DC and BLDC Motor Controllers – project by Szymon Lubański

Let’s start at the beginning – how did the idea of creating motor controllers come about, and what inspired you to get started? 
I was motivated to undertake this project by the need to use controllers for the motors in a small electric vehicle I was working on. I already had the power source and the electric motor, but I lacked a controller, which I decided to build myself. This experience sparked my passion for electronics.

How long have you been developing this project, and how has your idea evolved over time?
I have been working on this project since the end of my first year of school, so for almost four years. Over that time, the project has changed beyond recognition. I started with a simple circuit comprising a few transistors and contactors on a breadboard to control a small brushed motor. I am now developing a brushless DC motor controller on a printed circuit board of my own design.

You create controllers for both brushed and brushless motors. Which has been more challenging, and why?
Controlling a brushless motor has been far more challenging. With a brushed motor, all commutation is handled mechanically via brushes. In contrast, a brushless motor requires the commutation to be carried out using precisely controlled transistors, which must be managed very accurately by a processor.

How does your project differ from those available on the market?
My project is primarily educational. I develop it from scratch, allowing me to make any modifications and maintain detailed documentation, which gives me far greater control over its performance. Because my controller is much cheaper than commercial alternatives, it is more suitable for experimentation. Even in the event of a failure, I can replace individual modules rather than having to purchase an entirely new controller.

What are your plans for further development of your controller, and how do you assess its commercial potential?
Ultimately, I aim to design and build a brushless motor controller with reliability and functionality comparable to commercial products. I plan to test it in an electric vehicle of my own design. I am unsure whether it will have direct commercial potential, but the specialist knowledge gained during the project provides a thorough understanding of how commercial controllers work. These skills will allow me to propose modifications or improvements that enhance performance or adapt controllers for novel and unconventional applications, which could potentially have commercial value.

Apart from technical skills, which other competencies do you consider essential for developing projects like this?
The most important skill is self-education. It is essential to be able to independently source reliable scientific and technical information from the internet, including articles, component documentation, courses, training, and manuals. Knowledge of specialised technical vocabulary in English is crucial. It is also valuable to be able to establish contacts with experienced individuals who are willing to share their knowledge.

A brushless motor controller requires more advanced technical solutions. What were the biggest challenges you faced while developing it?
The greatest challenge was refining the control algorithm to achieve maximum efficiency without overloading the motor, while ensuring effective commutation. Another significant challenge was designing a printed circuit board that could support the optimal commutation algorithm and maintain a suitable operating environment.

You create controllers for a variety of projects, from go-karts to potential electric vehicles. Do you have plans for other applications in the future?
At present, my focus is primarily on e-mobility and small electric vehicles. However, potential applications are broad. With appropriate adjustments, the controller could operate three-phase motors used in industrial settings, such as lathes, milling machines, industrial robots, and production lines.

Could your solutions find applications in industry, and do you see potential interest from manufacturing or automotive companies?
I believe this type of controller could have very wide industrial applications due to the prevalence of electric motors in modern industry. Additionally, the knowledge gained from creating my own controller is invaluable for operating and servicing existing controllers and for proposing improvements or modifications to enhance the performance and functionality of electrically powered devices.

How did you acquire the knowledge necessary for the project? Did you rely mainly on self-study, or did you receive support from teachers, specialists, or students?
I sought to gain as much knowledge as possible from both general and vocational classes and honed my technical skills in school workshops. From the beginning, I acquired knowledge independently. Beginners can find a lot of information online of varying quality, but during internships, I met specialists who guided me and showed how to find reliable materials. Over time, the knowledge became more complex, and some problems became difficult to solve alone. At various stages, I received support from teachers, parents, university lecturers, and student science clubs. Nevertheless, self-education remains fundamental.

What kind of support would improve your work on this project or future initiatives?
An internship at a large company involved in designing inverters for electric vehicles or industrial motor drives would be invaluable, as it would provide insight into how such controllers are designed and manufactured in practice. Training in project management, advanced mechanical and electronic design software, simulation tools, and AI-assisted design would also be extremely useful. Access to specialist knowledge and financial support from companies or institutions would greatly facilitate the completion of more ambitious projects.

What do you think are the main obstacles for young people wishing to develop their ideas and skills?
A major obstacle is access to specialist knowledge and knowing where to find it. Lack of experience in work organisation and project or team management, limited funding opportunities, and heavy school workloads are additional challenges.

What advice would you give to your peers who want to start their own innovative technical project?
Be determined in what you do. Focus on a single area and continually deepen your knowledge and skills through self-education. Don’t be discouraged by setbacks—young people learn best from their mistakes, provided they draw the right conclusions. Push the project forward whenever possible and see it through to completion.

What are your professional dreams, and in which field do you see your future?
My professional ambition is to work as a lead engineer in a company designing and producing high-power motor controllers or in a company developing electronics for applications in automotive, aerospace, or space exploration.

Do you think Lublin is a place that supports technological development and talent?
From the perspective of a secondary school student, it is difficult to assess. The education system does not particularly encourage technological development or nurture talent. I was fortunate to attend a school that did provide such support, and I tried to make the most of its opportunities to develop my passion.

Thank you very much for your time, and we wish you continued success and great achievements in your future projects and career.