Well said Bob! HP and torque curves are just that, based on RPM and other factors...the key is they are curves! The controller PWM or otherwise will try to compensate for the changes in load and speed with current and voltage via frequency/duty cycle. DC motors also must compensate for the hysteresis of the magnetic field, which will also affect the torque at lower rpm than rated.
This all brings up another point I missed about what the original motor speed was (?) for the gear ratio it has, to achieve an optimum SFM. Over all I still think this motor/controller will serve fine as Bob does...but might take a hard look at that gear ratio to old motor spec, as to whether you continue with the gears or move to a pulley system. For instance if the old motor was 1725RPM and a 10:1 gear ratio puts the SMF at ~3k for wood, then operating your DC motor/controller around that 1725RPM value if its rated at 7k RPM, will put it at the lower end (lower duty cycle) of the rated output which will put more pressure on the controller/motor and result in more heat dissipation and likely less power. Not sure what kind of ratio the treadmill had originally but likely to have been a hi ratio to spin the belt so as to not flip people into the ditch. Maybe this is a mountain out of mole hill but thought it worth consideration from the armchair. ~PJ

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