As society advances, the demand for sophisticated motor technologies grows. In particular, high-precision modular servo systems have become indispensable in addressing complex real-life challenges, ranging from automation in manufacturing to precision control in robotics. The GEMS project is dedicated to developing an online course that offers detailed tutorials alongside affordable educational hardware, making advanced learning opportunities more accessible to mechatronic students.

This thesis begins with a review of motor technology advancements and their suitability for servo systems. In line with the educational GEMS project’s goal of cost-effectiveness, a permanent magnet brushed direct current (DC) motor was chosen as the core device for electromechanical power conversion due to its simplicity, ease of control, and low cost. The drivetrain system incorporates 3D-printed gears, ensuring affordability and easy replication. For feedback control, two small magnets combined with magnetic Hall-effect sensors function as low-resolution quadrature encoders, offering essential functionality while minimizing costs.

The drive system consists of four key modules: power, sensing, communication, and motion control. Each module's printed circuit board (PCB) functions are detailed based on schematic analysis. The thesis focuses on the motion control module, which is responsible for managing the motor's performance, including speed, position, and torque control. It deals with the low-resolution encoder feedback and implements the control algorithms.

A Simulink model was developed to simulate the DC motor with a 3D-printed drivetrain gearbox. Conventional cascaded PI control is applied, with a current loop as the inner loop and a speed/position loop as the outer loop. To address speed measurement challenges posed by low-resolution quadrature encoders, an encoder tracking algorithm was implemented in the Simulink model, enabling closed-loop control. Finally, the control firmware, based on the Simulink model, was developed in C for the ESP32 microcontroller. Prospective future work is also outlined.