AnyPCBA PCB and PCBA case studies
Our client, a manufacturer of high-performance electric bicycles, needed a powerful, feature-rich control system for their pedelec platform. The system required 48V 23A capability, 5-speed control, and advanced safety features including auto-lock, tilt protection, and automatic headlight control.
Key System Components:
Motor Controller: 48V 23A±1, based on Zhongying MCU
Smart Dashboard: Realtek-based display with speed, battery, and status indicators
Control Interfaces: Throttle, brake, assist sensor, headlight, turn signals, horn
HeMiao D5 Dashboard: Integrated display with 14-bar battery indicator
1. High-Power Drive System
Maximum Current: 23A ±1A – delivering powerful torque for hills and acceleration
Voltage: 48V battery system with 22-inch motor support
Five-Speed Control: Gear 1: 0-6mph (0-10km/h), Gear 2: 0-9mph (0-15km/h), Gear 3: 0-12mph (0-20km/h), Gear 4: 0-15mph (0-25km/h), Gear 5: 0-20mph (up to 55km/h with speed unlock)
Speed Unlock: Up to 55km/h with advanced unlock procedure
Unit Switching: KM/H or MPH with memory function
2. Smart Safety & Security Features
Auto-Lock System: Default lock on power-on; brake release; auto-lock after 5 seconds idle (with memory function)
Tilt Protection: Auto-disables throttle when severe tilt is detected (Gyro function, default enabled)
Automatic Headlight: Light sensor automatically controls front/rear lights; manual override available
Cruise Control: Auto-engages after 8 seconds of steady throttle (with buzzer confirmation; can be toggled on/off)
Motor Thermal Protection: Current reduces to 10A at 110°C to prevent overheating
3. Comprehensive Protection & Fault Diagnosis
| Protection | Specification |
|---|---|
| Low Voltage Protection | 40V ±0.5V (motor stop) |
| Over Current Protection | 23A ±1A limit |
| Motor Thermal Protection | Current reduces to 10A at 110°C |
| Stall Protection | Less than 7 seconds |
| Auto Shutdown | 10 minutes idle |
| Minimum Start Voltage | 20V |
Fault Codes:
| Code | Fault | Code | Fault |
|---|---|---|---|
| E1 | Hall sensor fault | E6 | Communication fault |
| E2 | MOSFET/short circuit | E7 | Over-voltage protection |
| E3 | Brake fault | E8 | Op-amp fault |
| E5 | Low-voltage protection | E9 | Motor lock protection |
4. Smart Dashboard Display
The integrated HeMiao D5 dashboard provides comprehensive vehicle status:
Speed (digital with unit indicator)
14-bar battery indicator (based on BMS SOC)
Gear position (1-5)
Lock/Park indicator
Walk assist indicator
Fault indicator
Turn signal indicators (left/right)
Brake indicators
Headlight status
Cruise control indicator
Tilt status
Throttle status
Total mileage & trip mileage
Light sensor
5. Intelligent Operation System
| Operation | Function |
|---|---|
| Long press ON/OFF (3s) | Power on/off (with buzzer) |
| Throttle ▲/▼ buttons | Gear up/down (0-5 gears) |
| 2x ON/OFF | Headlight/tail light on/off |
| 3x ON/OFF | KM/H ↔ MPH switching (with memory) |
| 4x ON/OFF | Tilt protection on/off (with memory) |
| Brake + 3x ON/OFF (during boot) | Auto-lock on/off (with memory; bypasses factory reset) |
| Brake + 5x throttle (during boot) | Speed limit unlock (up to 55km/h, with memory) |
| Brake + 8x throttle (during boot) | Factory reset (with buzzer confirmation) |
| Brake + 3x throttle (during boot) | Cruise control on/off toggle |
6. Battery Monitoring & Display
The dashboard displays battery level based on BMS SOC report:
| SOC Range | Bars Displayed |
|---|---|
| Greater than 85% | 14 bars |
| 75-85% | 12 bars |
| 65-75% | 11 bars |
| 55-65% | 10 bars |
| 50-55% | 8 bars |
| 45-50% | 6 bars |
| 35-45% | 4 bars |
| 25-35% | 2 bars |
| 0-25% (Less than 43V) | Battery icon flashing |
| Less than 40V | Low-voltage protection (motor stop) |
| Parameter | Specification |
|---|---|
| Battery Voltage | 48V |
| Maximum Current | 23A ±1A |
| Motor Type | 22-inch, left cable output |
| Controller MCU | Zhongying |
| Dashboard MCU | Realtek |
| Dashboard Model | HeMiao D5 |
| Sleep Current | Less than 20uA |
| Standby Current | Less than 100mA |
| Minimum Start Voltage | 20V |
| Low Voltage Protection | 40V ±0.5V |
| Gear 1 Speed | 0-6mph (0-10km/h) |
| Gear 2 Speed | 0-9mph (0-15km/h) |
| Gear 3 Speed | 0-12mph (0-20km/h) |
| Gear 4 Speed | 0-15mph (0-25km/h) |
| Gear 5 Speed | 0-20mph (unlockable to 55km/h) |
| Auto Shutdown | 10 minutes idle |
| Motor Thermal Protection | 110°C (current reduces to 10A) |
| Stall Protection | Less than 7 seconds |
| Cruise Control | 8s steady throttle (with memory) |
High Performance: 48V 23A system with 55km/h top speed capability
Advanced Safety: Auto-lock, tilt protection, and thermal management
Smart Features: Automatic headlight, cruise control, and intelligent dashboard
User Experience: 5-speed control with intuitive operation and memory functions
Comprehensive Protection: Full fault diagnosis and protection systems
Manufacturing Ready: Design optimized for production with auto-learning motor matching
High-performance electric bicycles (E-bikes)
Pedelec (pedal-assist) platforms
Mountain e-bikes
Urban commuter e-bikes
Shared mobility platforms
This case demonstrates AnyPCBA's capability to deliver high-performance, feature-rich control solutions for modern e-bike platforms:
✅ High-power motor control (48V, 23A)
✅ 5-speed intelligent control
✅ Advanced safety features (auto-lock, tilt protection)
✅ Smart connectivity (auto headlight, cruise control)
✅ Comprehensive dashboard integration
✅ Performance-grade engineering (55km/h capable)
Ready to develop your high-performance e-bike or pedelec project? Contact us to learn how AnyPCBA can support your product development and production.
