High-Performance Motor Controllers Factory Direct Supply

In addition to providing comprehensive motor solutions, Qianjiang Motor also supplies motor controllers, delivering reliable, high-performance, and high-efficiency electronic control systems for various hub motors.

What is a Motor Controller?

The hub motor controller serves as the core electronic control unit for brushless hub motors. It receives signals from the throttle, brakes, and communication systems to regulate three-phase current, thereby managing motor functions such as starting and stopping, acceleration and deceleration, torque output, reversing, and speed limiting.

This product utilizes a Field-Oriented Control (FOC) sinusoidal drive scheme and is compatible with both sensored (Hall-effect) and sensorless hub motors (featuring either internal or external rotors). It employs a dual closed-loop current-speed algorithm to ensure smooth starts without stuttering and stable operation without jitter at low speeds. It effectively resolves common issues associated with standard square-wave controllers such as excessive noise, strong vibration, and poor hill-climbing performance, making it an essential electronic control component for complete hub motor drive systems.

Key Product Advantages

1. FOC Sine Wave Drive

Our motor controllers utilize Field-Oriented Control (FOC) with sine wave output, ensuring smooth current delivery and minimal torque ripple. They provide gentle starts, quiet idling, and stable speeds on rough terrain, while eliminating high-frequency vibration noise.

2. Wide Voltage Compatibility

Supports multiple voltage ranges (24-48V, 48-60V, 60-72V) and rated power outputs from 150W to 8000W.

Compatible with 4-14 inch hub motors, including geared, gearless, single-shaft, dual-shaft, and differential rear-axle types.

3. Triple Closed-Loop Control

Supports three operating modes: high-torque locking for heavy-load hill climbing and constant speed maintenance for steady cruising. Power curves, start-up intensity, and acceleration rates can be customized via PC software.

4. Regenerative Braking

Energy recovery activates upon throttle release or braking, converting the wheel's kinetic energy into electricity to recharge the battery.

Provides smoother deceleration on downhills, reduces brake pad wear, and extends driving range by 10%–18%.

5. Intelligent Motor Self-Learning

One-touch self-learning for motor parameters automatically identifies Hall sensor phases and winding specifications. Allows for quick installation and replacement of different hub motors without manual phase debugging.

6. Diverse Signal Inputs

Compatible with analog throttles, PPM pulse speed control, RS485, CAN-Open, and encoder signals.

Integrates with PLCs, remote controls, instrument clusters, and industrial control boards to meet the electronic control needs of automation equipment.

7. Robust Thermal Management

Features a thickened aluminum alloy heat-dissipating housing, high-power internal MOSFETs, and heavy-duty pure copper terminals.

Ensures rapid heat dissipation under high-current loads, preventing overheating or power throttling during prolonged outdoor operation or heavy-load transport.

8. High-Level Waterproofing and Dustproofing

Standard controllers are rated IP54, with upgraded versions reaching IP67 waterproof ratings. Circuit boards are sealed with potting compound to withstand harsh conditions, including rain, mud, humidity, and dusty construction sites.

Detailed Technical Specifications

Comprehensive Feature Overview

1. Power Regulation Functions

1) Start-up Buffering: Soft-start settings prevent sudden lurching when the throttle is twisted abruptly, ensuring safer riding and equipment operation.

2) Multi-level Power Modes: One-touch switching between Economy, Standard, and High-Power (Climbing) modes; Economy mode conserves energy for extended range, while High-Power mode delivers peak torque to tackle steep inclines and heavy loads.

3) Controlled Reversing: Speed-limited reversing prevents accidents caused by excessive speed while backing up.

2. Braking and Energy Regeneration

Supports adjustable levels of regenerative braking intensity: gentle regeneration for daily commuting and high-intensity regeneration for slowing down on long descents.

Brake-priority power cutoff: motor power is instantly cut when the brake is applied, ensuring rapid braking response.

3. Fault Self-Diagnosis

The controller monitors Hall sensor lines, motor phase lines, operating temperature, and battery voltage in real-time. Faults trigger indicator light alerts, and diagnostic software allows for reading error codes to quickly identify wiring or motor issues, simplifying maintenance.

4. Software-Based Customization and Tuning

Connects to a PC via a USB debugging port for visual adjustment of acceleration curves, maximum RPM, current limits, regeneration intensity, and dead-zone parameters; facilitates convenient batch configuration and customized power settings.

Materials and Construction

● Automotive-grade MOSFETs: Feature low internal resistance, stable high-current output, and surge resistance, while minimizing heat generation.

● Thickened pure copper busbars and terminals: Ensure low conduction loss; terminals remain cool and resist oxidation during prolonged high-power operation.

● Thickened double-layer PCB with reinforced vias: Features precise SMT component assembly and excellent vibration resistance, making it suitable for the high-vibration conditions of automotive wheel environments.

● Waterproof, flame-retardant wiring harnesses and pluggable connectors: Facilitate easy installation, removal, and maintenance; harnesses are highly resistant to bending and abrasion.

Safety Protection System

1. Undervoltage protection: Automatically limits power when the battery is low to prevent deep discharge damage.

2. Overvoltage protection: Protects against excessively high battery voltage and reverse polarity to prevent component burnout.

3. Overcurrent and stall protection: Instantly cuts off output if wheels jam or the motor stalls under heavy load, protecting windings and power components.

4. Overtemperature protection: Automatically reduces power if the controller temperature exceeds limits and cuts off power entirely at critical high temperatures.

5. Brake-activated power cutoff.

6. Hall sensor fault protection: Allows switching to sensorless emergency operation if the Hall sensor fails.

7. Reverse polarity and short-circuit protection.

Suitable Applications

✔ Electric motorcycles, electric scooters, folding e-bikes, retrofitted rear hub motors

✔ Electric flatbed trucks, factory transport vehicles, warehouse AGVs, sightseeing vehicles

✔ Robot drive wheels, intelligent inspection equipment, amusement ride hub motors

✔ Mobility scooters for the elderly, electric wheels for medical equipment, differential rear axle hub motor assemblies

Installation Notes

1. Distinguish between positive and negative terminals, the three motor phase wires, and the Hall signal wires; connect them according to the wiring labels.

2. Install high-power controllers in a well-ventilated area to ensure airflow around the heat-dissipating casing.

3. For humid outdoor operating conditions, select the IP67 waterproof version.

4. After powering on for the first time, activate the motor self-learning function to match the parameters of the specific hub motor.

FAQ

Q: Is the motor controller compatible with both sensored (Hall-effect) and sensorless hub motors?

A: Yes. The controller software supports dual-mode operation (sensored/sensorless), allowing for switching after parameter configuration.

Q: Can a single controller drive dual hub motors?

A: Standard single-drive models can only power one motor; however, selecting a dedicated dual-channel hub motor controller enables independent dual-motor drive and electronic differential functionality.

Q: Will a controller failure damage my hub motor?

A: The controller features multiple built-in hardware protections. It instantly triggers safeguards in the event of phase-to-phase short circuits or abnormal currents, preventing motor winding burnout at the source.

Q: Can this controller be used with hub motors of different power ratings?

A: It is compatible as long as the controller's peak current exceeds the motor's peak current. We recommend that the controller's rated power be at least 1.2 times the motor's rated power to ensure sufficient headroom for heavy-load operations.