Educational BLDC Control Platform
Cost-effective ESP32-based BLDC motor controller for Maxon motors with Hall sensor and encoder support. Web-accessible platform for university lab courses.
Overview
This project was developed as my Bachelor’s thesis at Cracow University of Technology. The goal was to create a cost-effective, self-contained BLDC motor controller that could serve as an educational platform for continuous process control courses.
Students access the device through a web browser (via WiFi or Ethernet), design their own speed or position controllers, and interact with a real Maxon BLDC motor in real-time.
Hardware
The entire hardware was designed from scratch, optimized for cost and manufacturability:
- Microcontroller: ESP32 with integrated WiFi, sufficient PWM channels, and low cost
- Motor interface: 3-phase inverter stage compatible with Maxon BLDC motors
- Feedback: Hall sensor inputs and incremental encoder interface for position and speed measurement
- Connectivity: WiFi and Ethernet (LAN) for reliable access in a university lab environment
- Power supply: On-board regulation from a single DC bus input
Software
The firmware and web interface were developed in close collaboration with my thesis supervisor. My primary contribution was the complete hardware design; I was also heavily involved in the software architecture and integration:
- Web interface: Browser-based control panel where students configure and deploy custom controllers
- Controller framework: Modular architecture allowing students to build regulators (speed, position, cascaded) and test them on real hardware
- Data acquisition: Real-time measurement streaming for step responses, Bode plots, and transient behavior analysis
Educational Use
The platform was designed for laboratory sessions in continuous process control. Students connect via a browser with no software installation required, design a controller, set parameters, deploy it to the real motor, and observe real-time feedback. Multiple control strategies can be compared on identical hardware.
Results
The platform was successfully deployed for educational use and demonstrated that an ESP32-based system can deliver reliable motor control performance suitable for university-level teaching at a significantly lower cost than off-the-shelf alternatives.