Modeling of BLDC Motor with Enhanced Controller Tuning: Employing Golden Eagle Optimization for Efficient Automated Manufacturing Systems

BLDC motors are more energy-efficient and durable than DC motors or induction motors. Considering the reliable and substantial design, most modern industry applications prefer BLDC motors in their automated manufacturing plants. Control of a 3-Phase BLDC motor is quite complex compared to others. In this paper, the physical modeling of the 3-Phase BLDC motor and a six-step commutation logic design with a two-level MOSFET-based inverter configuration has been designed. Further, the closed-loop speed control using PI controller is developed using MATLAB Simulink. A novel nature-inspired algorithm called the Golden Eagle Optimization (GEO) technique is used to obtain the optimal gain for the PI controller by running the optimization algorithm in the obtained system model (transfer function) without affecting the physical design. The test has been performed using the Speedgoat performance real-time target machine for Hardware-In-the-Loop (HIL) testing. The real-time results for various setpoints and load conditions were obtained and discussed in detail.