Haileyesus Getenet - Ru 1550/09 Ru 2908/09 Ru 1465/09 Ru 2569/09 RT 0007/09

JIMMA UNIVERSITY
JIMMA INSTITUTE OF TECHNOLOGY

FACULTY OF ELECTRICAL AND COMPUTER ENGINEERING
PROJECT TITLE: - SPEED SYNCHRONIZATION OF BLDC MOTORS IN
TEXTILE INDUSTRIES
4TH YEAR INDUSTRIAL CONTROL STREAM
GROUP 2
GROUP MEMBERS ID NO.
1. HAILEYESUS GETENET----------------------------------RU 1550/09
2. AFEWORK MELESE RU 2908/09
3. DAGIM TEMESGEN RU 1465/09
4. HANA DEBELA RU 2569/09
5. YOSEF GIRMA RT 0007/09
ADVISOR: PRASHANTH A. (Dr.)
SUBMISSION DATE:JAN 15, 2021

SPEED SYNCHRONIZATION OF BLDC MOTORS IN TEXTILE INDUSTRIES 2021
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ACKNOWLEDGMENT
We appreciate God Almighty for strength, grace and enablement to start and complete the
project. We also grateful to our advisor Dr. Prashanth A. for his guidance and supervision, which
led us to the completion of this project.
Finally, we would like to thank all our friends who while working on their respective projects
created a great learning environment.
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TABLE OF CONTENTS
ACKNOWLEDGMENT..............................................................................................................................I
LIST OF FIGURES...................................................................................................................................III
ABSTRACT..............................................................................................................................................IV
ACRONYMS..............................................................................................................................................V
CHAPTER ONE.........................................................................................................................................1
INTRODUCTION......................................................................................................................................1
1.1....................................................................................................... BACKGROUND
1
1.2...............................................................................STATEMENT OF THE PROBLEM
2
1.3.......................................................................................................... OBJECTIVES
3
1.3.1....................................................................................... GENERAL OBJECTIVE
3
1.3.2.......................................................................................... SPECIFIC OJECTIVE
3
1.4............................................................................................ SCOPE OF THE STUDY
3
1.5................................................................................................. PROJECT OUTLINE
3
CHAPTER TWO........................................................................................................................................4
LITERATURE REVIEW............................................................................................................................4
CHAPTER THREE....................................................................................................................................6
METHODOLOGY AND SYSTEM BLOCK DIAGRAM.........................................................................6
3.1..................................................................................................... METHODOLOGY
6
3.2 BLOCK DIAGRAM........................................................................................................................8
3.2.1.......................................................................BLOCK DIAGRAM DESCRIPTION
9
CHAPTER FOUR....................................................................................................................................13
SYSTEM DESIGN...................................................................................................................................13
CHAPTER FIVE......................................................................................................................................17
SIMULATION RESULT AND DISCUSSION........................................................................................17
CHAPTER SIX........................................................................................................................................20
CONCLUSION AND RECOMMENDATION........................................................................................20
6.1......................................................................................................... CONCLUSION
20
6.2............................................................................................... RECOMMENDATION
21
REFERENCES.........................................................................................................................................22
APPENDIX..............................................................................................................................................23
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LIST OF FIGURES
Figure 3.1 Flow Chart......................................................................................................................7
Figure 3.2 Block Diagram...............................................................................................................8
Figure 3.3 Power Source..................................................................................................................9
Figure 3.4 LCD................................................................................................................................9
Figure 3.5 Arduino Uno.................................................................................................................10
Figure 3.6 DC Motor.....................................................................................................................11
Figure 3.7 Motor Drive..................................................................................................................11
Figure 3.8 Potentiometer...............................................................................................................12
Figure 3.9 Push-Button..................................................................................................................12
Figure 4.1 Arduino Uno Connection.............................................................................................13
Figure 4.2 LCD Connection..........................................................................................................14
Figure 4.3 Motor Drive Connection..............................................................................................14
Figure 4.3 Potentiometer Connection............................................................................................15
Figure 4.4 Push-Button Connection..............................................................................................15
Figure 4.5 System Design..............................................................................................................16
Figure 5.1 State of motors.............................................................................................................17
Figure 5.2 Result with 25% of duty cycle.....................................................................................18
Figure 5.3 Result with duty cycle of 75%.....................................................................................19
Figure 5.4 Result with duty cycle of 100%...................................................................................19
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ABSTRACT
There are several processes involved through which clothes come out of a mill from its basic raw
material. Besides, the requirements of the motors are different for different processes. For
instance, blowing process has a motor speed approximately twice than the looming process.
While the looming process has a motor speed almost twice as that of ginning process. So, in
various industries speed synchronization of the motor plays a major role mainly, in textile
industries. The main aim of this project is to synchronize the speed of this motors. So that
balanced tension is achieved to avoid clothes from getting damaged. In this project motors are
synchronized to reduce the differential speed error among multiple motors. One motor acts as a
master and the rest as slaves. Brush Less Direct Current Motors (BLDC) are used and operate on
the basis of potentiometer as a wide sense of Pulse Width Modulation (PWM) control. The pulse
width output (input potentiometer reading) from the microcontroller would be automatically
adjusted to maintain the DC power to the motor such that the desired speed percentage matches
the running Rotation Per Minute. The above operation is carried out by using L293D IC motor
drive for driving the BLDC motor which, duly interfaced from the microcontroller.
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ACRONYMS
BLDC – BRUSHLESS DIRECT CURRENT
PWM – PULSE WIDTH MODULATION
DC – DIRECT CURRENT
PI – PROPORTIONAL INTEGRAL
CAN – CONTROLLER AREA NETWORK
DSP – DIGITAL SIGNAL PROCESSING
RF – RADIO FREQUENCY
MOSFET – METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR
PCO – PROCESS CONTROL OUTLET
LCD – LIQUID CRYSTAL DISPLAY
CPU – CENTRAL PROCESSING UNIT
GND – GROUND
IC – INTEGRATED CIRCUIT
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CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND
Textile fibers provided an integral component in modern society and physical structure known
for human comfort and sustainability. Man is a friend of fashion in nature. The desire for better
garment and apparel result, the development of textile fiber production and textile manufacturing
process. Primarily the natural textile fibers meet the requirements for human consumption in
terms of the comfort and aesthetic trends. Cotton, wool and silk were the important natural fibers
for human articles, where cotton for its outstanding properties and versatile utilization was
known as king cotton.
Today, the textile industry encompasses a significant number and variety of processes that are
adding value in fiber. These processes may range over the yarn making through the garment
stitching, fabric embossing, and composite production. However, considering the textile fiber as
the basic building unit of any textile product, the textile manufacturing may clearly be identified
as the conventional and technical textiles. The conventional textile manufacturing process has a
long history of converting the natural fiber into useful products including fabric, home textiles,
and apparel and more recently into a technical textile through the utilization of special finishing
effects. In general, the conventional post-fiber formation processes may mainly be classified as
physical and chemical textile manufacturing processes. A physical process is required to convert
the textile fiber into yarn; nonwoven, woven, knitted and etc. while the chemical processes are
sizing, desizing, scouring, bleaching, printing, and etc. Thus to meet this processes many types of
electrical machines(motors) which depend on a wide range of parts and components to function
are used and mainly BLDC motors are used in these industries [1].
Due to the excellent torque characteristics, wide-speed range, high efficiency, reliability and high
power to volume ratio, the brushless DC motors are used in several distinctive applications like
industrial engineering. A high-precision positioning drives are possible with outstanding
controllability of this motor. These motors do not have brushes, but these must be electronically
commutated to have its functionality [2].
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The requirement of these motors are different for different processes. For instance, the ginning
process which is separating of seeds from the raw cotton has a motor speed of 250-1450 rpm.
While the looming processes which is weaving of yarn into cloth has 600-750 rpm motors’ speed
that is almost as double as ginning for lower speed considerations (300-400 rpm). On the other
hand, the blowing process which clean and opens up the ginned cotton has 1000-1500 rpm that is
almost as double as looming [1].
So, to meet these speed of motors for each stages, synchronization of these motors are required.
This synchronization motors’ speed is operating as one motor acts as a master and the rest as
slaves on the basis of potentiometer adjusting the motors speed to meet the desired speed. The
above operation is carried out by L2938D IC motor drive for driving the BLDC motor which,
duly interfaced from the microcontroller.
1.2 STATEMENT OF THE PROBLEM

Direct current (DC) motors have been widely used in many industrial applications such as
electric vehicles, steel rolling mills, electric cranes, and robotic manipulators due to precise,
wide, simple and Continuous control characteristics. The development of high performance
motor drives is very important in Industrial applications mainly in textile engineering. In textile
industries a sudden change in load cause hunting and oscillatory behavior in DC machine. This
behavior can be harmful to the process. Besides, differential speed error among multiple motors
creates the unbalanced tension which resulting clothes getting damaged. In addition to this the
non-linearity characteristics of a DC motors such as saturation in friction could reduce traditional
controller performance as traditional techniques are used to controller the speed motor.
So in order to avoid this outcome this project design the synchronization of this BLDC motors
which operate on the basis of adjusting potentiometer as a wide sense of Pulse Width Modulation
(PWM) control. This pulse width output (potentiometer variation) from the microcontroller
would be automatically adjusted to maintain the DC power to the motor such that the desired
speed percentage matches the running Rotation Per Minute. Having this the synchronization is
done by using microcontroller chip which controls the master slave operation i.e. the slave
motors’ speed
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is followed by the master motor’s speed by interfacing it with L2938D IC motor drive for driving
the BLDC motor. The system applicable area is on the early stages of the manufacturing process.
1.3 OBJECTIVES
1.3.1 GENERAL OBJECTIVE
The main objective of this project is to design and implement speed synchronization of
BLDC motors in industries using microcontroller.
1.3.2 SPECIFIC OJECTIVE
 To find out the all necessary components with their corresponding functions.
 To integrate all components of the circuit.
 To design the overall system.
 To implement the overall designed system.
1.4 SCOPE OF THE STUDY

This project is motor speed synchronization in its most basic form, having potentiometer which
uses for controlling the speed of a motors, motor drives and motors. All of this parameters are
interfaced to Arduino microcontroller which used to synchronize the speed of motors.
Moreover, based on required speed, microcontroller defines different ranges of speed and
updates those accordingly of the potentiometer readings.
1.5 PROJECT OUTLINE

This project outlined introduction containing background, statement of the problem, objectives
and scope of the study in chapter one, whereas chapter two deals with the literature review.
Subsequently, chapter three contains methodology and block diagram then again chapter four
contains design and modelling of overall system. Followingly, chapter five deals with
simulation result and discussion. Finally, chapter six allocates conclusion and recommendations.
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CHAPTER TWO
LITERATURE REVIEW
Mohamed S. Zaky [3] “Self-tuning PI controller for the speed control of electrical motor
drives” says that PI controller gains are adjustable parameters and depending on the speed error
that will be updated online. PI controller gives a high degree of accuracy in the presence of
external disturbance. PI controllers is not simultaneously meeting good step reference tracking
and also not provide good load torque rejection as well as it gives slow response large overshoots
and oscillations.
Xiaoyuan Zhu, Hui Zhang, Zinge Fang [4] “Speed synchronization control for
integrated automotive motor transmission power train system with random relays” says that
integrated motor transmission power train system in which driving motor and multi-gearbox is
directly connected. Controller Area Network (CAN) is used in that system with random delays in
in both feedback and forward channel and the speed synchronization is done and motor speed is
control. The drawback is that transient performance of control system is reduced with significant
overshoot and produce vibrations in the power train system. The steady state speed
synchronization error is very high and cannot be stabilized because of random oscillations.
F. Beltran-Carbajala, A. Valderrabano-Gonzalezb, J.C., Rosas-Carob, A. Favela-

Conrerasca Univesidad [5] stated the method for achieving the co-ordination and
synchronization of multiple motors on line using DSP is. The co-ordination and synchronization
control of motion of multiple motors is a challenging problem, since the synchronization of each
individual motor can be influenced by many factors. This paper presents the concept and
implementation of a scheme that uses a real time control approach to realize drive
synchronization of the multiple motors. A new Master-Slave configuration is developed.
Imperfect synchronization can be corrected on-line using DSP. Also, this paper shows the
advantages of using DSP controllers for such applications. Finally, experimental and simulation
results are provided to validate the performance. Since the system introduces the inaccessible
controllers to deal with its hard to implement the system as necessary as its to be.
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Aditya Sharma, Dhruva K. S. Rathore, Vidhi Verma [6] stated wireless speed
synchronization of Motors in industry. Many industries like textile industries, automation
industries, paper mills etc., conveyer belts are often used. These conveyer belts are used to
transfer the raw material or the produced material from one place to another. For a feasible
operation, the conveyer belt must run at exact speed at all locations. This means motors should
run at a synchronized speed. This project demonstrates a prototype to achieve synchronization of
multiple motors such that the motors can run exactly at the same speed, as desired by the user.
The speed is set for the master motor at the desired rate. Here a RF communication method is
used to transmit this speed to the other slave motors, so that those motors can run at the same
speed. For each motor, a speed sensing unit is attached to sense the speed. The speed controls of
the motors are achieved by each microcontroller connected with a MOSFET. The feedback value
from the sensor is not quite accurate as it depends on the intensity of light, and also the RF
communication is not feasible as its explained to be.
Ganiyu, R. A., Shoewu, O., Olantinwo, S. O., Omitalo, O. O. [7] “Development

of a Microcontroller Based Motor Speed Control System Using Intel 8051” says that the motor
speed control system requires a closed loop real time system where a very high optical encoder is
connected to motor shaft and provide a feedback signal through micro controller. Microcontroller
is acts as a proportional controller. However, at very high gain, it causes the speed response of
the control loop to becomes steady state oscillations and this increment in gain causes speed up
the motor and be damaged.
Having this, in order to rectify these drawbacks, we proposed another way to synchronize the
speed of BLDC motors in which one motor acts as a master and the rest as slaves. Brush Less
Direct Current Motors (BLDC) are used and operate on the basis of potentiometer as a wide
sense of Pulse Width Modulation (PWM) control. The pulse width output (input from
potentiometer reading) from the microcontroller would be automatically adjusted to maintain the
DC power to the motor such that the desired speed percentage matches the running Rotation Per
Minute. The above operation is carried out by using L2938D IC motor drive for driving the
BLDC motor which, duly interfaced from the microcontroller.
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CHAPTER THREE
METHODOLOGY AND SYSTEM BLOCK DIAGRAM
3.1 METHODOLOGY
The operation of the motors’ speed controlling system was well organized and coordinated for an
efficient performance. There were several stages that had been gone in order to complete this
project successfully. First the literature review of BLDC motors’ speed synchronization in textile
manufacturing were studied. In this stage, we try improving earlier project in order to make some
modification on it and also avoid some drawbacks from it. Then we chose compatible
components that could fit for the project. Subsequently, we studied how these components
integrated. Then we constructed block diagram for speed synchronization of BLDC motors in
textile industries using microcontroller based on the components integration and explained each
of the components.
Afterward, we designed and made modelling of the overall system. After that, we constructed the
circuit diagram depending on the designation and modelling made. Then using simulating
software called proteus we modelled and compiled the overall system and set the results we
gained. Accordingly, we discussed about each result we gained. Followingly, we concluded the
project based on the results and discussion. Finally, we gave recommendation.
As well the methodology we followed was shown in flow below.
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Start
Introducing system background

and objectives with problem
identification
Theoretical study of BLDC motors’ speed

synchronization in textile industries.
Study how the components are useful and integrated
Design block diagram and describe each components
Modelling the overall system
Test the result and making conclusion
Finish
Figure 3.1 Flow Chart
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3.2 BLOCK DIAGRAM
POWER
SUPPLY LCD 2
LCD 1
SLAVE
MOTOR
POT
MASTER SLAVE
MASTER MOTOR MICROCONTROLLER
MICROCONTROLLER
SLAVE
MOTOR
Figure 3.2 Block Diagram
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3.2.1 BLOCK DIAGRAM DESCRIPTION
POWER SUPPLY
It is a two terminal device which can maintain a fixed voltage and also it is the dual of a current
source.
VIN
230v
Figure 3.3 Power Source

LCD
LCD modules are very commonly used in most embedded projects, the reason being its cheap
price, availability and programmer friendly. Most of us would have come across these displays in
our day to day life, either at PCO’s or calculators. It has an operating Voltage of 4.7V to 5.3V. It
can display alphabets and numbers. Consists of two rows and each row can print 16 characters.
LCD2
LM041L
VSS VDD VEE
RS RW E
D0 D1 D2 D3 D49 8D57 D6 D7
21
54
Figure 3.4 LCD
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ARDUINO
Arduino Uno is the popular Arduino due to its smaller size and compatibility with software and
hardware in the system. The smaller size of the controller helps its easily fit with any
development board and designers can carry easily around the boarding system. It has a stronger
CPU similar to other Arduino microcontrollers. It has 14 digital input/output pins (of which 6
can be used as PWM outputs), 6 analog inputs, a 16MHz ceramic resonator, a USB connection, a
power jack, an ICSP header, and a reset button. It contains everything needed to support the
microcontroller. It has VIN, 5V, 3V3, GND as power ports and Serial: RX, TX, External
interrupts: 2 and 3, PWM: 3,5,6,9,10 and 11, SPI: 10, 11, 12, 13, LED: 13, TWI: A4 and A5,
AREF, Reset as communication ports.
ARD3
AREF
PB5/SCK 13 PB4/MISO 12
RESET ~PB3/MOSI/OC2A 11
~ PB2/SS/OC1B 10
~ PB1/OC1A 9
PB0/ICP1/CLKO 8
PD7/AIN1 7
ATMEGA328P-PU
1121
~ PD6/AIN0 6
A0
A1 PC0/ADC0 DI ~PD5/T1 5
AN
A2 PC1/ADC1 GI PD4/T0/XCK 4
A3 PC2/ADC2 AL
TA ~ PD3/INT1 3
A4 PC3/ADC3 O PD2/INT0 2
L
A5 PC4/ADC4/SDAG TX PD1/TXD 1
PC5/ADC5/SCL (~ RX PD0/RXD 0
IN
P
ARDUINO UNO R3
Figure 3.5 Arduino Uno
Has better feedback with simple system applications with sensors, GPS, motor controls, or alarm.
DC MOTOR
A DC motor is any of a class of rotary electrical motors that converts direct current electrical
energy into mechanical energy. The most common types rely on the forces produced by
magnetic fields. Nearly all types of DC motors have some internal mechanism, either
electromechanical or electronic, to periodically change the direction of current in part of the
motor.
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+88.8
Figure 3.6 DC Motor
MOTOR DRIVE
L293D is a typical motor drive which allows DC motor to drive on either direction. It’s a 16- pin
IC which can control a set of two DC motors simultaneously in any direction, meaning, two DC
motors can be controlled by single L293D IC. Its dual H-bridge motor driver integrated circuit.
16 8 U3
2 3
IN1 VSS VS OUT1
7 6
IN2 OUT2
1
EN1
9
EN2
10 11
IN3 OUT3
15 14
IN4 GND GND OUT4
L293D
Figure 3.7 Motor Drive
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POTENTIOMETER
A potentiometer is a three-terminal resistor with a sliding or rotating contact that forms an
adjustable voltage divider. If only two terminals are used, one end and the wiper, it acts as a
variable resistor or rheostat.
RV4
50%
1k
Figure 3.8 Potentiometer
PUSH BUTTON
A push-button or simply button is a simple switch mechanism to control some aspect of a
machine or a process. Buttons are typically made out of hard material, usually plastic or metal.
The surface is usually flat or shaped to accommodate the human finger or hand, so as to be easily
depressed or pushed.
Figure 3.9 Push-Button
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CHAPTER FOUR
SYSTEM DESIGN
DC VOLTAGE SOURCE
It is a two terminal device which can maintain a fixed voltage and also it is the dual of a current
source. In this project regulated power source with 5V value to the L293D IC and potentiometer
and 12V value for the DC motor is given.
ARDUINO UNO
In this project two Arduino Uno microcontrollers are used to control the speed of DC motors.
Each Arduino Uno is connected to motor drive IC, potentiometer, LCD and push-buttons.
Figure 4.1 Arduino Uno Connection
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LCD
In this project two LCD are used 16x2 and 16x4 to display the duty cycle of the speed of the
motors and state of the motors. Its connected to pins of the two Arduino Uno microcontrollers.
LCD2
LM016L
VSS VDD VEE
RS RW E
9 87D6 D7
21
54
D0 D1 D2 D3 D4 D5
GND SOURCE POT
4567
Figure 4.2 LCD Connection
MOTOR DRIVE
In this project two L293D IC are used which is connected to the three motors and the Arduino
Uno microcontrollers output pins.
DC SOURCE
168 U2
3
2 6
10 7
VSS
IN1 IN2 EN1 VS OUT1
9 OUT2
1
11
9 +88.8
EN2 IN3 IN4
10 11
15 OUT3 GND OUT4
14
GND
L293D
Figure 4.3 Motor Drive Connection
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DC MOTOR
In this project three DC motors is used one, which is connected to the master Arduino
microcontroller whereas, the other two motors are connected to the slave microcontroller. And
each motors are connected to L293D IC motor drive.
POTENTIOMETER
In this project a potentiometer is used as an input for adjusting desired motor speed. Its
connected to the master Arduino Uno microcontroller which then sent to the slaves by means of
parallel connection.
POTENTIOMETER
A0
50%
1k
Figure 4.3 Potentiometer Connection
PUSH BUTTON
In this project couple of push-buttons are used for each motors to start and stop these motors.
These push-buttons are connected to the two microcontrollers pins.
A1 A2
START STOP
Figure 4.4 Push-Button Connection
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The system designation is as follows; potentiometer, start and stop push-buttons are connected to
the input port of the master Arduino Uno microcontroller which is port A0, Al, A2 respectively.
Meanwhile, L293D IC motor driver and LCD are connected to the output ports of the master
Arduino Uno microcontroller which are port B and port D respectively. However, for the slave
four push-buttons are interfaced to Arduino Uno microcontroller while the two motors are
interfaced with single L293D IC motor drive with and LCD interfacing is similar as that of the
master.
The system designation is shown on the figure below.
LCD3
LM041L
RV3(2)
RV2(2) LCD1 RV3

LM016L
RV2
1k
ARD2
VSS VDD VEE
RS RW E
8 7 D6 D7
VSS VDD VEE
RS RW E
8 7 D6 D7
1k
21
54
D0 D1 D2 D3 D49D5
21
54
D0 D1 D2 D3 D49D5
ARD1
AREF
START M2 13
PB5/SCK 12
PB4/MISO 11
RESET
~PB3/MOSI/OC2A 10
ATMEGA328P-PU
STOP M2 ~ PB2/SS/OC1B 9
1121
DI ~ PB1/OC1A 8
A GIPB0/ICP1/CLKO
AREF N
RV1(2) T PD7/AIN1 7
PB5/SCK 13 A
PB4/MISO 12 A
L L ~PD6/AIN0 6
A0
RESET ~PB3/MOSI/OC2A 11 A1 PC0/ADC0 O (~ ~ PD5/T1 5
ATMEGA328P-PU
~ PB2/SS/OC1B 10 A2 PC1/ADC1 G P PD4/T0/XCK 4

RV1
1121
DI ~ PB1/OC1A 9 A3 PC2/ADC2 W ~ PD3/INT1 3

A PB0/ICP1/CLKO 8
GI A4 PC3/ADC3 M PD2/INT0 2 U2(VS)
3%
N T PD7/AIN1 7 A5 PC4/ADC4/SDA TX PD1/TXD 1

A A PC5/ADC5/SCL RX PD0/RXD 0
U2(UVS2S)
MOTOR2
L L ~PD6/AIN0 6 16 8
A0
A1 PC0/ADC0 O (~ ~ PD5/T1 5 U1(VS)
A2 PC1/ADC1 G P PD4/T0/XCK 4 ARDUINO UNO R3 2 IN1 VSS VS OUT1 3
1kA3 PC2/ADC2 W ~ PD3/INT1 3 U1(VSS)
STOP M3 7 IN2OUT2 6 +88.8
A4 PC3/ADC3 M PD2/INT0 2 1 EN1
A5 PC4/ADC4/SDA TX PD1/TXD 1
PC5/ADC5/SCL RX PD0/RXD 0 16 8 U1 START M3 MOTOR3
9 EN2
2 IN1 VSS VS OUT1 3 10 IN3 OUT3 11
ARDUINO UNO R3 7 IN2 OUT2 6 15 IN4 GND GND OUT4 14
1 EN1 MOTOR1 +88.8
9 EN2 L293D
10 IN3 OUT3 11 +88.8
15 IN4 GND GND OUT4 14
START M1 STOP M1
L293D
Figure 4.5 System Design
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CHAPTER FIVE
SIMULATION RESULT AND DISCUSSION
The working principle is that the motors can run solely meaning that motor1, motor2 and motor3
can run independently but when the three motors are running simultaneously the speed of motors
controlled by the slave microcontroller follows the speed of the motor controlled by the master
controller with a ratio of 2 and 0.5 for motor2 and motor3 respectively.
LCD3
LM041L
RV3(2)
RV2(2) LCD1 RV3

LM016L
RV2
1k
ARD2
VSS VDD VEE
RS RW E
D0 D1 D2 D3 D4 D5 D6 D7
21
54
87
VSS VDD VEE
RS RW E
21
54
87
D0 D1 D2 D3 D4 D5 D6 D7
1k
ARD1
AREF
START M2 PB5/SCK 13
12
PB4/MISO 11
RESET
~PB3/MOSI/OC2A 10
STOP M2 ~ PB2/SS/OC1B 9
~ PB1/OC1A 8
ATMEGA328P-PU
AREF PB0/ICP1/CLKO
RV1(2)
1121
PB5/SCK 13 PD7/AIN1 7
PB4/MISO 12 DI
A GI
A0 N ~ PD6/AIN0 6
RESET ~PB3/MOSI/OC2A 11 A1 PC0/ADC0 TA ~ PD5/T1 5
10 PC1/ADC1
AL L 4
RV1 ~ PB2/SS/OC1B A2 PC2/ADC2 O PD4/T0/XCK 3
(~
~ PB1/OC1A 9 8 A3
A4 PC3/ADC3 G
~ PD3/INT1
ATMEGA328P-PU
PB0/ICP1/CLKO P PD2/INT0 2 U2(VS)

IN
A5 PC4/ADC4/SDA
1121
W TX PD1/TXD 1
MOTOR2
50%
DI PD7/AIN1 7 PC5/ADC5/SCL M) RX PD0/RXD 0 U2(VSS)

A GI U2
6 16 8
A0 PC0/ADC0 N ~PD6/AIN0 5
A1 PC1/ADC1 AL
TA U1(VS)
L ~ PD5/T1 4
ARDUINO UNO R3 2 3
1kA2 PC2/ADC2 A3 PC3/ADC3 O
(~
PD4/T0/XCK 3
U1(VSS)
STOP M3 7 IN1 VSS VS OUT1 6
A4 PC4/ADC4/SDA
G ~ PD3/INT1 2 1 IN2 OUT2
A5 PC5/ADC5/SCL P PD2/INT0 1 EN1 0.00
IN W TX PD1/TXD 0 U1 START M3 MOTOR3
M) RX PD0/RXD 16 8
9
10 EN2
2 3 11
7 IN1 VSS VS OUT1 6 15 IN3 OUT3 14
ARDUINO UNO R3
1 IN2 OUT2 MOTOR1 IN4 GND GND OUT4
EN1
0.00
L293D
EN2
IN3 OUT3 11
15 IN4 GND GND OUT4 14
START M1STOP M1 +235
L293D
Figure 5.1 State of motors
As shown from the above figure motor1 is running while motor2 and motor3 are on stopping
state. On this similar reference motor2 and motor3 can run solely even if motor1 is not running.
That is, because of the master controller commands the speed to the slave microcontroller and
will send the state of the potentiometer to the motor2 and motor3 as soon as the power goes on.
This phenomenon helps the motor2 and motor3 to run solely.
17
G.C
As seen on the figure below the system is running at the duty cycle of 25%. In this phenomenon
motor1 is running at 123 rpm while motor2 is running at 246 rpm which is twice the speed of
motor1 whereas motor3 is running at 61.5 rpm which is half the speed of motor1
ARD2
VSS VDD VEE
RS RW E
8 7 D6 D7
D0 D1 D2 D3 D49D5
21
54
AREF
PB5/SCK 13
12
PB4/MISO
RESET 11
~PB3/MOSI/OC2A
~ PB2/SS/OC1B 10
~ PB1/OC1A 9
8
PB0/ICP1/CLKO
ATMEGA328P-PU
7
PD7/AIN1
1121
6
A0 A1 A2 A3 A4 A5
PC0/ADC0 PC1/ADC1 PC2/ADC2 PC3/ADC3 DI ~PD6/AIN0 5
A PC4/ADC4/SDA PC5/ADC5/SCL~PD5/T1
GI 4
N PD4/T0/XCK
TA ~ PD3/INT1 3
AL 2 U2(VS)
L PD2/INT0
O TX PD1/TXD 1
(~ MOTOR2
G RX PD0/RXD 0 U2(VSS)
P 168 U2
W
ARDUINO UNO R3 2 IN1 VSSVS OUT1 3
STOP M3 7 6
IN2 EN1 OUT2
1
+246
U1 START M3 MOTOR3
EN2
IN3 OUT311
3 15IN4 GND OUT414
6 MOTOR1 GND
+61.5
L293D
11
14 +123
Figure 5.2 Result with 25% of duty cycle
As show on the figure below the system is running at the duty cycle of 75%. In this condition
motor1 is running at 373 rpm whereas motor2 is running at 747 rpm which is twice the speed of
motor1 and motor3 is running at 187 rpm which is half the speed of motor1.
18
G.C
VSS VDD VEE

ARD2
RS RW E
8 7 D6 D7
21
54
D0 D1 D2 D3 D49D5
AREF
13
PB5/SCK 12
PB4/MISO 11
RESET ~PB3/MOSI/OC2A 10
~ PB2/SS/OC1B 9
~ PB1/OC1A
8
ATMEGA328P-PU
PB0/ICP1/CLKO
1121
DI 7
AN PD7/AIN1 6
GI ~ PD6/AIN0
A0 AL 5
PC0/ADC0 TA ~ PD5/T1
A1
PC1/ADC1 O 4
A2 L PD4/T0/XCK
PC2/ADC2 G 3
A3
PC3/ADC3 (~ ~ PD3/INT1
2
A4 IN PD2/INT0 U2(VS)
A5
PC4/ADC4/SDA P TX PD1/TXD
1
PC5/ADC5/SCL U2(VSS) MOTOR2
RX PD0/RXD
16 8 U2
ARDUINO UNO R3 2 3
0 IN1 VSS VS OUT1
7 6
IN2 OUT2
1 +747
EN1
U1 STOP M3 MOTOR3
9 EN2 11
3 10 IN3 OUT3
START M3
6
MOTOR1 15
IN4 GND GND OUT4
14
+187
L293D
11
14 +373
Figure 5.3 Result with duty cycle of 75%
As show on the figure below the system is running at the duty cycle of 100%. In this condition
motor1 is running at 496 rpm whereas motor2 is running at 993 rpm which is almost twice the
speed of motor1 and motor3 is running at 248 rpm which is half the speed of motor1.
21
54
87
AREF
13
PB5/SCK
12
PB4/MISO
RESET 11
~PB3/MOSI/OC2A
10
~ PB2/SS/OC1B 9
~ PB1/OC1A
8
ATMEGA328P-PU
PB0/ICP1/CLKO
1121
DI PD7/AIN1
7
A0 A GI ~ PD6/AIN0
6
PC0/ADC0 N 5
A1 TA ~ PD5/T1
PC1/ADC1 AL 4
A2
PC2/ADC2 O
L PD4/T0/XCK 3
A3
PC3/ADC3 (~ ~ PD3/INT1 2 U2(VS)
A4 G
PC4/ADC4/SDA P TX PD2/INT0 1
A5 PD1/TXD
PC5/ADC5/SCL W RX PD0/RXD 0 U2(VSS) MOTOR2
16 8 U2
ARDUINO UNO 2 3
R3 STOP M3 7
IN1 VSS VS OUT1
6
IN2 OUT2
1 +993
EN1
START M3 MOTOR3
U1
9 EN2 11
10 IN3 OUT3
3
6
MOTOR1 15
IN4 GND GND OUT4
14
+248
L293D
11
14 +498
L293D
Figure 5.4 Result with duty cycle of 100%
19
G.C
CHAPTER SIX
CONCLUSION AND RECOMMENDATION
6.1 CONCLUSION
Today, the textile industry encompasses a significant number and variety of processes that are
adding value in fiber. There are several processes involved through which clothes come out of a
mill from its basic raw material. These process are physical and chemical processes. A physical
process is required to convert the textile fiber into yarn; nonwoven, woven, knitted and etc. while
the chemical processes are sizing, desizing, scouring, bleaching, printing, and etc. Thus to meet
this processes many types of electrical machines(motors) which depend on a wide range of parts
and components to function are used and mainly BLDC motors are used in these industries.
Having this, this project design the synchronization of this BLDC motors which operate on the
basis of adjusting potentiometer as a wide sense of Pulse Width Modulation (PWM) control.
This pulse width output (potentiometer variation) from the microcontroller would be
automatically adjusted to maintain the DC power to the motor such that the desired speed
percentage matches the running Rotation Per Minute. The system applicable area is on the early
stages of the manufacturing processes like ginning, blowing, cording and looming.
20
G.C
6.2 RECOMMENDATION
In this project the system has tried to address the problems that can be faced in textile industries
and provides the solution to these problems. Yet the system has some drawbacks on how the
communication between the master and slave microcontrollers can be done. In order to meet
these drawbacks, the scope of the system can be further improved and expanded by using
wireless techniques meaning through internet based or using any other wireless modules. And
also by using PIC microcontrollers instead of Arduino microcontrollers.
21
G.C
REFERENCES
[1] JU’S, Drive Considerations for Textile industry (2016).
[2] Tarun Agarwal, How to Control Brushless DC Motor in Electrical Field (2014).
[3] Mohamed S. Zaky “Self tuning PI controller for the speed control of electrical motor drives”,
Electrical Power Systems Research 119 (2015) 293-303.
[4] Xiaoyuan Zhu, Hui Zhang, Zinge Fang “Speed synchronization control for integrated
automotive motor transmission power train system with random relays”,
Mechanical Systems and Signal Processing 64-65 (2015) 46-57.
[5] F. Beltran-Carbajala, A. Valderrabano-Gonzalezb, J.C., Rosas-Carob, A. Favela- Conrerasca

Univesidad “Method for achieving the co-ordination and synchronization of
multiple motors on line using DSP”, Electrical Power Systems Research vol.3
122(2015) 218-233.
[6] Aditya Sharma, Dhruva K. S. Rathore, Vidhi Verma “Wireless speed synchronization of
Motors in industry (2015).
[7] Ganiyu, R. A., Shoewu, O., Olantinwo, S. O., Omitalo, O. O. “Development of a

Microcontroller Based Motor Speed Control System Using Intel 8051.”
22
G.C
APPENDIX
// Master Microcontroller
#include <LiquidCrystal.h>
LiquidCrystal lcd(2, 3, 4, 5, 6,
7) #define potentiometer
A0 #define bt_F A1
#define bt_S A2
#define sender 0
#define M1_Ena 11
#define M1_in1 10
#define M1_in2 9
int read_ADC =0; int duty_cycle ; int duty_cycle_lcd; int set
=0; void setup()
{ Serial.begin(9600);
pinMode(potentiometer, INPUT);
pinMode(sender,OUTPUT);
pinMode(bt_F, INPUT_PULLUP);
pinMode(bt_S, INPUT_PULLUP);
pinMode(M1_Ena, OUTPUT);
pinMode(M1_in1, OUTPUT);
pinMode(M1_in2, OUTPUT);
lcd.begin(16,2);
lcd.setCursor(0,0);
lcd.print("Welcome to Mini");
lcd.setCursor(0,1);
lcd.print("Project");
delay(500);
lcd.clear();}
void loop(){
23
G.C
read_ADC =analogRead(potentiometer);
duty_cycle = map(read_ADC,0 ,1023,0,255);
duty_cycle_lcd = map(read_ADC, 0, 1023, 0, 100);
digitalWrite(M1_Ena, HIGH);
lcd.setCursor(0,0);
lcd.print("Duty cycle ");
lcd.print(duty_cycle_lcd);
lcd.print("% ");
if(digitalRead (bt_F) == 0){set =1;}
if(digitalRead(bt_S) == 0){set=0;}
lcd.setCursor(0,1);
if(set==0){
lcd.print(" M1 Stopping
"); digitalWrite(M1_in1,
LOW); digitalWrite(M1_in2,
LOW);} if(set==1){
lcd.print(" M1 Forward ");
analogWrite(M1_in1, duty_cycle);
digitalWrite(M1_in2, LOW);
analogWrite(sender,read_ADC);
}delay(50);}
// Slave Microcontroller
#include <LiquidCrystal.h>
LiquidCrystal lcd(2, 8, 4, 5, 6,
7); #define potentiometer
A0 #define bt_FS1 A1
#define bt_S1 A2
#define bt_FS2 A3
#define bt_S2 A4
24
G.C
#define M1_Ena 12
#define M1_in1 10
#define M1_in2 9
#define M1_in3 11
int read_ADC =0; int read_ADC1 =0; int read_ADC2 =0; int duty_cycle ; int
duty_cycle1 ; int duty_cycle_lcd; int duty_cycle_lcd1; int set =0; int set1 =0;
void setup()
{ Serial.begin(9600);
pinMode(potentiometer, INPUT); pinMode(bt_FS1, INPUT_PULLUP); pinMode(bt_S1, INPUT_PULLUP);
pinMode(bt_FS2, INPUT_PULLUP); pinMode(bt_S2, INPUT_PULLUP); pinMode(M1_Ena, OUTPUT);
pinMode(M1_in1, OUTPUT); pinMode(M1_in2, OUTPUT); pinMode(11, OUTPUT);
lcd.begin(16,4);
lcd.setCursor(0,0);
lcd.print("Welcome to
Mini"); lcd.setCursor(0,1);
lcd.print("Project");
delay(500);
lcd.clear();}
void loop(){read_ADC =analogRead(potentiometer);
int read_ADC1 = 0.5*read_ADC;
int read_ADC2 = 2*read_ADC;
duty_cycle = map(read_ADC1,0, 512, 0,255);
duty_cycle1 = map(read_ADC2,0 ,2047,0,255);
duty_cycle_lcd = map(read_ADC1, 0, 512, 0, 100);
digitalWrite(M1_Ena, HIGH);
lcd.setCursor(0,0);
lcd.print("Duty cycle ");
lcd.print(duty_cycle_lcd);
lcd.print("% ");
25
G.C
if(digitalRead (bt_FS1) == 0){set =1;}
if(digitalRead (bt_FS2) == 0){set1 =1;}
if(digitalRead(bt_S1) == 0){set=0;}
if(digitalRead(bt_S2) == 0){set1=0;}
lcd.setCursor(0,1);
if(set==0){
lcd.print(" M2 Stopping
"); digitalWrite(M1_in1,
LOW); digitalWrite(M1_in2,
LOW);} if(set1==0){
lcd.print(" M3 Stopping ");
digitalWrite(11, LOW);
digitalWrite(M1_in2, LOW);}
if(set==1){
lcd.print(" Forward M2");
analogWrite(M1_in1,duty_cycle1);
//analogWrite(11,duty_cycle);
if(set1==1){
lcd.print(" Forward M3 ");
//analogWrite(M1_in1,duty_cycle1);
analogWrite(11,duty_cycle);
}delay(50);}
26

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JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

SUBMISSION DATE:JAN 15, 2021

PWM – PULSE WIDTH MODULATION

CAN – CONTROLLER AREA NETWORK

DSP – DIGITAL SIGNAL PROCESSING

MOSFET – METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR

PCO – PROCESS CONTROL OUTLET

LCD – LIQUID CRYSTAL DISPLAY

CPU – CENTRAL PROCESSING UNIT

1.2 STATEMENT OF THE PROBLEM

1.3.2 SPECIFIC OJECTIVE

1.4 SCOPE OF THE STUDY

1.5 PROJECT OUTLINE

F. Beltran-Carbajala, A. Valderrabano-Gonzalezb, J.C., Rosas-Carob, A. Favela-

Ganiyu, R. A., Shoewu, O., Olantinwo, S. O., Omitalo, O. O. [7] “Development

As well the methodology we followed was shown in flow below.

Introducing system background

Theoretical study of BLDC motors’ speed

Study how the components are useful and integrated

Design block diagram and describe each components

Modelling the overall system

Test the result and making conclusion

Figure 3.1 Flow Chart

3.2 BLOCK DIAGRAM

Figure 3.2 Block Diagram

3.2.1 BLOCK DIAGRAM DESCRIPTION

Figure 3.3 Power Source

Figure 3.4 LCD

Figure 3.5 Arduino Uno

Figure 3.6 DC Motor

Figure 3.7 Motor Drive

Figure 3.8 Potentiometer

Figure 3.9 Push-Button

Figure 4.1 Arduino Uno Connection

VSS VDD VEE

Figure 4.2 LCD Connection

Figure 4.3 Motor Drive Connection

Figure 4.3 Potentiometer Connection

Figure 4.4 Push-Button Connection

The system designation is shown on the figure below.

RV2(2) LCD1 RV3

VSS VDD VEE

~ PB2/SS/OC1B 10 A2 PC1/ADC1 G P PD4/T0/XCK 4

DI ~ PB1/OC1A 9 A3 PC2/ADC2 W ~ PD3/INT1 3

N T PD7/AIN1 7 A5 PC4/ADC4/SDA TX PD1/TXD 1

Figure 4.5 System Design

RV2(2) LCD1 RV3

VSS VDD VEE

PB0/ICP1/CLKO P PD2/INT0 2 U2(VS)

DI PD7/AIN1 7 PC5/ADC5/SCL M) RX PD0/RXD 0 U2(VSS)

Figure 5.1 State of motors

VSS VDD VEE

Figure 5.2 Result with 25% of duty cycle

VSS VDD VEE

Figure 5.3 Result with duty cycle of 75%

Figure 5.4 Result with duty cycle of 100%

[5] F. Beltran-Carbajala, A. Valderrabano-Gonzalezb, J.C., Rosas-Carob, A. Favela- Conrerasca

[7] Ganiyu, R. A., Shoewu, O., Olantinwo, S. O., Omitalo, O. O. “Development of a

int read_ADC =0; int duty_cycle ; int duty_cycle_lcd; int set

=0; void setup()

duty_cycle = map(read_ADC,0 ,1023,0,255);