High-Performance Speed Control of BLDC Motor Drives Using a PI Sailfish Optimization Algorithm

BLDC motors are utilized in electric cars, robotics, drones, home appliances and medical equipment due to their effectiveness, dependability, and accurate control. PI controllers have been put forward to enhance the dynamic performance of brushless direct current (BLDC) motors, and they have been tested in many papers with various algorithms (such as PSO, GA, GWO, ACO and ABC) and strategies (such as PI/PID control, FOC, FLC, SMC and MPC). Meanwhile, in this research, and for the first time, the PI controller was tuned by the proposed Sailfish Optimization algorithm (SFO) with a direct torque control (DTC) strategy to enhance the dynamic performance of BLDC motors. Although DTC provides a very fast torque response, it still suffers from high torque ripple and noticeable instability at low speeds. These issues persist even when using conventional PI tuning or common optimization algorithms. Hence, in this research, we proposed an improved control strategy that combines DTC with PI tuning optimized by the Sailfish Optimization algorithm (SFO), which delivers smoother torque, more stable low-speed operation, and stronger robustness during sudden changes in load. In this regard, the PI controller was tested under different levels of torque and compared with the traditional Gray Wolf Optimization (GWO-PI) algorithm controller, as well as PI and PID controllers, and the performance of each of them was evaluated for different torque levels at speeds of 600 rpm and 2000 rpm during physical experiments. The simulation results showed that the Sailfish-PI controller, compared to the others, recorded the fastest response with a rise time of 2.1 ms and settling time of 2.9 ms under 2.39 Nm nominal torque at 2000 rpm speed; in addition, it continuously showed the lowest values of overshoot and undershoot as torque increased. It also maintained the most accurate and consistent performance, keeping the peak rpm almost flat and extremely near to the target of 2001 rpm. Therefore, in systems that require variable speed and torque while operating, such as electric automobiles, the proposed method is suitable for application.