EV Motor Controllers for 2 & 3 Wheelers

48 V, 2–4 kW BLDC / PMSM traction controllers for light EVs
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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.

PMSM/BLDC EV motor controller module (low-voltage traction controller) – top/angled view
Compact PMSM/BLDC motor controller for EV and mobility applications – side view

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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