Experimental Investigation of Energy Efficiency, SOC Estimation, and Real-Time Speed Control of a 2.2 kW BLDC Motor with Planetary Gearbox Under Variable Load Conditions

This study presents a comprehensive experimental investigation of a 2.2 kW brushless DC (BLDC) motor integrated with a three-shaft planetary gearbox, focusing on overall energy efficiency, battery state of charge (SOC) estimation, and real-time speed control under variable load conditions. In the first stage, the gearbox transmission ratio was experimentally verified to establish the kinematic relationship between the BLDC motor and the eddy current dynamometer shafts. In the second stage, the motor was operated in open loop mode at fixed reference speeds while variable load torques ranging from 1 to 7 N.m were applied using an AVL dynamometer. Electrical voltage, current, and rotational speed were measured in real time through precision transducers and a data acquisition interface, enabling computation of overall efficiency and SOC via the Coulomb counting method. The open loop results demonstrated that maximum efficiency occurred in the intermediate-to-high-speed region (2000 to 2800 rpm) and at higher load torques (5 to 7 N.m) while locking the third gearbox shaft produced negligible parasitic losses. In the third stage, a proportional–integral–derivative (PID) controller was implemented in closed loop configuration to regulate motor speed under the same variable load scenarios. The closed loop operation improved the overall efficiency by approximately 8–20 percentage points within the effective operating range of 1600–2500 rpm, reduced speed droop, and ensured precise tracking with minimal overshoot and steady-state error. The proposed methodology provides an integrated experimental framework for evaluating the dynamic performance, energy efficiency, and battery utilization of BLDC motor planetary gearbox systems, offering valuable insights for electric vehicle and hybrid electric vehicle (HEV) drive applications.