BLDC Motor Controller FAQ
Frequently Asked Questions.
The 12 questions buyers and engineers ask most often before a controller order. For sizing help send the four-number spec — bus voltage, motor power, control mode, communication protocol — to the inline quote above.
BLDC controller vs regular DC controller — what's the difference?
Brushed DC controllers need only an H-bridge or PWM regulator. BLDC controllers carry a three-phase MOSFET inverter plus an MCU that reads Hall sensors or back-EMF and energises phase pairs in sequence. More parts, more firmware — but higher efficiency and longer service life.
What current rating do I need?
Continuous = motor rated power ÷ bus voltage. Peak = 2–3× continuous. Add 30–50% margin for breakaway loads. A 48V 480W motor pulls about 10A continuous — BLD22010 is a tight match, BLD6010 is the safer pick for overload-heavy duty.
Can one controller drive multiple motors?
No. One three-phase controller drives one motor — inverter, Hall input and current sensors are dedicated. Multi-motor systems use one controller per motor and coordinate them over RS485 Modbus or CAN bus.
Hall sensor or sensorless?
Hall-sensor for AGV, conveyor, e-mobility and any application that needs strong startup torque. Sensorless for fans, pumps and air purifiers where wiring simplicity matters more than low-speed torque. Both are available on the BLD22010 / BLD6010 line.
What if supply voltage drops below the minimum?
Undervoltage protection triggers and the gate drivers shut off. Battery-powered systems should size the battery for the controller's continuous-undervoltage threshold, not just nominal voltage. BLD22010 minimum is around 16V (for the 18V spec).
How do I tune the PID loop?
On matched kits, PID is pre-set at the factory load bench. For standalone-controller deployments, start with the published default for the closest matched motor family, adjust Kp first (stiffness) and Ki second (overshoot). Send bench data and engineering returns tuned values inside 48 hours.
What is the regenerative braking story?
All three controllers recover energy on deceleration. On battery systems this charges the battery. On rectified-AC industrial systems (110V / 220V) a brake resistor across the bus dissipates the regen energy as heat — without one, overvoltage protection trips on heavy decel.
Modbus over RS485 — supported?
Yes — on every controller in the lineup. Speed setpoint, torque limit, direction and fault flags exposed as Modbus registers. Works with Siemens S7, Mitsubishi FX, Allen-Bradley CompactLogix, Omron Sysmac and Schneider Modicon.
CAN bus — supported?
BLDB6010 servo supports CAN bus. CANopen, J1939 and custom OEM IDs available under firmware engagement. BLD22010 and BLD6010 use RS485 / Modbus instead — engineering can quote a CAN bridge if required.
What is the MOQ?
1 piece for sample, 10 pieces for commercial first order on standard SKUs. 50–100 pieces for OEM-branded runs. ODM with custom firmware quoted per project, typically 100 pieces minimum after NRE.
What is the lead time?
Sample 7–10 days, production 2–3 weeks on standard controller SKUs. Matched motor + controller kits ship in the same window. OEM-branded runs add 1–2 weeks, ODM custom firmware 4–8 weeks.
Can the controller firmware be customised for an OEM?
Yes — custom CAN protocols, torque-limit curves, acceleration ramps, customer fault codes and integrated brake-resistor switching are all standard customisation paths. Feasibility note inside 5 working days under NDA, NRE quoted per project.
