Motor Controllers for Mid Drive Platforms in Electric 2 wheelers and 3 wheelers – Inside Access

The motor controller is the brain of an EV, intelligently managing and optimizing the electric motor’s performance for smooth and efficient driving. The efficiency of the motor controller directly impacts performance, range and battery life of an electric vehicle. At Embitel, we take immense pride in our in-house development of advanced motor controllers tailored specifically for mid-drive platforms in electric two and three-wheelers. Our state-of-the-art solutions are engineered to ensure optimal performance and efficiency within the 48V voltage range, leveraging sophisticated three-phase Motor Control Units (MCUs), among others.

Thoroughly tested and validated by our team of experts, our motor controllers are ready for immediate deployment and can be customized to meet the unique requirements of our clients.

Our unwavering commitment to innovation and quality has driven us to develop these cutting-edge solutions, which are indispensable in the rapidly evolving EV market. We understand the intricate demands of mid-drive systems and have meticulously designed our motor controllers to deliver unmatched efficiency, reliability, and performance.

Whether your project requires custom motor controller design, advanced thermal management solutions, or specialized software development, our offerings are scalable and flexible. This ensures seamless integration into a variety of EV platforms.

Features of Our Mid Drive Motor Controllers

Enhanced Efficiency: Our motor controllers feature a three-phase system that significantly reduces electrical losses, ensuring that more power is efficiently delivered to the motor. This results in enhanced overall efficiency and superior performance for your electric vehicles.

Precise Torque and Speed Control: Maintaining optimal performance and handling is critical, especially for two and three-wheelers. Our controllers provide precise control over torque and speed, enhancing the driving experience and vehicle stability, crucial for maintaining performance and handling.

Compact and Lightweight Design: Engineered with the limited space of smaller EVs in mind, our motor controllers are both compact and lightweight. This design makes them ideal for seamless integration into mid-drive platforms, without compromising on performance.

Thermal Management: We incorporate advanced cooling solutions to manage the heat generated during operation, ensuring that our motor controllers operate efficiently and reliably under all conditions. This feature is essential for maintaining the longevity and performance of the controllers in demanding environments.

Field-Oriented Control (FOC) Algorithm for Mid-Drive Platforms:

The FOC algorithm is central to our mid-drive motor control solutions, providing superior torque, speed, and efficiency for enhanced performance. Key components of FOC include:

• Park and Clarke Transformations: These transformations simplify control by converting three-phase currents to a two-axis system (d-q frame), facilitating more efficient motor control tailored for mid-drive applications.
• Decoupling of Torque and Flux: This feature optimizes motor performance by allowing independent control of torque and magnetic flux, essential for the dynamic demands of mid-drive systems.

PWM Modulation: Generating precise pulse-width modulation signals, this feature ensures high-efficiency motor driving, crucial for maintaining optimal performance in mid-drive platforms.

High Dynamic Response and Reduced Torque Ripple: Our FOC technology ensures quick adaptation to changing load conditions, resulting in smoother operation, a more comfortable ride, and extended vehicle range due to reduced energy consumption.

Expertise and Customization

At Embitel, we bring unparalleled expertise in motor controller solutions, offering a comprehensive range of services that include:

• Custom Motor Controller Design: Our designs are tailored to meet specific vehicle requirements, ensuring optimal performance and seamless integration. We work closely with clients to understand their needs and deliver solutions that enhance their EVs’ performance.
• Advanced Thermal Management: We offer innovative cooling solutions that maintain efficiency and reliability, even under the most challenging operating conditions. This ensures that our motor controllers perform consistently without overheating.
• Software Development: Our proprietary algorithms and control strategies are designed to enhance the performance and efficiency of EVs, providing a competitive edge in the market.
• Testing and Validation: We employ rigorous testing procedures to ensure that our motor controllers meet the highest standards of quality and reliability. This includes extensive simulations and real-world testing to verify performance under various conditions.
• Scalability and Flexibility: Our motor controllers are designed to be easily scalable and adaptable across different vehicle models and configurations, ensuring seamless integration across various EV platforms.

Mid Drive Platform Integration and Safety

Our motor control solutions are designed for seamless integration across various platforms, -both AUTOSAR and non-AUTOSAR This flexibility reduces development timelines and minimizes iterative efforts, enabling faster time-to-market and improved efficiency in project execution.

We are deeply committed to functional safety, adhering to MAC and ISO 26262 guidelines. Our motor control systems undergo rigorous coverage studies and simulations to ensure full compliance, providing safety and instilling confidence in our clients. This commitment to safety not only protects end-users but also builds trust in our solutions.

Advanced Control Features and Innovation

Our solutions offer advanced control features such as cruise control, regenerative braking, and field weakening, ensuring superior performance and energy efficiency. We continuously explore new technologies, including AI integration, advanced sensor integration, and wireless communication, to enhance motor control performance and connectivity.

• Cruise Control: Provides a constant speed, enhancing the driving experience and reducing driver fatigue.
• Regenerative Braking: Recaptures energy during braking, improving overall energy efficiency and extending vehicle range.
• Field Weakening: Extends the speed range of the motor, offering more flexibility and performance at higher speeds.

Business and Industrial Use Cases

Urban Delivery Services

Challenge: Urban delivery services require vehicles that are efficient, reliable, and capable of navigating through congested city streets while carrying significant loads.

Solution: Our motor controllers for mid-drive platforms ensure that electric two and three-wheelers used in urban delivery are highly efficient, providing precise torque and speed control. This leads to smoother acceleration and deceleration, essential for stop-and-go city driving. The regenerative braking feature extends battery life, reducing downtime for recharging and increasing operational efficiency.

Impact: Delivery companies can lower operational costs due to reduced fuel expenses and maintenance needs. The enhanced efficiency and reliability also mean fewer breakdowns and delays, improving service quality and customer satisfaction.

Last-Mile Transportation

Challenge: Last-mile transportation solutions require compact, lightweight, and efficient vehicles to ferry passengers or goods over short distances, often where traditional vehicles cannot operate effectively.

Solution: Our motor controllers are designed to be compact and lightweight, making them perfect for small electric vehicles used in last-mile transportation. The advanced Field-Oriented Control (FOC) algorithm ensures quick adaptation to varying load conditions, providing a comfortable and reliable ride.

Impact: Companies providing last-mile transportation services benefit from reduced operational costs and increased vehicle uptime. The efficient motor control also extends battery life, allowing for longer service hours between charges.

Public Transportation Fleets

Challenge: Public transportation vehicles need to be robust, reliable, and capable of handling continuous operation with minimal downtime.

Solution: Our motor controllers offer high dynamic response and reduced torque ripple, ensuring smooth operation even under continuous use. The advanced thermal management features keep the controllers operating efficiently, preventing overheating during long periods of operation.

Impact: Public transportation agencies can rely on these motor controllers to provide consistent and reliable service. The reduced maintenance requirements and operational costs contribute to a more sustainable and cost-effective public transportation system.

Industrial Logistics and Warehousing

Challenge: Industrial logistics and warehousing operations require vehicles that can operate efficiently within large facilities, often involving frequent stops and starts, carrying heavy loads.

Solution: Our motor controllers provide precise control over torque and speed, essential for the efficient handling of heavy loads. The regenerative braking system helps in energy recovery during frequent stops, enhancing overall efficiency.

Impact: Industrial logistics companies can achieve higher operational efficiency and lower energy costs. The improved control and reliability of the motor controllers also reduce the likelihood of vehicle downtime, ensuring smooth and uninterrupted operations.

Agriculture and Farming Equipment

Challenge: Agricultural equipment used in farming operations needs to be robust, efficient, and capable of operating in varied and often harsh conditions.

Solution: Our motor controllers are designed to handle the power requirements of agricultural equipment, providing enhanced efficiency and precise control. The advanced cooling solutions ensure that the controllers operate reliably in different environmental conditions.

Impact: Farmers and agricultural businesses benefit from the increased efficiency and reliability of their equipment. The reduced energy consumption and maintenance needs lead to lower operational costs, making farming operations more sustainable and profitable.

Recreational Vehicles

Challenge: Recreational electric vehicles, such as e-bikes and e-scooters, require efficient and reliable motor controllers to provide a smooth and enjoyable riding experience.

Solution: Our motor controllers offer precise torque and speed control, ensuring a smooth ride. The compact and lightweight design makes them ideal for recreational vehicles, while the regenerative braking feature enhances energy efficiency.

Impact: Manufacturers of recreational vehicles can provide their customers with high-performance, reliable, and energy-efficient products. This leads to increased customer satisfaction and brand loyalty, driving sales and market growth.

These use cases demonstrate the versatility and impact of our motor controller solutions across various industries. By leveraging our advanced technology, businesses can achieve greater efficiency, reliability, and cost-effectiveness in their operations

Innovations in Motor Control Technology

Our commitment to innovation drives us to continuously explore and develop new technologies in motor control. Some of our ongoing projects and areas of research include:

Artificial Intelligence (AI) Integration: We are utilizing AI to enhance the performance and predictive maintenance capabilities of our motor controllers, providing smarter and more efficient solutions.

Advanced Sensor Integration: Incorporating high-precision sensors to improve the accuracy of motor control and diagnostics, ensuring better performance and reliability.

Wireless Communication: Developing wireless communication protocols for real-time monitoring and control of motor systems, enhancing connectivity and data analysis capabilities.

Conclusion

The integration of advanced motor controllers with FOC algorithms in three-phase MCUs for 48V systems is pivotal for the next generation of electric two and three-wheelers. At Embitel, our expertise and innovative solutions ensure that these vehicles achieve superior performance, efficiency, and reliability, driving the future of sustainable transportation. For more information about our motor controller solutions and how they can enhance your EV projects, please contact us at sales@embitel.com .

Frequently Asked Questions

1. What are the benefits of using three-phase MCUs in 48V systems for mid-drive EV platforms?

Three-phase MCUs provide enhanced efficiency, precise torque and speed control, and superior thermal management. These benefits are crucial for maintaining the performance and reliability of mid-drive EV platforms.

2. How does the Field-Oriented Control (FOC) algorithm improve motor performance in electric vehicles?

The FOC algorithm optimizes torque and speed control by independently controlling torque and magnetic flux. It also provides high dynamic response and reduces torque ripple, resulting in smoother and more efficient motor operation.

3. Can Embitel’s motor controllers be customized for different EV models and configurations?

Yes, our motor controllers are designed to be highly scalable and adaptable, allowing for seamless integration across various EV models and configurations. We work closely with clients to tailor solutions to their specific needs.

4. What safety standards do Embitel’s motor control solutions adhere to?

Our motor control solutions comply with MAC and ISO 26262 guidelines, ensuring the highest standards of functional safety. We conduct rigorous coverage studies and simulations to ensure full compliance and reliability.

5. What advanced features are included in Embitel’s motor control solutions?

Our solutions include advanced features such as cruise control, regenerative braking, and field weakening. These features enhance the driving experience, improve energy efficiency, and extend the speed range of the motor.