Project Definition¶
Introduction¶
The MOTSEN TOOL project aims to develop a modular motor testing and characterization platform for electric motor development, production, commissioning, and quality assurance applications.
The tool is intended to automate common motor commissioning and diagnostic procedures that are traditionally performed manually using multiple laboratory instruments and engineering tools.
The first target of the project is Permanent Magnet Synchronous Motors (PMSM/IPMSM/BLDC), with future scalability for additional motor types and industrial interfaces.
Purpose¶
The MOTSEN TOOL provides a compact and extensible platform that combines, in a single device, the functions traditionally spread across multiple lab instruments and vendor tools:
Motor sensor verification
Electrical parameter characterization
Motor health diagnostics
Automated commissioning support
End-of-line (EOL) testing
Research and development support
Quality assurance measurements
By unifying these functions, the platform aims to reduce engineering effort, setup time, commissioning errors, and dependency on external laboratory equipment.
Problem Statement¶
Motor commissioning and validation processes are often fragmented and heavily manual.
Typical engineering workflows require multiple independent tools such as:
Oscilloscopes
LCR meters
Power analyzers
External signal generators
CAN analyzers
Vendor-specific tuning software
This creates several problems:
Long setup and validation times
Human-related configuration mistakes
Sensor wiring errors
Incorrect phase alignment
Unsafe first-time motor startup
Inconsistent measurement quality
Difficult manufacturing scalability
High engineering dependency
The MOTSEN TOOL addresses these issues through a unified automated testing platform.
Project Vision¶
The long-term vision of the project is to create:
“A modular Swiss Army Knife for motor commissioning, characterization, and diagnostics.”
The platform should evolve into a professional-grade tool suitable for:
Development laboratories
Production lines
Service departments
Educational environments
Motor inverter manufacturers
Automotive applications
E-bike and robotics industries
Project Scope¶
Included Scope¶
The project includes development of:
Embedded motor control firmware
Hardware power stage
Sensor interfaces
Measurement algorithms
Communication interfaces
PC software tools
Automated testing workflows
Documentation infrastructure
Manufacturing-ready architecture
The project also includes support for:
Hall sensors
Incremental encoders
Resolver interfaces (future)
CAN communication
UART communication
Data logging
Parameter storage
Excluded Scope¶
The following items are outside the initial project scope:
High-voltage industrial inverter development
Functional safety certification
SIL/ASIL compliance
Grid-connected power electronics
Traction inverter power stages above defined voltage/current limits
Commercial cloud infrastructure
Closed-loop servo product development
Target Users¶
The primary users of the MOTSEN TOOL are expected to be:
Motor control engineers
Embedded software developers
Power electronics engineers
Validation engineers
Production technicians
Quality assurance departments
University researchers
Technical laboratories
Application Areas¶
The platform may be used in:
E-bike motor development
Robotics systems
Industrial automation
Servo drive systems
Automotive auxiliary drives
Manufacturing end-of-line testing
Motor repair and service centers
Academic research projects
Core Functionalities¶
The project is built around two primary functional domains.
1. Sensor Health Check¶
The tool should validate:
Phase sequence correctness
Hall sensor alignment
Encoder direction
Sensor consistency
Electrical connectivity
Sensor signal integrity
The system should detect incorrect motor wiring before unsafe operation occurs.
2. Motor Characterization¶
The tool should estimate and measure:
Phase resistance (Rs)
D-axis inductance (Ld)
Q-axis inductance (Lq)
Back-EMF constant
Torque constant (Kt)
Electrical phase offset
Rotor position characteristics
Basic thermal behavior (future)
Development Philosophy¶
The project follows the following engineering principles:
Modular architecture
Hardware abstraction
MCU independence
Reusable software components
Scalable system design
Clear documentation structure
Test-driven validation
Incremental development
Open development workflow
Development Phases¶
Phase 1 — Proof of Concept (MVP)¶
Goals:
Validate architecture feasibility
Implement basic sensor checks
Implement basic parameter estimation
Create initial hardware prototype
Demonstrate motor communication and measurement
Characteristics:
Engineering-focused prototype
Limited automation
Minimal UI
Development-oriented hardware
Phase 2 — Full Feature Development¶
Goals:
Expand functionality coverage
Add advanced diagnostics
Improve automation
Improve measurement robustness
Add PC interface and workflow integration
Characteristics:
Feature-complete engineering platform
Improved usability
More modular architecture
Extended communication support
Phase 3 — Productization¶
Goals:
Prepare manufacturable hardware
Improve reliability
Improve serviceability
Finalize documentation
Standardize workflows
Characteristics:
Production-ready architecture
Manufacturing support
User manuals
Maintenance procedures
Commercial deployment readiness
Success Criteria¶
The project shall be considered successful if the platform can:
Safely identify motor sensor issues before powered operation
Estimate motor parameters with accuracy sufficient for FOC tuning
Operate reliably across multiple motor samples and types
Be reproduced and manufactured as a repeatable product
Future Expansion Possibilities¶
Potential future expansions include:
Automated PI tuning
Frequency response analysis
Thermal model estimation
Resolver support
EtherCAT support
CANopen support
Cloud-connected diagnostics
Machine learning assisted fault detection
Multi-axis testing support
Web-based user interface
Remote firmware updates