Zikodrive Motor Controllers - stepper motor drivers, brushless ESCs, bldc motor drivers, stepper motor controllers

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                                                                                             Case Studies

Zikodrive Motor Controllers - stepper motor drivers, brushless ESCs, bldc motor drivers, stepper motor controllers

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Zikodrive Motor Controllers is a trading name of Round Bank Engineering ltd. Registed Company Number 08288866. VAT Number: GB226504428

VERT ROTOR - optimised sensorless brushless DC motor controllers in low vibration compressors

Project Aim

To programme a standard ZDBL15 brushless motor driver (brushless ESC) to optimise the performance of a Vert Rotor compressor.

Major attention had to the start up phase of operation but also to optimising the top speed of the compressor (and thereby improving mechanical performance of the compressor).

How the project developed

The focus of the project was in replacing what had been low cost imported brushless ESCs with a longer term industrial solution such as the ZDBL15 brushless ESC.

In doing so the aim was both to increase the life of the controller, retain the performance of the compressor whilst at the same time exploring the possibilities offered by more advanced features such as the constant speed under variable load.

Key Challenges

The most important challenge in this application was optimising the startup sequence for the compressor. As many people are aware this is often the biggest challenge when using sensorless brushless DC motors and it is made even more difficult when working in applications where starting under load is also a requirement.

That said, our technical team have put a lot of time into optimising and developing successful start up procedures for such applications.

This has been achieved through a combination of carefully programmed acceleration curves, optimising the initial forced commutation for each motor specifically (this is why we always request a sample of the exact motor that is being used for your application).

By implementing these various procedures we were able to improve on the performance of the previous ESC considerably and add a range of performance options depending on the application.

From 5 bar to 15 bar

One of the fundamental design principles at the heart of all of our ‘off the shelf’ range has been to make the hardware as flexible as possible so that the controllers can operate in a wide range of applications.

In this way we are able to make savings on production costs by manufacturing in larger volumes and we can therefore pass these savings onto our customers who need only pay a small setup/programming fee to get a customised brushless ESC or stepper motor driver

ZDBL Series of Brushless ESCs and BLDC motor drivers used by Vert Rotor Compressors

In many respects, the Vert Rotor case study is therefore an example of this model at it’s simplest.

Whereas the company had previously been stuck between low cost, poorly performing brushless ESCs and much more expensive, highly complex brushless motor controllers (which cost too much to make the application viable), with the ZDBL15 brushless motor driver it was possible to quickly setup a custom programme, carefully optimised for the specific motor and application.

This delivered a technically better solution than either the low cost brushless ESCs or the more advanced controllers for a price that made the application work.


This case study clearly shows the importance of optimising programmes for motors and just how much of a benefit this can bring.

It also highlights the flexibility that comes from having programmable motor controllers which can be carefully optimised for your application by an expert team.

ZDBL Series of Brushless ESCs and BLDC motor drivers used by Vert Rotor CompressorsZDBL Series of Brushless ESCs and BLDC motor drivers

Frequently Asked Questions

Can I replace a DC motor with a brushless DC motor and controller?

How complex can the programming on the Zikodrive stock range of motor controllers be?

Can sensorless brushless motor controllers be used in dosing applications?

Can a sensorless brushless motor be started efficiently under load?

Can I purchase the IP rights to a bespoke designed controller?

Do you offer on site support and assistance setting up a new controller?

What are the typical costs associated with modifying an existing stock stepper motor controller or brushless motor driver?

Can I run a motor at a fixed speed under a variable or changing load?

Why choose brushless motors and controllers?

Can I start a sensorless brushless motor under load?

Replacing a brushed DC motor with a stepper motor?

ZDBL15 - Sensorless Brushless Motor Controller or BLDC Motor Driver

ZDBL Series Brushless Motor Drivers and Controllers are compact and lightweight and can be optimised for any BLDC motor. If you need help matching a brushless specification to a DC motor specification then CONTACT US and we will be happy to help.

Brushless ESCsZDBL15
Find out why optimising the ZDBL Series can deliver improved performance