Adaptive Microprocessor-Based Interval Type-2 Fuzzy Logic Controller Design for DC Micro-Motor Control Considering Hardware Limitations

The increasing adoption of high-performance DC motor control in embedded systems has driven the development of cost-effective solutions that extend beyond traditional software-based optimization techniques. This work presents a refined hardware-centric approach implementing real-time particle swarm optimization (PSO) directly executed on STM32 microcontroller for DC motor speed control, departing from conventional simulation-based parameter-tuning methods. Novel hardware-optimized composition of an interval type-2 fuzzy logic controller (FLC) and a PID controller is developed, designed for resource-constrained embedded systems and accounting for processing delays, memory limitations, and real-time execution constraints typically overlooked in non-experimental studies. The hardware-in-the-loop implementation enables real-time parameter optimization while managing actual system uncertainties in controlling DC micro-motors. Comprehensive experimental validation against conventional PI, PID, and PIDF controllers, all optimized using the same embedded PSO methodology, reveals that the proposed FT2-PID controller achieves superior performance with 28.3% and 56.7% faster settling times compared to PIDF and PI controllers, respectively, with significantly lower overshoot at higher reference speeds. The proposed hardware-oriented methodology bridges the critical gap between theoretical controller design and practical embedded implementation, providing detailed analysis of hardware–software co-design trade-offs through experimental testing that uncovers constraints of the low-cost microcontroller platform.