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Author: Abouseda, Ayman IbrahimHas files: false

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    Article
    Citation - WoS: 7
    Citation - Scopus: 8
    Parameter Identification and Speed Control of a Small-Scale BLDC Motor: Experimental Validation and Real-Time PI Control with Low-Pass Filtering
    (MDPI, 2025) Abouseda, Ayman Ibrahim; Doruk, Resat Ozgur; Amini, Ali
    This paper presents a structured and experimentally validated approach to the parameter identification, modeling, and real-time speed control of a brushless DC (BLDC) motor. Electrical parameters, including resistance and inductance, were measured through DC and AC testing under controlled conditions, respectively, while mechanical and electromagnetic parameters such as the back electromotive force (EMF) constant and rotor inertia were determined experimentally using an AVL dynamometer. The back EMF was obtained by operating the motor as a generator under varying speeds, and inertia was identified using a deceleration method based on the relationship between angular acceleration and torque. The identified parameters were used to construct a transfer function model of the motor, which was implemented in MATLAB/Simulink R2024b and validated against real-time experimental data using sinusoidal and exponential input signals. The comparison between simulated and measured speed responses showed strong agreement, confirming the accuracy of the model. A proportional-integral (PI) controller was developed and implemented for speed regulation, using a low-cost National Instruments (NI) USB-6009 data acquisition (DAQ) and a Kelly controller. A first-order low-pass filter was integrated into the control loop to suppress high-frequency disturbances and improve transient performance. Experimental tests using a stepwise reference speed profile demonstrated accurate tracking, minimal overshoot, and robust operation. Although the modeling and control techniques applied are well known, the novelty of this work lies in its integration of experimental parameter identification, real-time validation, and practical hardware implementation within a unified and replicable framework. This approach provides a solid foundation for further studies involving more advanced or adaptive control strategies for BLDC motors.
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    Experimental Investigation of Energy Efficiency, SOC Estimation, and Real-Time Speed Control of a 2.2 kW BLDC Motor with Planetary Gearbox under Variable Load Conditions
    (MDPI, 2025) Abouseda, Ayman Ibrahim; Doruk, Resat; Emin, Ali; Lopez-Guede, Jose Manuel
    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.