Use of Sensorless BLDC Motors for the Hydraulic Power Unit of an Oil Pipeline Inspection Robot

Leonardo F. P. M. Martins; Sebastian M. G. Martins; Anselmo L. Silva Jr.; Augusto P. Souza; Fabrízio P. Maziero; Luís F. Oliveira; Victor B. Coch; Elsio Varela; Hugo F. L. Santos

doi:10.18618/REP.e202450

Authors

Leonardo F. P. M. Martins Serviço Nacional de Aprendizagem Industrial https://orcid.org/0009-0001-2738-5102
Sebastian M. G. Martins Serviço Nacional de Aprendizagem Industrial https://orcid.org/0000-0002-5244-7889
Anselmo L. Silva Jr. Serviço Nacional de Aprendizagem Industrial https://orcid.org/0000-0002-7522-2164
Augusto P. Souza Serviço Nacional de Aprendizagem Industrial https://orcid.org/0009-0000-1315-9545
Fabrízio P. Maziero Serviço Nacional de Aprendizagem Industrial https://orcid.org/0000-0001-9555-6850
Luís F. Oliveira Serviço Nacional de Aprendizagem Industrial https://orcid.org/0000-0002-1431-9827
Victor B. Coch Serviço Nacional de Aprendizagem Industrial https://orcid.org/0000-0003-3468-0588
Elsio Varela Serviço Nacional de Aprendizagem Industrial
Hugo F. L. Santos Petrobras (Brazil)

DOI:

https://doi.org/10.18618/REP.e202450

Keywords:

sensorless motor control, long oil pipelines, inspection robot, oil and gas industry

Abstract

The challenges encountered in the oil and gas industry require complex solutions and development effort. Related to oil lifting and gathering, it concerns severe conditions as space restraints. Given the confined space inside oil pipelines, robots for inspection requires technologies compatible with it, increasing its complexity, where the minimum required and maximum effective components of the robot is crucial for its construction. In this scenario, the use of sensorless BLDC motors becomes a key point, increasing robustness and reducing harness, being important factors in terms of feasibility, due to connector limitations. Thus, the more motors used — which contributes to the robot's movement — the more advantageous this approach becomes, considering that there is no need for sensing signals for controlling. This work presents an extended version of a paper published on COBEP/SPEC 2023, with new achievements: development of a baseboard motor controller, using TMS320F28027F MCU and DRV8353RSRGZR driver; practical results for sensorless controlling motor; hardware thermal analysis. As results, considering the set point of 5000 rpm rotation speed and a load pressure of 300 bar, the control system obtained a maximum error of 2%.

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Author Biographies

Leonardo F. P. M. Martins, Serviço Nacional de Aprendizagem Industrial

received his B.S. degree in Control and Automation Engineering from the Federal Institute of Amazonas in 2018 and his M.S. degree in Automation and Systems Engineering from the Federal University of Santa Catarina in 2021, where he contributed to the renewable energy research group with focus on Airborne Wind Energy. Since 2021, he has been a researcher at the SENAI Innovation Institute for Embedded Systems, leading the institute's firmware team in the development of innovation projects. His current research interests are embedded control algorithms, robotic systems for the oil and gas industry, edge AI and IoT applications.

Sebastian M. G. Martins, Serviço Nacional de Aprendizagem Industrial

received his B.S. degree in Electrical Engineering from the Regional University of Northwestern Rio Grande do Sul in 2016 and his M.S. and Ph.D. degrees in Electrical Engineering from the Federal University of Santa Maria in 2018 and 2024, respectively, carrying out research related to the development of a CC-CC converter applied to LED lighting systems in resonant LLC converters. Since 2022 he has been a hardware researcher at the SENAI Innovation Institute for Embedded Systems. His current research interests are microcontrolled circuit designs, LED lighting drivers, BLDC motors and MPPT circuits for photovoltaic systems.

Anselmo L. Silva Jr., Serviço Nacional de Aprendizagem Industrial

obtained a Bachelor's degree in Electronic Engineering in 2015 and a Master's degree in 2018, both from the Federal University of Santa Catarina. He has 4 years of experience in the development of analog integrated circuits and modeling of MOS transistors, being part of the team at the Integrated Circuits Laboratory - LCI at UFSC. Since 2015, he has worked as a researcher at the SENAI Innovation Institute for Embedded Systems. He has extensive experience in the development of embedded hardware and leading multidisciplinary teams in complex projects.

Augusto P. Souza, Serviço Nacional de Aprendizagem Industrial

received his B.S. degree in Mechanical Engineering in 2016 and his M.S. degree in Mechanical Engineering from the Federal University of Santa Catarina in 2024, where he contributed to the Integrated Product Development Laboratory group with focus on Multidisciplinary Product Development and Systems Engineering. Since 2017 he has been a mechanical design researcher at the SENAI Innovation Institute for Embedded Systems, working directly on development of innovation projects. His current research interests are systems engineering, product development and integration, and robotic systems for the oil and gas industry.

Fabrízio P. Maziero, Serviço Nacional de Aprendizagem Industrial

received his B.S. degree in Electrical Engineering from University of Passo Fundo in 2014 and his M.S. degree in Electrical Engineering form Federal University of Santa Catarina in 2016, focusing on hardware functional verification for space critical application. He works as a researcher at SENAI Innovation Institute for Embedded Systems since 2016, leading the institute's hardware team in the development of innovation projects. His main areas of work is hardware development for a wide range of applications, from industrial IoT devices, subsea robotics and nanosatellite electronics.

Luís F. Oliveira, Serviço Nacional de Aprendizagem Industrial

received his B.S. degree in Machatronics Engineering from Federal Institute of Santa Catarina in 2023. Since 2024, he works as a researcher at SENAI Innovation Institute for Embedded Systems, working on the development of firmware solutions for innovation projects. His current research interests are real-time operating systems for microcontrollers, machine learning and image acquisition and processing.

Victor B. Coch, Serviço Nacional de Aprendizagem Industrial

earned his Bachelor’s degree in Automation Engineering from the Federal University of Rio Grande in 2022 and went on to complete a Master’s in Computer Engineering there in 2024. During his graduate studies, he contributed to the development of a robotic gait training platform for children with cerebral palsy. Since 2024, he has served as a researcher at the SENAI Innovation Institute for Embedded Systems, where he actively works on innovative projects. His current research interests include control algorithms, embedded systems, and robotic systems for the oil and gas industry.

Elsio Varela, Serviço Nacional de Aprendizagem Industrial

obtained his Technologist degree in Industrial Mechatronics from Federal Institute of Santa Catarina in 2010. He is currently a researcher at the SENAI Innovation Institute for Manufacturing Systems. He has interest and experience in robotics, assembly and testing of mechanical and automation systems.

Hugo F. L. Santos, Petrobras (Brazil)

received his B.S. degree in Mechanical Engineering from the Military Institute of Engineering (IME) in 2008, graduating as the top student, and his M.S. degree in Robotics from the Pontifical Catholic University of Rio de Janeiro (PUC-Rio) in 2011. He has led and contributed to multiple innovation projects at Petrobras, including Annelida and Robin, focusing on well engineering and robotics. His work has earned him more than 30 awards, including the ANP Innovation Award and multiple Petrobras Inventor Awards. He holds 13 national, and 88 international patents. His current research interests include well engineering, robotic systems, and

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