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Signal processing of the brushed DC motor current was developed in this paper to obtain information about a rotor speed from a measured motor current. The brushed DC motor current contains a signal with a frequency proportional to the rotor speed. This signal is the outcome of a commutation process occurring in the brushed DC motor, and it is called a ripple component. Since the number of ripples in the measured motor current per one rotation is constant, the rotor speed can be estimated. A discrete bandpass filter with a floating bandwidth was developed as the main part of signal processing. This new interpretation of the bandpass filter was used to extract a frequency of the ripple component from the measured motor current. This frequency was used to acquire information about the estimated rotor speed. The estimated speed was set as a feedback value to a cascade control structure to provide sensorless speed control. The advantages and limitations of this approach are presented in this paper. Based on simulations and experimental results, it was confirmed that the proposed sensorless speed control is robust, accurate, and works precisely in a wide range of speeds.

Sensorless Speed Control of Brushed DC Motor Based at New Current Ripple Component Signal Processing