BLDC MOTOR SPEED CONTROL SYSTEM BASED ON

SEGWAY USING PID METHOD

By
HEGAR PANDU WIRATAMA SAKTI
Electrical Engineering Program
Concentration Automotive Mechatronics
Atlas Nusantara Engineering College Malang
Email: hegarpandu@Gmail.com

ABSTRAK

Speed on segway system derived from the rotation of the motor contained in each wheel. Motor
is used as a prime mover on the segway. The motors which widely available in the market are DC
motors ,but DC motors still have many obstacles in terms of efficiency and power of the motor. Segway
requires a motor with a high torque to be moving well.
BLDC motor is required to run the motor driver circuit, by giving input to the value of our
drivers can adjust the speed of the BLDC motor. There are 3 phases motor driver that we can use to run
the BLDC motor contained on segway. Arduino microcontroller used to provide reference input on the
drivers that will run the BLDC motors.
By testing and realizing the system has acquired tool as expected, but there are still some
shortcomings. This tool can make a BLDC motor rotates according to the reference input we give, Kp
values obtained by 2, the value of Ti 0.1.

Keywords: Speed Control, Microcontroller ARDUINO UNO, BLDC motor drivers

1. PRELIMINARY

Speed on segway system derived from the rotation of the motor contained in each wheel. Each of
these motors move the wheels to run according to the needs, but there is a problem in terms of
determining the motor that will be used to run maximum. The motors are given the same voltage, do not
always give a stable response each time spinning, sometimes the value of the speed of each motor
changeable despite having been given the same voltage for a spin.

Along with the times, the need for an efficient electric drive systems, speed and high torque and
maintenance cost increases. However, the motor current induction motors and DC motors have not been
able to meet the need for it. Therefore, to meet the need for high efficiency, high torque and high speed
then use brushless DC motors (Abe Dharmawan, Brushless DC Motor Control Method Using Sinusoidal
PWM ATmega16). BLDC motors require precise timing computing change in control so that the motor is
able to work with constant torque and speed.

It also occurs on systems that use the segway BLDC motors as the propulsion system. In order
BLDC motor speed control system better and stable, it is necessary that the controller can control the
system.

Segway uses 2 BLDC motors which are used to move, rotation of the BLDC motor is what
affects the speed segway. Round of the BLDC motor that makes riding stable can move to the maximum,
it is requiring control in order to obtain a stable BLDC motor rotation. From the above conditions, there is
the issue of how the speed setting on the BLDC motor in each wheel requires control to be moved in
accordance with a predetermined reference. By setting the BLDC motor speed in motor, segway expected
to spin stabilized according to the references we wanted and errors that occur at smaller system.

Based on the above problems, the author take the title "Design of BLDC Motor Speed Control
System on a Segway". Expected BLDC motors can move stably in accordance with what we expect after
being created on a segway speed control system, so that the rotation of the BLDC motor can rotate
maximumly.

2. LITERATURE REVIEW
2.1 Segway
Segway is basically a robot known as "balancing robot". Balancing robot works by rotating
both wheels so that his body remains upright. If the robot body increasingly tilted forward, then the
wheels will also be more quickly around to the front, so that the position of the robot body will be a
straight back, and vice versa. But there is a difference between balancing robot and segway, the Segway
can turn left and turn right. In order to turn left or right, then the speed of the wheels must be made
differently. The speed difference is determined by the position of the handlebars.

2.2 Hall Sensor

In contrast to conventional DC electric motors, commutation of the BLDC motor system must be
set electronically for wire windings on the stator must be switched - off (on-off) or on-energize
sequentially and orderly. Therefore, the sensor is needed to provide precise information to the controller
to set the windings which should be electrified.
BLDC motors use three Hall sensor mounted at a distance of 120o on the stator to detect the
rotor section which will be affected by the magnetic flux. Hall sensor is a transducer that produces a
voltage when there is a difference varying magnetic field. When the rotor spins, major changes the
magnetic field between the permanent magnet and the electromagnetic force of the coil wire is detected
by a Hall sensor as an input controller. So that the commutation process can be run simultaneously and
continuously.

2.3 Microcontroller
Microcontroller is a simple example of a computer system that is included in the category of
embedded computer. In a microcontroller there are components such as processor, memory, clock,
peripheral I / O, etc.. The microcontroller has the ability to manipulate the data (information) based on a
sequence of instructions (program) created by the programmer. A microcontroller is an electronic device
that is packaged in the form of an IC (Integrated Circuit).

2.4 PID Control

Each of the advantages and disadvantages of each controller P, I and D can cover each other by
combining all three in parallel into controller proportional, integral, and differential (PID controller). PI
controller elements and DI respectively overall aim to accelerate the reaction system, eliminating the
offset and produce large initial changes.

2.5 BLDC Motors

One type of electric motor most widely used lately is a Brushless DC (BLDC) motor, which does
not use the DC motor Brush (brush) for the commutation process. BLDC motors are widely used in
cutting-edge automation technology, such as: industrial automation of manufacturing and non-
manufacturing automation (robots, UAV, ROV, aero modeling, to RC cars). Very simple construction into
consideration the use of BLDC motors in the automation field development. In addition, electric cars and
hybrid cars are becoming a trend lately, BLDC motors are also used as a driving force because it has a
very large efficiency up to 95%. BLDC motors are also used in the motor of the hard disk that requires
speed and high resilience.

2.6 Optocoupler
Optocoupler is a component consisting of infrared and photodiode incorporated in one package.
The figure below illustrates the construction of an optocoupler.
Optocoupler is a device that consists of two parts: a transmitter and a receiver, which is a-
emitting light and a receiver in one component. Optocoupler usually used as an electronic switch, which
works automatically. Basically optocoupler is a component connector (coupling) which works based on
optic light trigger.

2.7 Motor Driver

To run the BLDC motor, the motor driver is required to drive the BLDC motor function on
segway. In addition, by using a driver, the motor speed can be set by the PWM signal from the
microcontroller is transmitted to the driver.

To generate power/3 phases voltage then used driver. These drivers are composed of three pairs
of MOSFET P75NF75. To generate a voltage, each mosfet should be given the control signals following
the sequence. Control signals which given in the form of a periodic signal are divided into 6
circumstances.

In order BLDC can be well controlled (speed and torque constant), the needed changes
commutation timing is right. If the changes commutation timing is not right, the BLDC motor will slip.
By using three sensors hall, will result on different combinations. This combination indicates sixth
commutation timing changes. As of the third hall sensor obtained certain combinations, the PWM signal
in a step to be changed in accordance with the combination obtained.

3. TOOLS DESIGN
In chapter planning and manufacture of BLDC motor speed control device on a segway will
discuss the components of the design, manufacture tools, work process systems, mechanical design,
hardware design and software design.

3.1 System planning

Block diagram of the system consists of a microcontroller, sensors, driver motors, BLDC
motors. Overall, a block diagram is shown in the following figure:

Picture 3.1 System planning

a.Microcontroller
Microcontroller functions as processing data received from the sensors in the form of a voltage that has
been converted into binary data. The processed data is data from the speed sensor and setting point on the
microcontroller.
b.Sensor
The sensor used is using the speed sensor. Then converted by the driver so that it can be processed by a
microcontroller.
c. Motor Driver
As the processing given to the BLDC motor to spin from the microcontroller. A signal is sent to the motor
driver will then give the command to the BLDC motor to rotate in accordance with what we want.

3.2 Tools Working Principle

Serial monitor (setting point) to determines how the desired speed on BLDC motor, then after
setting point determined the speed sensor will read the speed of the BLDC motor if it is not setting point
the microcontroller will process the input value is given to the driver of BLDC motor, gradually until
speed as specified. If the speed has reached the set will be maintained continuously.
3.4 Hardware Design
In the design and manufacture of hardware (Hardware) include arduino microcontroller circuit,
BLDC motors and speed sensor.

Gambar 3.4 Design Control

BLDC motors as actuators run through input entering the motor driver. The BLDC motor driver
has a 3-phase cable which must be properly installed on the BLDC motor so that the motor can rotate. To
determine the value of the speed of the BLDC motor can be seen from reading the voltage value is
converted to the value of the speed on the microcontroller. In the motor driver already has features
voltage readings that can be put on the microcontroller as an input readout speed of the BLDC motor, the
cable is then inserted into the pin analog arduino that will be converted.

3.5 Software Design

The software discussed a program that entered the arduino uno.. The software is based on the
principle of working tools to be created. The main program over the entire course of the program include
certain functions required for control systems such as the reading of the results of sensor and control
BLDC motor rotation.

Picture 3.5 Flow BLDC Motor Speed Adjustment Program

3.6 DESIGN OF PLANT IDENTIFICATION

To get the transfer function of the plant in this study used Ziegler Nichols method by finding the response
graph of the plant, then the withdrawal line through the point of tangency of plant response graph. Point
of contact is obtained by multiplying the value of steady state with constant value of 0.6328. The
intersection of the tangent with the abscissa is a measure of the dead time, and the intersection with a
maximum line delay time is measured from the time point L.
4. RESULTS AND ANALYSIS
In this chapter will be shown the results of design and design contained in the previous chapter,
well construction design, electrical design, software design and measurement.

4.1 Plant Identification Results

The identification of the response speed of the BLDC motor using existing speed sensor on the
motor driver, the result of identification by RLS order one, where the process of data collection is done by
taking every 0.1 seconds in order to get the response data is more accurate speed changes. The process of
data collection is done as much as 1 times and then the data is processed into a graph using Ms. Excel.

Gambar 4.1 Plant Identification Results BLDC Motor Speed

4.2 Speed Response Planning Results

After getting the results of the identification of a change of pace with the speed sensor, the
response obtained as shown above, and then to get a response speed is better then this plant uses PID
control. From the results of the design will speed response obtained mathematical models as follows :
Dimana :
Kecepatan Maksimal = 3300 rpm
Kecepatan Minimal = 0 rpm
A = KecMak KecMin = 3300-0 = 3300 rpm (1)
The above results to determine the speed difference obtained from data retrieval.
B = A * 0,632 = (3300 * 0,632) = 2085.6 (2)
From a distance the speed above is then multiplied by 0.632 obtained from formula.
Then the results of B is the midpoint to be searched using ziegler Nichols. Here is a graph that
will be sought mathematical models :

Gambar 4.2 Withdrawal of Straight Lines

 Tabel 4.2 Rumus Ziegler-Nichols

By using the type of PID controller then obtained the following value :
Kp = 1,2 (T/L) = 1,2*(15/250) = 0.06 (4)
Ti = 2L = 2*250 = 500 (5)
Td = 0,5L = 0,5*250 = 125 (6)
Ki = Kp/Ti = 0.00012 (7)
Kd = Kp*Td = 7.5 (8)

4.3 In Overall Equipment Testing Results

Testing is done to see the response that has been controlled system works, it is also
done to determine whether the planning control parameters are mathematically correspond with the motor
work. The following graphic image control signal that has been entered on the microcontroller :

Gambar 4.15 Graph control signal that has been entered on the microcontroller

4:15 From chart image can be seen that the control signal is already approaching the reference
input is given, but the application to run when the system turned out to be some problems. At the
beginning we can upload the program to enter the reference input we wanted, but after being put another
reference input did not change the speed on BLDC motors.
Calculations are mathematically proven to make a BLDC motor speed follows the reference
input that we give, but in the process occurs a few constraints as above. Modeling by modifying the
parameters that have previously been defined as a solution for determining the value of control like what
is in accordance with our employment system. The method of trial and error is necessary to find out and
see how much the error value resulting from changes in the parameters that we have done.

4.2 Tests after Modified PID Control

After making some changes to the control parameters, parameters are found close to the value of
the reference input. Found parameters had not experienced the error again when we want to change the
value of the reference input. Obtained value of Kp = 2, the value of Ki = 0.1, and the value of Kd = 0,
parameter control is that upload the back on a microcontroller. The following graphic image at the time of
the reference input speed = 3100 rpm
 Gambar 4.16 Grafik sinyal dengan nilai kp = 2, ki = 0.1, kd = 0

Response system work was able to follow the desired reference input for rotation Rpm ranging
from 2900rpm to 3300rpm, but still there are errors in the system. Rotation of the motor sometimes still
unstable, parameter control still can not rotate the motor according to the reference input perfectly.
To determine what the error steady state then we have to add up the value of the data at the time of steady
state, then we look for the value of the average speed, and then we subtract the value of the average speed
during steady state with a reference input that we give. The result of the difference between the average
speed during steady state divided by the reference input and then multiplied by 100 is the error steady
value statenye. At the time of measurement BLDC motor speed reference input given at 3100rpm, it was
found that the steady-state error values obtained at 2,548%.

5. CONCLUSIONS AND RECOMMENDATIONS

5.1 CONCLUSION
From the discussion of the BLDC motor rotation speed controller then it can be inferred from
some formulation of the problem.
a. Controls the rotation speed of the BLDC motor by using PID for increases and decreases in the
value of PWM to adjust the speed of the BLDC motor to a predetermined set point.
b. Implementation of PID control on the rotation speed control system in the system segway where
Kp is 0:06, Ti is 500, and 125 Td is still not obtained a good response, so do the implementation
of the control value PI.
c. The average error in the steady state simulation implementation closeloop PI control in BLDC
motor rotation speed controller in a certain reference point error steady state had an average
speed of all points at 2.548% of the reference.

5.2 RECOMMENDATIONS
As for suggestions that the author wants to convey on this occasion is as follows:
a. Driver BLDC motors as motor controllers are expected to rotate the BLDC motor without using
a hall sensor, hall sensor so that later can be used as the input value BLDC motor speed.
b. Electrical design of the motor needs to be changed so that does not take place and tidier.
c. Read the output speed value must be through calculation the value of the hall sensor on the
microcontroller, so it can be compared with the reading speed through a feature on the drivers
that have been provided.
d. Determining control parameters can be searched again for BLDC motor rotation can spin well,
on the low round

.
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diakses pada tanggal 11Desember 2015
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ARDUINO & GENUINO PRODUCTS. 2015. Arduino UNO. https://www.arduino.cc/.
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