Design and Development of an Efficient and Cost-Effective Brushless DC (BLDC) Motor Speed Controller for Electric Vehicle Application

Abstract

The global transition toward sustainable transportation has intensified the development of efficient and affordable electric vehicle (EV) propulsion systems. Among various electric motor technologies, the Brushless Direct Current (BLDC) motor has emerged as a preferred choice due to its high efficiency, high torque-to-weight ratio, and low maintenance requirements. However, the performance of BLDC motors in EV applications largely depends on the effectiveness of the motor speed controller responsible for regulating electrical power delivery. This study therefore designed and developed an efficient and cost-effective BLDC motor speed controller suitable for electric vehicle applications. The controller architecture integrates a microcontroller-based control unit, Hall-effect sensor feedback system, MOSFET three-phase inverter bridge, and Pulse Width Modulation (PWM) switching technique for speed regulation. The proposed system was modeled and simulated using PROTEUS software, followed by hardware implementation through the fabrication of a custom printed circuit board (PCB). Experimental testing was conducted using a 48 V BLDC motor under varying load conditions to evaluate speed regulation, efficiency, and switching performance. Simulation results indicated stable operation within a PWM switching range of 10–20 kHz with voltage ripple below 5%. Experimental results showed that the motor achieved a maximum speed of approximately 3000 RPM with a peak efficiency of 94% and maintained efficiency above 85% under load conditions. The findings demonstrate that the developed controller provides an efficient and cost-effective solution for electric vehicle propulsion systems.