Overview
EV motor controller family for electric 2- & 3-wheelers using BLDC / PMSM traction motors in the 2–4 kW class, built on Versa Drives’ low-voltage EV drive platform.
The current standard variants are optimised for 48 V DC battery systems, delivering up to 4 kW or 8 kW peak output power (controller variant dependent) with drive efficiency >96%. Based on the same control and power platform, variants for 60 V and 72 V battery packs can be developed as part of OEM programmes. The underlying architecture is suitable for typical EV pack voltages such as 24 / 48 / 60 / 72 / 96 V DC, and can be adapted for other voltage and power levels as required.
These controllers are designed for high starting torque, smooth low-speed control and automotive-grade protection, with Hall / resolver feedback options and compliance to AIS-004 for EV applications.
Key Features
- EV motor controller family for 2- & 3-wheelers – designed for electric scooters, motorbikes and 3-wheelers using BLDC / PMSM traction motors in the 2–4 kW range.
- 48 V standard variants, extendable to 60 / 72 V – current off-the-shelf controllers are designed for 48 V DC packs, with 2 kW and 4 kW controller options supporting up to 4 kW / 8 kW peak output power. The same platform can be adapted for 60 V and 72 V battery systems in new OEM programmes.
- BLDC & PMSM motor support – drives 3-phase BLDC and PMSM traction motors with high efficiency and good low-speed torque, suitable for passenger and cargo vehicles.
- High drive efficiency – motor-side efficiency >90% and drive efficiency >96% (typical), helping improve vehicle range and thermal behaviour.
- Hall / resolver feedback – supports Hall sensor and resolver feedback options for rotor position, allowing use with both cost-optimised and higher-performance traction motors.
- Automotive I/O set – digital inputs for ignition, brake and forward / reverse selection, digital outputs for fault and status indication, and analog inputs for throttle and motor temperature.
- Integrated protections – undervoltage, overvoltage, overcurrent, overload, short-circuit, phase loss, locked rotor and motor over-temperature protection built into the controller.
- Rugged enclosure – IP68 enclosure rating with operating temperature from 0 to 50 °C and up to 95% non-condensing humidity, suitable for typical EV environmental conditions.
- AIS-004 compliant design – designed to meet AIS-004 requirements for EV motor controllers along with applicable EMC and safety requirements for automotive use.
- OEM-friendly platform – 2 kW and 4 kW variants share a common control and power platform, allowing OEMs to cover multiple vehicle models with a similar controller family; the platform can be extended to other pack voltages and power levels in new programmes.
Applications
- Electric scooters and motorbikes using BLDC / PMSM traction motors
- Passenger 3-wheelers (e-rickshaws) on light EV battery systems
- Cargo 3-wheelers and light commercial 3-wheelers
- Low-speed neighbourhood EVs and small utility vehicles within the 2–4 kW power class
- Other EV traction applications requiring a compact, IP68-rated motor controller in this power range
Technical Specifications
Representative values for current 48 V, 2 kW and 4 kW variants.
| DC bus / battery voltage | 48 V DC nominal (current standard variants) |
|---|---|
| Input current | 45 A (2 kW variant), 90 A (4 kW variant) |
| Drive output peak power | 4 kW (2 kW controller), 8 kW (4 kW controller) |
| Supported motor types | 3-phase BLDC and PMSM traction motors |
| Typical shaft power | ~1.7 kW (2 kW variant), ~3.4 kW (4 kW variant) |
| Motor phase voltage | 34 Vac (typical) |
| Motor phase current | 100 Arms (2 kW variant), 200 Arms (4 kW variant) |
| Motor electrical frequency | Up to 450 Hz |
| Feedback options | Hall sensor and resolver feedback |
| Control method | Advanced vector / FOC-based control for PMSM / BLDC traction motors |
| Drive output frequency | Up to 500 Hz |
| Drive efficiency | > 96% |
| Digital inputs | Ignition, brake, forward / reverse selection |
| Digital outputs | Fault indication, status indication |
| Analog inputs | Throttle, motor temperature |
| Auxiliary supply | 5 V / 100 mA for feedback sensor |
| Protection functions | Undervoltage, overvoltage, overcurrent, overload, short-circuit, phase loss, locked rotor, motor over-temperature |
| Standards / compliance | AIS-004 (EV motor controller), relevant EMC / safety standards as per application |
| Enclosure | IP68 |
| Operating temperature | 0 to 50 °C |
| Humidity | Up to 95% RH, non-condensing (max.) |
Enquiry Note
If you are interested, please share a few lines about your product, motor rating and supply voltage. We will review your requirement, map it to the closest Versa motor–drive platform and get back to you with next steps.
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