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