Electric Vehicle Motor Controller

Most ordinary low-cost controllers on the market use square-wave control, resulting in low-speed vibration, jerky operation, severe motor noise, and uneven movement.

The electric vehicle motor controller offered by Qianjiang factory features an FOC field-oriented sine-wave control algorithm, providing smooth and precise current output and fully linear speed control, fundamentally solving the common problems of powered carts.

● Ultra-Smooth Low-Speed Operation: Matches normal walking speed, providing no vibration, sudden acceleration, or buzzing noise during low-speed movement, making close-range precision transportation more controllable.

● Linear and Smooth Acceleration: The vehicle responds naturally to throttle input with gradual acceleration and deceleration, eliminating sudden bursts of power. Even when fully loaded, the cargo is less likely to tip over, making operation safer.

● Quiet Operation: Eliminates high-frequency motor whine, providing a quieter experience when used for outdoor camping, parks, markets, and other environments.

Dedicated Outdoor Tuning

Specifically optimized for camping, mountainous areas, slopes, and stepped terrain, the controller incorporates intelligent slope detection + automatic speed stabilization and locking logic, effectively addressing the safety risks of rolling backward or accelerating downhill under heavy loads.

This is also a core requirement for electric hand-push carts.

● Automatic Anti-Rollback: When the system detects that the vehicle is tilted downhill, it automatically stabilizes and locks the speed, preventing gravity-driven acceleration. Even with a full load of equipment, the cart can descend at a controlled and uniform speed.

● Smooth Slope Starting: Prevents rollback and hesitation when starting uphill, providing continuous power output and easily handling grass, dirt roads, gravel roads, and conventional slopes of up to 15°.

● Walking-Speed Adaptation: Precisely matches the pace of manual pushing, neither too fast nor too slow, allowing elderly users and beginners to operate it easily.

Three Intelligent Speed Modes

The controller features three speed modes that can be switched according to requirements, balancing endurance and load performance for various outdoor applications.

● Level 1 Low Speed (Eco Mode): Suitable for flat roads, leisurely use in parks, and lightly loaded camping. Low-power operation significantly extends battery endurance.

● Level 2 Medium Speed (Standard Mode): Suitable for daily transportation, market shopping, and flat-road commuting, providing balanced power for most conventional applications.

● Level 3 High Speed (Off-Road Heavy-Load Mode): Suitable for sand, mud, gravel, uneven roads, and heavy-load operation on steep slopes, providing maximum power and stronger obstacle-escape capability.

Nine-Layer Safety Protection

Outdoor carts operate under complex conditions involving vibration, water exposure, overload, locked-rotor conditions, and high temperatures.

This controller incorporates a completely intelligent protection system that monitors electrical and operating conditions in real time.

It automatically limits current or cuts power when abnormalities are detected, preventing motor burnout, short circuits, and wiring damage.

● Locked-Rotor Protection: When the wheels are blocked by stones, stuck in mud, or completely immobilized, the controller automatically cuts power to prevent the motor from burning out.

● Overload/Overcurrent Protection: Limits current under excessive loads or forced escape from difficult terrain, protecting the battery, motor, and wiring.

● Low-Voltage/Undervoltage Protection: Automatically shuts down when the battery is depleted, preventing excessive battery discharge and extending battery life.

● High-Temperature/Overheat Protection: During prolonged heavy-load operation or work under strong summer sunlight, the system automatically limits current when temperatures become too high, preventing overheating and burnout.

Precision Heat Dissipation and Waterproof Design

Specifically designed for harsh outdoor environments, the controller features robust hardware materials and upgraded heat dissipation and protection, addressing the fragility and high failure rates of ordinary controllers.

● All-Aluminum Heat-Dissipating Housing: One-piece die-cast aluminum-alloy housing with a large heat-dissipation contact area rapidly dissipates heat during continuous full-load operation, preventing heat accumulation, power reduction, and shutdown.

● Sealed Waterproof Structure: Internal potting and sealing technology combined with waterproof aviation connectors provides protection against moisture, dust, and splashing water, allowing operation during rainy camping trips, muddy conditions, and damp environments with morning dew.

● Vibration and Shock Resistance: Internal components are reinforced and secured, reducing the risk of solder-joint failure or malfunction during outdoor bumps and off-road vibration, ensuring stable and durable operation during long-term, high-frequency use.

Highly Compatible and Easy to Install

The electric vehicle motor controller offers excellent versatility and requires no complicated programming or adjustment. It is compatible with most electric hand-push camping cart power systems on the market, making it suitable for modification, replacement, repair, and new-vehicle assembly.

● Dual-Mode Automatic Adaptation: Supports automatic identification of Hall and sensorless motors and is compatible with both new and older hub motors.

● Error-Proof Connectors: Dedicated wiring harness connectors feature foolproof designs to prevent incorrect connections and motor burnout, allowing installation even without professional experience.

● Wide-Voltage Compatibility: Supports 24V/36V/48V multiple voltage systems, covering household, outdoor, and light industrial applications.

Intelligent Energy-Saving Algorithm

The controller incorporates dynamic power adjustment logic. The system intelligently distributes power in real time according to load, vehicle speed, and road conditions, reducing power consumption under light loads while maintaining sufficient power under heavy loads and eliminating unnecessary energy consumption.

Compared with ordinary controllers, overall endurance can be increased by more than 20%, providing sufficient range for full-day camping, multiple transportation trips, and long-distance outdoor travel without exaggerated range claims.

Core Product Specifications

FAQ

Q1: What voltage and motor power does this controller support? Is it universal?

This controller supports 24V/36V/48V/72V wide-voltage compatibility and is compatible with 250W, 450W, 500W, 1000W, and 2000W brushless hub motors available on the market. It is specifically tuned for electric vehicles and both low- and high-speed walking conditions. It supports Hall and sensorless motors and can be directly used for modifications, replacements, and original-equipment applications across new and older vehicle models, providing excellent versatility.

Q2: What is the difference between a sine-wave controller and an ordinary square-wave controller? Why is this one better?

Ordinary square-wave controllers can cause low-speed vibration, noticeable jerking, high motor noise, and whistling, resulting in unstable operation on slopes. This controller uses FOC sine-wave vector control, providing smooth and linear current output, gentle startup, uniform acceleration, and quiet operation without vibration or sudden vehicle movement. It also provides lower energy consumption and longer endurance. Its stability under heavy loads, steep slopes, and complex terrain is significantly better than ordinary square-wave controllers, making it more suitable for long-term, high-frequency outdoor use.

Q3: Is the controller really waterproof? Can it be used in rain and mud?

It provides outdoor waterproof and dustproof protection. The controller uses fully potted internal sealing + waterproof aviation connectors, allowing it to handle rainy riding conditions, road splashes, grass dew, muddy terrain, and sandy environments while effectively preventing moisture and dust intrusion.

Friendly Reminder: It is designed for everyday splash protection only. Prolonged immersion in water and direct high-pressure water-jet spraying are prohibited to prevent water damage.

Q4: Is installation complicated? Could incorrect wiring burn out the controller?

The controller is plug-and-play and requires no commissioning. The connectors use foolproof and error-prevention designs, with clearly separated wiring harnesses. No programming or parameter adjustment is required, allowing installation without professional experience. It also supports automatic adaptation to Hall and sensorless motors, allowing direct connection and normal operation.

Q5: Is it normal for the controller to heat up during operation? Will high temperatures damage it?

Slight heating during normal light-load and flat-road operation is normal. The controller may experience some temperature increase during prolonged heavy-load operation, hill climbing, and off-road escape. The unit uses an all-aluminum heat-dissipating housing for rapid heat dissipation and incorporates intelligent high-temperature protection. When the temperature becomes too high, it automatically limits current, reduces heat generation, and provides shutdown protection, preventing burnout and power-device failure while improving durability during outdoor exposure and continuous operation.

Q6: What causes the motor to hesitate, stop running, or operate intermittently?

Common causes and solutions include:

① Loose, wet, or oxidized wiring connectors — reconnect and secure the wiring harness.

② Wheel obstruction, mud entrapment, or locked-rotor conditions — locked-rotor protection may be triggered; power off and restart to restore operation.

③ Battery voltage too low — undervoltage protection may be triggered; recharge the battery promptly.

④ High-temperature power reduction after prolonged heavy-load operation — allow the system to cool down. This does not necessarily indicate a controller fault.

Q7: What applications are the three speed modes suitable for?

● Level 1 Eco Mode: Suitable for flat-road leisure use, lightly loaded camping, and slow precision transportation. It saves energy and provides longer endurance.

● Level 2 Standard Mode: Suitable for daily shopping and conventional outdoor transportation, balancing power and endurance.

● Level 3 Off-Road Heavy-Load Mode: Suitable for sand, mud, gravel roads, steep slopes, and heavy-load operation, providing maximum power and stronger obstacle-escape capability.