Sensorless Design and Analysis of a Brushed DC Motor Speed Regulation System for Branches Sawing

Saw rotational speed critically influences cutting force and surface quality yet is often destabilized by variable cutting resistance. The sensorless detection method for calculating rotational speed based on current ripple can prevent the contact of wood chips and dust with Hall sensors. This paper introduces a speed control system for brushed DC motors that capitalizes on the linear relationship between current ripple frequency and rotational speed. The system achieves speed regulation through indirect speed measurement and PID control. It utilizes an H-bridge circuit controlled by the EG2014S driver chip to regulate the motor direction and braking. Current ripple detection is accomplished through a 0.02 Ω sampling resistor and AMC1200SDUBR signal amplifier, followed by a wavelet transform and Savitzky–Golay filtering for refined signal extraction. Experimental results indicate that the system maintains stable speeds across the 2000–6000 RPM range, with a maximum error of 2.32% at 6000 RPM. The improved ripple detection algorithm effectively preserves critical signals while reducing noise. This enables the motor to quickly regain speed when resistance is encountered, ensuring a smooth cutting surface. Compared to traditional Hall sensor systems, this sensorless design enhances adaptability in agricultural applications.