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The ongoing technological advancements of brushless DC motors (BLDCMs) have found a wide range of applications. For instance, ground-based electric vehicles, aerial drones and underwater scooters have already adopted high-performance BLDCMs. Nevertheless their adoption demands control systems to monitor torque, speed and other performance characteristics. Precise design structure and the particular motor functional characteristics are essential for the suitable configuration and implementation of an appropriate controller to suit a wide range of applications. Techniques which do not use Hall sensors should be used then. This paper deals with the analysis of hardware and software aspects during the development of such a microcontroller based and low cost speed controller for motors up to 500 W, along with its practical implementation. The sensorless method employed is based on the zero crossing point (ZCP) detection of the back-electromotive forces’ (back-EMF) differences, as the ZCPs of these quantities match to the time points at which the commutation sequence changes. Additionally, the study presents hardware and software details through calculations, figures, flowcharts and code, providing an insight of the practical issues that may arise in such a low cost prototype. Finally, results obtained by experiments validate the presented hardware/software architecture of the controller.

Development and Implementation of a Low Cost μC- Based Brushless DC Motor Sensorless Controller: A Practical Analysis of Hardware and Software Aspects