Implementation of FOC in PMSM using Low-Cost Hall Effect Sensors

Permanent Magnet Synchronous Motors (PMSMs) have replaced DC motors in various applications due to their higher efficiency, compact size, and superior performance in dynamic environments. Typically, Field-Oriented Control (FOC) for PMSMs relies on high-resolution encoders or resolvers to accurately measure rotor position, enabling precise real-time motor current control. However, these components increase system costs, limiting FOC's adoption in cost-sensitive contexts. This study demonstrates the use of low-cost, in-built Hall effect sensors to estimate rotor position and speed, reducing expenses without sacrificing control accuracy. The control scheme was implemented on a dsPIC33CK256MP508 low-voltage motor control board, interfaced with Hall sensor signals via a 6-pin connector, and tested on a 45ZWN24-40 motor (24V, 40W, 4000 RPM). Development and validation were performed using MPLAB X IDE and MATLAB Simulink. This paper presents the implementation of Hall-based FOC, validated through hardware results, as a viable, economical solution for industrial and automotive applications.