Search Results (97)

This paper presents a high-performance sensorless control strategy for Brushless DC (BLDC) motors based on predictive current control combined with back-EMF-based speed and position estimation. The main objective is to achieve accurate speed regulation and fast dynamic response without the need for mechanical speed sensors, thereby reducing system cost, improving reliability, and simplifying hardware complexity. The proposed predictive current control algorithm ensures precise current tracking and rapid torque production under varying operating conditions, including speed reference changes and load torque disturbances. A comprehensive comparative analysis is conducted between the proposed sensorless approach and a conventional sensored control scheme. The obtained results demonstrate that the sensorless controller achieves speed, torque, and current performance that is nearly identical to the sensored system, with negligible differences in rise time, overshoot, steady-state error, and torque ripple. The dynamic response remains smooth and well-damped, confirming the effectiveness of the proposed estimation technique in maintaining accurate rotor synchronization under transient conditions. In addition, the influence of a proportional–integral speed controller with and without anti-windup compensation is investigated. The results show that the anti-windup mechanism significantly improves transient performance by reducing overshoot, eliminating startup undershoot, shortening settling time, and mitigating speed estimation errors during large reference changes and actuator saturation conditions, while preserving zero steady-state error. To validate the real-time feasibility of the proposed control strategy, a Processor-in-the-Loop (PIL) co-simulation platform is implemented using the C2000 LaunchXL-F28379D digital signal processor. The PIL results confirm that the algorithm can be executed under strict real-time constraints with acceptable computational burden, memory usage, and execution time. Overall, the proposed sensorless predictive current control strategy demonstrates strong robustness, high accuracy, and practical applicability for industrial BLDC motor drive systems operating under diverse and dynamic conditions. Full article

This paper presents a bidirectional power flow control strategy for a grid-connected solar photovoltaic (PV)-based water pumping system employing a brushless DC (BLDC) motor drive. The proposed system enables continuous water pumping operation under varying solar irradiance conditions without the use of phase-current sensors while maintaining the motor at its rated operating speed. A single-phase voltage source converter (VSC) employs a unit vector template (UVT)-based control scheme that regulates bidirectional power flow between the utility grid and the dc-link, thereby supporting both grid-to-load and PV-to-grid power transfer. Excess photovoltaic energy can be exported to the utility grid during periods of reduced pumping demand, improving overall utilization of the available solar power. The voltage source inverter (VSI) driving the BLDC motor employs a PWM_ON_PWM switching scheme to reduce torque ripple while operating at fundamental frequency to minimize switching losses. The proposed system also incorporates maximum power point tracking (MPPT), power factor correction, and harmonic mitigation to improve power quality and ensure compliance with IEEE-519 requirements. The effectiveness of the proposed control strategy is evaluated through detailed MATLAB/Simulink R2023a simulations under various operating conditions. The simulation results demonstrate stable dc-link voltage regulation, bidirectional power flow capability, continuous pumping operation, and reduced torque ripple, highlighting the suitability of the proposed system for grid-interactive solar water pumping applications. Full article

Conventional maize fertilization suffers from uneven distribution, fertilizer waste, and environmental pollution. To address these issues and achieve precision fertilization for maize, a straight grooved-wheel fertilizer apparatus (SGWFA) was designed and optimized using the discrete element method (DEM). The blocking characteristic of the SGWFA was also evaluated. The optimal configuration (eight grooves, inner diameter of 26 mm) yielded a minimum discharge uniformity coefficient of variation of 2.50% and mild blocking, with a maximum total force of 161.884 N. Furthermore, a nonsingular terminal sliding mode control (NTSMC) algorithm was proposed for the speed loop of the brushless DC (BLDC) motor drive, while the current loop used conventional proportional-integral (PI) control. The overall system achieved dual closed-loop speed and current regulation with finite-time convergence of the speed tracking error. Simulations showed that, compared with conventional PI and fuzzy PI controllers, NTSMC had the smallest overshoot of 3.4%, the shortest settling time of 0.165 s, and the fastest disturbance rejection. Bench tests confirmed that the coefficient of variation under NTSMC was 2.85%, markedly better than fuzzy PI’s 3.15% and conventional PI’s 4.03%. It is also basically consistent with the simulation results. Field tests at 6, 9, and 12 km/h demonstrated over 95% per-row fertilization accuracy, with a maximum relative error of only 4.61%. This integrated system can effectively achieve precise fertilizer application under variable field conditions. Full article

Accurate and robust control of robotic joints is essential for high-performance robotic systems. However, conventional proportional–integral–derivative (PID) controllers suffer from limited adaptability when applied to brushless direct current (BLDC) motor-driven joints operating under nonlinear and time-varying conditions. To address this issue, this paper proposes a Radial Basis Function (RBF) neural network-enhanced self-tuning PID control strategy. The RBF neural network serves as an online identifier to approximate the nonlinear dynamics of the BLDC motor and to estimate the system Jacobian online. Based on the estimated Jacobian, the PID gains (K_p, K_i, and K_d) are adaptively updated using a gradient descent mechanism, enabling continuous adjustment to varying operating conditions. Simulation and experimental results demonstrate that the proposed method achieves negligible overshoot, faster settling performance, and improved steady-state accuracy compared with conventional PID and PI controllers. In addition, the proposed controller exhibits enhanced disturbance rejection capability and robust performance under abrupt speed variations and start–stop conditions. The proposed approach effectively combines the simplicity of PID control with the adaptability of neural networks, providing a practical and efficient solution for high-precision robotic joint control. Full article

Due to their vast potential, Unmanned Aerial Vehicles (UAVs) are increasingly being utilized in various applications. To prevent in-flight failures and loss of control, implementing Internet of Things (IoT)-based Predictive Maintenance (PdM) systems is crucial. However, data collected from PdM systems often contains outliers, which can significantly degrade the accuracy and performance of predictive models. In this paper, we present a comparative performance analysis of several outlier detection methods, namely K-Nearest Neighbors (KNN), Autoencoder (AE), and Isolation Forest (IForest). The datasets used to evaluate these methods were acquired from a UAV predictive maintenance system designed to estimate the Remaining Useful Life (RUL) of Li-ion batteries and detect faults in Brushless DC (BLDC) motors. Ultimately, this study aims to determine the most effective outlier detection method for UAV predictive maintenance datasets. Full article

This paper presents the design and multi-domain evaluation of three chaos-based excitation strategies for brushless DC (BLDC) motor drives implemented using Chua circuit-generated deterministic chaotic signals injected at three distinct control points: the PWM duty cycle, the commutation sequence, and the current feedback loop. A systematic design methodology is established for each injection architecture, including signal normalization, amplitude parameterization, and injection point characterization, evaluated across the electromagnetic, thermal, mechanical, and acoustic domains through MATLAB (R2024a) simulation and physical test stand validation. PWM injection produces controlled spectral dispersion with 5–7% speed reduction and a 10–15 dB SNR decrease, making it the recommended design choice for acoustic signature masking in stealth UAV applications. Commutation injection achieves severe system destabilization with speed reduction exceeding 56% and SNR losses greater than 30 dB, establishing it as a design tool for accelerated stress testing and fault emulation. Current feedback injection delivers a balanced excitation profile with 12–20% efficiency loss and 16–30% SNR reduction, making it suitable as a design method for online parameter identification and adaptive control development. This study establishes the first multi-domain comparative design framework for application-specific selection of chaos excitation strategies in BLDC drives, supported by nonparametric statistical validation and experimental acoustic confirmation, providing drive engineers with quantitative selection criteria across four physical domains. Full article

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

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

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

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

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

Brushless DC (BLDC) motors are widely used in many engineering fields such as transportation, industrial automation, pumping systems, household devices, and renewable energy applications. Their popularity mainly arises from advantages like high power density, low noise, long service life, and high efficiency. This study contributes to the literature by comprehensively addressing the types, applications, faults, and diagnostic methods of BLDC motors. This review systematically examines recent studies to identify and classify common mechanical, electrical, magnetic, thermal, and sensor-related faults. Diagnostic approaches reported in these studies are then analyzed and compared. The methods are grouped into several categories, including signal processing, model-based, data driven, artificial intelligence-supported, and thermal or magnetic monitoring techniques. The review results show that hybrid and intelligent diagnostic strategies, which combine different analysis methods, significantly improve the accuracy of fault detection and enable earlier fault identification. These improvements also contribute to higher reliability and safer operation of BLDC systems. In the discussion, attention is given to the growing use of artificial intelligence and data fusion in fault diagnosis. These trends are likely to guide the next generation of condition monitoring systems for BLDC motors. Overall, this study emphasizes the importance of developing reliable and sustainable diagnostic frameworks to enhance energy efficiency and system performance. The results can provide a useful reference for researchers and engineers working on BLDC motor technologies. Full article

This paper presents an adaptive reinforcement learning (RL)-based control strategy for a wireless power transfer (WPT)-fed brushless DC (BLDC) motor drive, aimed at enhancing efficiency in industrial applications. Conventional control methods for BLDC motors often result in higher energy consumption and increased torque ripple under dynamic load and voltage variations. To address this, an adaptive RL framework is implemented with pulse density modulation (PDM), enabling the controller to augment motor speed, torque, and input power in real time. The system is modeled and tested for a 48 V, 1 HP BLDC motor, powered through a 1.1 kW WPT system. Training is carried out across 10 learning episodes with varying load torque and speed demands, allowing the RL agent to adaptively minimize losses while maintaining performance. Results indicate a significant reduction in torque ripple to a minimum of 0.20 Nm, stable speed regulation within ±30 rpm, and improved power utilization compared to existing controllers. The integration of RL with WPT provides a robust, contactless, and energy-efficient solution that is suitable for sustainable industrial motor-pump applications. Full article