Design-and-Implementation-of-an-Improved-Automatic-DC-Motor-Speed-Control-Systems-Using-Microcontroller.pdf

www.idosr.org Edozie et al
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©IDOSR Publication
International Digital Organization for Scientific Research ISSN:2579-079X
IDOSR JOURNAL OF SCIENCE AND TECHNOLOGY 9(1):107-119, 2023.
Design and Implementation of an Improved Automatic DC Motor Speed
Control Systems Using Microcontroller
1
Enerst Edozie, 2
Eze Val Hyginus Udoka, 1
Wantimba Janat
1
Department of Electrical Engineering, Kampala international University, Uganda
2
Department of Publication and Extension, Kampala International University, Uganda
ABSTRACT
Energy wastage is one of the major challenges that is facing the world now as there is
insufficient supply of energy and the little ones supplied was not appropriately used. This
energy wastage has made many researchers to engage more on the research to stop this
energy waste as a result of inappropriate allocation of energy to some devices even when
they don’t need it. This research work was able to design and implement an improved
automated DC Motor speed controller system using microcontroller successfully. The
software used for this research work were Fritzing software and Arduino Nano. This project
was able to improve on the working system of the DC Motors and energy was automatically
and successfully saved. The system runs entirely on Bluetooth technology which consumes
less power than other devices. The Android application is user-friendly with enhanced
Wireless communication. This design was successfully developed and implemented with 80%
accuracy. The design was able to work effectively by increasing the cutting speed when the
softness of the material decreases and as the cutting tool material becomes stronger, the
cutting speed increases. This showed that the design is effectively and efficiently developed
with less energy/power consumption which is the earnest desire of an Engineer as it reduces
cost.
Keywords: Microcontroller, Improved Automatic DC Motor, Energy, Arduino, PWM
INTRODUCTION
Most of the industrial process requires to
be run on the certain parameters since
almost all the industries require motors in
their operation to either increases or
decrease the speed of the machine. Speed
control of dc motor could be achieved
using various mechanical or electrical
techniques but this research project will
basically focus on Pulse with Modulation
(PWM) technique. Pulse with modulation is
a modulation technique that generates
variable pulses width to represent the
amplitude of an analog input signal. By
using pulse with modulation (PWM)
technique, it is easy to control the average
power delivered to a load and hence made
it easy to control the speed of the DC
motor. Pulse width modulation control
works by switching the power supplied to
the motor on and off very rapidly and the
DC voltage is converted to a square wave
signal, alternating between full (nearly
12v) and zero, giving the motor a series of
power “kicks”. Pulse width modulation
techniques is a technique for speed control
which can overcome the problem of poor
starting performance of a motor
[1][2][3][4][5].
The electric drive systems used in many
industrial applications require higher
performance, reliability and variable
speed. The speed control of DC motor is
important in applications where precision
and protection are of importance. DC
Motors are used in many systems in our
day to day life which include running
cranes, lifts, hair drier, electric footing,
vacuum cleaner and in speed regulation
applications such as wiper. DC motor is an
electric motor that runs on direct current
power. It works on the fact that a current-
carrying conductor placed in a magnetic
field experiences a force that causes it to
rotate with respect to its original

108
position. Practical DC Motor consists of
field windings to provide the magnetic flux
and armature which acts as the conductor.
The input of a brushless DC motor is
current/voltage and its output is torque
[6][7][8][9][10][4].
Furthermore, the challenge of controlling
speed of motors used by different
machines to a desired speed level required
by the machine is always paramount to
avoid wastage of energy. This problem of
machines not been rated according to the
required energy consumption which made
the DC motor to be running at high speed
while it needs to be operating at low speed
has led to high energy or power
consumption [2][1] [13] [14].
From the extensive review, it was observed
that many others have never considered
the problem of wastage of energy as many
DC motors in machine were designed to be
consuming energy more than required as
there is no auto-regulator embedded on it.
This research work will solve the problem
of inappropriate allocation of DC motors in
a machine without auto-control system.
This research work will showcase the best
way to control the speed of DC Motor using
Pulse Width Modulation (PWM) technique
coupled with android mobile phone
Bluetooth applications. Smart phones have
in-built Bluetooth technology which an
external Bluetooth module and Arduino
Uno microcontroller will be interfaced
them for easy communication [15] [16] [17]
[18] [19] [20]. The Bluetooth module
receives command from the android
mobile phone through the help of Arduino
whereas MOSFET can be used to vary the
voltage as well as the speed of the DC
motor using PWM technique. The main
objective of this research paper is to
Design and Implement an Improved
Automatic DC Motor Speed Control
Systems Using Microcontroller that will be
conservative in saving power/energy.
METHODOLOGY
This system was designed based on the
following sequential methods:
i. The system was designed using
the Fritzing software which is a
circuit design simulation
software
ii. A circuit board was used to
connect the different electronic
components following the
circuit design that was done
using Fritzing software.
iii. Microcontroller was
programmed using Arduino
Uno/C++ software language
with a computer.
iv. A Control Panel interface was
made using Bluetooth software
and an android phone was used
to connect to the Bluetooth
Module first and then the control
panel will be used to run the
entire system. This means that
the Control Panel is able to
switch the system ON or OFF and
also control the speed.
System design
The system design of the proposed system
uses two architecture designs which
involve the power supply, input stage,
control stage and output stage. This setup
consists of two basic primary elements
communicating Bluetooth devices such as
(i) Bluetooth of smartphone which is
connected to the Arduino microcontroller,
and DC Motor interfaced with a switch and
(ii) a Bluetooth module HC-05. Figure 1 is
the systematic block diagram of energy
flow in the designed system.

109
Input stage Controller stage Output stage
Figure 1: Block Diagram of Energy flow in the circuit
Bluetooth Module
Bluetooth serial communication module is
one of the input device in this project
design and it has two work modes: order-
response work mode and automatic
connection work mode. And there are three
work roles at the automatic connection
work mode. When the module is at the
automatic connection work mode, it will
follow the default way set lastly to
transmit the data automatically. When the
module is at the order response work
mode, user can send the AT command to
the module to set the control parameters
and sent control order. The work mode of
this Module can be switched by controlling
the module PIN (PIO11) input level. In this
project Bluetooth module is used to send
signals from the Arduino Uno.
Figure 2: Bluetooth module
Arduino Nano is one of the controller in
this research design on 8-bit ATmega328P
microcontroller. It also consists of other
components such as crystal oscillator,
serial communication, voltage regulator,
etc. to support the microcontroller.
Arduino Nano has 14 digital input/output
pins (out of which 6 can be used as PWM
outputs), 8 analog input pins, a USB
connection, A Power barrel jack, an ICSP
header and a reset button. The
ATmega328P microcontroller provides
UART TTL (5V) serial communication
Power
supply
ARDUINO NANO
(Microcontroller)
Sends signals to DC
Motor as per the
value of data
packets
Android
App sends
Data
packets
DC Motor
Bluetooth
module
receives
these data
packets

110
which can be done using digital pin 0 (Rx)
and digital pin 1 (Tx).
Figure 3: Arduino Nano
Android Phone: Android phone was used
as an input which contains the Control
Panel that will be used to control the
system.
Table 1: Component used for the Design and its Specifications
Items Quantity Items Quantity
NE555P TIMER IC 1 100 nF Capacitor 2
1KΩ Resistor 2 1N4007 Diode 3
100KΩ
Potentiometer
1 Transistor (Darlington TIP122) 1
12V Power Supply 1 12V DC Motor 1
Connecting Wire ½ roll Transformer (12-0-12) 1
1N4007 Diode 4 Capacitor (470 μF, 25V) 1
Capacitor (0.1 μF) 2 Regulator (IC2 7812) 1
4.7 KΩ Resistor 1 LED bulb 1
Designing steps 1: The components of the system have been connected as shown in the
circuit diagram of figure 4.
Figure 4: Schematic Circuit Diagram of a Dc Motor Using Pulse Width Modulation

111
The system has been designed by Fritzing
software since it is among the best latest
of circuit design software and corporate all
of the devices used to come up with the
prototype. Figure 4 is a simple illustration
of how the system was implemented and
the various components that’s made up
the system.
Step 1b: The connection of the Arduino
and Bluetooth module: This circuit is built
using only three components: Arduino
NANO, the Bluetooth module HC05, and a
Darlington transistor TIP122. The HC05
has four interfacing pins: Vcc, GND, Tx,
and Rx. Here, the Vcc pin is given a 5-V
supply from the Arduino board and the
GND pin is connected with the board’s
ground. The Tx and Rx pins are connected
with Arduino’s pins D4 and D5,
respectively.
Figure 5: Schematic Circuit Diagram of Arduino NANO and Bluetooth module HC05
The circuit connections were followed
below to build the System. The PWM output
pin D3 drives the 12-V DC motor using the
TIP122. It’s connected to TIP122’s base
terminal through the current limiting 330-
ohm resistor. The TIP122 is used to
amplify the current, providing the
required current to the motor. The DC
motor is connected between the collector
output and the 12-V supply. The TIP122’s
emitter terminal is connected to the
ground.
Step 1c: connection of the Dc motor and power supply
Figure 6: Schematic Circuit Diagram of a Dc Motor and TIP 122 Transistor
D3 connected to the
Base of TIP 122
Collector
Emitter
Ground terminal

112
Circuit operation: The circuit controls the
speed of the 12-V DC motor using the
Android app on a smartphone. The app
sends the commands to start or stop the
motor and to change the speed of the
motor via the smartphone’s Bluetooth.
These commands are received by the HC05
module, which passes them on to the
Arduino NANO via the Tx and Rx pins. As
per the commands sent over, Arduino will
run or stop the DC motor, or vary its speed
from minimum to maximum. Arduino
generates a PWM signal on its D3 pin to run
or stop the motor or to vary the motor
speed. To stop the motor, the pulse width
on the pin D3 is 0 (0%). And to run the
motor at full speed, it’s 255 (100%). So, as
Arduino changes the pulse width on its D3
pin, the motor speed changes from min to
max — or vice versa. Arduino can also send
a change in motor speed (0 to 100 %) from
the HC05 module to the smartphone’s app.
The Android app will then display this
motor speed value on an analog dial (or
speed dial).
Step 2: Launch the “blink program” to
test the board status: Open your Arduino
software from your computer and follow
the steps as shown in the figure 7
Figure 7: How launch the “blink program” to test the board status
Step 3: Select the Arduino Nano Board type

113
Figure 8: Selection of Arduino Nano Board type
Step 4: The program code in the Arduino software: Copy and paste this gate code in your
Arduino software as shown below:
#include<SoftwareSerial.h>
SoftwareSerial bt_ser(4,5);
char c[6];
int i=0, speed_value=150,send_value;
bool fan_on_flag = false;
void setup()
{
Serial.begin(9600);
bt_ser.begin(9600);
analogWrite(3,0);
Serial.println(“DC Motor speed control using android app”);
}
void loop()
{
while(bt_ser.available())
{
if(bt_ser.available()>0)
{
c[i] = bt_ser.read();
Serial.print(c[i]);
i++;
}
if(c[i-1]==’N’)
{
analogWrite(3,speed_value);
fan_on_flag = true;
i=0;
}
if(c[i-1]==’F’)
{
analogWrite(3,0);
fan_on_flag = false;
i=0;

114
}
if(c[i-1]==’#’)
{
speed_value = (c[1]-48)*100+(c[2]-48)*10+(c[3]-48)*1;
send_value = map(speed_value,100,255,0,100);
if(fan_on_flag) analogWrite(3,speed_value);
Serial.print(speed_value);
Serial.print(‘t’);
Serial.println(send_value);
bt_ser.print(“*D”);
bt_ser.print(send_value);
bt_ser.print(‘*’);
i=0;
}
}
}
Step 5: Select serial COM port: Connect
the Arduino NANO to the computer’s USB
port using a using a USB cable and then
select the Serial COM port to be used. For
example, in the illustration figure 10 serial
COM port 15 was selected.
Figure 9: Select Board type
Step 6: Verify and upload the Arduino software program

115
Figure 11: Verified Arduino software and Uploaded Arduino software program
Step 6: Build the Android app or Panel:
The Android application is built using the
“Bluetooth Electronics” application, which
is available for free on Google Play. First,
download and install the “Bluetooth
Electronics” app on your Android phone
and open it. It will ask if you want to turn
“ON” the device’s Bluetooth. Allow it to do
so. Once the app starts, you’ll see a few
readymade control panels that control
Arduino-based projects. Perhaps the most
interesting feature of this app. It also
allows the users to build a customized
panel to control Arduino projects.
The Arduino panel that controls the app
is built as show below: The panel consists
of a green and red button to turn the
mother “ON” or “OFF.” It also has one
slider to vary the motor speed and one dial
to view the motor speed.
1. Select one green button. Then, go to the
right corner of the screen and edit the
button properties as follows:
Press Text: N
Release Text:
2. Choose the text size with either a small
or medium font, and write “Motor ON.”
3. Select one red button and edit its
properties as follows:
Press Text: F
Release Text:
4. Choose the text size with either a small
or medium font, and write “Motor OFF.”
5. Select the biggest slider from the slider
options and edit its properties as follows:
Min Value: 100
Max value: 255
Select “Send on slider change”
String starts with: *
String Ends with: #
6. Go to the indicator options and choose
the analog dial. Edit its properties like this:
Receive character: D
Min Text: 0
Max Text: 100
min value: 0
max value: 100
leave default all others
7. Write all of the other text, such as “min”,
“max”, “motor speed”, “speed indicator”
etc., as you choose.
And that’s it! Your android app is ready to
control the DC motor speed.
Running the project

116
1. Connect the circuit as per the given
schematic on the bread board or on the
general purpose PCB.
2. Give the 12-V power supply to the
circuit.
3. Initially, the motor is not moving and is
in the stop position. The HC05 module will
start blinking to indicate it’s searching for
the device.
4. Start the “Bluetooth electronics”
application in your smartphone, ensuring
the Bluetooth is “ON.”
5. Press the connect button so it searches
for the HC05 module. When the device is
found, select “HC05” and press connect.
When doing so for this first time, you’ll
have to enter passkey “1234.”
6. Once the HC05 is connected, press done.
7. Now, you can run your panel.
8. From the panel, press the green button
to start the motor or the red button to stop
it.
9. While the motor is running, change the
slider to vary the motor speed.
10. As the slider moves, the speed dial will
indicate the motor speed (from 0 to 100%).
Table 2: Description of Methodology
Objective Method Description / purpose
Types motor
uses
-Interview
-Statistical
analysis
Factories and industries will be visited randomly for an
interview schedule aimed at getting the following data; to
know the different motors in their factories and industries.
The purpose of this exercise is to know the advantages and
disadvantages of different types of motors in those
factories and industries and also to know problems
associated with different motors in different factories and
industries.
Methods
speed control
of motors.
-Interview
-Internet
-search
Engineers from different factories and industries will be
interviewed about the different methods the employ in
controlling the speed of motors in these different factories
and industries. The purpose of this is to know the
challenges these factories and industries face during speed
control of motors.
PWM
technique
-Library and
internet
search
The university academic library and the internet sites will
be visited to obtain the following; relevant engineering text
books to discover the right information required upon the
pulse width modulation. The purpose of this research will
help in material selection to be used.

117
RESULTS AND DISCUSIONS
Figure 12: Hardware Assembly of the Components
The hardware assembly of the components
as diagram of the circuit was as shown in
figure 12, this showed the sequential flow
of the programs in the system.
RESULTS
This designed system has to undergo
testing which will require running the
system using the Control Panel of the
phone which should be able to switch the
system ON or OFF and vary the speed of
the DC Motor from Minimum to Maximum
speeds.
Table 3: Cutting Rotational Speed for Material
No Tests (Material) Results (RPM)
1. Mild steel 100
2. Carbon steel 80
3. Aluminum 230-235
4. Soft brass 175
5. Cast Iron 100
6. Annealed stainless 80-100
Table 4 showed the cutting speed (usually
in feet per minute) of a tool when it is
cutting the work. It is observed from table
4 that as the softness of the material
decreases, the cutting speed increases and
as the cutting tool material becomes
stronger, the cutting speed increases. This
showed that the design is effective and
efficient and as well conserves energy and
power usage.
Table 4 showed the cutting rotation speed
of an electrical machine in radian per
minute. It was observed from table 4 that
all ultra-high-speed materials were
operated on jointly with power electronics
and control systems. This obviously safes
Table 4: Cutting Rotational speed of Electrical Machines
No Tests (Material) Results (RPM)
1. Axial Machines 30,000-48,000
2. Hysteresis motors 30,000-60-000
3. Turbo molecular pumps 200-1,000,000
4. Turbine Generators 700,000-840,000
5. Robot/mechatronics 400,000
6. Electric motor and small power
spindles
200,000
7. Drilling machine 85,000-370,000

118
energy and power the rotation speed is
relative to the material it is operating on
whereas same material observes the same
speed.
Summary of the findings
The testing is done in stages, this helped
to identify the current and voltage flow in
the circuit. It was done in different
intervals to confirm the current and
voltage in the circuits. The results from the
tests done, confirmed that the design and
implementation of thesystem is
doingexactly what it was designed for and
therfore the deisgn was succesful.
CONCLUSION
Energy consumption is increasingly
becoming high over time, which is
becoming costly because of no speed
control measures. This project was able to
improve on the working system of the
Motors which shall be used to run the
machines using an automated control
system which saves energy and power
from being wasted. The system runs
entirely on Bluetooth technology which
consumes less power than other devices.
The Android application is user-friendly
with enhanced Wireless communication.
This design was successfully developed
and implemented with 80% accuracy. The
design was able to work effectively by
increasing the cutting speed when the
softness of the material decreases and as
the cutting tool material becomes
stronger, the cutting speed increases. This
showed that the design is effective and
efficient and as well conserves energy and
power usage which is the earnest desire of
an Engineer as it reduces cost.
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