400W BLDC Controller and Motor Solution Design
Budget: $750 – $1,500 NZD
I need a production-ready hardware solution that lets a 400 W BLDC motor run smoothly from 0 rpm up to 250 rpm while maintaining full torque across the entire range. I have been studying the STM32 ZeST algorithm and believe it provides the low-speed field-oriented control we require, although you may recommend alternate solutions based on your experience. Your task is to engineer the electronics that bring the required motor capability to life at the lowest possible per-unit cost.
Core requirements
• Precise and progressive speed control and rock-steady torque
• Whisper-smooth rotation with no cogging at crawl speeds and minimal noise
• Solution designed for easy transition to mass production, including consideration of sourcing components
Scope of work
1. Select the most suitable STM32 (or alternate) device and power stage topology.
2. Produce schematic, PCB layout, and a BOM that keeps component cost lean without sacrificing performance.
3. Integrate encoder or sensorless feedback, tuning for the 0–250 rpm window.
4. Provide reference firmware settings or tweaks needed for the ZeST algorithm (or alternative selected) so the board is ready for bench testing.
5. Deliver manufacturing files (Gerbers, pick-and-place, assembly notes) plus brief documentation so my team can build and validate the prototype.
If you’ve previously designed low-speed, high-torque BLDC drive solutions let’s talk.
Core requirements
• Precise and progressive speed control and rock-steady torque
• Whisper-smooth rotation with no cogging at crawl speeds and minimal noise
• Solution designed for easy transition to mass production, including consideration of sourcing components
Scope of work
1. Select the most suitable STM32 (or alternate) device and power stage topology.
2. Produce schematic, PCB layout, and a BOM that keeps component cost lean without sacrificing performance.
3. Integrate encoder or sensorless feedback, tuning for the 0–250 rpm window.
4. Provide reference firmware settings or tweaks needed for the ZeST algorithm (or alternative selected) so the board is ready for bench testing.
5. Deliver manufacturing files (Gerbers, pick-and-place, assembly notes) plus brief documentation so my team can build and validate the prototype.
If you’ve previously designed low-speed, high-torque BLDC drive solutions let’s talk.