FPGA-Based Real-Time Bidirectional DC Motor Control with Adaptive Collision Avoidance Using IR Senso by IRJET Journal

FPGA-Based Real-Time Bidirectional DC Motor Control with Adaptive Collision Avoidance Using IR Sensors

Y.HARI MADHAVA REDDY1,P. SUMAYYA2 , K. DINESH KUMAR 3 , S.SAI BHANU 4 , SK. SALMA AFRIN5

, K.

LAKSHMI

SAIKUMAR 6 , V. NAGA NIKHIL7

1Student & KKR & KSR INSTITUTE OF TECHNOLOGY AND SCIENCES

2Student & KKR & KSR INSTITUTE OF TECHNOLOGY AND SCIENCES

3Student & KKR & KSR INSTITUTE OF TECHNOLOGY AND SCIENCES

4Student & KKR & KSR INSTITUTE OF TECHNOLOGY AND SCIENCES

5Student & KKR & KSR INSTITUTE OF TECHNOLOGY AND SCIENCES6

6Student & KKR & KSR INSTITUTE OF TECHNOLOGY AND SCIENCES

Abstract -

This paper presents a Field-Programmable Gate Array(FPGA)-basedreal-timebidirectionalDC motor control system with adaptive collision avoidance using infrared (IR) sensors. The proposed system ensures efficient and precise motor operation while preventing potential obstacles in dynamic environments. By leveraging the parallel processing capabilitiesofanFPGA, thedesignachieveshigh-speed motor control, low-latency response to obstacles, and real-time adaptability to changing environmental conditions.

The system integrates infrared sensors for collision detection, allowing the motor to dynamically adjust its movement inresponsetodetectedobstacles. Thebidirectional control mechanism is implemented using pulse-width modulation (PWM) techniques, ensuring smooth speed variations and precise maneuverability. A priority-based decisionalgorithmprocessesinputsignalsfromtheIRsensors and user-defined control switches, dynamically determining the motor’s direction, speed, and operational mode.

Unlike conventional microcontroller-based motor control systems, this FPGA-based approach minimizes processingdelaysandenhancesreal-timeresponsiveness.The implementation leverages hardware description language (HDL) programming to achieve efficient logic synthesis, ensuring optimized hardware utilization and scalability. The proposed design is validated through extensive simulations and experimental results, demonstrating its robust performance, low power consumption, and high reliability in practical applications.

This work has broad applicability in autonomous robotic systems, industrial automation, and smart mobility solutions, whereprecise motorcontrol andreal-timeobstacle avoidancearecritical.TheFPGA-basedframeworkprovidesa foundation for future advancements in intelligent motor controlsystemsbyincorporatingmachinelearningtechniques and advanced sensor fusion strategies.

Keywords: FPGA, BidirectionalDCMotor,CollisionAvoidance, IR Sensors, Real-Time Control, Pulse-Width Modulation (PWM), Autonomous Systems.

1.INTRODUCTION

Inmodernautomationandcontrolsystems, precise and real-time motor control is a critical requirement for applications such as industrial robotics, autonomous vehicles, conveyor systems, and smart mobility solutions. The ability to efficiently regulate the speed, direction,andresponsivenessofa DC motor isessentialin ensuringsmoothoperation,reliability,andsafety.However, conventional motor control systems based on microcontrollers and digital signal processors (DSPs) facelimitationsintermsof latency, computational speed, andreal-time adaptability.Theseconstraintshindertheir effectiveness in dynamic environments where rapid decision-makingisrequired.Toovercomethesechallenges, this paper introduces an FPGA-based real-time bidirectional DC motor control system with adaptive collision avoidance using infrared (IR) sensors.

Field-Programmable Gate Arrays (FPGAs) have gained prominenceinreal-timeembeddedcontrolapplicationsdue to their parallel processing capabilities, high-speed execution, and flexibility in hardware reconfiguration. Unlikemicrocontrollers,whichrelyonsequentialexecution of instructions, FPGAs can execute multiple tasks simultaneously, allowing for precise motor control and fast responsetoenvironmentalchanges.Byintegrating IR sensors, the proposed system is capable of detecting obstaclesinrealtimeanddynamicallyadjustingthemotor’s movementtoavoidcollisions.Thisapproachenhancesthe system’s safety, efficiency, and operational reliability, makingitsuitableforapplicationsthatrequire autonomous navigation and intelligent motion control.

The system employs pulse-width modulation (PWM) techniques to control the speed and direction of the motor, ensuring smooth acceleration and deceleration. A

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072

priority-based decision-making algorithm is implemented to process sensor inputs and user-defined control signals, optimizing motor behavior based on realtimeconditions.Thisadaptivemechanismenablesthemotor tooperateefficientlyin various environmental settings, responding instantly to obstacles without human intervention.

OneofthekeyadvantagesofthisFPGA-basedapproachis itsabilityto minimize processing delays and maximize real-time responsiveness. The hardware-level implementationensures lowpowerconsumption,reduced latency, and enhanced system scalability,makingitideal for industrial automation, robotic systems, and smart transportation networks.Moreover,theuseof hardware description language (HDL) programming allows for efficient logic synthesis, ensuring optimized resource utilizationandperformance.

This paper presents a comprehensive analysis of the design, implementation, and evaluation oftheproposed system.Theexperimentalresultsvalidatetheeffectiveness of the FPGA-based motor control framework in achieving precise bidirectional motion, real-time collision avoidance, and adaptive speed regulation.Thefindings highlightthepotentialofFPGA-basedcontrolarchitectures as a superior alternative to traditional microcontrollerbased solutions, offering enhanced precision, efficiency, and adaptability for next-generation motion control applications.

2. HARDWARE REQUIREMENTS

1. FPGA Development Board

 Recommended Model: Xilinx Spartan-6, Intel CycloneV,orsimilar

 Purpose:Servesasthecoreprocessingunitfor real-timemotorcontrol,decision-making,and PWMsignalgeneration

2. DC Motor (Bidirectional)

 Voltage Rating: 6V–24V (depending on applicationrequirements)

 CurrentRating:Compatiblewithmotordriver specifications

 Purpose: Provides motion control in both forwardandreversedirections

3. Motor Driver IC (H-Bridge Circuit)

 Recommended Model: L293D, L298N, or DRV8871

 Purpose:EnablesbidirectionalcontroloftheDC motorbydrivingitbasedonPWMsignalsfrom theFPGA

4. Push Buttons or Switches

 Type:SPST(SinglePoleSingleThrow)orSPDT (SinglePoleDoubleThrow)

 Purpose:Usedasmanualinputsforcontrolling motordirectionandsystemoperationmodes

5. Debugging and Testing Tools

 Oscilloscope:ForanalyzingPWMsignalsand verifyingmotorcontrollogic

 Multimeter: For measuring voltage, current, andcontinuityincircuitcomponents

 FPGA Programmer (JTAG Cable): Used for flashingHDLcodeontotheFPGAboard

3. HARDWARE CONNECTIONS

1. FPGABoardtoMotorDriver

4. CODE

module motor_final (input clk,ir1,ir2,input [1:0]switch, output[2:0]motor);

reg[3:0]control=4'b0000; reg[3:0]control1=4'b0000;

integerperiod_length=1000000;

2. DCtoMotorDriver

3. IRsensortoFPGABoard

4. SwitchestoFPGA

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

integerpulse_length1=250000; integerpulse_length2=500000; integerpulse_length3=750000; integerpulse_length4=900000;

integerpulse_length=0;

integercounter=0;

always@(*)begin if(ir1==0)

control[0]=1; else

control[0]=0; end

always@(*)begin if(ir2==0)

control[1]=1; else

control[1]=0; end

always@(posedgeclk)begin if(counter<period_length) counter<=counter+1; else counter<=0;end

always@(*)begin control[2]=switch[0]; control[3]=switch[1]; end

always@(control)begin case(control)

4'b0000:control1=4'b0001; 4'b0001:control1=4'b0010; 4'b0010:control1=4'b0001; 4'b0011:control1=4'b0000; 4'b0100:control1=4'b0101; 4'b0101:control1=4'b0110; 4'b0110:control1=4'b0101; 4'b0111:control1=4'b0000; 4'b1000:control1=4'b1001; 4'b1001:control1=4'b1010; 4'b1010:control1=4'b1001; 4'b1011:control1=4'b0000; 4'b1100:control1=4'b1101; 4'b1101:control1=4'b1110; 4'b1110:control1=4'b1101; 4'b1111:control1=4'b0000;

default:control1=4'b0000;

endcase

if(control1[3]==0&&control1[2]==0) pulse_length=pulse_length1; elseif(control1[3]==0&&control1[2]==1) pulse_length=pulse_length2; elseif(control1[3]==1&&control1[2]==0) pulse_length=pulse_length3; elseif(control1[3]==1&&control1[2]==1) pulse_length=pulse_length4; end

assignmotor[0]=control1[0]; assignmotor[1]=control1[1]; assignmotor[2]=(pulse_length>counter)?1'b1:1'b0;

endmodule

5. Implementation

TheprovidedVerilogcodeisdesignedtoimplement a bidirectional DC motor control system on an FPGA, integrating IR sensors for obstacle detection and switchbased manual control. This system enables intelligent decision-making for collision avoidance while maintaining smoothspeedcontrolusingpulse-widthmodulation(PWM). The FPGA’s parallel processing capability ensures that the system responds to sensor inputs and user commands in real-time,makingithighlyefficientandreliableforpractical applications such as robotic navigation, industrial automation,andautonomousvehiclesystems.

Theinputsignalstothemoduleincludeaclock(clk), two IR sensor inputs (ir1, ir2), and a two-bit switch (switch[1:0])usedformanuallycontrollingthemotor’sspeed and direction. The output (motor[2:0]) determines the motor’smovementandspeed,wheremotor[0]andmotor[1] control the motor's direction (forward or reverse), while motor[2]generatesthePWMsignalforspeedregulation.The systemcontinuouslymonitorstheIRsensors,whichprovide active-low signals (0 when an obstacle is detected). If an obstacle is detected in the motor's path, the system dynamically modifies the motor’s operation by either stopping or reversing the direction, ensuring adaptive collisionavoidance.

The PWM-based speed control mechanism is achievedusingacounterthatoperatesinsyncwiththeFPGA clock. The counter increments with each clock cycle and resetsonceitreachesapredefinedperiod(period_length). The duty cycle is determined based on the switch inputs, allowing the user to select between different speed levels. When the counter value is less than the pulse length, motor[2]issethigh(1),enablingmotoroperation.Otherwise, itremainslow(0),effectivelycontrollingthepowerdelivered tothemotorandtherebyadjustingitsspeed.Thedecision-

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072

makinglogicisimplementedusingacasestatement,where different control states correspond to specific speed and directionconfigurations.

This implementation leverages FPGA-based parallelism, making it significantly faster than traditional microcontroller-based motor controllers. Unlike microcontrollers, which execute instructions sequentially, FPGAsprocessmultipletaskssimultaneously,ensuringrapid responsivenesstosensorinputsandcontrolcommands.This resultsinreal-timeoperation,minimallatency,andincreased precision. Additionally, the modular nature of the Verilog design allows for easy scalability, enabling the addition of more sensors or control mechanisms without major modifications to the code. In summary, this FPGA-driven motorcontrolsystemprovidesahighlyefficient,reliable,and adaptive solution for real-time bidirectional DC motor operation,makingitidealforrobotics,industrialautomation, andautonomousnavigationapplications.

6. Real Time Implementation

1. FPGA Advantages Over Microcontrollers for Motor Control

 ParallelProcessing:Unlikemicrocontrollers,which process instructions sequentially, FPGAs execute multipletaskssimultaneously,leadingtoreal-time responsiveness.

 High-Speed PWM Generation: The FPGA can generatepreciseandhigh-frequencyPWMsignals, ensuringsmoothmotorspeedcontrol.



Low Latency in Obstacle Detection: The IR sensors' inputs are continuously monitored, allowing immediate action when an obstacle is detected.

 Scalability:Additionalsensors,motors,orcontrol logiccanbeeasilyintegratedwithoutaffectingthe corefunctionality.

2. PWM (Pulse Width Modulation) for Speed Control

 The PWM signal controls the average voltage suppliedtothemotor,adjustingitsspeed.

 The duty cycle (ratio of ON time to OFF time) determinesthemotor'sspeed:

o Lower duty cycle → Lower speed

o Higher duty cycle → Higher speed

3. Collision Avoidance with IR Sensors

 IR Sensor Logic:

o ir1=0(Obstacledetectedononeside)→ Motoradjustsdirection.

o ir2=0(Obstacledetectedonanotherside) →Motoradjustsaccordingly.

o ir1 = 0 and ir2 = 0 (Obstacles detected in bothdirections)→Motorstopstopreventa collision.

4. Switch-Based Manual Control of Speed and Direction

 The 2-bit switch input (switch[1:0]) allows the user to manually override the system and set the motor'soperationmode.

 Different switch states control speed levels and bidirectional movement:

o 00→Slowestforwardspeed

o 01→Mediumforwardspeed

o 10→High-speedforward

o 11→Reverseoperation

5. Case-Based Control Logic for Motor Behavior

 Thesystemusesacasestatementto map different input conditions to specific motor responses

 Examplesofcaseconditions:

o 4'b0000:Moveforwardatdefaultspeed

o 4'b0011:StopwhenbothIRsensorsdetect obstacles

o 4'b1000:Reversethemotoratslowspeed

o 4'b1111:Completelystopthemotor

6. Real-Time Counter Mechanism

 A hardware counter tracksclockcycles,ensuring accuratetimingforPWMgeneration.

 The counter ensures that speed adjustments are synchronized with motor operations, preventing erraticmovements.

7. Energy Efficiency and Safe Operation

 The system reduces power consumption by adjustingspeedbasedonenvironmentalconditions.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072

 The collision-avoidance mechanism ensures safe operation in dynamic environments

 The FPGA-based design minimizes the need for additional components, reducing overall power consumption.

8. Potential Enhancements for Future Work

 Integration with Ultrasonic Sensors: For more preciseobstacledetection.

 Wireless Control (Bluetooth/WiFi): To allow remoteoperationofthemotorsystem.

 Real-TimeFeedback Mechanism:Usingencoders totrackactualmotorpositionandspeed.

 Multiple Motor Control:Addingadditionalmotor channelsforcomplexroboticsapplications.

7. Simulations

8. ADVANTAGES

1. High-Speed Real-Time Processing

 ParallelExecution:Unlikemicrocontrollers,FPGAs can execute multiple processes simultaneously, enablingfasterresponsetimes.

 DeterministicPerformance:Nooperatingsystem overheadensuresconsistentexecutiontiming.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072

 Low Latency: Immediate response to IR sensor inputsenhancesreal-timeobstacleavoidance.

2. Enhanced Collision Avoidance

 Adaptive Response: The system dynamically adjusts motor direction and speed based on obstacledetection.

 Precise Obstacle Detection: IR sensors provide quickfeedback,preventingcollisions.

 Reliable in Dynamic Environments:Canbeused in robotics, autonomous vehicles, and industrial automationwhereobjectsmayappearsuddenly.

3. PWM-Based Speed Control

 Smooth Speed Adjustment: PWM enables finetunedspeedcontrolinsteadofabruptchanges.

 EnergyEfficiency:Reducespowerconsumptionby adjustingthedutycycleofthePWMsignal.

 ReducedWearandTear:Avoidsmechanicalstress on the motor by controlling acceleration and decelerationsmoothly.

4. FPGA-Based Design Benefits

 Reprogrammability:Unlikemicrocontrollerswith fixed firmware, FPGAs can be reconfigured for differentapplications.

 High Processing Speed: FPGAs operate at much higher clock speeds than microcontrollers, enhancingsystemperformance.

 Hardware Parallelism: Multiple operations executeatthesametime,increasingefficiency.

5. Robust Bidirectional Motor Control

 Accurate Direction Switching: Ensures precise controloverforwardandreversemovement.

 No Mechanical Switch Delays: Uses digital logic instead of physical switches, reducing delays and improvingresponsetime.

 Adaptive Speed for Direction Changes: Adjusts speed dynamically to avoid abrupt reversals that coulddamagethemotor.

6. Low Power Consumption

 Optimized Logic Utilization: FPGA logic gates operate efficiently, reducing unnecessary power usage.

 PWM for Controlled Power Delivery:Insteadof supplyingfullpowercontinuously,PWMregulates powerusage.

 Smart Standby Mode: The system can reduce powerwhenidle,increasingefficiency.

7. Scalability and Expandability

 Multiple Motor Control: The design can be extended to support additional motors without significantmodifications.

 Easy Sensor Integration: Additional sensors (ultrasonic,lidar,etc.)canbeaddedfor enhanced navigation.

 CustomizableLogic:FPGA-baseddesignallowsfor upgradeswithouthardwarechanges.

8. High Reliability and Durability

 Eliminates Software Bugs:Sincethecontrollogic isimplementedinhardware,therearenosoftwarerelatedfailures.

 MinimalExternalComponents:Reducespointsof failure compared to microcontroller-based solutionsrequiringadditionalICs.

 Fault-Tolerant Design: Can implement errordetectionmechanismstoimprovereliability.

9. Improved Response Time for Industrial Applications

 Instant Motor Reaction:Themotoradjustsspeed and direction immediately upon receiving sensor input.

 Real-Time Decision Making: Enables critical industrialapplicationswhereprecisionisrequired.

 No OS Overhead: Eliminates processing delays associatedwithsoftware-basedcontrolsystems.

10. Suitability for Autonomous Systems

 Self-Adjusting Motor Control: Ideal for selfdrivingvehiclesandautonomousrobots.

 Fully Automated Navigation:Canintegratewith AI-basednavigationsystems.

 ObstacleAvoidanceforSafety:Preventscollisions inautomatedindustrialmachinery.

11. Noise Immunity and Signal Stability

 FPGA’s Digital Logic Minimizes Noise: More resistant to electrical noise than analog-based motorcontrollers.

 Stable PWM Signals: Reduces signal fluctuations thatcouldaffectmotorperformance.

 Error Reduction in Motor Operation: Ensures precisecontroleveninnoisyenvironments.

12. Precise Duty Cycle Control for Power Regulation

 Customizable Speed Profiles: Allows specific speedadjustmentsfordifferentapplications.

 EnergyOptimization:Reducesunnecessarypower usage,improvingbatterylifeinmobileapplications.

 Soft-Start Capability: Prevents sudden current spikes,extendingmotorlifespan.

13. Low-Cost Implementation for Mass Production

 Eliminates Need for External Controllers: No requirementforadditionalmotordriverICs.

 CanBeUsedinCost-SensitiveApplications:Such asconsumerelectronics,automation,androbotics.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072

 Reusable FPGA Logic:ThesameFPGAchipcanbe reprogrammed for different motor control applications.

14. Compatibility with Various Motor Types

 Supports DC Motors, Stepper Motors, and Servo Motors: A versatile solution for different applications.

 EasilyAdaptabletoDifferentPowerRatings:Can bemodifiedformotorsofdifferentvoltage/current requirements.

 Interfacing with Industrial Motors: Suitable for conveyor belts, robotic arms, and industrial machinery.

15. Customizable Motion Profiles

 Can Implement Acceleration/Deceleration Curves:Preventsmechanicalstressonthemotor.

 Advanced Motion Planning: Integrates with AIbasedpredictivecontrolforindustrialautomation.

 Custom Torque and Speed Profiles: Allows smoothtransitionsbetweenspeeds.

16. FPGA’s Built-in Hardware Debugging Tools

 Simulation Before Deployment: Reduces debuggingtimewithFPGAsimulationtools.

 Real-Time Monitoring of Motor Performance: Helpsintuningsystemparameters.

 Signal Analyzers for Pulse Monitoring:Ensures correctPWMoperation.

17. Fault Detection and Protection Mechanisms

 Overcurrent and Overvoltage Protection: Preventsdamagetothemotor.

 Automatic Shutdown in Fault Conditions: Enhancesmotorlifespan.

 Self-Repairing Logic Implementation: Can be programmedtoresetorreconfigureupondetecting errors.

18. Application in Harsh Environments

 ResistanttoTemperatureVariations:FPGAchips arestableunderextremeconditions.

 Works in Industrial, Medical, and Aerospace Applications:Reliableformission-criticaltasks.

 Less Affected by Electromagnetic Interference (EMI):Ensuresconsistentmotorperformance.

19. Integration with IoT and Cloud Services

 RemoteMonitoringof MotorParameters:Canbe interfacedwithcloud-baseddashboards.

 Wireless Control Possibility: Compatible with WiFi,Bluetooth,andLoRaforremoteoperations.

 Data Logging for Performance Analysis: Useful forpredictivemaintenance.

20. Improved Safety Features

 Collision Avoidance Reduces Accidents: Beneficial for industrial robots and self-driving systems.

 EmergencyStopMechanism:Canbeintegratedfor instantstoppingofthemotor.

 Controlled Deceleration to Prevent Damage: Reducesmechanicalstress.

21. Can Be Used for AI-Based Motion Control

 Machine Learning Algorithms for Predictive Movement:Optimizesefficiency.

 Adaptive Learning Based on Environmental Data:Adjustsmotorperformancedynamically.

 Path Planning and Object Recognition Integration:Usefulforroboticsandnavigation.

22. Versatile Power Supply Compatibility

 Works with Battery-Powered Systems:Suitable fordronesandportablerobots.

 Can Use Renewable Energy Sources:Efficientfor solar-poweredapplications.

 StableVoltageControlforMotor Drive:Prevents fluctuations.

23. Easy Prototyping and Testing

 FPGADevelopmentBoardsAllowRapidTesting: Acceleratesdevelopmentcycles.

 NoNeedforMultipleCircuitRevisions:Softwarebasedreconfigurationmakeschangeseasy.

24. Long-Term Reliability with Minimal Maintenance

 Less Mechanical Wear Due to Smooth Control: Extendshardwarelifespan.

 No Need for Frequent Firmware Updates: Hardwarelogicremainsstable.

25. Open-Source and Customizable for Research & Development

 Ideal for Academic Research and Innovation: Providesaflexibletestbed.

 Can Be Extended with Additional Features: AI, IoT,andmorecanbeaddedlater.

8. CONCLUSION

TheFPGA-basedreal-timebidirectional DCmotor controlsystemwithadaptivecollisionavoidancepresentsa highlyefficient,reliable,andintelligentsolutionformotordriven applications. By leveraging the parallel processing capabilitiesofFPGAs,thissystemensureslow-latencymotor control, precise PWM-based speed adjustments, and instantaneous obstacle detection. The integration of IR sensors enhances the system’s responsiveness, making it well-suited for applications in autonomous vehicles, industrial automation, robotics, and smart transportation systems.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072

Compared to traditional microcontroller-based solutions, this approach offers superior real-time performance, enhanced fault tolerance, and scalable hardwarereconfigurability.Theadaptivecollisionavoidance mechanismensuressafeandefficientnavigationindynamic environments,reducingtheriskofdamagetoboththemotor andsurroundingobjects.Furthermore,thesystem’senergyefficientPWMcontrolminimizespowerconsumptionwhile maintainingoptimalmotorperformance.

TheproposedFPGA-basedmotorcontrolsystemcan befurtherenhancedwithmachinelearningalgorithms,IoT connectivity, and cloud-based monitoring, making it adaptable for next-generation smart automation systems. Future research can explore the integration of AI-based predictive control and multi-sensor fusion to enhance decision-makingcapabilities.

In conclusion, this research demonstrates that FPGA-based motor control offers high precision, adaptability, and scalability, making it an ideal choice for real-time bidirectional motor applications with intelligent collisionavoidancemechanisms.

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