AnyPCBA PCB and PCBA case studies
Our client, a manufacturer of light electric vehicles, needed a high-power, reliable controller for their four-wheel electric vehicle platform. Unlike the lightweight smart luggage systems we had developed previously, this required significantly higher current capacity, dual-motor drive capability, and an integrated user interface for vehicle control.
Key System Components:
Main Controller: 24V 38A±1, GD MCU-based, for four-wheel EV platform
Dash Control Panel: Integrated panel with display, headlight switch, horn button, USB port, speed control, and throttle joystick
Key Switch: Physical key-operated on/off control
Dual-Motor Support: Designed for rear-wheel dual-drive configuration
1. High-Power Drive System
Maximum Current: 38A ±1A – supporting powerful motors and heavier loads
Dual-Motor Capability: Designed for rear-wheel dual-drive configurations
Voltage: 24V battery system with 7-inch motor support
2. Integrated Dash Control Panel
The controller integrates with a full-featured dash panel including:
LCD display for speed and status
Headlight on/off switch
Horn button
USB charging port
Speed adjustment dial
Throttle joystick
Power on/off via key switch
3. Intelligent Protection Systems
| Protection | Threshold |
|---|---|
| Over-Voltage Protection | Greater than 30.5V with audible alarm |
| Low-Voltage Protection | Less than 18V with audible alarm |
| Over-Current Protection | 38A ±1A limit |
| Thermal Protection | Motor stops at 85°C |
| Stall Protection | Less than 7s shutdown |
| Auto Shutdown | 30 minutes idle (throttle disabled) |
4. Safety & Convenience
Audible buzzer confirmation on power-on
Key switch for secure power control
Zero-start design for safety
30-minute idle auto-shutdown feature
Alarm warnings for over/under voltage conditions
| Parameter | Specification |
|---|---|
| Battery Voltage | 24V |
| Maximum Current | 38A ±1A |
| Motor Type | 7-inch, rear-wheel dual-drive |
| Controller MCU | GD |
| Sleep Current | Less than 20uA |
| Standby Current | Less than 100mA |
| Minimum Start Voltage | 15V |
| Low-Voltage Protection | 18V ±0.5V |
| Over-Voltage Protection | Greater than 30.5V |
| Forward Speed (no-load) | 0-7km/h |
| Reverse Speed (no-load) | 0-3km/h |
| No-Load Current | Less than 1A |
| Thermal Protection | 85°C |
| Stall Protection Time | Less than 7 seconds |
| Idle Auto Shutdown | 30 minutes |
| Control Interface | Joystick (push-pull) |
High-Power Solution: Delivered 38A controller capable of powering heavy-duty electric vehicles
Dual-Motor Expertise: Demonstrated capability in dual-motor drive control
Integrated Design: Combined controller with full-featured dash control panel
Comprehensive Protection: Multiple safety features ensured reliable operation
Manufacturing Ready: Design optimized for production
Mobility scooters / electric wheelchairs
Golf carts
Light electric vehicles
Industrial transport vehicles
Four-wheel EV platforms
This case demonstrates AnyPCBA's capability to deliver high-power, feature-rich control solutions for electric vehicles:
✅ High-current motor control (38A, dual-motor)
✅ Integrated vehicle interface (display + controls)
✅ Comprehensive protection design (voltage, current, thermal)
✅ Industrial-grade reliability
✅ Complete system solution (controller + dash panel)
Ready to develop your electric vehicle or high-power mobility project? Contact us to learn how AnyPCBA can support your product development and production.
