Selecting the right size BLDC motor can make or break your application’s performance. Whether you’re designing an electric bike, an industrial automation system, or a robotic arm, matching your motor size to your load requirements is essential for efficiency, durability, and control. In this guide, we’ll walk you through the key factors in BLDC motor sizing — and how X-TEAM brushless motors simplify your selection process.
Why BLDC Motor Sizing Matters
Undersized motors can overheat, stall, or fail prematurely. Oversized motors, on the other hand, waste energy, space, and cost. Correct sizing ensures:
Optimal torque output
Efficient power consumption
Stable speed control
Long operating life
Key Factors to Consider When Choosing BLDC Motor Size
Required Torque
Start by calculating the continuous and peak torque needed by your application.
Formula:
Torque (Nm) = Force (N) × Radius (m)
For example, a conveyor belt or robotic joint will need different torque profiles. Make sure to consider load friction, inertia, and acceleration torque.
Operating Speed (RPM)
BLDC motors are available in various speed ranges, from low-speed (<1000 RPM) high-torque models to high-speed (>10,000 RPM) designs for drones or tools.
At X-TEAM, our motors range from 100 RPM to 20,000 RPM, depending on your voltage and control system.
Voltage and Current Limits
Match the motor’s rated voltage to your power supply. Common BLDC motors come in 12V, 24V, 36V, 48V and high-voltage options.
Check the continuous current rating and ensure your controller and wiring can handle it.
Load Type: Constant or Dynamic
For steady loads like fans or pumps, sizing is simpler. For dynamic loads like robotic joints or AGV wheels, consider acceleration, deceleration, and inertia.
Other Factors to Evaluate
Size constraints (diameter, length)
Weight limits
Thermal environment (cooling requirements)
Mounting options
Sensor vs Sensorless operation
How X-TEAM Simplifies BLDC Motor Sizing
At X-TEAM, our brushless motors are engineered for modular adaptability and high performance. We offer:
Free sizing consultation
CAD models for simulation
Custom shaft & housing options
Matched controllers & drivers
Whether you’re prototyping or scaling for mass production, our support team ensures you get the right motor — not just a motor.
Choosing the right size BLDC motor starts with understanding your torque, speed, voltage, and load conditions. With X-TEAM’s wide range of high-performance brushless motors and expert support, you’re just a step away from perfecting your motion system.