AnyPCBA PCB and PCBA case studies
Our client, a manufacturer of high-performance electric motorcycles, needed a controller capable of delivering exceptional power and speed for their latest e-motorcycle platform. The system required 65A current capability, 90km/h top speed, and robust thermal management for sustained high-power operation.
Key System Components:
Motor Controller: 48V 65A, 12-tube design, based on Artery MCU
Control Interfaces: Key switch, multifunction handlebar controls (lights, turn signals, horn)
Dashboard: Customer-supplied display unit
Note: Dashboard is customer-supplied; our scope focused on high-power controller design and manufacturing.
1. High-Power Drive System
Maximum Current: 65A – delivering exceptional torque and acceleration
Voltage: 48V battery system with 16-inch motor support
12-Tube Design: Robust power stage for high-current applications
Three-Speed Control:
Gear 1 (No-load): 0-31km/h
Gear 2 (No-load): 0-51km/h
Gear 3 (No-load): 0-90km/h
Load Speeds:
Gear 1: 0-30km/h
Gear 2: 0-50km/h
Gear 3: 0-67km/h
2. Thermal Management (Critical)
Cooling Requirement: Controller must be mounted against aluminum heat sink plate
Enclosure: Prohibited from being sealed or wrapped to ensure airflow
Temperature Rating: Designed for sustained operation up to 100°C
No Built-in Controller Temperature Sensor: Thermal management relies on system-level cooling design
3. Comprehensive Protection
| Protection | Specification |
|---|---|
| Low Voltage Protection | 40.5V ±0.5V (motor stop) |
| Over Voltage Protection | Greater than 59.5V (motor stop) |
| Over Current Protection | 65A limit |
| Stall Protection | Less than 7 seconds |
| Auto Shutdown | 10 minutes idle |
| Minimum Start Voltage | 12V |
4. Multifunction Control System
The controller integrates with the vehicle's multifunction handlebar switches:
Key switch: Power on/off (clockwise/counterclockwise)
Headlight/tail light control (short press)
Gear shifting (+ and - buttons)
Horn control (short press)
Brake light activation (tail light high-brightness on brake)
5. Intelligent Features
Auto-Learning: First power-on auto-matching with motor (normal behavior)
Zero-Start: Default start mode
No Controller Temperature Sensor: Cooling relies on external heat sink design
| Parameter | Specification |
|---|---|
| Battery Voltage | 48V |
| Maximum Current | 65A |
| Motor Type | 16-inch, gear disc left |
| Controller MCU | Artery |
| Dashboard MCU | Customer-supplied |
| Tube Configuration | 12-tube design |
| Sleep Current | Less than 20uA |
| Standby Current | Less than 100mA |
| Minimum Start Voltage | 12V |
| Low Voltage Protection | 40.5V ±0.5V |
| Over Voltage Protection | Greater than 59.5V |
| Gear 1 Speed (No-load) | 0-31km/h |
| Gear 2 Speed (No-load) | 0-51km/h |
| Gear 3 Speed (No-load) | 0-90km/h |
| Gear 3 Speed (Loaded) | 0-67km/h |
| Auto Shutdown | 10 minutes idle |
| Thermal Rating | Sustained operation up to 100°C |
| Stall Protection | Less than 7 seconds |
| Cooling Requirement | Aluminum heat sink plate (not sealed/wrapped) |
High-Power Performance: Delivered 65A controller capable of 90km/h top speed
Thermal Management Expertise: Provided critical design guidance for system-level cooling
Reliable Protection: Comprehensive voltage and current protection
Manufacturing Excellence: 12-tube design optimized for production
Flexible Integration: Compatible with customer-supplied dashboard
Proven Capability: Demonstrates high-current EV controller manufacturing expertise
High-performance electric motorcycles (e-motorcycles)
Speed-focused EV platforms
High-power electric two-wheelers
Performance electric vehicles
Custom e-motorcycle builds
This case demonstrates AnyPCBA's capability to deliver high-power, high-performance control solutions for demanding EV applications:
✅ High-current motor control (65A)
✅ High-speed capability (up to 90km/h)
✅ Thermal management expertise (heat sink design integration)
✅ 12-tube high-power design
✅ Comprehensive protection systems
✅ Performance-grade engineering
Ready to develop your high-performance e-motorcycle or EV project? Contact us to learn how AnyPCBA can support your product development and production.
