Commercial-grade EV Motor Controller Design
Budget: ₹12,500 – ₹37,500 INR
I am looking for an experienced power electronics engineer to design a commercial-grade EV motor controller for e-scooter, e-rickshaw, and e-loader applications.
## System Requirements:
### Input:
* 40V – 90V DC (supports 48V, 60V, 72V battery systems)
* Automotive voltage variation and transients must be handled
### Output:
* 3-phase BLDC motor control
* 60A continuous current, 80A peak
### Control Type:
* Preferred: Sine wave or FOC (Field Oriented Control)
* Smooth acceleration and low noise required
---
## Functional Features:
* Throttle input (0–5V analog)
* Brake input (cutoff + regenerative option if possible)
* Reverse function
* Hall sensor interface (mandatory)
* Speed limiting and soft start
---
## Protection Requirements:
* Overcurrent protection (hardware + software)
* Overvoltage protection
* Undervoltage cutoff (battery protection)
* Thermal protection (MOSFET + PCB temperature monitoring)
* Short circuit protection
---
## Hardware Requirements:
* High-current MOSFET power stage (40–80A class)
* Proper gate driver design
* Current sensing (shunt or Hall sensor)
* Wide input DC design (40–90V)
* Integrated DC-DC supply (battery → 12V → 5V/3.3V)
---
## PCB Requirements:
* High-current PCB layout (2oz–4oz copper)
* Proper grounding and EMI control
* Thermal design for MOSFET heat dissipation
* Designed for aluminum heatsink enclosure
---
## Mechanical:
* PCB suitable for mounting on aluminum heat sink base
* Compact layout for rugged enclosure
* Provision for connectors (battery, motor, throttle, hall)
---
## Deliverables:
* Full schematic (with explanation)
* PCB layout (preferred: EasyEDA / Altium / KiCad)
* Gerber files (manufacturing ready)
* BOM with exact part numbers
* Firmware (mandatory)
* Basic tuning guide and documentation
* Debug/test support after prototype (important)
---
## Experience Required:
* Prior EV motor controller design (mandatory)
* Experience with BLDC / FOC control
* High-current PCB design experience
* Knowledge of automotive-grade protection
---
## Application:
* E-scooter
* E-rickshaw
* E-loader
---
## Goal:
Develop a reliable, production-ready EV controller suitable for commercial deployment and long-term operation.
---
## Proposal Requirements:
Please include:
* Details of similar projects completed
* Controller topology and MCU you plan to use
* Approach to thermal and current handling
* Timeline and milestones
## System Requirements:
### Input:
* 40V – 90V DC (supports 48V, 60V, 72V battery systems)
* Automotive voltage variation and transients must be handled
### Output:
* 3-phase BLDC motor control
* 60A continuous current, 80A peak
### Control Type:
* Preferred: Sine wave or FOC (Field Oriented Control)
* Smooth acceleration and low noise required
---
## Functional Features:
* Throttle input (0–5V analog)
* Brake input (cutoff + regenerative option if possible)
* Reverse function
* Hall sensor interface (mandatory)
* Speed limiting and soft start
---
## Protection Requirements:
* Overcurrent protection (hardware + software)
* Overvoltage protection
* Undervoltage cutoff (battery protection)
* Thermal protection (MOSFET + PCB temperature monitoring)
* Short circuit protection
---
## Hardware Requirements:
* High-current MOSFET power stage (40–80A class)
* Proper gate driver design
* Current sensing (shunt or Hall sensor)
* Wide input DC design (40–90V)
* Integrated DC-DC supply (battery → 12V → 5V/3.3V)
---
## PCB Requirements:
* High-current PCB layout (2oz–4oz copper)
* Proper grounding and EMI control
* Thermal design for MOSFET heat dissipation
* Designed for aluminum heatsink enclosure
---
## Mechanical:
* PCB suitable for mounting on aluminum heat sink base
* Compact layout for rugged enclosure
* Provision for connectors (battery, motor, throttle, hall)
---
## Deliverables:
* Full schematic (with explanation)
* PCB layout (preferred: EasyEDA / Altium / KiCad)
* Gerber files (manufacturing ready)
* BOM with exact part numbers
* Firmware (mandatory)
* Basic tuning guide and documentation
* Debug/test support after prototype (important)
---
## Experience Required:
* Prior EV motor controller design (mandatory)
* Experience with BLDC / FOC control
* High-current PCB design experience
* Knowledge of automotive-grade protection
---
## Application:
* E-scooter
* E-rickshaw
* E-loader
---
## Goal:
Develop a reliable, production-ready EV controller suitable for commercial deployment and long-term operation.
---
## Proposal Requirements:
Please include:
* Details of similar projects completed
* Controller topology and MCU you plan to use
* Approach to thermal and current handling
* Timeline and milestones