This paper presents a structured and experimentally validated approach to the parameter identification, modeling, and real-time speed control of a brushless DC (BLDC) motor. Electrical parameters, including resistance and inductance, were measured through DC and AC testing under controlled conditions, respectively, while mechanical and electromagnetic parameters such as the back electromotive force (EMF) constant and rotor inertia were determined experimentally using an AVL dynamometer. The back EMF was obtained by operating the motor as a generator under varying speeds, and inertia was identified using a deceleration method based on the relationship between angular acceleration and torque. The identified parameters were used to construct a transfer function model of the motor, which was implemented in MATLAB/Simulink R2024b and validated against real-time experimental data using sinusoidal and exponential input signals. The comparison between simulated and measured speed responses showed strong agreement, confirming the accuracy of the model. A proportional–integral (PI) controller was developed and implemented for speed regulation, using a low-cost National Instruments (NI) USB-6009 data acquisition (DAQ) and a Kelly controller. A first-order low-pass filter was integrated into the control loop to suppress high-frequency disturbances and improve transient performance. Experimental tests using a stepwise reference speed profile demonstrated accurate tracking, minimal overshoot, and robust operation. Although the modeling and control techniques applied are well known, the novelty of this work lies in its integration of experimental parameter identification, real-time validation, and practical hardware implementation within a unified and replicable framework. This approach provides a solid foundation for further studies involving more advanced or adaptive control strategies for BLDC motors.

Accurate modeling and performance analysis of brushless DC (BLDC) motors are essential for high-efficiency control in modern drive systems. In this article, a BLDC motor was modeled using system identification techniques. In addition, experimental data were collected from the BLDC motor, including its speed response to various input signals. Using system identification tools, particularly those provided by MATLAB/Simulink R2024b, an approximation model of the BLDC motor was constructed to represent the motor’s dynamic behavior. The identified model was experimentally validated using various input signals, demonstrating its accuracy and generalizability under different operating conditions. Additionally, a series of mechanical load tests was conducted using the AVL eddy-current dynamometer to evaluate performance under practical operating conditions. Fixed load torques were applied across a range of motor speeds, and multiple torque levels were tested to assess the motor’s dynamic response. Electrical power, mechanical power, and efficiency of the entire system were computed for each case to assess overall system performance. Moreover, the real-time state of charge (SOC) of Lithium-ion (Li-ion) battery was estimated using the Coulomb counting method to analyze the impact of Li-ion battery energy level on the BLDC motor efficiency. The study offers valuable insights into the motor’s dynamic and energetic behavior, forming a foundation for robust control design and real-time application development.

This study presents a comprehensive experimental investigation of a 2.2 kW brushless DC (BLDC) motor integrated with a three-shaft planetary gearbox, focusing on overall energy efficiency, battery state of charge (SOC) estimation, and real-time speed control under variable load conditions. In the first stage, the gearbox transmission ratio was experimentally verified to establish the kinematic relationship between the BLDC motor and the eddy current dynamometer shafts. In the second stage, the motor was operated in open loop mode at fixed reference speeds while variable load torques ranging from 1 to 7 N.m were applied using an AVL dynamometer. Electrical voltage, current, and rotational speed were measured in real time through precision transducers and a data acquisition interface, enabling computation of overall efficiency and SOC via the Coulomb counting method. The open loop results demonstrated that maximum efficiency occurred in the intermediate-to-high-speed region (2000 to 2800 rpm) and at higher load torques (5 to 7 N.m) while locking the third gearbox shaft produced negligible parasitic losses. In the third stage, a proportional–integral–derivative (PID) controller was implemented in closed loop configuration to regulate motor speed under the same variable load scenarios. The closed loop operation improved the overall efficiency by approximately 8–20 percentage points within the effective operating range of 1600–2500 rpm, reduced speed droop, and ensured precise tracking with minimal overshoot and steady-state error. The proposed methodology provides an integrated experimental framework for evaluating the dynamic performance, energy efficiency, and battery utilization of BLDC motor planetary gearbox systems, offering valuable insights for electric vehicle and hybrid electric vehicle (HEV) drive applications.

This study presents an experimental investigation of open- and closed-loop speed control applied to a 2.2 kW brushless DC (BLDC) motor integrated with a planetary gearbox and evaluated under variable-speed and fixed-load conditions. The aim is to characterize the dynamic response, energy-conversion efficiency, and battery state-of-charge (SOC) behavior of the powertrain under real-time control strategies. A complete laboratory platform was developed using a commercial BLDC motor controller, a 60 V–17.4 Ah lithium-ion battery pack, an optical speed sensor, and an eddy-current dynamometer capable of applying load torques from 1.5 to 7.5 N·m. Open-loop operation regulated speed through direct voltage modulation, whereas closed-loop control was implemented using a proportional–integral–derivative (PID) algorithm executed in real time on a microcontroller. Real-time measurements of voltage, current, torque, and speed were used to compute electrical power, mechanical power, and system efficiency, while battery SOC variation was estimated using the Coulomb-counting method. The results indicate that open-loop control exhibits substantial speed-tracking errors, pronounced transient power surges during speed transitions, reduced efficiency, and an increased SOC depletion rate over the investigated speed range of 1000–2600 rpm. In contrast, the closed-loop PID controller maintains steady-state speed errors within approximately 1 % across all load levels, suppresses current fluctuations, mitigates transient losses, and enhances overall system efficiency by approximately 14–19 percentage points. Closed-loop operation further reduces SOC depletion by 0.49–0.75 percentage points, depending on the applied load torque. These findings demonstrate the effectiveness of feedback control in improving stability, energy utilization, and electric powertrain performance in BLDC-based propulsion systems, with direct relevance to electric-vehicle and hybrid powertrain systems.