AnyPCBA PCB and PCBA case studies
Our client, a manufacturer of high-performance electric scooters, needed a smart control system that could deliver both power and connectivity. The system required a 36V 15A controller with Bluetooth integration, enabling APP-based control and monitoring for modern mobility products.
Key System Components:
Motor Controller: 36V 15A±1, based on Zhongying MCU, with Bluetooth module
Smart Dashboard: Tuya bare-chip based display with speed, battery, and status indicators
Control Interfaces: Throttle, brake, headlight, turn signals, horn
Mobile App: Tuya Smart APP for remote control and vehicle monitoring
1. Powerful 15A Drive System
Maximum Current: 15A ±1A – delivering high torque and acceleration
Voltage: 36V battery system with 8.5-inch motor support
Three-Speed Control: 1st gear (0-10km/h ECO), 2nd gear (0-15km/h D), 3rd gear (0-20km/h S)
Speed Unlock: Up to 25-30km/h with speed limit release
Unit Switching: KM/H or MPH with memory function
2. Bluetooth Smart Connectivity
Built-in Bluetooth module with unique name "RSX"
Tuya Smart APP integration for full vehicle control
Auto-reconnect with memory function
Real-time vehicle monitoring (speed, battery, mileage, location)
3. Full-Featured APP Control
| Function | Description |
|---|---|
| Vehicle unlock/lock | Motor lock with "P" display |
| Gear switching | 1st/2nd/3rd gear selection |
| Zero-start toggle | Enable/disable zero-start |
| Cruise control | Enable/disable with memory |
| Headlight control | On/off via APP |
| Unit switching | KM/H ↔ MPH |
| Live tracking | Real-time GPS location, riding time, mileage, average speed |
| Data clearing | Clear total mileage |
4. Multi-Function Dashboard
The integrated dashboard displays:
Speed (digital with unit indicator)
Battery level (5-bar indicator)
Bluetooth connection status
Cruise control status
Headlight status
Fault codes (E1-E8)
Gear position indicator
"P" lock indicator
5. Intelligent Operation System
| Operation | Function |
|---|---|
| Long press ON/OFF | Power on/off (with buzzer) |
| 2x ON/OFF | Gear switching (with memory) |
| 1x ON/OFF | Headlight/tail light on/off |
| 3x ON/OFF | KM/H ↔ MPH switching (with memory) |
| 4x ON/OFF | Cruise control on/off (with memory) |
| 5x ON/OFF | Zero-start on/off (with memory) |
| 9x ON/OFF | Clear total mileage |
| Brake + 6x ON/OFF | Speed limit unlock/lock (with memory) |
| Brake + 10x ON/OFF | Vehicle lock/unlock |
| Brake + ON/OFF (boot) | Bluetooth pairing reset ("UC" display) |
| Long press ON/OFF (12s) | Factory reset |
6. Comprehensive Protection & Fault Diagnosis
| Protection | Specification |
|---|---|
| Low Voltage Protection | 31V ±0.5V (motor stop) |
| Over Voltage Protection | Greater than 34V |
| Over Current Protection | 15A ±1A limit |
| Stall Protection | Less than 7 seconds |
| Auto Shutdown | 10 minutes idle |
| Thermal Protection | 85°C motor stop |
Fault Codes:
| Code | Fault | Code | Fault |
|---|---|---|---|
| E1 | Brake fault | E5 | Hall sensor fault |
| E2 | Throttle fault | E6 | Motor lock protection |
| E3 | Communication fault | E7 | Under-voltage protection |
| E4 | MOSFET/over-current | E8 | Over-voltage protection |
7. Battery Monitoring & Display
| Bars | Voltage Range |
|---|---|
| 5 bars | 41.0V – 42.0V |
| 4 bars | 40.0V – 40.9V |
| 3 bars | 37.0V – 39.9V |
| 2 bars | 36.0V – 36.9V |
| 1 bar | 34.0V – 35.9V |
Low voltage warning: Less than 34V (1 bar flashing)
Under-voltage protection: Less than 31V (motor stop)
| Parameter | Specification |
|---|---|
| Battery Voltage | 36V |
| Maximum Current | 15A ±1A |
| Motor Type | 8.5-inch, right cable output |
| Controller MCU | Zhongying |
| Dashboard MCU | Tuya (bare chip) |
| Bluetooth | Built-in, name "RSX" |
| APP Platform | Tuya Smart |
| Sleep Current | Less than 20uA |
| Standby Current | Less than 100mA |
| Minimum Start Voltage | 24V |
| Low Voltage Protection | 31V ±0.5V |
| Gear 1 Speed | 0-10km/h (ECO) |
| Gear 2 Speed | 0-15km/h (D) |
| Gear 3 Speed | 0-20km/h (S, unlockable to 25-30km/h) |
| Auto Shutdown | 10 minutes idle |
| Thermal Protection | 85°C |
| Stall Protection | Less than 7 seconds |
Smart Connectivity: Integrated Bluetooth and APP control for modern mobility
High Performance: 15A controller with 25-30km/h top speed capability
User Experience: Multi-function operation system with intuitive controls
Comprehensive Protection: Full fault diagnosis and protection systems
Manufacturing Ready: Design optimized for production
Memory Function: User preferences saved across power cycles
High-performance electric scooters
Shared mobility platforms
Urban commuting vehicles
Personal mobility devices
Smart travel products
This case demonstrates AnyPCBA's capability to deliver smart, connected control solutions for modern personal mobility products:
✅ Bluetooth integration & APP control
✅ Multi-function dashboard design
✅ High-current motor control (15A)
✅ Comprehensive protection systems
✅ Smart operation with memory functions
✅ Connected vehicle solutions
Ready to develop your smart scooter or connected mobility project? Contact us to learn how AnyPCBA can support your product development and production.
