Design and Validation of an Online PID Tuning Tool for Mechatronic Systems: Application to a Dual-BLDC Balancing Platform

This paper presents the design, implementation, and experimental validation of an online Proportional–Integral–Derivative (PID) tuning and visualization tool applied to a Dual Brushless DC (BLDC) motor balancing platform. The proposed system integrates an Arduino-based embedded controller with a C# desktop application to enable dynamic adjustment of control parameters and online visualization of system responses. A custom bidirectional serial communication protocol was developed to ensure data exchange, while a multithreaded asynchronous architecture maintained continuous operation, high responsiveness, and robust data integrity. The system was validated using both a MATLAB-based virtual plant and a physical dual-BLDC balancing platform. Experimental results demonstrated closed-loop operation, real-time gain adjustment, and stable visualization performance. Hardware testing further revealed that communication latency and electromagnetic interference from the BLDC motors influenced sensor accuracy and control smoothness, highlighting the significance of controller update rate and hardware shielding. The tool demonstrates a robust communication architecture, achieving a sustained data rate of 66 Hz with zero packet loss, enabling effective manual tuning that stabilized a dual-BLDC platform. Experimental results quantify the critical relationship between Arduino processing capability and achievable stability.