The Electric Scooter Controllers: The Brain of Your Scooter

The electric scooter controller is the brain and central nervous system of an electric scooter. It is a combination of circuits, sensors, and firmware that act as your onboard computer, and control all of the scooter’s critical functions. They are used for all electric scooters, usually installed in a small box inside the scooter deck. Single-motor scooters have one controller, while higher-performance dual-motor models have two controllers - one for each motor.

The controller’s rating depends on the current (in amperes) and voltage that can be passed through the controller. Voltage is a key indicator of controller function. It is measured in volts and tells you the strength of the current passing through the circuit.

Typically, electric scooter controllers belong to one of the following six categories: 36V, 48V, 52V, 60V, 72V, and 84V. The higher the voltage, the more power it generates, resulting in greater torque, faster acceleration, and higher top speed. Current is measured in amperes and is the rate at which current flows through a circuit. Like voltage, it is a useful indicator of the strength of the controller.

Typically, the amperage of electric scooter controllers belongs to one of the following five categories: 10A, 25A, 30A, 40A, and 50A. The higher the current, the faster the controller responds to signals and inputs from the scooter’s electrical components. Its most significant impact is greater torque, faster acceleration, and higher top speed. For example, high-performance scooters equipped with a large 60V 30Ah battery and a powerful 60V 1000W motor will be equipped with a high-voltage (60V) and high-current (40A) controller to match the rest of the scooter.

The controller’s main function is to act as the brain and central nervous system of the electric scooter. They are a combination of circuits, sensors, and firmware that act as your onboard computer, and control all of the scooter’s critical functions.

They are used for all electric scooters, usually installed in a small box inside the scooter deck. The primary purpose of the controller is to allow you to precisely control the speed. When you press the throttle of the scooter, it activates the magnetic field inside the motor. The magnetic field voltage is detected by a sensor and transmitted to the controller. Then, this input is used to send the correct voltage to the motor, allowing it to rotate at the speed required by the throttle.

No matter how hard you press the throttle, the voltage of the magnetic field will be matched by the controller. For example, if your scooter is equipped with a 60V controller and you gently press the throttle, it may only output 20V, resulting in slow and steady speed. But if you press the throttle all the way, the controller will output the maximum power of 60V, resulting in faster and higher acceleration.

When braking, the controller stops the flow of electricity between the battery and the motor. This overrides all other signals and prevents the motor and brake from interfering with each other. Electronic, regenerative, and anti-lock braking systems all rely on controller input to function. When applying electronic brakes, the controller sends current to the electromagnet inside the motor hub. This creates a magnetic field that applies force to the rotating central axis, slowing down the wheels.

Similarly, if your scooter has a regenerative braking system, the controller will send current back to the battery from the motor. This means that the motor no longer provides power to the wheels, but instead charges the battery. Since the scooter is still moving forward when braking, kinetic energy keeps the motor spinning. This generates electricity, which is then guided back to the battery for storage. By taking energy from the motor in the form of electricity, resistance is generated, which slows down the rotation of the wheels.

As for anti-lock braking systems, also known as ABS, they also rely on controller input to function. Anti-lock braking systems are designed to prevent the wheels from locking up so that you always stay safe and in control. Their operation involves sensing when the wheels are about to lock up, and then rapidly reducing and increasing brake pressure multiple times per second. This keeps the wheels moving when the scooter decelerates, rather than locking up.

 There is a speed sensor on each wheel. They detect when the brakes are locked and immediately send a signal to the controller. Once the controller receives the signal, it activates the ABS. When the cruise control function of the scooter is activated, the controller uses the speed sensors on each wheel to keep the scooter running at a constant speed. Once engaged, you can remove your thumb or finger from the throttle and let the controller do all the hard work for you.

 Overvoltage protection is a function that shuts off power when the voltage exceeds a preset level. Most power supplies use overvoltage protection to prevent damage to electronic components. The effects of overvoltage can cause some components to perform poorly and in some cases, cause malfunctions or fires.

The controller’s most significant function is to continuously monitor the battery voltage to prevent overcharging. Low voltage protection is a control that prevents the battery pack from being over-discharged. When your electric scooter battery voltage is low (i.e., low battery), keeping it in a discharged state puts it at a higher risk of being fully discharged. In this case, if your battery happens to discharge beyond the standard cutoff point, its performance will be significantly reduced, and its lifespan will be significantly shortened.

Therefore, the controller’s role is to monitor the battery voltage and then disconnect it from the load when it detects that the voltage has dropped below the minimum limit.

Overcurrent protection, also known as current limiting, is the process of limiting or completely disabling current. It is a safety mechanism that prevents current from exceeding the rated value of the circuit or device. Uncontrolled overcurrent can cause excessive heat, fire hazards, and may damage equipment.

Therefore, monitoring and preventing this situation is very important. In electric scooters, the controller monitors the flow of electricity between the battery and the motor. If the current rises too high, the controller will limit it to prevent permanent damage. Overtemperature protection is a system that limits or shuts off power when the internal temperature exceeds a safe value. Here, the controller monitors the temperature of the transistors that regulate the current inside the motor. If they become too hot, the controller will shut them off to prevent overheating.