Project Files of 540 RC Motor Library for Proteus Simulation

540 RC MOTOR LIBRARY FOR PROTEUS SIMULATION - V1.0 (a 540 brushed motor in a 1/10 RC car, with a pop-up)
Designed by The Engineering Projects
www.TheEngineeringProjects.com

IMPORTANT LINKS
Article (read it first - pictures, step by step, every feature explained):
  https://www.theengineeringprojects.com/2026/11/540-rc-motor-library-for-proteus.html
Report a bug or suggest a feature (our forum):
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library
The demo runs on our Arduino UNO V4.0 (included) - working LEDs, RESET and a
built-in serial monitor, no Virtual Terminal to wire - its own article:
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
The demo drives the motor through our BTS7960 Motor Driver library (a SEPARATE library - install it too):
  https://www.theengineeringprojects.com/2026/10/bts7960-motor-driver-library-for-proteus-v1-0.html
Support us (the libraries are free):
  https://www.theengineeringprojects.com/donate

FILE STRUCTURE
540-RC-Motor-TEP-v1.0/
|-- Proteus Library Files/
|   |-- ArduinoV4TEP.LIB                              201.9 KB   TEP Arduino boards V4.0 (UNO) -> LIBRARY
|   |-- TEPRC540.LIB                                   13.1 KB   the library -> LIBRARY folder
|-- Proteus Model Files/
|   |-- TEPARDUINO.DLL                                883.5 KB   the Arduino board model -> MODELS folder
|   |-- TEPRC540.DLL                                  318.5 KB   the model -> MODELS folder
|-- Proteus Simulation/
|   |-- RC540_Demo.hex                                 13.0 KB   the demo firmware
|   |-- RC540-Car-BTS7960-ArduinoUnoV4.pdsprj          21.2 KB   the demo project
|   |-- TEPARDUINO.DLL                                883.5 KB   copy of the board model
|   |-- TEPRC540.DLL                                  318.5 KB   copy of the model
|-- Arduino Code/
|   |-- RC540_Demo/RC540_Demo.ino                       3.8 KB   the demo sketch (source of the .hex)
|-- README.txt                                        ~14.3 KB   this file
Total: 2.61 MB (unzipped). The C++ source code of the models is not included.

WHAT IS IT?
The 540-size brushed motor of RC cars, boats and robots - the 7.2 V "540" - drawn at true scale from
a maker's catalogue drawing
(a 35.8 x 50 mm can, a 3.17 mm shaft with a 20-tooth pinion, the black end bell with its tabs), our
own drawing:
  * The model: the motor's winding and brushes (81.4 mohm), its torque constant (2.86 mN.m/A), the
    brush friction, the viscous and windage
    loss and the rotor's inertia; rated 3.6 - 7.2 V.
  * Modelled from the maker's catalogue data at 4.8 V: 15,400 RPM / 2.0 A free, best efficiency 26.0
    mN.m at 13,010 RPM and 10.9 A, stall
    167 mN.m / 59 A. The model gives 15,420 RPM / 2.0 A, 26.7 mN.m at 13,010 RPM / 11.1 A and 167
    mN.m stalled; about 23,300 RPM free at
    7.2 V.
  * It drives a 1/10 RC car (properties or chips in the pop-up): the final drive (9.9 : 1, 85 %
    efficient), 66 mm wheels, the tyres' grip
    (they spin when the motor out-pushes it), 1.6 kg, rolling resistance, air drag and the slope; or
    the car on a stand.
  * Click it at Run for the pop-up: the car on the road, the motor's speed, current and efficiency
    curves at the present voltage with the
    working point, the launch (0 to 20 km/h), the top speed and braking measured, graphs, an event
    log and a check page.
The body is drawn as on the real part and to true scale against our Arduino.
The TEP signature and the pop-up are TEP additions.

ONE DEVICE (search "RCMOTOR" in Pick Devices):
  RCMOTOR540TEP  "540 RC Motor V1.0" in TEPRC540.LIB (Electromechanical > Motors), prefix M, model
  TEPRC540.DLL (analog). Pins + (the
                 red lead) and - (the black lead). The name starts with RC so that it sorts after
                 the embedded ARDUINO UNO V4.0.
The demo's driver is our BTS7960 (BTS7960ADVTEP in TEPBTS7960.LIB / TEPBTS7960.DLL): a separate
library - install it from its own package.

THE POP-UP
Click the part at Run. The chips on top change the road: On the stand, Flat road, Uphill 10 %,
Uphill 20 %, Downhill 10 %. Tabs:
    Car        the car on the road (its wheels turning, smoke when they spin, the lane marks passing
    with its speed), the motor's speed,
               current and efficiency curves at the present voltage with the working point, and
               eight live values: car speed, motor speed,
               current, voltage, power in and at the shaft, efficiency, 0 to 20 km/h, top speed and
               distance.
    Graphs     the live values over the last 2, 6 or 15 s. Live / Freeze.
    Event log  every change and warning; filters All / Changes / Warnings, Pause, Clear
    Check      what the part is doing and what to look at, each with a verdict (green = fine, amber
    = check, red = wrong)
    Settings   theme, text size, open at Run, window size
    Help       report a bug, suggest a feature, article, updates, donate, forum; Copy diagnostics
    for a bug report

TEST STATUS
V1.0: verified in Proteus 8.5 on 8 Nov 2026 (the demo project as shipped: an A4 sheet, an Arduino UNO V4.0).
What the runs showed (the model's own numbers and the sketch's monitor):
  * The project loads and starts cleanly; the 19 s program runs in about four minutes on our PC
    (with the pop-up open).
  * The launch (full throttle, 7.2 V pack): about 63 A at the start - the tyres spin (WHEELSPIN:
    10.1 km/h on the road, the tyres 11 km/h
    faster); 0 to 20 km/h in 0.68 s. Top speed 28.2 km/h at 7.12 V: 22,500 RPM, 4.7 A, 41 %
    efficient (33.8 W in, 13.9 W out).
  * Half throttle: steady 14.1 km/h at 3.56 V, 11,220 RPM, 2.5 A, 33 % efficient. Braking (the motor
    shorted): stopped from 13.8 km/h in
    1.00 m, 0.82 s. Reverse at 40 %: 10.5 km/h backwards, 8,360 RPM.
  * Uphill 20 % (a chip in the pop-up): steady 26.5 km/h at 7.06 V, 21,215 RPM, 8.7 A, 63 %
    efficient; coasting from 24.6 km/h the hill
    slows it to 18.3 km/h within 0.6 s; braked: stopped from 10.6 km/h in 0.53 m, 0.48 s.
  * On the stand (a chip): 23,146 RPM free at 7.16 V with 2.75 A - the tyres would run 29.1 km/h.
  * The pop-up: Car (the car on the road, the speed / current / efficiency curves with the working
    point, eight values), Graphs, Event
    log, Check - all four followed the run; the road chips worked while running.

INSTALLATION (about 2 minutes)
1. Close Proteus. Extract the WHOLE ZIP to a normal folder (e.g. Desktop).
2. Copy everything in "Proteus Library Files" (TEPRC540.LIB and our Arduino library V4.0,
ArduinoV4TEP.LIB, with the ARDUINO UNO V4.0 used by the demo) to the LIBRARY folder of Proteus, for
example:
     C:\Program Files (x86)\Labcenter Electronics\Proteus 8 Professional\LIBRARY
   (use the folder that already holds Proteus's own .LIB files).
3. Copy TEPRC540.DLL and TEPARDUINO.DLL from "Proteus Model Files" to the MODELS folder (...\Proteus
8 Professional\MODELS).
4. Delete TEPRC540.IDX from the LIBRARY folder if it is there (Proteus makes a new index).
5. Start Proteus. In Pick Devices (P) search "RCMOTOR".

RUN THE DEMO
"Proteus Simulation\RC540-Car-BTS7960-ArduinoUnoV4.pdsprj" (an A4 sheet) - keep the .hex file and
the DLLs beside the project.
  ARD1:   Arduino UNO V4.0 running RC540_Demo.hex, its serial monitor built in (window "TEP Arduino
  UNO - ARD1").
  DRV1:   our BTS7960 driver: RPWM = D5 (forward), LPWM = D6 (reverse), R_EN = D7, L_EN = D8, VCC 5
  V, B+ = +7.2V (the pack), B- = GND.
  M1:     the 540 in a 1/10 car: LOAD CAR, MASS 1.6 kg, GEAR 9.9, WHEEL 66 mm, SLOPE 0.
  1. Full throttle (the launch, the wheelspin, the top speed), half throttle, brake, reverse at 40
  %, brake.
  2. Uphill 20 % (a chip): full throttle, coast, brake.   3. On the stand (a chip): full throttle -
  the motor's free speed.
Closed the monitor? Click the UNO's USB port.

WIRING (the same in Proteus and on a real board)
  the motor's + and - to a driver or an ESC that can carry its current - tens of amps at the launch
  (59 A stalled at 4.8 V); a 6 - 7.2 V
  pack (NiMH 6 cells or LiPo 2S); PWM on one input for forward, the other for reverse; both low with
  the driver enabled brakes.
REAL HARDWARE:
 * A 540 at the launch or stalled draws tens of amps: use a driver or ESC rated for it, thick wires
   and a fuse.
 * Fit a 0.1 uF capacitor across the terminals (and one from each terminal to the can) against the
   brushes' electrical noise.
 * Gearing sets the balance of top speed and push: too tall (a small ratio) and the motor overheats
   on a heavy car or a hill.
 * Let it cool between runs; brushed motors wear their brushes and commutator.

THE DEMO SKETCH ON THE SERIAL MONITOR (RC540_Demo V1.0, 9600 baud)
The sketch runs its program, then waits. Type a command to drive the car yourself (it ends the
program):
  f 80    forward at 80 %        r 30    reverse at 30 %        b    brake        c    coast
EXPECTED MONITOR OUTPUT
  TEP 540 RC Motor - a 1/10 car on a BTS7960, 7.2 V
  0.50 s  full throttle: the launch
  3.00 s  half throttle

PROPERTIES (double-click the part > Edit Properties)
  Load (LOAD)                          CAR (on the road) or STAND (the wheels in the air)
  Car mass (MASS)                      kg (1.6)
  Final drive (GEAR)                   motor turns per wheel turn (9.9)
  Wheel (WHEEL)                        diameter, mm (66)
  Slope (SLOPE)                        %, + uphill, - downhill (0)
Every run starts again from the properties.

LINKS.INI (OPTIONAL)
The Help page cards of the pop-up open web pages. To point them somewhere else without a new DLL,
put a text file named links.ini next to TEPRC540.DLL with lines KEY=URL, for example:
  ARTICLE=https://www.theengineeringprojects.com/...
Keys: WEBSITE, FORUM, BUG_REPORT, FEATURE_REQUEST, ARTICLE, USER_GUIDE,
UPDATE_CHECK, DONATE. Only http:// and https:// links are used; lines starting
with # are comments.

TROUBLESHOOTING
* WHEELSPIN at the launch is normal: the motor out-pushes the tyres' grip; ease the throttle in for
  a faster start.
* STALLED: a steep hill, a heavy car or too tall a gear; the motor draws tens of amps and heats -
  gear it down.
* HIGH CURRENT: over 25 A for 2 s - lower the gearing or the load.
* OVER-VOLTAGE: over 8.6 V average across the motor (rated 3.6 - 7.2 V).
* The part is not simulated: TEPRC540.DLL is missing from MODELS and from the project folder. No UNO
  / no monitor window: TEPARDUINO.DLL is missing, or click the UNO's USB port.

BUG REPORTS AND FEATURE REQUESTS
Please post them in our forum with a screenshot, the Serial Monitor text, the
simulation log and the pop-up's Copy diagnostics text:
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library

SUPPORT US
This library is free. If it saves you time, please support our work:
  https://www.theengineeringprojects.com/donate

WEBSITE
  https://www.theengineeringprojects.com/

LICENCES AND THIRD-PARTY NOTES
* The model (TEPRC540.DLL), the symbols and artwork, the other parts of ours in the demo and the
  Arduino Library V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL, with its built-in TEP Serial Monitor
  Advance) are made by The Engineering Projects. The models use only standard Windows libraries; no
  Visual C++ redistributable is needed.
  The C++ source code is not included.
* Arduino UNO V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL, our Arduino Library V4.0 - its
  microcontroller is Proteus's own AVR model): The Engineering Projects,
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
* The .hex file is built from the demo sketch and the Arduino AVR core 1.8.6, which includes
  LGPL-licensed code; its source code is available at
  https://github.com/arduino/ArduinoCore-avr/tree/1.8.6
* Proteus is a product of Labcenter Electronics and is not included. Arduino is a trademark of Arduino SA.
  This library is not made or endorsed by Arduino or Labcenter.

REBUILDING THE FIRMWARE (OPTIONAL)
The HEX file is supplied; Arduino IDE is not needed to run the demo. To edit the sketch, open
Arduino Code\RC540_Demo\RC540_Demo.ino, select Arduino Uno and use Sketch > Export Compiled Binary.
Replace the simulation's .hex with the exported HEX. The sketch needs 4,454 bytes of flash and 459
bytes of RAM.

MODEL SCOPE AND LIMITS
Modelled: the motor (winding and brush resistance, back-EMF, brush friction, viscous and windage
loss, inertia) with its driver in one
circuit; the car: the final drive and its efficiency both ways, the wheels' inertia, the tyres' slip
curve, mass, rolling resistance, air
drag and slope; braking and coasting through the driver.
Not modelled: the motor's inductance and commutation ripple, heating and brush wear, the steering,
the suspension, the battery's sag.

VERSION
TEP 540 RC Motor library V1.0 (Nov 2026). Device RCMOTOR540TEP (TEPRC540.LIB / TEPRC540.DLL). Demo
sketch RC540_Demo V1.0. Demo board: ARDUINO UNO V4.0 (TEP Arduino Library V4.0) with its built-in
serial monitor; driver: our BTS7960 library.