BLDC Motor Controller

Project Introduction
Summary
The goal of our final project was to implement commutation of a brushless DC motor on the RP2040 from scratch.
The logic executed by the RP2040 determines the proper controls to apply to each phase of the motor based on feedback
from hall effect sensors. To meet the strict timing requirements for control, we implemented part of this logic on PIO state
machines. We implemented a closed-loop motor control system, where a user can input a target velocity via the serial terminal.
The electrical systems behind our motor controller are fully customized and implemented on a printed circuit board (PCB).
Typically, BLDC motor controllers are wrapped into pre-manufactured, out-of-the-box chips. This gives little insight into the
logic being performed to generate proper control signals. We did this project to fully understand and implement the logic behind
BLDC control, and in doing so removed much of the “black-box” effect you typically get with BLDC controller chips. In designing a customized
PCB for the electrical systems, we also gained a deeper understanding of circuit considerations behind BLDC motor control, and all the hardware
bugs that come with it.
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Detailed Project Description

BLDC Motor Controller is an embedded-systems build that integrates sensors, actuators, a microcontroller and firmware into one working device, with the design decisions and test results documented so it can be reproduced.

How It Works
1. Input devices (sensors, buttons, encoders, wireless links) are connected to the microcontroller.
2. Firmware samples the inputs at a fixed rate and runs the control/processing logic (often with interrupts, timers or PIO for precise timing).
3. Outputs (motors, LEDs, displays, audio, radio) are driven according to the result.
4. The system is tested against its specification and tuned for reliability and responsiveness.

Key Components and Their Role
- RP2040: dual-core Cortex-M0+ microcontroller with programmable I/O used for precise, low-level timing.

Implementation Steps
1. Collect the components and study each module's datasheet (pin-out, voltage, interface).
2. Wire the circuit on a breadboard following the pin mapping; power sensors from the correct rail (3.3 V / 5 V).
3. Install C, Arduino IDE and the required libraries; flash a minimal test sketch for each module separately.
4. Write the main firmware: read sensors → process → drive outputs / send data.
5. Configure network or cloud credentials and test communication end-to-end.
6. Calibrate thresholds, add error handling (reconnect, sensor time-out) and run a long-duration test.
7. Finalise on a PCB / enclosure and document wiring, code and results.

Key Features
- Real-time firmware
- Custom hardware integration
- Measured performance
- Documented design and trade-offs

Expected Output
On completion the student will have a demonstrable device that meets its functional specification, with wiring diagram, code and results.

Deliverables
- Complete source code with comments
- Circuit diagram and pin mapping
- Project report with screenshots and results
- Demonstration-ready build