Implement Sensorless Field-Oriented Control for BLDC Motors with Arduino

Implementing Sensorless Field-Oriented Control for a BLDC Motor Using TMC5160 with Arduino for Precise Speed Regulation

This tutorial will guide you through the process of implementing sensorless field-oriented control (FOC) for a Brushless DC (BLDC) motor using the TMC5160 driver and an Arduino. By the end of this guide, you will be able to achieve precise speed regulation for your BLDC motor.

Prerequisites

• Basic knowledge of Arduino programming
• Understanding of BLDC motor operation
• Familiarity with electronics and circuit design

Parts/Tools

• Arduino board (e.g., Arduino Uno or Mega)
• TMC5160 stepper motor driver
• BLDC motor
• Power supply suitable for your motor (e.g., 12V, 24V)
• Connecting wires
• Arduino IDE installed on your computer
• Library for TMC5160 (e.g., TMCStepper library)

Steps

1. Connect the Hardware
   • Connect the TMC5160 driver to the Arduino:

     
                     Arduino Pin   TMC5160 Pin
                     --------------------------
                     GND            GND
                     5V             VCC
                     D2             STEP
                     D3             DIR
                     D4             CS
                     

   • Connect the BLDC motor to the TMC5160 according to the manufacturer’s wiring diagram.
   • Make sure to connect the power supply to the TMC5160 driver.
2. Install Required Libraries
   • Open the Arduino IDE.
   • Go to Sketch > Include Library > Manage Libraries…
   • Search for and install the TMCStepper library.
3. Write the Arduino Code
   • Open a new sketch in Arduino IDE.
   • Include the necessary libraries:

     
                     #include 
                     #define EN_PIN           8
                     #define DIR_PIN          3
                     #define STEP_PIN         2
                     #define CS_PIN           10
                     

   • Initialize the TMC5160 in the setup function:

     
                     TMC5160Stepper driver(CS_PIN);
                     void setup() {
                         Serial.begin(115200);
                         driver.begin();
                         driver.rms_current(600); // Set motor RMS current
                         driver.en_pwm_mode(1); // Enable PWM mode
                     }
                     

   • Implement the loop function for control:

     
                     void loop() {
                         // Add speed control logic here
                     }
                     

4. Implement Sensorless FOC
   • Write the algorithm for sensorless control incorporating the TMC5160’s features.

     
                     void loop() {
                         float speed = readSpeed(); // Function to read desired speed
                         driver.set_pwm_freq(1000); // Set PWM frequency
                         driver.set_direction(speed); // Control direction based on speed
                     }
                     

   • Test the motor at various speeds to ensure performance.

Troubleshooting

• If the motor does not spin:
  • Check all connections and ensure the power supply is adequate.
  • Verify the code for correct pin assignments.
  • Make sure the driver is properly enabled.
• If the motor spins erratically:
  • Adjust the PWM frequency settings.
  • Check the current settings to ensure they match your motor’s ratings.

Conclusion

By following this tutorial, you’ve successfully implemented sensorless field-oriented control for a BLDC motor using the TMC5160 driver with Arduino. You should now have a system capable of precise speed regulation. Experiment with different parameters and settings to optimize performance further!