www.astesj.com 1118 Design and Implementation a Novel System for Estimation Precise Transfer Function of DC Motor Falih Salih Alkhafaji *,1 , Wan Zuha Wan Hasan 2 , Nasri Sulaiman 3 , Maryam bt. Mohd. Isa 3 1 Ministry of Industry, State Company for Electrical and Electronic Industries,10052, Baghdad, 10001, Iraq 2 Institute of Advanced Technology (ITMA), University Putra Malaysia, 43400, Serdang, Selangor, 45500, Malaysia 3 Department of Electrical and Electronic Engineering, Faculty of Engineering, UPM, 43400, Serdang, Selangor, 45500, Malaysia A R T I C L E I N F O A B S T R A C T Article history: Received: 30 June, 2020 Accepted: 04 October, 2020 Online: 20 October, 2020 A precise modelling plant system is substantial to improve the design of the DC motor controller, where a low accurate model may cause an unacceptable controller system. This study presents a hardware-in-the-loop (HIL) system for design a high speed motor data acquisition system (HSMDAQS) and injected collected data (ICD) Simulink model to estimate accurately the transfer function (TF) of a DC motor, without needing motor’s specification, providing high accuracy estimation tool that can be used to develop the design of a DC motor controller. The proposed system generates synching data to be imported into system identification (Sys Ident) application through a serial port. To show the performance design, a comparative study has been conducted between the experimental realization and simulation results in terms of dead time(td), rise time(tr), and settling time(ts), using a scope simulator. It was used three different DC motors to demonstrate the effectiveness of our approach in terms of average error step responses (AE-SR). The estimation results show that the best FIT between the response of the estimated TF and the collected data augmented by 95.03 % and stabilized despite using different motor’s speed. A comparison step response between experimental and simulation shows a very low deviation and minimized AE-SR below 10% for all tested motors. The developed system could be applied in a wide range of industrial applications, offering faster with accurately capturing data, high precision stabilized platform, a simpler implementation for dynamic systems, lower computational cost design, and flexibility. Keywords: HSMDAQS TF PI controller DC motor Estimation 1. Introduction This paper is an extension of work originally presented in the Prime Asia 2019 conference [1]. DC motors are being used in robotic systems, home appliance and an electric vehicle and many other applications in case of simple structure, high performance, low-cost installation, and easy control speed. However, DC motor systems still have nonlinear parameters, variation in load dynamics, unpredictable inputs and disturbances, that affect their quality. Therefore, these motors should be controlled and analyzed to improve their performance [2-5].The concept of a real-time processing must be considered when an engineer designs develops and deploys a new automation and control system[6].The improvement of DC motors’ control arrangement to enhance their response characteristics is one way of reducing the amount of consumed energy and enhance the efficiency of the machines[7]. Control systems engineering requires a knowledge of at least two basic components: (1)the plant model which describes the mathematically modeled behavior of the system;(2)the desired output [8]. For those systems are known their specifications, The DC motor can be mathematically modelled by using the dynamic equivalent circuit of DC motors based on the second order system as given in equation 1 [9, 10] . () = ̇ () = (+)(+)+ 2 [/] (1) For DC motor with zero load, the TF from can be simplified as a first order system as given in equation 2. () = 1 +1 = +1 [/] (2) ASTESJ ISSN: 2415-6698 * Corresponding Author: Falih Salih Alkhafaji, falih_alkafaji1@yahoo.com Advances in Science, Technology and Engineering Systems Journal Vol. 5, No. 5, 1118-1125 (2020) www.astesj.com https://dx.doi.org/10.25046/aj0505136