Muhammad Abdillah Zakka, Rizky Ajie Aprilianto
Industrial conveyor systems require an intelligent control mechanism to adapt motor speed to dynamic load variations, ensuring stable performance and optimal energy efficiency. However, conventional conveyor controllers with static speed regulation often result in energy waste, slow response, and mechanical wear. This research proposes a fuzzy logic-based motor speed control system implemented on an ESP32 microcontroller and integrated with a PLC Outseal. The proposed system uses a load cell and infrared sensors to measure load weight and motor speed and adjusts the PWM signal to the BTS7960 driver based on real-time fuzzy inference. The Modbus RTU protocol integrates the system with the Node-RED Dashboard to facilitate flexible monitoring and manual control. The fuzzy controller is designed with a 3× 3 rule base, using load weight and material level as inputs, and PWM duty cycle as output. Experimental validation shows that the system reaches a steady state in less than 4.1 seconds with an error of less than 5%, and the rise time is less than 2.01 seconds at all speed levels. In addition, energy consumption is reduced by 72%, outperforming conventional systems with fixed speed. These results demonstrate the system's effectiveness in providing stable, responsive, and energyefficient motor control, especially suitable for small- to medium-scale industrial automation environments. © 2025 IEEE.
Universitas Negeri Semarang, Department of Electrical Engineering, Semarang, Indonesia
