Custom Motor Control Solution for Connected Fitness Equipment

iFIT, a global leader in connected fitness technology, required a custom BLDC motor control solution for their exercise equipment that exceeded the capabilities of standard off-the-shelf controllers. The system needed to deliver exceptionally low torque ripple for smooth, natural resistance during exercise, while also tolerating being back-driven by the user without risking damage to the power electronics. These demanding performance requirements called for specialist field-oriented control (FOC) expertise and careful control-loop tuning, combined with solid embedded and electronics design.

Working in partnership with Beeleader, a mechatronics company specialising in sports science and health-focused motion systems, Plextek developed a fully integrated custom motor control PCB and firmware solution.

The development process included:

• Motor control implementation: FOC algorithms incorporating Park and Clarke transforms, PID control, and space vector modulation.
• Simulation and analysis: We performed magnetic flux density and electrical current analysis to understand torque ripple sources. Simulation of the motor’s magnetic core identified areas of magnetic saturation, guiding adjustments in the control algorithm and confirming the limits of the physical design.
• Custom validation rig: We designed and built a custom mechanical test rig capable of fully automated, Python-script-driven, repeatable testing. Using torque, temperature, and position sensors, the system exercised the motor across defined control profiles and varying loads over extended test cycles.
• System integration: The controller was designed to function as a native part of iFIT’s system architecture rather than a bolt-on component.

By taking on this technically complex part of the design, we enabled iFIT to avoid a steep learning curve, reduce development risk, and retain a proven motor control design as an IP block for future products. This freed their engineers to focus on the features and user experience that define their product.

We developed a bespoke motor control solution that delivered the precise torque performance and system integration iFIT’s application required. The custom controller achieved exceptionally low torque ripple for smooth resistance control and robust operation when back-driven by users.

The solution demonstrated specialist motor control expertise in applications where standard drive systems cannot deliver the required performance. The same cross-disciplinary capability combining embedded systems, FOC control, and system integration applies wherever precise, efficient and reliable motor control is critical, including medical devices, industrial automation, robotics, and consumer products.