Speed Control of Three Phase

BLDCM Using IoT for EVs

Submitted by

SYED KUMAIL FAIZ 70095557

MURAD ALI 70100339
MUHAMMAD FAIZAN 70100362

AZFAR TARIQ 70100408

Thesis Supervisor

ENGR. DR. TANVEER YAZDAN

Department of Electrical Engineering

Faculty of Engineering and Technology
THE UNIVERSITY OF LAHORE
JUNE 2023
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 Certificate of Approval

This is to certify that the project/thesis work presented in this thesis, entitled “Speed Control
of Three Phase BLDCM Using IoI for EVs” was conducted by

Syed Kumail Faiz (Reg # 7009557), Murad Ali (Reg # 70100339), Muhammad Faizan (Reg

# 70100362) and Azfar Tariq (Reg # 70100408) under the supervision of Engr. Dr. Tanveer
Yazdan.

Student’s Name: Syed Kumail Faiz Signature: _________________

Student’s Name: Murad Ali Signature: _________________

Student’s Name: Muhammad Faizan Signature: _________________

Student’s Name: Azfar Tariq Signature: _________________

FYP Cell Representative: Signature: _________________

With date

Supervisor’s Name: Engr. Dr. Tanveer Yazdan Signature: _________________

with date

Head of Department: Engr. Dr. Ghulam Abbas Signature: _________________

with date

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 Dedication

“Dedicated to our beloved parents, whole family, my teachers, and

friends whose unwavering support and collaboration helped us
achieve this amazing feat “.

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 Acknowledgments

We are thankful to our Creator Allah Almighty who guided us throughout this academic
session, and for every new thought, which came to our mind that led us towards improvement.
After that, we feel great pleasure and honor to express our special appreciation and heartfelt
thanks to our supervisor Engr. Dr. Tanveer Yazdan, who proved himself as a perfect mentor
during our studentship. His continuous supervision and generous support play a vital role in
the growth of our academic abilities from a research nonprofessional. He helped us to
understand the difficult concepts of engineering, mathematics, and thesis writing. All this
knowledge is an invaluable resource for us. Without his kind support, it was impossible to
complete our work in a short time with outcomes even beyond expectations. Would like to
thank our parents who played a big role in finalizing our project by helping with financial
problems and making our journey easier. We also want to thank team members (Murad Ali,
Faizan Awan, Syed Kumail Faiz) for encouragement in designing and making project creative.
It was a great experience to work with each other in a comfortable, pleasant and congenial
manner. We are also thankful to Head of Department Engr. Dr. Ghulam Abbas and other faculty
members of Department of Electrical Engineering for providing us with excellent guidance and
academic environment throughout our bachelor studies.

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 Abstract

The speed control of a three-phase brushless DC (BLDC) motor is essential in electric vehicle
(EV) applications. In this paper, we propose an Internet of Things (IoT)-based approach for
controlling the speed of a BLDC motor used in an EV. The proposed system consists of a
BLDC motor, a motor driver, and an IoT-based controller. The controller is designed to receive
speed commands from a mobile application and send them to the motor driver to adjust the
motor's speed. The proposed system is implemented using a Wi-Fi module which is Node MCU
and Arduino UNO. The system's performance is evaluated by measuring the motor's speed and
current consumption, and the results show that the proposed system can accurately control the
motor's speed and direction and reduce the motor's energy consumption. The proposed system's
IoT-based architecture enables remote monitoring and control of the EV's motor, enhancing
the vehicle's performance and user experience, respectively.

Key Words: Speed control, Power controller, Power electronic converter

(MOSFETS/IGBTS), BLDC motor, EV’s (electrical vehicles) chassis.

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Table of Contents
Certificate of Approval ..........................................................................2
Dedication..............................................................................................3
Acknowledgments .................................................................................4
Abstract ..................................................................................................5
List of Figures........................................................................................9
Table of Abbreviations ........................................................................10
Chapter 1 ............................................................................................11
Introduction and Literature Review ...............................................11
1.1 Background Theory .......................................................................11
1.2 Literature Review ..........................................................................12
1.2.1 Three-Phase BLDCM Speed control mechanism ....................................................... 13

1.3 Problem Statement ........................................................................13

1.4 Motivation behind the Thesis ........................................................14
1.5 Thesis Objectives ..........................................................................15
1.6 Proposed System and Methodology ..............................................15
1.7 Thesis Outline................................................................................16
Chapter 2 ............................................................................................17
Mathematical Modeling and Software Simulation ........................17
2.1 Mathematical Model of BLDCM ..................................................17
2.2 MOSFET IRFZ44N.......................................................................21
2.3 Voltage Regulator IC 7805: ..........................................................22
2.3.1 Types of IC Voltage Regulators .................................................23
2.3.2 Performance Specifications ......................................................................................... 23
2.3.3 Features ....................................................................................................................... 24

2.4 PI Controller ..................................................................................25

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2.5 LCD ...............................................................................................26
2.6 IoT (Internet of Things).................................................................26
2.7 Buck Converter..............................................................................27
2.8 PWM Converter ............................................................................28
2.9 AURDINO UNO ...........................................................................28
2.9.1 Arduino Mini Pro ........................................................................................................ 29

2.10 Arduino Code ..............................................................................30

2.11 Filter Capacitor ............................................................................43
2.11.1 Working of Filter Capacitor ...................................................................................... 43
2.11.2 Filter Capacitor Applications .................................................................................... 44

2.12 Wi-Fi Module ..............................................................................44

2.12.1 Feautures ................................................................................................................... 45

2.13 Methodology ...............................................................................45

2.13 BLDC simulation in MATLAB/Simulink ............................ 46DC
Chapter 3 ............................................................................................51
Hardware Implementation ...............................................................51
3.1 DC Power Supply ..........................................................................51
3.2 PEC ................................................................................................51
3.3 Methodology .................................................................................52
Chapter 4 ............................................................................................57
Engineering and Society ...................................................................57
CHAPTER 5.......................................................................................58
Environment and Sustainability ......................................................58
CHAPTER 6.......................................................................................60
Conclusions and Future Road Map .................................................60
References ..........................................................................................62

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8
 List of Figures

Figure 1 Equivalent circuit of BLDC motor including the inverter circuit ............................. 17
Figure 2 Mathematical Model of BLDC .................................................................................. 18
Figure 3 Driving principle of three phase BLDC motor .......................................................... 20
Figure 4 MOSFET ................................................................................................................... 21
Figure 5 MOSFET Block Diagram .......................................................................................... 22
Figure 6 Voltage Regulator ...................................................................................................... 22
Figure 7 Fundamental Block Diagram of Three-Terminal IC Voltage Regulator................... 23
Figure 8 IC Voltage Regulator ................................................................................................. 25
Figure 9 IC Voltage Regulator ................................................................................................. 27
Figure 10 Arduino UNO .......................................................................................................... 29
Figure 11 Connections of Arduino UNO ................................................................................. 29
Figure 12 Arduino Mini Pro .................................................................................................... 30
Figure 13 Filter Capacitor ........................................................................................................ 43
Figure 14 Node MCU .............................................................................................................. 44
Figure 15 System Block Diagram ............................................................................................ 45
Figure 16 Simulation................................................................................................................ 46
Figure 17 Simulation regarding PWM (Pulse width modulation) subsystem. ........................ 47
Figure 18 Stator Current Waveform ........................................................................................ 47
Figure 19 Input and Output simulated rpm results .................................................................. 48
Figure 20 Gate Pulses of three phase BLDC motor ................................................................. 48
Figure 21 Line-Line Voltages .................................................................................................. 49
Figure 22 Recovery time of change in rotor speed (rpm) waveform ....................................... 49
Figure 23 Truth Table of Gate Pulses and Back EMF ............................................................. 50
Figure 24 IC and Gate pulses circuit........................................................................................ 53
Figure 25 PWM Inverter Circuit .............................................................................................. 53
Figure 26 IoT based circuit. ..................................................................................................... 54
Figure 27 PWM Inverter .......................................................................................................... 54
Figure 28 Relay Open/Close Loop Circuit .............................................................................. 55
Figure 29 Bipolar Relay ........................................................................................................... 55
Figure 30 Hardware Results..................................................................................................... 56

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Table of Abbreviations

AC Alternating Current

DC Direct Current

PWM Pulse Width Modulation

RBS Regenerative Braking System

BLDC Brushless Direct Current

MOSFET Metal-Oxide Semiconductor Field-Effect Transistor

IGBT Insulated Gate Bipolar Transistor

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 Chapter 1

Introduction and Literature Review

Electric vehicles (EVs) have become increasingly popular in recent years due to their ability to
reduce harmful emissions and improve fuel efficiency. As such, their performance and
reliability must be improved in order to meet the needs of the modern world. For this, the
control of the 3-phase Brushless Direct Current (BLDC) motor is essential. Traditional methods
of motor control are often time-consuming and prone to errors. This thesis will explore the
potential of using Internet of Things (IoT) for electric vehicle applications. It is expected that
this research will provide insights into the control and monitoring of the BLDC motor, allowing
for faster and more efficient operation of EVs.

Additionally, the use of IOT will allow for remote monitoring and control through data
analytics, providing improved safety, better power management and more efficient operations
for electric vehicle applications etc.

1.1 Background Theory

The use of electric vehicles (EVs) has become increasingly popular in recent years due to their
environmental friendliness, efficiency, and potential cost savings. One of the critical
components of an EV is the electric motor, which must be controlled to provide the necessary
power and efficiency for the vehicle to operate effectively. In particular, the speed control of
the motor is essential for regulating the vehicle's acceleration, speed, and energy consumption.

Three-phase brushless DC (BLDC) motors are widely used in EV applications due to their high
efficiency, low maintenance, and compact size. BLDC motors are characterized by their
permanent magnets and electronic commutation, which eliminates the need for brushes and
reduces friction, wear, and noise.

Before the latest incarnation of electric vehicles, cars already used BLDC motors for
windshield wipers, cd players, and power windows. Today’s automakers use three different
types of electric motors in green cars: the BLDC motor, brushed dc motor, and ac induction
motor. The BLDC motor has a permanent-magnet rotor surrounded by a wound stator. The
winding in the stator gets commuted electronically, instead of with brushes. This makes the

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BLDC motor etc. These motors can also operate at “unity power factor,” meaning the drive
can operate at its maximum efficiency levels.

However, controlling the speed of a BLDC motor can be challenging due to the complex
relationship between the motor's voltage, current, and rotational speed.

To address this challenge, various control techniques have been developed, including pulse
width modulation (PWM), field-oriented control (FOC), and sensor less control. These
techniques use feedback signals from sensors or estimators to regulate the motor's speed and
torque. However, traditional control techniques may not be suitable for EV applications, which
require real-time and remote-control capabilities. The Internet of Things (IoT) has emerged as
a promising technology for enhancing the control and monitoring of EV systems.

IoT-based approaches enable remote access to vehicle data and control systems, facilitating
real-time monitoring, predictive maintenance, and energy management. In particular, IoT-
based speed control of BLDC motors can enable dynamic adjustments of the motor's speed
based on road conditions, traffic, and driver preferences. Therefore, in this context, the
background theory of speed control of 3-phase BLDC motor using IoT for electric vehicle
applications involves a combination of motor control techniques, IoT-based communication
protocols, and energy management strategies. The integration of these components can lead to
an efficient, reliable, and scalable system for controlling the speed of a BLDC motor in an EV
respectively.

1.2 Literature Review

This literature review basically examines the potential of using Internet of Things (IoT)
technology to control the speed of a three-phase Brushless Direct Current (BLDC) motor for
electrical vehicle applications. It begins by discussing the characteristics of BLDC motors and
the challenges associated with controlling their speed. It then reviews the existing literature on
the use of IoT technology for controlling BLDC motor speed and presents the potential
advantages of such a system. Finally, the literature review outlines the potential benefits of
using IoT-based speed control, such as improved efficiency, safety, and performance. Overall,
this literature review demonstrates the potential of using IoT technology for controlling the
speed of a BLDC motor in electric vehicle applications.

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1.2.1 THREE- PHASE BLDC MOTOR SPEED CONTROL MECHANISM

A 3-phase BLDC (Brushless DC) motor is a type of motor that uses electronic commutation
instead of brushes and a commutator to control the speed and direction of the motor. The speed
control mechanism of a 3-phase BLDC motor can be achieved through the following methods:

1. Voltage Control: The speed of the motor can be controlled by varying the applied
voltage to the motor. This is achieved by adjusting the pulse width modulation (PWM)
duty cycle of the voltage applied to the motor. A higher duty cycle results in a higher
voltage and a faster motor speed, while a lower duty cycle results in a lower voltage
and a slower motor speed.
2. Current Control: Another method of speed control is to regulate the current supplied
to the motor. This is done by controlling the duty cycle of the current waveform applied
to the motor. A higher duty cycle results in a higher current and a faster motor speed,
while a lower duty cycle results in a lower current and a slower motor speed.
3. Sensor less Control: In this method, the speed of the motor is controlled without
using any external sensors. Instead, the motor's speed is estimated by analyzing the
back electromotive force (EMF) generated in the motor's windings. The PWM duty
cycle is then adjusted to maintain the desired speed. This method is more complex and
requires advanced control algorithms, but it has the advantage of not requiring any
additional sensors, which can reduce cost and complexity.

Overall, the speed control mechanism of a 3-phase BLDC motor can be achieved through
voltage control, current control, or sensor less control, depending on the application and
specific requirements of the motor.

1.3 Problem Statement

The speed control of a three-phase brushless DC (BLDC) motor is crucial in electric vehicle
(EV) applications as it directly impacts the vehicle's acceleration, speed, and energy
consumption. Traditional control techniques, such as pulse width modulation (PWM) and field-
oriented control (FOC), have limitations in terms of real-time and remote-control capabilities,
which are necessary for EV applications. Moreover, these techniques require physical sensors,
which increase the system's cost, complexity, and maintenance requirements. To overcome
these challenges, an IoT-based approach for controlling the speed of a BLDC motor in an EV

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has been proposed. However, this approach requires addressing several technical and practical
issues. For instance, the IoT-based controller must be designed to receive and transmit signals
in real-time, even in noisy or unreliable communication environments. Moreover, the controller
must be compatible with various types of mobile applications and user interfaces, ensuring a
seamless and user-friendly experience.

To overcome these challenges, an IoT-based approach for controlling the speed of a BLDC
motor in an EV has been proposed. However, this approach requires addressing several
technical and practical issues. For instance, the IoT-based controller must be designed to
receive and transmit signals in real-time, even in noisy or unreliable communication
environments. Moreover, the controller must be compatible with various types of mobile
applications and user interfaces, ensuring a seamless and user-friendly experience.

Therefore, the problem statement of speed control of 3-phase BLDC motor using IoT for
electric vehicle applications involves designing a reliable, efficient, and user-friendly system
that integrates IoT-based speed control into the existing EV system. The system must address
technical and practical challenges, including real-time communication, compatibility with
mobile applications, power management, safety, and security, to provide an optimal solution
for controlling the speed of a BLDC motor in an EV respectively.

1.4 Motivation behind the Thesis

The primary motivation behind this thesis is to investigate the potential of using Internet of
Things (IoT) for electric vehicle applications. It is expected that the advances in technology
will enable faster and more efficient control of 3-phase Brushless Direct Current (BLDC)
motors, important components of electric vehicles. This thesis will explore the control of the
motor using IOT, allowing for remote monitoring and control through data analytics. This
could provide improved safety, better power management, and more efficient operations for
electric vehicle applications. Additionally, this research is expected to provide insights into the
potential of using IOT for real-time monitoring and control of electric vehicle motors
respectively.

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1.5 Thesis Objectives

The main objective of this thesis is to develop an Internet of Things (IoT) based system for
speed control of a three-phase Brushless Direct Current (BLDC) motor in electric vehicle
applications. The system will incorporate a microcontroller-based control circuit that utilizes
pulse width modulation (PWM) technique to regulate the overall motor speed. The control
circuit will be connected to an IoT platform, which will enable real-time monitoring and control
of the motor speed remotely. The proposed system will be designed to be highly efficient,
reliable, and easy to use, making it suitable for various electric vehicle applications. The thesis
will investigate the effectiveness of the proposed system in controlling the speed of a 3-phase
BLDC motor, ensuring optimal performance and energy efficiency of electric vehicles. The
research will include a thorough analysis of the system's performance, testing, and validation,
to demonstrate the feasibility and practicality of the proposed system respectively.

1.6 Proposed System and Methodology

The proposed system for speed control of a 3-phase BLDC motor using IoT for electric vehicle
applications consists of three main components: the BLDC motor, a microcontroller-based
control circuit, and an IoT platform. The control circuit is connected to an IoT platform, which
allows users to monitor and control the motor speed using a mobile application. The control
circuit is responsible for regulating the motor speed by adjusting the pulse width modulation
(PWM) signal. The IoT platform facilitates real-time monitoring of the motor's speed and
provides control access to authorized users. The system architecture is shown in Figure 1-1.

Methodology:

The following steps will be followed to develop the proposed system:

• Literature Review: Conduct a comprehensive review of the existing literature to

identify the current state-of-the-art techniques for controlling the speed of a 3-phase
BLDC motor and integrating it with IoT platforms.

• Design and Simulation: Design the microcontroller-based control circuit using a

suitable development board, such as Arduino or Raspberry Pi. The circuit will
incorporate a driver IC to generate the PWM signal to control the motor speed. The
circuit will be simulated using software tools like Proteus or LT Spice to ensure its

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 proper functioning.

• Hardware Implementation: Implement the designed circuit on a printed circuit board

(PCB) and integrate it with the BLDC motor. The motor and control circuit will be
connected to an IoT platform, such as Amazon Web Services (AWS) or Google Cloud
Platform (GCP), using an appropriate communication protocol, such as MQTT or
HTTP.

• Mobile Application Development: Develop a mobile application to provide users with

real-time monitoring and control of the motor speed. The application will communicate
with the IoT platform to send commands and receive data from the motor.

• Testing and Validation: Test the system in a laboratory environment to ensure its
proper functioning and validate its performance. The system's efficiency, reliability,
and response time will be evaluated under different load and speed conditions.

• Performance Analysis: Analyzed the whole system's performance based on the

experimental results and compared it with the existing state-of-the-art techniques for
controlling the speed of a 3-phase BLDC motor.

Conclusion: Summarize the findings and draw conclusions about the feasibility and
practicality of the proposed system for electric vehicle applications.

1.7 Thesis Outline

This thesis is mainly subdivided into seven chapters, each of which is dedicated to a particular
aspect of the research. The first chapter is an introduction, providing an overview of the
project’s purpose and goals. The second chapter will examine the current state of electric
vehicles and their applications, as well as the control of 3-phase Brushless Direct Current
(BLDC) motors. The third chapter will discuss the fundamentals of Internet of Things (IoT)
and its potential applications for electric vehicle applications. The fourth chapter will focus
mainly on the design and implementation of a hardware prototype for the control of the BLDC
motor using IOT. The fifth chapter will evaluate the results of the prototype and discuss the
implications. The sixth chapter will provide a summary of the key findings and propose
recommendations for further research. The seventh and final chapter will be the conclusion,
summarizing the research and outlining the achievable outcomes respectively.

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 Chapter 2

Mathematical Modeling and Software Simulation

This chapter guides you thoroughly about the mathematical derivations, software simulations
and results of speed control mechanism of BLDC motor etc. Firstly, starting from the
discussion of the generalized mathematical model of BLDC motor.

2.1 Mathematical Model of BLDCM

A brushless DC motor is a type of electric motor that uses a permanent magnet rotor and stator
consisting of multiple windings. It operates based on the interaction between magnetic field of
rotor and rotating magnetic field created by the stator windings. The mathematical model
of a BLDC motor is typically described by the following equations like voltage equation, torque
equation, electromagnetic force equation, electrical angle equation etc.

Consider the given circuit as shown below:

Figure 1 Equivalent circuit of BLDC motor including the inverter circuit

Equivalent circuit of BLDC motor including the inverter circuit. This circuit diagram
shows the mathematical model of Brushless motor. Fig.1 shows the equivalent circuit of
brushless DC motor and inverter circuit which drives the motor [3]. R represents the
resistance of BLDC motor; L represents the inductance and C is the capacitance. We are

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using the 3-Phase RL load so the value of capacitance will be zero. In ea, eb and ec are
the back emfs of motor. There are six switches (S1 to S6) are involved in this circuit.

Figure 2 Mathematical Model of BLDC

The BLDC motor model contains two primary elements: the motor's torque and current
and the mechanical component responsible for generating rotational motion. With these
considerations in mind, the electrical characteristics of the BLDC motor can be represented
in following manner:

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The stator phase currents must maintain balance

Phase back EMF in PMBLDC motor exhibits a trapezoidal waveform. This waveform is
dependent on motor speed 9wm and the rotor position angle, as illustrated in Figure 2.
From this, the phase back EMF’S can be expressed as.

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 Figure 3 Driving principle of three phase BLDC motor

Figure 3 illustrates the relationship between the signals obtained from Hall effect sensors
(H1, H2, H3) and the back electromotive forces (EMFs) generated by the stator windings
during the six-step drive. It also demonstrates the connection between sensor signals and the
phase currents. Within this framework, it is presumed that each sensor generates a digital
high level signal upon detecting the north pole, whereas it produces a low level signal when
sensing the south pole. According to the sensor signals, it is imperative to perform
commutation, which involves changing the active phase winding responsible for producing
torque, at intervals of 60 electrical degrees during rotation. This ensures a consistent and
uninterrupted torque output. In instances of reverse rotation, switching sequence based on
Hall Effect sensor signals must be adjusted accordingly.

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2.2 MOSFET IRFZ44N

A MOSFET, is a device with four terminals: the source (S), gate (G), drain (D), and body (B).
In majority of cases, body terminal of MOSFET is connected to source terminal, creating a
three-terminal configuration that resembles a field-effect transistor. MOSFETs are widely
recognized as transistors and are used in various analog and digital circuit applications. This
concise overview serves as a fundamental introduction to MOSFETs.

The general structure of a MOSFET is as follows:

Figure 4 MOSFET

• The MOSFET relies on the p-type semiconductor as its fundamental building block.

• Both base types are extensively doped with an impurity of n-type, denoted as n+ in the
diagram.

• Sources and drains of clamps originate from heavily doped regions of the base.

• The base layer is coated with a silicon dioxide layer to provide insulation.

• On top of the silicon dioxide, a thin metal plate is positioned as an insulated capacitor.

• The gate terminal is composed of a thin metal plate.

• To establish a DC circuit, a voltage source is connected between these two regions of n-

type.

The symbols and basic construction for both MOSFET configurations are shown below:

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 Figure 5 MOSFET Block Diagram

2.3 Voltage Regulator IC 7805:

Integrated circuit voltage regulators are three-terminal devices designed to provide stable and
constant DC output voltage, regardless of fluctuations in input voltage, output load current, and
temperature.

Figure 6 Voltage Regulator

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2.3.1 Types of IC Voltage Regulators

There are three clearly discernible categories of integrated circuit voltage regulators, namely
IC switching voltage regulators, IC linear voltage regulators, and DC/DC converter chips.

• IC switching voltage regulators utilize components such as inductors, transformers, or

capacitors to store energy. Subsequently, this energy is transferred from input to the
output in discrete packets, facilitated by a low-resistance switch.

• IC linear voltage regulators employ an active pass element to decrease input voltage
and ensure consistent output voltage level.

• Another classification of IC voltage regulators, referred to as DC/DC converter chips,

produce a regulated direct current voltage by converting an alternative, unregulated
input voltage. DC/DC converters provide advantages such as noise isolation and the
capability to regulate power buses. Each type of IC voltage regulator allows for either
a fixed or adjustable output voltage within a specified range.

2.3.2 Performance Specifications

Performance specifications of IC voltage regulators encompass:

Figure 7 Fundamental Block Diagram of Three-Terminal IC Voltage Regulator

• In continuous mode, the regulated output voltage (in volts) can vary within a specified

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 range, representing minimum and maximum values of DC voltage. This mode allows
for both fixed and variable output voltages to be achieved.

• Certain circumstances are used to measure the output current (IOUT). VD represents
the smallest voltage reduction across the regulator that must be sustained in order to
maintain output voltage regulation. Small dropout voltage IC voltage regulators use less
internal power but have relatively good efficiency.

• The quiescent current, measured in amperes (A), is never able to reach the load when
the engine is idle.

• Flow of power from battery to regulator itself is what enables its operation within the
specified temperature range.

2.3.3 Features

IC voltage regulators are offered with diverse range of features.

• Multiple outputs or channels.

• Internal circuits to regulate and control current output.

• Error flags that monitor output levels and detect deviations from nominal values.

• Reverse voltage protection to safeguard against potential damage caused by accidental

battery polarity reversal.

• Thermal shutdown protection, which activates when the temperature surpasses a

predefined limit, shutting off the IC voltage regulator.

• Shutdown (inhibit) pins that allow for the disabling of regulator outputs when
necessary.

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 Figure 8 IC Voltage Regulator

2.4 PI Controller

A proportional- integral (PI) controller is a type of feedback control system commonly used
in industrial applications to regulate a process variable, such as temperature, pressure, or
speed. The controller uses a combination of proportional and integral control actions to reduce
the error between the desired setpoint and actual value of the process variable.

In the context of speed control of a 3-phase BLDC motor for electric vehicle applications, a
PI controller can be used to adjust the motor speed based on desired performance and
conditions of the vehicle. The controller receives feedback from sensors that measure the speed
of the motor and compares it to the desired speed setpoint. It then calculates an error signal and
uses this signal to adjust the motor speed etc.

The proportional component of PI controller is proportional to current error between setpoint

and actual speed. This component causes the motor’s speed to increase or decrease in
proportion to the error signal, providing a fast response to sudden changes in the load or speed
setpoint etc. The integral component of PI controller is proportional to the accumulated error
over time. This component helps to eliminate any steady state error and ensures that the motor’s
speed is precisely controlled, even in the presence of disturbances or variations in the load etc.

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Overall, a PI controller can provide accurate and stable control of the speed of a 3-phase BLDC
motor in an electric vehicle, ensuring that the vehicle operates efficiently and safely. By using
feedback from sensors and incorporating both proportional and integral control actions, the PI
controller can effectively regulate the motor’s speed, even in dynamic or uncertain operating
conditions respectively.

2.5 LCD

LCD is a shortened form of liquid crystal display, which refers to a specialized electronic
display module extensively utilized in various circuits and devices, including televisions, cell
phones, calculators, computers, and other electronics. These displays commonly employ seven-
segment and multi-segment LEDs. The key advantages of utilizing LCD modules encompass
their cost-effectiveness, ease of programming, ability to showcase animations, and the
boundless potential for displaying customized characters, original animations, and more.

2.6 IoT (Internet of Things)

The internet of things (IOT) is basically a network of physical devices, vehicles, home
appliances, and other items that are embedded with electronics, software, sensors, and
connectivity, allowing them to exchange data and connect to the internet. According to the IOT
idea, intelligent devices may observe events going on around them, combine the data from
many sensors, utilize both local and distributed intelligence to decide on the best course of
action, and then act to modify or control physical things etc. This technology is used to develop
applications that allow the integration of data collected from various devices and sensors to
be used in multiple applications respectively.

In electric vehicle applications, the IOT (internet of things) technology controls the speed of
3-phase BLDC motors etc. The speed of the motor is controlled using the data collected from
various sensors such as temperature, pressure, and acceleration, which is then send to the motor
controller. The controller then adjusts the speed of the motor accordingly. This allows for
precise speed control and improved efficiency and performance of the motor. Additionally, the
sensors can also be used to detect potential problems or faults in the motor and take corrective
action before the issue becomes worse respectively.

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2.7 Buck Converter

In SMPS circuits, the Buck Converter is utilized when it is necessary to reduce the DC output
voltage below the DC input voltage. DC input can be sourced from any DC supply or rectified
AC. The Buck Converter proves advantageous in scenarios where there is no need for electrical
isolation between the switching circuit and the output. Nevertheless, in cases where input is
obtained from a rectified AC source, incorporating a primary isolating transformer can ensure
the essential electrical isolation between AC source and rectifier.

Buck Converter functions by utilizing a switching transistor that alternates between the on and
off states at a high frequency. This enables the efficient transfer of energy between the input
and output. When the switching transistor is on, the circuit harnesses the energy stored in the
inductor L to supply power to the load. Stored energy is subsequently employed during the off
periods to maintain a continuous output. Circuit's functionality is based on the concept of a
flywheel circuit, which exhibits behavior akin to a mechanical flywheel. Similar to a flywheel's
smooth and consistent rotation, the circuit maintains a constant energy flow by effectively
managing periodically spaced energy pulses.

Figure 9 IC Voltage Regulator

The buck converter, which falls under the category of DC-to-DC converters, possesses the
ability to receive a direct input from a DC source, such as battery. Furthermore, it can also
acquire its input from the AC mains (line) through a rectifier and a reservoir capacitor circuit,
ultimately yielding a DC output. The AC input for the rectifier circuit may be directly sourced
from the AC mains supply at a high voltage, or it can be derived from a step-down transformer

27
at a lower voltage. Irrespective of the method used to generate the DC input for the Buck
Converter, it is transformed into a high-frequency AC waveform through the utilization of a
switching transistor, often referred to as a "chopper." This switching transistor is driven by a
square wave, typically modulated by pulse width modulation. The outcome of this process is
the production of a high-frequency AC wave. Subsequently, the AC waveform can be
transformed into DC with significantly higher efficiency compared to the circuits outlined in
the power supplies module.

2.8 PWM Converter

It is possible to produce pulses with a changing duty cycle frequency using pulse width
modulation (PWM). The utilization of a PWM signal with fast rising and falling edges serves
to minimize the transition time during switching and reduce associated switching losses. In the
context of this article, the PWM technique is employed to regulate the speed of a DC motor.
By modifying the duty cycle of the PWM signal, it is possible to regulate voltage applied to
the motor terminals, thus exerting control over the speed of the motor.

Measurements were taken of the motor voltage and revolutions per minute (RPM) at different
duty cycle settings. The motor receives higher electricity as the duty cycle rises. As a result,
the magnetic flux inside the armature winding is strengthened and the number of rotations rises.

Investigations were made on the features and functionality of a DC motor speed control system.
DC motor speed control system circuit in this article uses a PIC microcontroller and converter.
By including two buttons to increase and increase the duty cycle speed, the microcontroller
gives the circuit versatility. At various duty cycle rates ranging from 19% to 99%, the
characteristics and performance of an engine speed controller using a mica controller were
examined.

2.9 AURDINO UNO

Arduino Uno, a microcontroller board, utilizes ATmega328P as its foundation. Its components
include 16 MHz quartz crystal, 6 analogue inputs, 14 digital I/O pins (with 6 capable of
functioning as PWM outputs), USB port, power jack, ICSP header, and a reset button. By
employing preloaded software and considering the accelerator input, the Arduino effectively
produces the required pulse-width modulation signal output for the class E chopper.

28
 Figure 10 Arduino UNO

The following connections of Arduino UNO board are given below;

Figure 11 Connections of Arduino UNO

2.9.1 Arduino Mini Pro

The Arduino Uno is equipped with 6 analogue inputs, an on-board resonator, 14 digital I/O
pins (with 6 of them capable of operating as PWM outputs), an on-board reset button, and
mounting holes for pin headers. In order to supply USB power and establish connectivity with
the board, one can connect a six-pin header to either an FTDI cable or a Spark fun breakout
board.

Arduino Pro Mini is a versatile little board specially crafted for temporary installations in

29
exhibitions and other imaginative projects. Its unique feature of lacking pre-mounted headers
gives you the freedom to employ various connectors or even solder wires directly. The Arduino
Mini ingeniously accommodates the pin arrangement of your choice. Excitingly, there are two
flavors of the Pro Mini available: one operates at a charmingly low voltage of 3.3V and a
modest 8 MHz, while the other boasts a bolder 5V power supply and a zippy 16 MHz clock
speed

Figure 12 Arduino Mini Pro

2.10 Arduino Code

//For Speed and Direction Control

#include <Servo.h> // Include servo as an object by going to Sketch->Include Library and then
from there, choose "servo from the list"

#include <LiquidCrystal.h>

LiquidCrystal lcd(3,4,5,6,7,8);

#include <SoftwareSerial.h>

SoftwareSerial mySerial(9, 10); //TX,RX

Servo esc; //Creating a servo class with name as esc

30
const int hallPin=2;

const unsigned long sampleTime=1000;

const int maxRPM = 10000;

#define voltagePin A0

float amp_pin = A1; //Defining and initializing the voltage

float amp = 0;

long Voltage, V1;

int Speed=0, rpm=0, level=0, value=0, timer;

String data="";

int com=0;

#define relay 12

void setup() {

Serial.begin(9600);

mySerial.begin(9600);//Starting serial comunication

esc.attach(11); //Specify the esc signal pin,Here as D8

esc.writeMicroseconds(1000); //initialize the signal to 1000

pinMode(relay,OUTPUT);

pinMode(hallPin,INPUT);

31
 pinMode(voltagePin,INPUT);

pinMode(amp_pin,INPUT);

lcd.begin(16, 2);

lcd.setCursor(0,0);

lcd.print(" WELCOME To ");

lcd.setCursor(0,1);

lcd.print("");

delay(2000);

lcd.clear();

void loop() {

Voltage = analogRead(voltagePin);

//Serial.println(Voltage);

V1 = Voltage;

level = map(Voltage,300,420,0,100);

amp = 0;

for(int i = 0; i < 500; i++) {

amp = amp + (.0864 * analogRead(amp_pin) -44.13) / 500;

rpm=getRPM();

//Speed = map(rpm,0,2400,0,120);

32
lcd.setCursor(0,1);

lcd.print("B:");

//lcd.print(level);

//lcd.print("% ");

lcd.print((Voltage/100)%10);

lcd.print((Voltage/10)%10);

lcd.print(".");

lcd.print(Voltage%10);

lcd.print("v ");

//lcd.setCursor(0,1);

//lcd.print("S:");

//lcd.print(Speed);

//lcd.print(" ");

lcd.setCursor(10,1); //Column 0 row 1

lcd.print(amp,2); //current

lcd.print("A "); //Ampers

lcd.setCursor(3,0);

lcd.print("RPM: ");

lcd.print(rpm);

lcd.print(" ");

while(mySerial.available()>0) {

char inChar = (char)mySerial.read();

33
 if(inChar == '\n' or inChar == '\r'){

}else{data += inChar;}

if (inChar == '\n' or inChar == '\r') {

String dataInS = data.substring(1, data.length()); // Extract only the number. E.g. from "A120"
to "120"

if(data.charAt(0) == 'A'){ Speed=dataInS.toInt(); Serial.print(Speed);}

else if(data.charAt(0) == 'B'){ com = dataInS.toInt(); Serial.print(com);

if(com==1){digitalWrite(relay, 0);}

if(com==2){digitalWrite(relay, 1);}

data="";

}//END OF ONE LINE

}//END OF SERIAL AVAILABLE

if(timer==0){timer=3; mySerial.print("A");mySerial.println(rpm);}

timer = timer-1;

if(com>0)value = map(Speed,0,100,1000,2000);

else{value = 800;}

esc.writeMicroseconds(value); //using val as the signal to esc

delay(500);

int getRPM(){// sample for sampleTime in millisecs

34
int kount=0;

boolean kflag=LOW;

unsigned long currentTime=0;

unsigned long startTime=millis();

while(currentTime<=sampleTime){

if(digitalRead(hallPin)==HIGH){kflag=HIGH;}

if(digitalRead(hallPin)==LOW && kflag==HIGH){

kount++;

kflag=LOW;

currentTime=millis()-startTime;

int kount2rpm = int(60000./float(sampleTime))*kount;

return kount2rpm;

//For the display on LCD and Wi-Fi Module

#define PWM_MAX_DUTY 255

#define PWM_MIN_DUTY 0

#define PWM_START_DUTY 0

byte bldc_step = 0, motor_speed, pin_state;

void setup()

DDRD |= 0xE0; // configure pins 5, 6 and 7 as outputs

PORTD = 0x00;

35
 DDRB |= 0x0E; // configure pins 9, 10 and 11 as outputs

PORTB = 0x31;

// Timer1 module setting: set clock source to clkI/O / 1 (no prescaling)

TCCR1A = 0;

TCCR1B = 0x01;

// Timer2 module setting: set clock source to clkI/O / 1 (no prescaling)

TCCR2A = 0;

TCCR2B = 0x01;

// ADC module configuration

ADMUX = 0x60; // configure ADC module and select channel 0

ADCSRA = 0x84; // enable ADC module with 16 division factor (ADC clock = 1MHz)

PCICR = EIMSK = 0; // disable all external interrupts

pinMode(2, INPUT_PULLUP);

pinMode(3, INPUT_PULLUP);

pinMode(4, INPUT_PULLUP);

// pin change interrupt 2 (PCINT2) ISR

ISR (PCINT2_vect)

if( (PIND & PCMSK2) != pin_state )

return;

// BEMF debounce

for(byte i = 0; i < 20; i++)

36
 {

if(bldc_step & 1){

if(PIND & PCMSK2) i -= 1;

else {

if(!(PIND & PCMSK2)) i -= 1;

bldc_move();

bldc_step++;

bldc_step %= 6;

// BLDC motor commutation function

void bldc_move()

switch(bldc_step)

case 0:

AH_BL();

BEMF_C_FALLING();

break;

case 1:

AH_CL();

BEMF_B_RISING();

37
 break;

case 2:

BH_CL();

BEMF_A_FALLING();

break;

case 3:

BH_AL();

BEMF_C_RISING();

break;

case 4:

CH_AL();

BEMF_B_FALLING();

break;

case 5:

CH_BL();

BEMF_A_RISING();

void loop()

SET_PWM_DUTY(PWM_START_DUTY); // setup starting PWM with duty cycle =

PWM_START_DUTY

int i = 5000;

// motor start

38
 while(i > 100)

delayMicroseconds(i);

bldc_move();

bldc_step++;

bldc_step %= 6;

i = i - 20;

motor_speed = PWM_START_DUTY;

PCICR = 4; // enable pin change interrupt for pins PCINT23..16 (Arduino 0 to 7)

while(1)

ADCSRA |= 1 << ADSC; // start conversion

while(ADCSRA & 0x40); // wait for conversion complete

motor_speed = ADCH; // read ADC data (8 bits only)

if(motor_speed < PWM_MIN_DUTY)

motor_speed = PWM_MIN_DUTY;

SET_PWM_DUTY(motor_speed);

void BEMF_A_RISING()

39
 PCMSK2 = 0x04; // enable Arduino pin 2 (PCINT18) interrupt, others are disabled

pin_state = 0x04;

void BEMF_A_FALLING()

PCMSK2 = 0x04; // enable Arduino pin 2 (PCINT18) interrupt, others are disabled

pin_state = 0;

void BEMF_B_RISING()

PCMSK2 = 0x08; // enable Arduino pin 3 (PCINT19) interrupt, others are disabled

pin_state = 0x08;

void BEMF_B_FALLING()

PCMSK2 = 0x08; // enable Arduino pin 3 (PCINT19) interrupt, others are disabled

pin_state = 0;

void BEMF_C_RISING()

PCMSK2 = 0x10; // enable Arduino pin 4 (PCINT20) interrupt, others are disabled

pin_state = 0x10;

void BEMF_C_FALLING()

PCMSK2 = 0x10; // enable Arduino pin 4 (PCINT20) interrupt, others are disabled

40
 pin_state = 0;

void AH_BL()

PORTD &= ~0xA0;

PORTD |= 0x40;

TCCR1A = 0; // turn pin 11 (OC2A) PWM ON (pin 9 & pin 10 OFF)

TCCR2A = 0x81; //

void AH_CL()

PORTD &= ~0xC0;

PORTD |= 0x20;

TCCR1A = 0; // turn pin 11 (OC2A) PWM ON (pin 9 & pin 10 OFF)

TCCR2A = 0x81; //

void BH_CL()

PORTD &= ~0xC0;

PORTD |= 0x20;

TCCR2A = 0; // turn pin 10 (OC1B) PWM ON (pin 9 & pin 11 OFF)

TCCR1A = 0x21; //

void BH_AL()

41
 PORTD &= ~0x60;

PORTD |= 0x80;

TCCR2A = 0; // turn pin 10 (OC1B) PWM ON (pin 9 & pin 11 OFF)

TCCR1A = 0x21; //

void CH_AL()

PORTD &= ~0x60;

PORTD |= 0x80;

TCCR2A = 0; // turn pin 9 (OC1A) PWM ON (pin 10 & pin 11 OFF)

TCCR1A = 0x81; //

void CH_BL()

PORTD &= ~0xA0;

PORTD |= 0x40;

TCCR2A = 0; // turn pin 9 (OC1A) PWM ON (pin 10 & pin 11 OFF)

TCCR1A = 0x81; //

void SET_PWM_DUTY(byte duty)

OCR1A = duty; // set pin 9 PWM duty cycle

OCR1B = duty; // set pin 10 PWM duty cycle

OCR2A = duty; // set pin 11 PWM duty cycle

42
2.11 Filter Capacitor

The filter capacitor serves as a valuable component in electrical circuits, playing the role of
selectively eliminating particular frequencies or a range of frequencies. Its primary function
involves blocking low-frequency signals, often referred to as DC signals, which possess
frequencies close to zero. By employing this capacitor, unwanted frequencies can be effectively
filtered out, making it an essential element found in various electrical and electronic equipment
across different industries.

Figure 13 Filter Capacitor

2.11.1 Working of Filter Capacitor

The capacitive reactance principle is the key governing factor in how this capacitor functions.
It simply refers to the alteration of a capacitor's impedance in relation to the frequency of a
signal traversing through it. A resistor, which is a nonreactive component, provides a signal
with a resistance that is similar regardless of the signal's frequency. This observation suggests
that when a resistor with equal resistance is involved, impulses at 1Hz and 100 KHz pass
through it uniformly. However, capacitors exhibit a distinct behavior due to their impedance
or resistance, the variation in impedance of capacitors is dependent on the frequency of
transmitted signal. Capacitors are categorized as reactive components, exhibiting low
resistance to high-frequency signals and high resistance to low-frequency signals. This
behavior can be mathematically represented using formulas, for example:

XC= 1/2πfc

Capacitor demonstrates diverse impedance values in response to signals of varying frequencies.

When integrated within a circuit, it has the ability to function as a resistor.

43
2.11.2 Filter Capacitor Applications

The applications of this include the following.

• The line filter capacitor is used in a variety of industrial loads and appliances to protect
them from line voltage noise as well as other equipment on the same line from noise
created inside the circuit.

• These capacitors are versatile components that can be employed in different types of
signal processing filters. A notable example is their utilization in audio equalization,
where they amplify low, high, and medium frequency tones across multiple frequency
bands.

• It is applied to clean up glitches on DC power rails.

• The elimination of RFI permits the ingress or egress of power or signal lines into/out
of the equipment.

• For achieving a consistent DC power supply, it is recommended to connect this

capacitor downstream of the voltage regulator.

• This capacitor finds application in audio, IF, or RF filters.

2.12 Wi-Fi Module

The NodeMCU is an open-source development board that features the ESP8266 Wi-Fi module,
which allows it to connect to Wi-Fi networks and communicate over the internet. It is widely
used for various IoT (Internet of Things) projects due to its affordability, ease of use, and rich
set of features.

Figure 14 Node MCU

44
The ESP8266 is a low-cost Wi-Fi chip produced by Espressif Systems, a Chinese
semiconductor company. It became popular in the maker community due to its powerful
capabilities and low price point. The NodeMCU board was created to make it even easier for
developers to work with the ESP8266 module.

2.12.1 Features

• programable WiFi module.

• Arduino-like (software defined) hardware IO.
• Can be programmed with the simple and powerful Lua programming language or
Arduino IDE.
• USB-TTL included plug & play.
• 10 GPIOs D0-D10, PWM functionality, IIC and SPI communication, 1-Wire and
ADC A0 etc. all in one board.
• Wi-Fi networking (can be used as access point and/or station, host a web server),
connect to internet to fetch or upload data.
• Event-driven API for network applications.
• PCB antenna.

2.13 Methodology

This section describes the BLDC motor simulation. This method is divided into two parts.
Firstly, BLDC motor is simulated and then the simulation of speed control of 3-phase BLDC
motor is given. Figure 15 illustrates a comprehensive block diagram of simulated system.

Figure 15 System Block Diagram

45
In this following block diagram, a dc voltage source is provided to power electronic converter
and then power electronic converter like MOSFETS provide input voltage and current to three
phase BLDC motor to further produce torque (t) and angular speed (w) at output end etc.
Through actual output angular speed and torque, we provide feedback signal through feedback
sensors to PI controller and then PI controller further analyze the error difference between
desired speed input through mobile application and actual angular speed (w) and torque to get
desired angular speed (w) respectively.

2.14 BLDC simulation in MATLAB/Simulink

In the universal switch block subsystem, IGPTs/diodes were selected as a switch. The
following simulation of this project is given below:

Figure 16 Simulation

In this simulation, we can basically provide reference speed (rpm) input to PI controller and
then PI controller further analyzed the error difference between reference speed input and
actual output angular speed (w) and set the motor output angular speed according to our desired
angular speed (w) respectively.

46
 Figure 17 Simulation regarding PWM (Pulse width modulation) subsystem.

In this simulation, a permanent magnet synchronous motor is attached at the end to see the
behavior of the motor. We know that motor also works as a generator. When motor gets
mechanical energy, it converts mechanical energy into electrical energy and stored it to the
battery then the energy stored in battery is used to move the wheels of the EV’s. The following
simulation regarding the motor as a generator is given below:

Figure 18 Stator Current Waveform

47
 Figure 19 Input and Output simulated rpm results

Figure 20 Gate Pulses of three phase BLDC motor

This diagram shows the gate pulses of all three phases of the BLDC motor operating in a
producing mode. The gate pulses for a three-phase BLDC motor can be generated using a
microcontroller or a specialized motor driver IC. The basic idea is to send a sequence of digital

48
signals to the motor driver that correspond to the desired trapezoidal commutation sequence.
Each signal represents a gate pulse that is sent to one of the motor's three phases.

Figure 21 Line-Line Voltages

Figure 22 Recovery time of change in rotor speed (rpm) waveform

49
Figure 23 Truth Table of Gate Pulses and Back EMF

50
 CHAPTER 3

Hardware Implementation

In this chapter, we will discuss the hardware design, components and the working of this
project. The system is divided into the following parts:

• Power Supply

• Power converters

• The Control Unit

• Prime Mover

• The Feedback Devices

• Mechanical Load

3.1 DC Power Supply

A DC power supply is an electronic device used to provide a constant and stable direct current
(DC) voltage to power various electronic circuits, devices, and systems. Unlike AC power,
which oscillates in both positive and negative cycles, DC power flows consistently in one
direction.

DC power supplies are commonly used in various applications, including electronics testing
and development, powering electronic devices, charging batteries, and providing power to
circuits that require a steady DC voltage.

Linear DC Power Supply: This type of power supply uses a transformer to convert the AC
voltage to a lower voltage, followed by a rectifier to convert it to DC. Then, a linear regulator
regulates the DC output voltage to provide a stable output. Linear power supplies are simple
and have low noise but are less efficient and generate more heat compared to other types.

3.2 PEC

A power electronic converter is a device or circuit that converts electrical power from one form
to another, typically changing voltage, current, or frequency levels. These converters play a

51
crucial role in modern power electronics and are used in a wide range of applications, including
power generation, distribution, motor drives, renewable energy systems, electric vehicles, and
more.

Inverter: An inverter is a converter that converts DC to AC. It changes the DC voltage into a
variable-frequency AC output, commonly used in motor drives, renewable energy systems (like
solar inverters), and uninterruptible power supplies (UPS).

3.3 Methodology

We first provide the power supply to the circuit. Then connect the Wi-Fi module using hotspot
with the mobile application, once the connection is established, Wi-Fi module will flash a blue
light and then we can vary the speed from 0 to 720 rpm using a slider on the app. Moreover,
we can also stop/start and give directions from the app too.

When 24 volts are supplied across the voltage regulator, the voltage regulator turns it into 20
volts and delivers it to the next IC, which then changes the 20 volts into 12 volts and delivers
it to the mosfet driver ICs. Also, the voltage regulator sent 12 volts to the Buck converter,
which was positioned in front of the Arduino and converted it to 5 volts before sending it to
the Arduino and other circuits. The Arduino's 5V signal is intercepted by the MOSFET driver
IC, which transforms it into 12V to drive the MOSFET. The MOSFET driver also reads the
feedback to prevent simultaneous operation of both switches.

The circuit contains 12 field-effect transistors. There are three wires attached to the MOSFET
in total: one for the n channel, one for the p channel, and one for feedback. Two MOSFET are
linked in series to form one pair, and this pair is then placed in parallel with another pair to
easily create one phase of positive and negative sequence. This feedback wire is then connected
to the Arduino, where the 24-volt signal is converted to 5 volts by the VDR mounted over the
Arduino.

52
 Figure 24 IC and Gate pulses circuit.

As we know, the inverters are controlled by IR2104, so the first circuit provides the MOSFET’s
signals to either operate in forward biasing or reverse biasing.

Figure 25 PWM Inverter Circuit

53
Figure 26 IoT based circuit.

Figure 27 PWM Inverter

54
 Figure 28 Relay Open/Close Loop Circuit

Figure 29 Bipolar Relay

This project involved a practical simulation study focused on the speed and direction control
of a BLDC motor utilized in an EV. The credibility of the acquired outcomes was assured by
implementing a carefully designed application setup. BLDC motor was operated at different
speeds and directions, demonstrating a highly useful application for EVs. Here you can see few
results of hardware:

55
 Figure 30 Hardware Results

As you can see, these are the results of hardware setup. Finally, we can control the motor’s
speed and direction using IoT up to 45 meters of range and we can also start/stop the motor
using the same application.

56
 CHAPTER 4

Engineering and Society

Engineers play a crucial role in developing technologies that impact society, and the use of IoT
(Internet of Things) for the speed and direction control of BLDC (Brushless DC) motors is a
prime example of their innovative efforts. BLDC motors are widely used in various
applications, such as electric vehicles, industrial automation and robotics. Here’s how
engineers are using IoT for the speed and direction control of BLDC motors:

IoT-enabled Control System: Engineers design a control system that incorporates IoT devices,
such as microcontrollers or single-board computers, to control the BLDC motor. These devices
can connect to the internet and interact with other smart devices or cloud-based services.

Sensor Integration: IoT systems use various sensors to gather data about the motor's speed,
position, temperature, and other relevant parameters. Common sensors include encoders, hall
effect sensors, temperature sensors, and current sensors.

Data Transmission: The data collected by the sensors is transmitted in real-time over the
internet to a cloud platform or a central server. This data can be analyzed and used for
monitoring the motor's performance and health.

Remote Control: Using a mobile application or web interface, users can remotely control the
speed and direction of the BLDC motor. This feature is especially useful for scenarios where
manual intervention is not practical, such as in an industrial setup or an unmanned vehicle.

Energy Efficiency: Engineers can optimize the motor's operation by analyzing usage patterns
and adjusting speed and torque levels based on real-time demand. This leads to better energy
efficiency, reducing overall power consumption and environmental impact.

Safety and Security: Engineers must implement robust security measures to protect the IoT-
enabled control system from unauthorized access or cyber threats. Security is vital, especially
when these systems are integrated into critical infrastructure or autonomous vehicles.

By combining IoT technology with BLDC motors, engineers can create intelligent,
interconnected systems that offer enhanced control, monitoring, and efficiency. These
advancements can have a positive impact on various industries, contributing to a more
sustainable and interconnected society.

57
 CHAPTER 5

Environment and Sustainability

The use of BLDC (Brushless DC) motors in Electric Vehicles (EVs) and incorporating IoT
(Internet of Things) technology can significantly contribute to environmental sustainability.
Here are some ways in which the combination of BLDC motors and IoT can promote a greener
and more sustainable future for EVs:

Energy Efficiency: BLDC motors are known for their high efficiency and superior power-to-
weight ratio compared to traditional internal combustion engines. When integrated with IoT,
the motor's speed and torque can be optimized based on real-time data, ensuring that the motor
operates at its most efficient levels, thus reducing energy consumption and extending the
vehicle's range.

Regenerative Braking: IoT-enabled BLDC motor systems can be equipped with regenerative
braking capabilities. Regenerative braking allows the motor to act as a generator, converting
kinetic energy during braking into electrical energy, which can be stored in the vehicle's
battery. This feature helps improve overall energy efficiency and increases the driving range
of the EV.

Smart Charging: IoT technology can enable smart charging solutions for EVs, where the
charging process can be managed and optimized based on grid conditions and energy demand.
By charging during off-peak hours or when renewable energy sources are abundant, the
environmental impact of charging EVs can be minimized.

Battery Management: IoT sensors can be used to monitor the health and performance of the
EV's battery. By collecting real-time data on battery status, temperature, and usage patterns,
engineers can optimize battery charging and discharging, extending its lifespan and reducing
the need for premature battery replacements.

Predictive Maintenance: IoT systems can predict and detect potential issues with the BLDC
motor and other components in the EV. Early detection of faults allows for timely maintenance
and reduces the risk of sudden breakdowns, promoting a longer service life for the vehicle and
its components.

Data-Driven Design: By analyzing data collected from IoT sensors, engineers can make data-
driven design improvements for both the BLDC motor and the overall EV system. These

58
improvements can lead to more energy-efficient and environmentally friendly EVs.

Emission Reduction: BLDC motors produce lower emissions compared to internal combustion
engines, which helps reduce greenhouse gas emissions and air pollution. When combined with
the use of renewable energy sources for charging, EVs with BLDC motors can have a
significantly smaller carbon footprint compared to traditional vehicles.

End-of-Life Recycling: IoT technology can aid in tracking and monitoring the recycling
process of end-of-life EV components, including the BLDC motor and batteries. Proper
recycling ensures that valuable materials are recovered, reducing the environmental impact of
EV disposal.

Overall, the combination of BLDC motors with IoT technology in Electric Vehicles offers
numerous environmental benefits, including increased energy efficiency, reduced emissions,
smarter charging practices, and improved sustainability throughout the vehicle's lifecycle. This
integration represents a positive step toward creating a more sustainable transportation sector
and reducing the overall environmental impact of mobility.

59
 CHAPTER 6

Conclusions and Future Road Map

This study indicates the significance of determining all the limits during this project. This may
be executed by providing a GPS connection and increasing the range of operating this from
anywhere in the world. Moreover, we can advance with the more industrial applications in this
project by providing a complete road map of how to beneficially use these features in the
industry. A huge role can be played by Solar panels if used in EV with this project in the
replacement of DC power supply. More advancements like measuring of different other
parameters like temperature, humidity around the motor can be interpreted.

The future of BLDC motors using IoT in Electric Vehicles (EVs) is poised to bring about
significant advancements, making EVs more efficient, intelligent, and interconnected. Here's a
glimpse of the potential future map of BLDC motors using IoT in EVs:

Smart Grid Integration: IoT-enabled BLDC motors in EVs will communicate with smart grids
to optimize charging schedules based on electricity demand, grid stability, and renewable
energy availability. This will help balance the grid and promote the use of clean energy sources.

V2X Communication: BLDC motors in EVs will be equipped with Vehicle-to-Everything

(V2X) communication capabilities, allowing them to exchange data with other vehicles,
infrastructure, and pedestrians. This will enhance safety, enable efficient traffic management,
and optimize energy consumption.

Over-The-Air (OTA) Updates: EVs with IoT-connected BLDC motors will receive regular
OTA updates, allowing manufacturers to improve motor control algorithms, battery
management systems, and overall vehicle performance over time.

Real-Time Performance Monitoring: IoT sensors integrated with BLDC motors will
continuously monitor motor performance, temperature, and efficiency. This data will be sent
to the cloud for analysis, enabling predictive maintenance and optimization of motor
performance.

Energy Harvesting: IoT technology will be utilized to harvest energy from various sources
within the EV, such as regenerative braking, vibration, and solar panels, to power the IoT
components and further improve energy efficiency.

60
AI-Driven Energy Management: Artificial Intelligence (AI) algorithms will optimize BLDC
motor performance and battery usage based on driving patterns, road conditions, and user
preferences, maximizing the EV's range and energy efficiency.

Enhanced Driver Assistance: BLDC motors integrated with IoT will enable advanced driver
assistance features, such as adaptive cruise control, lane-keeping assistance, and automatic
emergency braking, enhancing safety and reducing driver fatigue.

Data-Driven Design and Manufacturing: Manufacturers will use data from IoT-connected
BLDC motors to refine motor designs, leading to more efficient and lightweight motors,
thereby improving overall vehicle performance.

In-Wheel Motor Integration: IoT-driven BLDC motors integrated into the wheels will become
more prevalent. This will enable more compact EV designs, freeing up space for increased
battery capacity and improving handling and stability.

Energy Trading: EVs with IoT-connected BLDC motors will participate in energy trading
systems, allowing them to buy and sell electricity based on market prices, grid demand, and
the vehicle's charging needs, contributing to a more dynamic and sustainable energy ecosystem.

Personalized User Experience: IoT-connected BLDC motors will offer personalized driving
experiences, such as customized performance profiles, preferred charging locations, and
optimized route planning based on individual preferences.

As technology continues to evolve, the future map of BLDC motors using IoT in EVs will
likely be characterized by greater connectivity, intelligence, and efficiency, driving the
widespread adoption of electric mobility and fostering a more sustainable transportation future.

61
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