proposes a composite torque control strategy integrating an Adaptive Nonsingular Fast Terminal Sliding-Mode Observer (ANFTSMO) with an Adaptive Sliding-Mode Controller (ASMC). The ANFTSMO achieves precise back-EMF estimation and electromagnetic torque reconstruction by eliminating singularities, reducing chattering, and adaptively adjusting observer gains. Meanwhile, the ASMC employs an adaptive switching gain function to achieve asymptotic current convergence with suppressed chattering, thereby ensuring accurate current tracking. System stability is verified via Lyapunov analysis. Simulation and experimental results demonstrate that, compared with conventional constant-current control, the torque smoothness and disturbance rejection of the proposed method are improved, enabling precise and stable reaction wheel torque delivery for high-accuracy spacecraft attitude regulation. Full article

Brushless DC motors are widely used for their high power density and efficiency. However, sensorless control remains challenging due to the difficulty of accurate rotor position detection, especially at low speeds. This paper proposes a novel sensorless trapezoidal control method based on Maximum Likelihood Estimation (MLE) for rotor sector detection. Unlike conventional back-EMF zero-crossing techniques, the proposed method uses a statistical algorithm to generate a probability map from prior motor state data, enabling accurate rotor position estimation without sensors. The MLE method operates with a typical computation time of 50–100 $\mathrm{\mu }$s, offering a balanced tradeoff between speed and accuracy. It is significantly faster than Kalman filter-based approaches (200–1000 $\mathrm{\mu }$s) and comparable to observer-based methods (20–80 $\mathrm{\mu }$s), while being more robust than zero-crossing techniques (<5 $\mathrm{\mu }$s). This makes it a practical and cost-effective solution for applications demanding high efficiency and reliability, such as electric mobility systems. Full article

This study presents a comprehensive experimental investigation of a 2.2 kW brushless DC (BLDC) motor integrated with a three-shaft planetary gearbox, focusing on overall energy efficiency, battery state of charge (SOC) estimation, and real-time speed control under variable load conditions. In the first stage, the gearbox transmission ratio was experimentally verified to establish the kinematic relationship between the BLDC motor and the eddy current dynamometer shafts. In the second stage, the motor was operated in open loop mode at fixed reference speeds while variable load torques ranging from 1 to 7 N.m were applied using an AVL dynamometer. Electrical voltage, current, and rotational speed were measured in real time through precision transducers and a data acquisition interface, enabling computation of overall efficiency and SOC via the Coulomb counting method. The open loop results demonstrated that maximum efficiency occurred in the intermediate-to-high-speed region (2000 to 2800 rpm) and at higher load torques (5 to 7 N.m) while locking the third gearbox shaft produced negligible parasitic losses. In the third stage, a proportional–integral–derivative (PID) controller was implemented in closed loop configuration to regulate motor speed under the same variable load scenarios. The closed loop operation improved the overall efficiency by approximately 8–20 percentage points within the effective operating range of 1600–2500 rpm, reduced speed droop, and ensured precise tracking with minimal overshoot and steady-state error. The proposed methodology provides an integrated experimental framework for evaluating the dynamic performance, energy efficiency, and battery utilization of BLDC motor planetary gearbox systems, offering valuable insights for electric vehicle and hybrid electric vehicle (HEV) drive applications. Full article

This paper presents a magnetic-flux-based encoder for BLDC drives that maintains high accuracy under rotor eccentricity and dynamic transients. Conventional Hall-sensor-based angle estimators rely on ideal sinusoidal flux assumptions and degrade in the presence of air-gap distortion or misalignment. To overcome these limitations, a nonlinear autoregressive network with exogenous inputs (NARXNet) is proposed as a temporal neural observer that learns the nonlinear, time-dependent mapping between measured flux densities and the true electrical rotor angle. A physics-informed data augmentation framework combines experimentally measured magnetic flux maps with dynamic simulation to generate diverse training scenarios at low and variable speeds. Validation demonstrates mean angular errors below 2°, 95th-percentile errors under 5°, and negligible drift, with enhanced resilience to eccentric displacement and acceleration transients compared to classical methods. The proposed approach provides a compact, data-driven sensing solution for robust, encoderless electric drive control. Full article

A promising approach to advancing sustainable urban mobility is the increased use of light electric vehicles, such as e-cycles and their cargo-carrying variants: e-cargo cycles. These micromobility vehicles fall between e-cycles and conventional vehicles in terms of transport capacity, range, and cost. A key advantage of e-cargo cycles over their non-electrified counterparts is the electric powertrain, which enables them to carry heavier payloads, travel longer distances, and reduce driver fatigue. Since the primary use of e-cargo cycles is urban parchment deliveries, trip efficiency plays a critical role in their effectiveness within urban logistics. This efficiency is influenced by factors such as travel distance, traffic density, and the weight and volume of the delivery payload. While higher delivery capacity generally enhances efficiency, studies have shown that as the drop size increases, the efficiency of e-cargo cycle delivery trips tends to decline. A practical way to address this limitation is the use of cargo attachments, such as trailers. These micromobility solutions are already widely implemented globally and significantly enhance transport capacity. This paper reports the process of designing and testing the control algorithm of an electrical system for an experimental attachment demonstrator that can be used to convert most cycle vehicles into cargo variants. The system integrates two 250 W BLDC hub motors, two 576 Wh lithium-ion batteries, dual load-cell sensing in the coupling element, and an STM32-based controller to provide independent propulsion and synchronization with the leading cycle. The force-based control strategy enables automatic adaptation to varying payloads typically encountered in urban logistics, which is supported by the variable storage volume capable of transporting payloads of up to 200 kg. Full article