Description

Course Structure

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Module 1: Introduction to Control Systems

Topics Covered:

• What is a Control System?

• Open-Loop vs. Closed-Loop Systems

• Applications: Drones, Gimbals, Balancing Bots, Satellite Attitude Control

• Overview of Self-Leveling Platform Project

Activities:

• Identify Real-World Control Systems (Open vs. Closed Loop)

• Simulate a Basic Open-Loop System in Python using Matplotlib

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Module 2: Transfer Functions and System Dynamics

Topics Covered:

• Differential Equations for Physical Systems

• Transfer Functions: Definition and Derivation

• First- and Second-Order Systems

• Time vs. Frequency Domain Analysis

• Poles, Zeros, and System Stability

Activities:

• Plot Step Response using Python (SciPy) and MATLAB

• Damped Second-Order System Analysis and Tuning

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Module 3: ESP32 and Hardware Introduction

Topics Covered:

• ESP32 Overview: GPIO, PWM, ADC, Communication Interfaces

• BLDC Motor, ESC, and Power Setup

• Frame Design, Rotor Assembly, and Battery Configuration

Hands-on Tasks:

• Blink an LED using Arduino IDE

• Wire ESC + BLDC Motor with Proper Safety

• Perform a Dry-Run Test: Spin the Motor with Test PWM

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Module 4: GPIO, PWM, and Motor Control

Topics Covered:

• PWM Generation on ESP32

• ESC Calibration and Safety Practices

• Motor Speed Control using PWM

• Resolution, Deadband, and Latency Considerations

Hands-on Tasks:

• Control BLDC Motor using PWM

• Sweep Motor Speeds and Analyze Behavior

• Tune Safe and Responsive Operating Range

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Module 5: Sensor Integration with MPU-9250

Topics Covered:

• MPU-9250: Accelerometer, Gyroscope, Magnetometer

• Sensor Fusion: Complementary vs. Madgwick Filter

• I2C Communication Protocol

• Noise Filtering and Real-World Data Handling

Hands-on Tasks:

• Interface MPU-9250 with ESP32

• Read Pitch, Roll, and Yaw Angles

• Implement Complementary Filter for Angle Stabilization

• Visualize Orientation using Serial Plotter or Processing 3

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Module 6: Feedback Control and PID Basics

Topics Covered:

• Control Loop Architecture: Sensor → Controller → Actuator

• PID Control: Concepts of Kp, Ki, Kd

• System Performance: Overshoot, Stability, Settling Time, Steady-State Error

Simulation Activities:

• Simulate PID-Based Angle Stabilization using Python/MATLAB

• Visualize and Tune Control Response with Matplotlib

• Analyze Effects of PID Gains

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Module 7: Real-Time PID on ESP32

Topics Covered:

• Translating PID Logic to Arduino C++

• Sampling Rate and Loop Timing Optimization

• Handling Real-World Sensor Noise and Latency

• Motor Response Testing and Calibration

Hands-on Tasks:

• Implement PID Control Loop on ESP32

• Use MPU-9250 Feedback to Stabilize Platform Pitch

• Tune PID Gains in Real-Time for Stability and Responsiveness

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Module 8: Final Project – Self-Leveling Platform

Project Overview:

Build a Single-Axis Self-Leveling Platform using ESP32, MPU-9250, and a BLDC Motor. The platform will detect tilt and auto-correct using a PID-controlled actuator.

Hardware Requirements:

• ESP32 Development Board

• BLDC Motor + ESC

• MPU-9250 IMU

• Rotor/Actuation System

• LiPo Battery

• 3D-Printed Tilt Platform

Deliverables:

• Functional Self-Leveling Prototype

• Documentation of PID Tuning and System Behavior

• Optional Add-ons:

  • Dual-Axis Stabilization

  • Web-Based PID Monitor/Control Interface

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Learning Outcomes

By the end of this course, participants will:

• Grasp Fundamental Concepts in Control Systems

• Simulate Dynamic Systems and Controllers in Python & MATLAB

• Interface Sensors and Actuators with ESP32

• Build and Tune a Functional Feedback Control System

• Deploy Real-Time PID Control on Embedded Hardware

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Tools & Software Used