Search Results (26)

Saw rotational speed critically influences cutting force and surface quality yet is often destabilized by variable cutting resistance. The sensorless detection method for calculating rotational speed based on current ripple can prevent the contact of wood chips and dust with Hall sensors. This paper introduces a speed control system for brushed DC motors that capitalizes on the linear relationship between current ripple frequency and rotational speed. The system achieves speed regulation through indirect speed measurement and PID control. It utilizes an H-bridge circuit controlled by the EG2014S driver chip to regulate the motor direction and braking. Current ripple detection is accomplished through a 0.02 Ω sampling resistor and AMC1200SDUBR signal amplifier, followed by a wavelet transform and Savitzky–Golay filtering for refined signal extraction. Experimental results indicate that the system maintains stable speeds across the 2000–6000 RPM range, with a maximum error of 2.32% at 6000 RPM. The improved ripple detection algorithm effectively preserves critical signals while reducing noise. This enables the motor to quickly regain speed when resistance is encountered, ensuring a smooth cutting surface. Compared to traditional Hall sensor systems, this sensorless design enhances adaptability in agricultural applications. Full article

In this study, a stepper driver, which is suitable for use in the automotive industry, designed for general use, capable of adaptive learning in the systems in which it is used, and with CAN and universal asynchronous receiver–transmitter (UART) communication options, was designed. This design was made with a PIC18F25K22 microcontroller unit (MCU). Rotor speed, armature current, and terminal voltage can be measured on the proposed brushed DC motor drive system. It gives the desired response by evaluating obstacles and other situations in which high currents are drawn from the source. The speed measurement of the vehicle and the open and closed status of an automatic door can be monitored. The main contribution of the designed PCB is an adaptive learning algorithm (ALA) that uses the pulses of the encoder, estimates the position of the step, and manages the operation process to prevent mechanical damage at the final point of the motor. Furthermore, unexpected hitting and pinching which are defined as obstacles to the driver can be controlled by monitoring the current value drawn from the driver. The benefit of this method is that the life of the mechanical step is increased due to the management of the forward and backward step operation, preventing potential accidents. Full article

Brushed DC motors and generators (DCMs) are extensively used in various industrial applications, including the automotive industry, where they are critical for electric vehicles (EVs) due to their high torque, power, and efficiency. Despite their advantages, DCMs are prone to premature failure due to sparking between brushes and commutators, which can lead to significant economic losses. This study proposes two approaches for determining the temporal and frequency evolution of Shannon entropy in armature current and stray flux signals. One approach indirectly achieves this through prior analysis using the Short-Time Fourier Transform (STFT), while the other applies the Stockwell Transform (S-Transform) directly. Experimental results show that increased sparking activity generates significant low-frequency harmonics, which are more pronounced compared to mid and high-frequency ranges, leading to a substantial rise in system entropy. This finding enables the introduction of fault-severity indicators or Key Performance Indicators (KPIs) that relate the current condition of commutation quality to a baseline established under healthy conditions. The proposed technique can be used as a predictive maintenance tool to detect and assess sparking phenomena in DCMs, providing early warnings of component failure and performance degradation, thereby enhancing the reliability and availability of these machines. Full article

This comprehensive study presents a pioneering approach to limb lengthening, leveraging the advancements in wireless technology to enhance orthopedic healthcare. Historically, limb lengthening has been a response to discrepancies caused by fractures, diseases, or congenital defects, utilizing the body’s innate ability to regenerate bone and surrounding tissues. Traditionally, this involved external or internal fixation devices, such as the Ilizarov and Taylor Spatial frames or the Precice nail and Fitbone. The focal point of this research is the development and testing of a wireless intramedullary nail implant prototype, controlled remotely via a mobile application. This implant comprises a microcontroller, Bluetooth Low Energy module, a brushed DC motor controlled through an H-bridge, and a force sensor, all powered by medical-grade batteries. The integration of wireless technology facilitates patient autonomy in managing limb lengthening, reducing the need for frequent clinical visits. The methodology involves a detailed block diagram for our proposed work, outlining the process from treatment planning to the initiation of limb lengthening via the mobile application. Osteogenesis, the formation of new bone tissue, plays a crucial role in this procedure, which includes pre-surgery assessment, osteotomy, latency, distraction, consolidation, and removal phases. Key challenges addressed include custom battery design for efficient operation, size constraints, and overcoming signal interference due to the Faraday cage effect. Attenuation testing, simulating human tissue interaction, validates the implant’s connectivity. In conclusion, this research marks a significant stride in orthopedic care, demonstrating the feasibility of a wireless implant for limb lengthening. It highlights the potential benefits of reduced clinical visits, cost efficiency, and patient convenience. Despite limitations such as battery requirements and signal interference, this study opens avenues for future enhancements in patient-centered orthopedic treatments, signaling a transformative shift in managing limb length discrepancies. Full article

Brushless DC machines have demonstrated significant advantages in electrical engineering by eliminating commutators and brushes. Every year, these machines increase their presence in transportation applications. In this sense, early fault identification in these systems, specifically in the electronic speed controllers, is relevant for correct device operation. In this context, the techniques reported in the literature for fault identification based on the Hilbert–Huang transform have shown efficiency in electrical systems. This manuscript proposes a novel technique for early fault identification in electronic speed controllers based on the Hilbert–Huang transform algorithm. Initially, currents from the device are captured with non-invasive sensors in a time window during motor operation. Subsequently, the signals are processed to obtain pertinent information about amplitudes and frequencies using the Hilbert–Huang transform, focusing on fundamental components. Then, estimated parameters are evaluated by computing the error between signals. The existing electrical norms of a balanced system are used to identify a healthy or damaged driver. Through amplitude and frequency error analysis between three-phase signals, early faults caused by system imbalances such as current increasing, torque reduction, and speed reduction are detected. The proposed technique is implemented through data acquisition devices at different voltage conditions and then physical signals are evaluated offline through several simulations in the Matlab environment. The method’s robustness against signal variations is highlighted, as each intrinsic mode function serves as a component representation of the signal and instantaneous frequency computation provides resilience against these variations. Two study cases are conducted in different conditions to validate this technique. The experimental results demonstrate the effectiveness of the proposed method in identifying early faults in brushless DC motor drivers. This study provides data from each power line within the electronic speed controller to detect early faults and extend different approaches, contributing to addressing early failures in speed controllers while expanding beyond the conventional focus on motor failure analysis. Full article

With the recent conversion of internal combustion engines to electric vehicles, new noise issues have arisen, and among them, the noise generated by internal vehicle auxiliary systems is being considered. This study introduces an electronic filter designed with a motor model featuring vibration components, aiming to minimize the noise and vibrations generated by a Brushed DC (BDC) motor commonly employed in vehicle internal systems. It introduces a method to identify the connectors and internal parameters used in the motor for the matching of the model and experimental motor, and to measure and estimate these parameters. The model is separated and executed to ensure convergence, and it is validated by comparing the analysis results with the measured values. A filter is designed using the model to reduce current oscillations in the motor, confirming a subsequent reduction in noise and vibration. This research suggests the potential to attenuate noise and vibration in already produced motors by attaching only a filter without modifying the internal motor structure. Moreover, it is anticipated that a filter can be designed to predict and mitigate the noise and vibration components of the motor based on changes in load. Full article

Increasing the productivity and reliability of mining infrastructure facilities is an important task in achieving future goals. Mining dump trucks are an important part of coal mine infrastructure. In this article, to determine the reliability indicators in a brush–commutator unit and the residual life of electric motor brushes, a mathematical model for processing statistical data has been developed, which allows for the classification of types of failures and, unlike existing models, the determination of the life of the brushes according to the maximum extent of their wear. A method for predicting the residual life of an electric brush in a DC electric motor is presented, which contains a list of controlled reliability indicators, included a mathematical model. The described model improves the accuracy of the prediction and detection of DC motor failures. The derivation of the general formula for calculating the residual life of electric brushes is given. Based on the proposed mathematical model, we studied and calculated the reliability of the brush–commutator unit, the minimum height of the brush during operation, the average rate of its wear, the standard deviation and the mathematical expectation of brush wear. A nomogram of the failure-free operation time of the brush–commutator unit in a DC electric motor was modeled using the height of the brush during operation. Output parameters after the implementation of this monitoring system include the reliability of the electric motor operation. At the same time, diagnostic characteristics are improved twofold, and the residual life of the brush-switching unit is increased by 28–30%. Full article

Improving the productivity and reliability of mining infrastructure is an important task contributing to the mining performance enhancement of any enterprise. Open-pit dump trucks that move rock masses from the mining site to unloading points are an important part of the infrastructure of coal mines, and they are the main transport unit used in the technological cycle during open-pit mining. The failure of any of the mining truck systems causes unscheduled downtime and leads to significant economic losses, which are associated with the need to immediately restore the working state and lost profits due to decreased site productivity and a disruption of the production cycle. Therefore, minimizing the number and duration of unscheduled repairs is a necessity. The most time-consuming operations are the replacement of the diesel engine, traction generator, and traction motors, which requires additional disassembly of the dump truck equipment; therefore, special reliability requirements are imposed on these units. In this article, a mathematical model intended for processing the statistical data was developed to determine the reliability indicators of the brush collector assembly and the residual life of brushes of electric motors, which, unlike existing models, allow the determination of the refined life of the brushes based on the limiting height of their wear. A method to predict the residual life of an electric brush of a DC electric motor is presented, containing a list of controlled reliability indicators that are part of the mathematical model. Using the proposed mathematical model, the reliability of the brush-collector assembly, the minimum height of the brush during operation, and the average rate of its wear were studied and calculated. Full article

The paper introduces the development stages of a MOSFET-based controller for a DC brush motor. The main objective was to design a controller that could be integrated with the existing telemetry system, offering full configurability through an Android application. This controller aims to provide real-time analysis of data collected from the measurement system, including motor revolutions and current draw. Based on the analyzed data and the conditions set in the Android application, the controller adjusts the motor’s operational characteristics accordingly. The paper provides a comprehensive description of the controller system’s functioning. The proposed control system is particularly relevant in applications where minimizing energy consumption for driving a DC motor is of utmost importance. Full article

For Brush-less DC motors to function better under various operating settings, such as constant load situations, variable loading situations, and variable set speed situations, speed controller design is essential. Conventional controllers including proportional integral controllers, frequently fall short of efficiency expectations and this is mostly because the characteristics of a Brush-less DC motor drive exhibit non linearity. This work proposes a hybrid gray wolf optimization and proportional integral controller for management of the speed in Brush-less DC motors to address this issue. For constant load conditions, varying load situations and varying set speed situations, the proposed controller’s efficiency is evaluated and contrasted with that of PID controller, PSO-PI controller, and ANFIS. In this study, two PI controller are used to get the more stability of the system based on tuning of their coefficients with meta heuristic method. The simulation findings show that Hybrid GWO-PI-based controllers are in every way superior to other controllers under consideration. In this study, four case studies are presented, and the best-case study was obtained 0.18619, 0.01928, 0.00030, and 0.01233 for RMSE, IAE, ITAE, and ISE respectively. Full article

This study proposes 1D modeling that considers the noise and vibration of a vehicle window-brushed DC motor. The electrical and mechanical components of the brush DC motor are included, creating a model that considers noise and vibration. The model has a back electromagnetic force (EMF) including vibration components and is constructed based on an electric circuit and transfer functions. To ensure the reliability of the model, the back EMF, noise, and vibration experiment environment of the brushed DC motor were configured. The measured back EMF was applied to the model, and it was confirmed that the simulation results of the model were consistent with the measured noise and vibrations. Full article

The development of a proportional–integral–derivative (PID) control system is a simple, practical, highly effective method used to control the angular rotational velocity of electric motors. This paper describes the optimization of the PID control of a brushed DC motor (BDCM) with an embedded low-cost magnetic quadrature encoder. This paper demonstrates empirically that the feedback provided by low-cost magnetic encoders produces some inaccuracies and control artifacts that are not usually considered in simulations, proposing a practical optimization approach in order to improve the step overshoot and undershoot controller response. This optimization approach is responsible for the motion performances of a human-sized omnidirectional mobile robot using three motorized omnidirectional wheels. Full article

Mobile robots are increasingly used in industrial applications. There are many constructive solutions for mobile robots using various variants of actuation and control. The proposed work presents a low-cost variant of a mobile robot equipped with Mecanum wheels, which uses brushed DC motors, controlled by the PWM method as the actuation solution. In the first part, a multicriteria analysis based on the AHP method was performed for the selection of the actuation solution. Then, using the software tools Simscape Multibody, Matlab, and Simulink, models were developed that allowed the simulation of the operation of the proposed robot, based both on its kinematics and dynamics. Using these models, both the Mecanum wheel drive version and the differential drive version were studied by means of simulation. The simulations mainly aimed at identifying the way the currents vary through the wheel drive motors, in order to find methods to reduce them. The values obtained by the simulation were later compared with those obtained experimentally, and the corresponding conclusions with regard to the accuracy of the models were drawn. Full article

Brushed (B) and Brushless (BL) DC motors constitute the cornerstone of mechatronic systems regardless their sizes (including miniaturized), in which both position and speed control tasks require the application of sophisticated algorithms. This manuscript addresses the initial step using time series analysis to forecast Back EMF values, thereby enabling the elaboration of real-time adaptive fine-tuning strategies for PID controllers in such a control system design problem. An Auto-Regressive Moving Average (ARMA) model is developed to estimate the DC motor parameter, which evolves in time due to the system’s imperfection (i.e., unpredictable duty cycle) and influences the closed-loop performance. The methodology is executed offline; thus, it highlights the applicability of collected BDC motor measurements in time series analysis. The proposed method updates the PID controller gains based on the Simulink ™ controller tuning toolbox. The contribution of this approach is shown in a comparative study that indicates an opportunity to use time series analysis to forecast DC motor parameters, to re-tune PID controller gains, and to obtain similar performance under the same perturbation conditions. The research demonstrates the practical applicability of the proposed method for fine-tuning/re-tuning controllers in real-time. The results show the inclusion of the time series analysis to recalculate controller gains as an alternative for adaptive control. Full article

This paper is concerned with designing a dynamical synchronization (via a robust cooperative control) of an electromechanical system network (EMSN), consisting of nonidentical brushed DC motors, where only the motors’ angular velocity measurements are available. The challenge of the proposed approach is that the actuation provided by the motor needs to handle external disturbances to achieve the velocity tracking task and handle the interaction between both motors cooperatively to share the load and the disturbance rejection. The control’s basis involves differential flatness and an active disturbance rejection control (ADRC) framework augmented using ideas from the graph theory analysis and multi-agent networks. Experimental results verify the theoretical developments and show the effectiveness of the proposed control strategy despite unexpectedly changing load disturbance and parameters uncertainties. The proposed algorithm is suitable for embedded use due to its simplicity. It can be applied to a broad spectrum of mechatronic systems where dual-motor drive arrangements are necessary. Full article