AnyPCBA PCB and PCBA case studies
Our client, a manufacturer of innovative smart travel products, needed a complete electronic control system for their electric smart luggage. The system required reliable motor control, intuitive user interface, and comprehensive protection features – all in a compact form factor suitable for travel applications.
Key System Components:
Motor Controller: 36V 8A±1, 6-tube design, based on Zhongying MCU
Dashboard Display: 4-inch screen with speed, battery, and fault indicators, powered by Lingdong Micro MCU
Control Interfaces: Throttle, brake, Hall sensor, communication port
Mechanical Integration: Telescopic handle control, motor phase output, sensor mounting
1. Intelligent Control Features
Auto power-on/off with buzzer indication
Two-speed operation: forward (0-10km/h) and reverse (0-3km/h) with combined throttle+brake activation
Telescopic handle switch for easy extension/retraction
Zero-start design for safety
2. Comprehensive Protection System
Motor thermal protection (stops at 110°C)
Low-voltage protection at 31V (±0.5V)
Over-current protection at 8A (±1A)
Fault code diagnosis (E0-E9) for quick troubleshooting
3. Battery Monitoring & Display
5-segment battery indicator with ±0.5V accuracy
Low-voltage warning (below 35V)
Emergency low-voltage shutdown at 31V (E7 fault code)
Real-time voltage and range display
4. Fault Protection & Diagnosis
| Code | Fault Type | Code | Fault Type |
|---|---|---|---|
| E0 | Communication fault | E5 | Hall sensor fault |
| E1 | Controller fault (shielded) | E6 | Motor lock protection |
| E2 | Throttle fault | E7 | Low-voltage protection |
| E3 | Brake fault | E8 | Over-voltage protection |
| E4 | MOSFET over-current | E9 | Over-temperature protection |
| Parameter | Specification |
|---|---|
| Battery Voltage | 36V |
| Maximum Current | 8A ±1A |
| Motor Type | 5-inch, right cable output |
| Controller MCU | Zhongying |
| Dashboard MCU | Lingdong Micro |
| Screen Size | 4 inches |
| Sleep Current | Less than 20uA |
| Standby Current | Less than 100mA |
| Forward Speed (no-load) | 0-10km/h |
| Reverse Speed (no-load) | 0-3km/h |
| Thermal Protection | 110°C motor stop |
| Low-Voltage Protection | 31V ±0.5V |
| Operating Temp Range | Standard industrial grade |
| Controller Dimensions | 65.3 x 71.5mm (approx.) |
| Dashboard Dimensions | 32 x 25mm (approx.) |
Complete System Solution: Delivered integrated motor controller and dashboard PCBA
Reliable Protection: Comprehensive thermal, voltage, and current protection ensured product safety
User-Friendly Interface: Intuitive battery indicator and fault codes simplified user experience
Compact Integration: Space-efficient design suitable for travel product form factors
Manufacturing Ready: Design optimized for small-to-medium batch production
Smart luggage / electric travel luggage
Personal mobility devices
Electric scooters and light vehicles
Short-distance transportation products
Smart travel accessories
This case demonstrates AnyPCBA's capability to deliver complete electronic system solutions for smart mobility products:
✅ System-level integration (controller + display + controls)
✅ Motor control expertise (36V, 8A, Hall sensor)
✅ Comprehensive protection design (thermal, voltage, current)
✅ User interface development (dashboard display, fault diagnosis)
✅ Consumer product manufacturing (compact, reliable, cost-effective)
Ready to develop your smart mobility or consumer electronics project? Contact us to learn how AnyPCBA can support your product development and production.
