Chronicle
Motors and Drives

Electronic Speed Controllers (ESCs)

ESC types, specifications, calibration, programming, and practical interfacing with brushless motors in robotics

Electronic Speed Controllers (ESCs)

An ESC is the "brain" controlling a brushless motor. It takes a simple PWM signal and outputs sophisticated three-phase power to spin the motor at any desired speed.

SimonK ESC electronic speed controller

Figure: Electronic Speed Controller (ESC) - Controls brushless motor speed and direction

What ESCs Do

ESC Functions

Why Not Direct Battery?

Direct battery connection: Motor spins full RPM (no control)
ESC connection: Fine-grained control over entire RPM range
Plus: Built-in protection, current limiting, safety features

ESC Specifications

Key Ratings

Current rating:

ESC 30A specification means:
- Can handle 30A continuous current
- Peak: Usually 50-100A for short bursts

Voltage range:

ESC rated "2-6S" means:
- 2S LiPo: 7.4V minimum
- 6S LiPo: 22.2V maximum

Firmware types:

  • BLHELI (most common)
  • SimonK (good for racing)
  • DShot (latest, digital communication)

Example Specifications: 40A ESC

Continuous current:     40A
Burst current:          60A
Voltage range:          2-6S LiPo (7.4-22.2V)
BEC output:             5V / 2A (for receiver)
Firmware:               BLHELI
Switchable frequency:   8 kHz or 16 kHz
Weight:                 28g

Motor Compatibility

Matching ESC to Motor

Motor KV rating (RPM per volt):
Motor KV 920 at 12V = 920 × 12 = 11,040 RPM max

ESC must handle this RPM:
Most ESCs: 200,000 ERPMs (electronic RPM)
Some racing ESCs: 400,000+ ERPMs

Check: Motor RPM < ESC max RPM (with margin)

Power Calculation

Power (W) = Voltage (V) × Current (A)

Example: 12V 30A ESC
Maximum power = 12V × 30A = 360W

ESC Connections

Standard Wiring

From battery:
  Red wire    → Battery positive
  Black wire  → Battery negative/GND

To motor:
  Three wires → Three motor coils (order can be reversed for direction)

From controller:
  Signal (white/yellow)   → PWM input
  Power (red)            → 5V from BEC
  Ground (black)         → Common ground

Three-Phase Motor Wires

ESC outputs: A, B, C phases
Motor coils: Phase A, B, C (color coded)

Connection: ESC A → Motor coil A, B → B, C → C
Reverse: Swap any two wires (e.g., A ↔ B) to reverse direction

BEC (Battery Elimination Circuit)

ESC supplies 5V regulated power to receiver/controller:

Battery → ESC
          ├─ Powers motor (high current)
          └─ BEC outputs 5V (2A typical)
                └─ Powers flight controller

Advantage: Only one battery needed
Disadvantage: ESC failure = no control

ESC Calibration

Why Calibration?

ESCs need to know PWM input range:

  • Minimum signal (motor off)
  • Maximum signal (full throttle)

Calibration Steps

Standard Throttle Calibration

  1. Connect battery (but not to ESC yet)
  2. Set transmitter/controller to maximum throttle
  3. Connect battery to ESC (beep sequence indicates calibration mode)
  4. Set transmitter to minimum throttle (beep confirms)
  5. Motor is now calibrated

Alternatively:

  1. Send maximum PWM (2000 µs)
  2. Send minimum PWM (1000 µs)
  3. Send neutral PWM (1500 µs)

Done!

Program Settings

Many ESCs allow programming (via transmitter clicks or PC):

  • Rotation direction: CW or CCW
  • Brake strength: 0% to 100%
  • Cut-off voltage: Low voltage protection
  • Frequency: 8kHz or 16kHz switching
  • BEC voltage: 5.2V or 6.0V

Use manufacturer software or transmitter commands.

Reverse Motor Direction

Three methods (in order of preference):

1. Swap any two wires:

Original: Motor A → ESC A, B → B, C → C (CCW)
Swap A↔B: Motor A → ESC B, B → A, C → C (CW)

2. Software setting: Most ESCs can reverse via programming

3. ESC menu (if available): Menu option: Direction → Reverse


ESC Protection Features

Built-in Protections

1. Over-current protection
   └─ If current exceeds rating, throttle reduces
   
2. Low voltage cutoff (LVC)
   └─ Stops motor before battery dies completely
   
3. Over-temperature
   └─ Reduces current if ESC gets too hot
   
4. Stall protection
   └─ If motor can't spin, reduces power to prevent damage

Example: 40A ESC with 30A sustained

Motor jams (locked): Wants to draw 100A
ESC 40A limit: Throttles back to 40A
Over-current protection: Reduces to 30A after 5 seconds
Result: Motor protected, system doesn't burn out

ESC Troubleshooting

ProblemCauseSolution
Motor won't spinNot calibratedRecalibrate ESC
No signalCheck PWM connection
Low voltageCheck battery
Motor spins slowlyCalibration offRecalibrate with full range
PWM frequency wrongCheck controller frequency
Motor stutters/jerksBad connectionReflow solder on wires
Firmware issueUpdate BLHELI
Excessive heatContinuous overloadReduce load or use larger ESC
Poor connectionsCheck solder joints
Beeping patternsVarious codesCheck manual (armed/disarmed)

Advanced ESC Features

DShot Protocol

Newest ESC standard using digital communication (not PWM):

Advantages:
✓ Precise control (11-bit resolution vs 8-bit PWM)
✓ Low latency (~25 µs vs 1000+ µs)
✓ Can read ESC telemetry (temperature, current)
✓ CRC error checking

Requirements:
- DShot-compatible flight controller
- DShot-compatible ESC
- Special cabling

Example: BLHeli_32 with DShot600

Telemetry

Some advanced ESCs send back data:

Data available:
- Actual RPM
- Current draw (amps)
- Temperature
- Voltage

Usage:
- Monitor motor health
- Detect problems early
- Adjust control in real-time

Programmable Features

Many ESCs allow adjustment via programming:

FeatureDefaultRangeEffect
BrakeOn0-100%Motor braking force
LVC6.0V4.5-8.0VLow voltage cutoff
Start Force100%50-150%Startup power
PWM Frequency8kHz8/16 kHzSwitching frequency

Practical Example: Quadcopter ESC Setup

Battery: 4S LiPo (14.8V nominal)
Motors: 4× 920KV (11,040 RPM max at 14.8V)
ESCs: 4× 40A rated

Wiring:
Battery → Power Distribution Board (PDB)
PDB → ESC 1, 2, 3, 4 (power)
ESC 1,2,3,4 → Motors 1,2,3,4 (three-phase wires)

Signal:
Flight controller → ESC 1,2,3,4 (PWM on pins 1,2,3,4)

Calibration:
1. Max throttle on transmitter
2. Connect battery
3. Min throttle on transmitter (calibration complete)

Common ESC Models

ModelCurrentVoltageTypePriceUse
Turnigy Plush40A2-6SAnalog$Multirotor
BLHeli_3230-50A2-6SBLHELI$$Racing
KISS ESC24A2-6SUltra-fast$$$FPV Racing
DJI ESC40A2-6SDShot$$$Phantom
Littlebee20A1-3STiny$Micro drones

Summary

ESC Essentials:

✓ ESC turns simple PWM into three-phase motor control ✓ Match ESC current rating to motor requirements ✓ Calibration ensures full throttle range works ✓ Built-in protections prevent damage ✓ Reverse motor by swapping two wires

Selection Guide:

  1. Calculate motor current at full power
  2. Choose ESC rated 20-30% higher
  3. Verify voltage range matches battery
  4. Check firmware (BLHELI, DShot, etc.)
  5. Calibrate before first use

For Different Applications:

  • Multirotor: Standard BLHELI 40-80A ESCs
  • Racing: DShot, ultra-fast ESCs
  • Robotics arm: 10-20A smooth torque ESC
  • Rover: 60+ A high-current ESC

How is this guide?