You did not mention any hardware for current sensing. I would suggest starting with a hall effect sensor, which outputs a voltage proportional to the current. You will then need to convert this analog signal to a digital signal which could be fed into an N.I. data acquisition device for further analyses. By connecting the results to a graph, you will be able to see the finger print of a typical current inrush, normal, and stall. Your controls on your front panel will need to be set in your program to adjust the parameters of the particular motor in which you are connected at the time. One major difference between in rush current and stall current is time. Both will have high current values, but inrush will be a set amount, for a set time. All motors are designed to handle a certain amount of stall current for a certain amount of time. This too, should be a variable controll on your front panel. Even a well designed simple program should give you the protection, I believe you are looking for. You should not have to get into complicated algorithm's. You can set thresholds base upon time in your program. Good luck!
