Hub Motor Control for Electric Two Wheelers and Three Wheelers

About the Customer

This case study is part of Embitel Technologies’ portfolio, demonstrating the successful implementation of a 48V hub motor control system. The insights presented here are valuable for any Tier 1 customer seeking innovative and efficient motor control solutions for electric vehicles.

Business Challenges

The project aimed to design and develop a 48V hub motor control system that integrates multiple operational modes, including throttle mode, walking mode, pedal assist mode (PAS), and cruise control mode. Embitel Technologies, with its extensive industry experience, identified the following challenges:

• Mode Transition: Ensuring seamless transitions between different operational modes to enhance rider comfort and safety.
• Sensor Accuracy: Maintaining the precision and robustness of sensor data under varying conditions to ensure reliable motor control.
• User Interface: Creating an intuitive and user-friendly interface for mode selection and activation, ensuring riders can easily switch modes and understand system status.

Embitel’s Solution

Embitel Technologies approached the project with a comprehensive strategy that included design, simulation, prototype development, and extensive testing. The key components and steps of the solution were as follows:

• System Overview: The control system comprised a Motor Control Unit (MCU), sensors, and an inverter to manage motor speed, torque, and overall performance. The 48V hub motor was integrated into the wheel hub of a test vehicle for real-world testing and validation.
• Design and Simulation: The design phase involved creating a simulation model of the BLDC motor and control system using MATLAB/Simulink. These simulations helped optimize control algorithms and validate performance before physical implementation.
• Prototype Development: A prototype system was built by integrating the BLDC motor, MCU, sensors, throttle, and other components into a test vehicle. This allowed for real-world testing and validation.
• Testing and Calibration: Extensive testing was conducted to validate the system’s performance in various modes. Calibration was performed to fine-tune control algorithms for optimal performance and smooth transitions between modes.

Embitel’s Impact

The implementation of the 48V BLDC motor control system resulted in significant advantages in terms of versatility, efficiency, and safety. The project had a profound impact on the following areas:

• Versatility: The control system supported multiple operational modes, providing flexibility and enhancing the overall user experience.
• Efficiency: The use of Field-Oriented Control (FOC) ensured smooth and efficient motor operation under varying conditions.
• Safety: The intuitive user interface and seamless mode transitions contributed to a safer and more comfortable riding experience.

Tools and Techniques

• Design and Simulation: MATLAB/Simulink
• Prototype Development: Integration of BLDC motor, MCU, sensors, and throttle
• Testing and Calibration: Real-world testing and fine-tuning of control algorithms

By addressing the business challenges and leveraging advanced tools and techniques, Embitel Technologies successfully delivered a 48V hub motor control system that enhances electric mobility, making it more accessible and enjoyable for users.