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Article 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 ManuelThis 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.Conference Object A Lithium-Ion Battery Fast Charging Algorithm Based on Electrochemical Model: Experimental Results(Amer Soc Mechanical Engineers, 2024) Anwar, Sohel; Pramanik, Sourav; Amini, AliLithium-Ion batteries have become the principal battery technology for EVs to date. However, one of the principal factors limiting the widespread usage of the EVs is the length of charging times for the lithium-ion battery packs. The appropriate charging algorithm is critical to shorten the battery charging times while keeping the battery safe. In our earlier work, we proposed a novel optimal strategy for charging the lithium-ion battery based on electrochemical battery model using A performance index that aimed at achieving a faster charging rate while maintaining safe limits for various battery parameters. A more realistic model, based on battery electro-chemistry has been used for the design of the optimal charging algorithm as opposed to the conventional equivalent circuit models. Simulation results showed that the proposed optimal charging algorithm is capable of shortening the charging time of a lithium-ion cell by as much as 30% when compared with the standard constant current charging. Here we present the results from a number of experiments using Lithium-Ion cylindrical cells that were charged using the proposed algorithm and compared the charging times with the standard constant current-constant voltage (CC-CV) charging algorithms. A Maccor Series 4300 battery testing system was used to carry out the experiments. The experimental results showed that the proposed algorithm offered shorter charging times by up to 16% when compared to the CC-CV charging algorithms under the same battery initial conditions such as SOC and temperature of the cells.
