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Sep 01, 2026
During the development of electric vehicles, the motor controller is the core component of the entire vehicle's power system. The selection of the motor controller directly affects the power output performance and operational stability of the vehicle, and also relates to the cost of subsequent project modifications.
However, before making the selection, we need to focus on which parameters of the electronic control products to pay attention to. I have comprehensively sorted out the evaluation criteria for the selection, helping engineering and procurement personnel quickly screen out the motor controllers that are suitable for the project.
1. Matching core electrical specification parameters
Electrical parameter matching is the foundation for the stable operation of the electric vehicle controller. All electric vehicle projects are based on the perfect compatibility of the electronic control system, battery, and motor. Therefore, when evaluating a product, it is necessary to carefully verify the entire set of electrical specification parameters to ensure that the electronic control product is fully compatible with the vehicle's battery pack and motor. This includes the working voltage range, peak current, rated power, and peak power. After all, different vehicle models have different electrical parameter requirements for the electronic control system. Only by achieving precise electrical parameter matching can the vehicle ensure smooth power output under any working conditions.
2. Optimizing Thermal Management and Environmental Adaptability Performance
During high-power and long-duration operation, the electronic control unit generates a large amount of heat. If the heat dissipation efficiency of the electronic control unit is poor, the accumulated heat will cause a significant degradation of the unit's performance. Additionally, non-road and commercial vehicles operating outdoors are constantly exposed to complex environments such as dust, rain, and vibrations. At this point, the environmental tolerance of the product becomes extremely crucial. Therefore, when selecting, special attention should be paid to the cooling method and protection level of the electronic control unit to ensure that the equipment can maintain stable heat dissipation performance and operational performance under high-temperature and heavy-load conditions.
High-quality electronic control units on the market are generally liquid cooled ev controllers. The cooling medium uses a 50% water and ethylene glycol mixture coolant. This cooling method enables the electronic control unit to achieve stable heat dissipation during long periods of high-power operation. For commercial vehicles and non-road vehicles, the electronic control equipment will face complex environments. A high-reliability IP67 motor controller for ev is the best choice. It has excellent dustproof and waterproof capabilities and will not malfunction due to environmental factors.
3. Stringent Vehicle-Grade Safety Protection
The motor controller is a core safety component of the entire vehicle, and the integrity and compliance of its protection mechanism directly affect driving safety. Standard vehicle-grade motor controllers must have a complete set of hardware protection mechanisms that can monitor the operating status in real time and promptly avoid various equipment damages and safety hazards caused by electrical faults.
For high-safety requirements in applications such as commercial vehicles and engineering vehicles, it is necessary to carefully verify whether the product's software and hardware architecture complies with the ISO 26262 automotive functional safety standard. Through multi-level redundancy protection design, the probability of sudden faults during vehicle operation and work can be minimized, meeting the strict requirements of vehicle-grade usage.
4. Reliable Communication and Software Capabilities
Efficient data exchange between the controller and the entire vehicle is crucial for the coordinated operation of the vehicle. The communication capabilities and methods of the controller, as well as its intelligent functions, directly affect the control logic and fault maintenance efficiency of the entire vehicle. When making a choice, it is necessary to focus on the core communication interface specifications and preferentially select electronic control products equipped with standardized diagnosis and remote upgrade functions, which can significantly reduce the costs of later operation and modification.
Choose a professional commercial‑grade can bus motor controller. This type of electronic control supports CAN2.0 and CAN FD communication interfaces; generally, UDS diagnostic function can be selected, which can efficiently complete fault reading and troubleshooting; OTA remote upgrade can be selected to simplify the later firmware iteration work.
5. Compatibility of Position Sensors
Position sensors are the core feedback components that enable precise control of motor operation by the controller. The type of sensor adaptation, anti-interference capability, and stability directly determine the speed and torque control accuracy of the motor, and affect the overall driving smoothness of the vehicle.
When selecting, it is essential to carefully verify the sensor adaptation scheme of the controller. Prioritize the matching of position feedback devices that are resistant to vibration, can withstand high temperatures, and have strong stability. This can effectively avoid signal interference and data deviation issues in complex working conditions, ensuring the smooth operation of the motor. The rotary transformer, as a position feedback device, is resistant to vibration and high temperatures and is highly suitable for commercial vehicles and construction machinery.
6. Two High-Performance Motor Controller Products Suitable for Multiple Scenarios
Based on the above comprehensive selection criteria, we have launched two highly adaptable, highly reliable, and automotive-grade motor controllers, covering medium and high power requirements and precisely matching various electric vehicle development and production projects.
- 320V Plug-in Hybrid and Pure Electric Platform Controller
Adaptable to 320V voltage platform, equipped with TC725 chip and automotive-grade IGBT, following ISO 26262 functional safety architecture, with built-in intelligent protection algorithm, achieving low-speed anti-shake and enhancing driving and riding quality. Liquid cooling cooling combined with IP67 protection, suitable for long-term heavy load and harsh outdoor environments; Resolver resolver transformer is resistant to vibration and high temperature; CAN2.0/CAN FD communication, optional UDS diagnosis, OTA upgrade, and quick high-voltage insertion for simplified assembly. Power range 40-80kW with multiple gear options to meet diverse power requirements.
- 320V/540V Plug-in Hybrid and Pure Electric Platform Controller
Targeting medium and large power commercial and engineering equipment, with a wider voltage range, supporting 800V platform customization. Automotive-grade IGBT + ISO26262 safety architecture, featuring low-speed anti-shake and complete intelligent protection. Liquid cooling + IP67 protection, suitable for high-intensity outdoor operations; Resolver ensures vibration environment control accuracy; optional diagnosis and OTA upgrade, quick high-voltage insertion interface for convenient integration. Power range 60-100kW.
Selection Quick Reference Table
Category
Key Parameters
Our Product Specifications
Cooling & Protection
Cooling / Protection Rating
Liquid‑cooled (50% Water‑Ethylene Glycol) / IP67
Communication Interface
Bus
CAN2.0 / CAN‑FD
Sensor
Position Feedback
Resolver
Comprehensive Performance
System Efficiency
98.5%
Want to know more?
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If you need to confirm technical parameters, develop customized solutions, conduct sample tests, or engage in bulk cooperation, please send your project requirements to the official email: wisedrv@wiseelec.cn. You can also visit the "Contact Us" page to submit project information. Our engineering team will provide you with one-on-one professional technical consultation and exclusive project support.
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