Fault‐Tolerant Control of <scp>BLDC</scp> Motors: Fault‐Tolerant Control Methodology for Hall‐Effect Sensor Fault Detection and Energy Efficiency Optimization

ABSTRACT Electrical motors' effectiveness, optimization, and dependability have led to significant developments in the industrial revolution. Rotor commutation is essential for smooth operation and is done by energizing the proper rotor. The study introduces an innovative methodology for fault‐tolerant control of Hall‐Effect sensors governing brushless direct current (BLDC) motors. The implemented result validates the substantial saving of energy. The implementation here is unique and effective because the BLDC motor will be operated even if there is a fault in the Hall‐Effect sensor. It will run smoothly and efficiently unless the two sensor failures are detected. This method addresses situations where the signal from a Hall Effect sensor stays consistently low or high for short periods. This developed system is mature enough to handle the subsystem when the data from the sensor detects faults, identifies faulty signals, and creates a replacement signal. The proposed research work uses MATLAB Simulink and the TI‐DSP (TMS320F2812) KIT to show the high‐speed simulation. The simulation results were validated through different motor speeds from 3500 to 2000 rpm. Drawbacks like cost and reliability have been overcome in the implemented research work. In the implemented research work, the simulation outcome shows approximately 10% better results in generating more torque than the existing methods using sinusoidal windings.