Build a Mini Motor Dyno Using SOLO

More than 60% of electric motor projects fail at the prototype stage due to lack of proper testing. This simple but powerful insight tells us that motor testing is not optional—it’s essential.

If you’re a robotics developer, a DIY enthusiast, a university engineering student, or part of a startup designing electric vehicles, understanding how your motors perform under load is critical. And the best way to do that? Build a mini motor dyno using the SOLO Motor Controller.

What Is a Mini Motor Dyno?

A mini motor dyno is a small-scale motor testing setup used to measure:

    • Torque (Nm)
    • Rotational speed (RPM)
    • Electrical current (A)
    • Voltage (V)
    • Mechanical and Electrical Power (Watts)
    • Efficiency (%)
    • Motor heating and stability under load

Using a motor dynamometer helps you analyze how your motor behaves under different loads, speeds, and control methods. A mini version is compact, budget-friendly, and perfect for labs, home workshops, or prototyping setups.

Front view of the compact Solo Motor Test Bench enclosed in a transparent protective casing, showcasing its controls and test motor mount.

Why Use the SOLO Motor Controller?

The SOLO Motor Controller is a compact, intelligent, and plug-and-play motor controller that works with:

    • DC Brushed Motors
    • BLDC Motors
    • PMSM Motors

It supports both sensor-based and sensorless Field-Oriented Control (FOC), offering precision, flexibility, and real-time feedback, making it the perfect match for building your own motor dyno.

Complete Guide: How to Build a Mini Motor Dyno Using SOLO

Materials and Components

Component
SOLO Motor Controller
Test Motor
Load Motor
Torque Sensor
Encoder / Rotational Speed Sensor
Power Supply
Data Logger / SOLO Studio GUI
Mechanical Frame & Couplings
Cooling Fan or Heat Sink
Purpose
Controls and monitors the test motor
Motor under examination
Acts as the brake to simulate load
Measures torque generated by the motor
Tracks the speed of the motor shaft
Powers both the test motor and load motor
For visual monitoring and logging performance data
Mounts and aligns both motors and sensors
Prevents overheating during long test sessions

Mechanical Assembly and Wiring Overview

    • Mount both motors on the frame: Use stable rigid construction like a T-Slot plate
    • Mount a Torque Sensor and attach it between test and load motor shafts using couplings
    • Add a Rotational Speed Sensor to test motor shaft
    • Connect SOLO Motor Controller to your test motor
    • Connect Power Supply to SOLO and load motor (through another SOLO or different driver), check that the power matches voltage/current requirements for both motors
    • Make sure that the system has any safety loop to prevent mechanical failures during tests (Use SOLO Safe Torque Off or learn more about safety in our articles)
    • Use SOLO Studio GUI via USB or UART to configure parameters and view live data
    • For testing use manual control via SOLO GUI or either a specific test profile can be provided using CAN line
Close-up collage of SOLO motor controller boards designed

Applications of a Mini Motor Dyno with SOLO

Use Case
Motor Research & Development
Education & Learning
DIY Robotics
EV Prototyping
Quality Control
How It Helps
Validate performance under load conditions
Perfect for labs and courses on mechatronics or motor control
Helps hobbyists tune motors for mobile robots and drones
Test motors for e-bikes, scooters, and small electric vehicles
Ensure motors meet torque, speed, and thermal criteria
Engineers operating the compact Solo Motor Test Bench in a lab environment with live motor diagnostics displayed on a connected laptop.

Advantages of Building a Mini Motor Dyno Using SOLO

Feature
SOLO Test Bench Software
FOC Sensorless + Encoder Modes
Real-Time Data Monitoring
SOLO Studio GUI
Multi-Motor Compatibility
Safe and Scalable
Cost-Effective
Advantage
Works in parallel with load side motor controllers and provides logging and real time data acquisition for such characteristics like: Rotational Speed (RPM), Mechanical Torque (Nm), Consumed Current (A), Lane Voltage (V), Mechanical and Electrical Efficiency (%), Temperature (C) and others
Flexible setup based on budget or precision needs
Adjust control strategies and see immediate feedback
User-friendly interface for beginners and pros alike
Supports DC, BLDC, PMSM motors out of the box
Small form factor, over-current and over-temperature protections built-in
Much cheaper than lab-grade dynamometers
Field-Oriented Control (FOC) block diagram illustrating PI controllers, coordinate transformations, PWM inverter, and motor feedback loops for efficient motor control.

Dyno Build Challenges (and How to Solve Them)

Challenge
Mechanical misalignment
Data noise from sensors
Load motor control complexity
Heat buildup in motors or controller
Torque sensor cost or inaccuracy
Why It Matters
Can cause vibration, which affects test results and damage couplings and motors
Leads to incorrect efficiency readings
Can over-brake or under-brake the test motor
Shortens test time, may damage electronics
May distort performance testing
How to Solve It
Use rigid frame and precision mounts
Use shielded cables and grounding techniques
Use matching load motor to allow the test motor show its full performance
Add fans, heat sinks, or even water cooling if necessary
Ensure sensor range matches the measurement limits to prevent over- or under-saturation errors

Pros and Cons Summary Table

Pros
Professional-grade motor testing at low cost
Modular and easy to expand
Live monitoring and adjustable parameters
Accurate testing of motor torque and efficiency
Compatible with multiple motor types
Cons
Requires basic understanding of mechanical system building and electrical wiring
Needs careful alignment to avoid extra mechanical stress
Setup can be time-consuming for absolute beginners
Limited by sensor quality and load motor response
High-speed or high-power testing requires additional safety

Educational Tip: Understanding Key Motor Dyno Terms

Term
Torque (Nm)
Rotational Speed (RPM)
Efficiency (%)
Back EMF
Regenerative Braking
What It Means
Rotational force generated by the motor
Revolutions per minute - how fast the motor shaft spins
How well the motor converts electrical energy to mechanical energy
Voltage generated when motor shaft rotates (useful in sensorless control)
Technique where the load motor returns energy to the system
Build a Mini Motor Dyno Using SOLO 1

Sample Output Metrics You Can Measure

Parameter
Rotational Speed vs Torque
Power Consumption
Motor Temperature
Voltage & Current
Efficiency Curve
Why It’s Useful
Shows Mechanical Performance under load
Understands electrical efficiency
Prevents thermal failures and Examine Durability
Tracks power quality
Visualize peak motor performance

Expandability and Add-ons

You can take your dyno even further with:

    • Arduino or Raspberry Pi integration for custom logging
    • LabVIEW or MATLAB Simulink for advanced data visualization
    • Battery emulators for real-world power source simulation
    • Wi-Fi or Bluetooth modules for wireless monitoring

Conclusion

By using SOLO Motor Controller, you gain a high-performance, flexible, and user-friendly motor testing platform. It helps you build, test, and tune motors for robotics, EVs, automation systems, and education—all from your bench or lab.

Additionally, SOLO helps you to receive a motor performance curve in a very short time, which makes the motor evaluation faster and easier.

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