Air conditioning piping connects the four major components of the system—the compressor, condenser, evaporator and expansion valve—to form a closed system, within which the refrigerant is stored or circulates. When the air conditioning system is in operation, the refrigerant circulates continuously, exchanging heat with the outside environment to achieve the cooling function. To ensure the refrigerant transfers heat smoothly and efficiently, the routing of the pipework must be well-designed, facilitating both assembly and disassembly, whilst also being easy to manufacture and cost-effective.

Aluminium tubing, rubber hoses and pipe fittings

These three components are joined together to connect the various parts of the air-conditioning system. Aluminium pipes and rubber hoses are joined using a crimping process; however, there may be slight variations in crimping dimensions between different pipe models and those from different manufacturers. Engine vibrations can cause damage to the pipework; the use of flexible hoses for the pipework connecting the compressor’s suction and discharge ports helps to absorb these vibrations, improve the system’s seal integrity and extend the service life of the pipework. Furthermore, some sections of pipework, such as the condenser–evaporator line, may be constructed entirely from aluminium tubing. This is primarily due to the minimal relative movement between the condenser and the evaporator.

If the design leaves little clearance between the pipework and surrounding components, or if they are already in close contact, the use of wear-resistant sleeves such as heat-shrink tubing, corrugated tubing or foam may be considered. If there is little clearance between the air-conditioning pipework and the engine exhaust manifold, thermal insulation measures must be taken, such as wrapping the hose in an aluminium foil heat-insulation sleeve. 

Pipe fittings and O-rings

Pipe fittings are used to connect air-conditioning pipework and the various components of the system. Those commonly used at present include: clamp fittings, threaded fittings and quick-connect fittings.

The function of an O-ring is to seal the pipe joint. The material currently used for O-rings is HNBR.

Pipe clamp

The purpose of pipe clamps is to secure the air-conditioning pipework to the vehicle body, preventing relative movement between the two, thereby avoiding interference between the vibrating pipework and surrounding components, as well as preventing refrigerant leaks at the joints.

In addition to metal pipe clamps, plastic pipe clamps can also be used to secure air conditioning pipework. At present, there is a limited range of plastic pipe clamps used on the S-platform’s air conditioning system; however, the development of plastic pipe clamps may be considered in future, taking into account factors such as new projects and cost reduction.

When using pipe clamps, rubber liners must also be fitted to the inside of the clamps to dampen vibrations and prevent noise caused by direct contact between the aluminium pipe and the clamp.

Low-pressure filling port

Their function is to charge and recover refrigerant, as well as to check the system pressure. The high-pressure charging port is usually fitted on the condenser–evaporator line, although some are fitted on the compressor–condenser line. The low-pressure charging port is fitted on the evaporator–compressor line. The appearance of the charging ports is shown in the figure. Furthermore, the charging ports must be fitted with dust caps. These are generally green in colour (although there is now a requirement to change this to blue) and are made of PP.

Pressure switches/sensors

A pressure switch/sensor is a pressure-detection component that monitors the internal pressure of a system in real time, protecting the air-conditioning system by shutting down the compressor in the event of abnormal pressure, thereby safeguarding the system. It is also used to control the speed of the cooling fan. The pressure switch/sensor is shown in the figure.

Silencer

Where design flaws in an air-conditioning system cause noise in the pipework, silencers may be fitted at the identified source of the noise to eliminate it. Silencers are typically installed on the low-pressure pipework, usually near the compressor’s suction inlet. The exact installation location must be determined through testing. It is preferable to prevent noise from occurring in the first place by optimising the system.

Gas-liquid separator

When an air-conditioning system is incorrectly sized, resulting in liquid refrigerant present in the low-pressure piping, this can cause liquid hammer in the compressor; the use of a gas-liquid separator can protect the compressor from damage. It is fitted on the evaporator–compressor line. This component is now rarely found in modern vehicles, as the problem can be avoided through proper system sizing.

In the case of welded clamp piping, the clamp is welded to the pipe after the pipe has been bent. The head of the clamp is machined, ensuring relatively precise dimensional control. In contrast, for swaged clamp piping, the clamp (which has no head structure) is first slipped onto the pipe, and the pipe is then swaged to secure it firmly to the clamp. The torque applied to this clamp must meet the specified requirements. (Currently, the torque requirement for clamps on ￠12 and ￠16 pipes is 11 N·m, whilst for ￠10 pipes it is 6 N·m.) The pipe ends are then formed using a pipe end forming machine, a grooving machine or similar equipment. The final stage is the pipe bending process.

As piping is subject to the constraints of moulds and machinery during fabrication, we should bear the following points in mind when preparing piping data.

① The bending radii for aluminium tubes are R15/20 (￠10), R20 (￠12) and R25 (￠16). These are generally 1.5 times the outer diameter of the tube.

② The length of the shortest straight section of the pipeline centreline must be greater than 20 mm. This length is primarily limited by two factors:

1) Thickness limitations for pipe bending dies.

2) If the pipe is too short, it may come into contact with the pipe bender whilst being bent, resulting in damage or deformation.

③ The minimum distance L between the cutting point and the crimped pipe along the centreline of the aluminium tube must be greater than 16 mm; there must be no other components in the direction of the crimped pipe that could interfere with the crimping process.

④ The length of the shortest straight section at the end of the flared end is 20 mm. This value varies slightly depending on the pipe diameter. The above values should also be determined with reference to the route of the pipework.

The diagram showing the relationship between pipe bending parameters is as follows:

Pressure switches are classified as either three-position or two-position; the operating principle of a three-position pressure switch is analysed below.

1) When the refrigerant pressure is ≤ 0.12 ± 0.02 MPa, as the elastic force of the diaphragm, disc spring and upper spring exceeds the refrigerant pressure, the high- and low-pressure contacts open (OFF), causing the compressor to stop, thereby providing low-pressure protection.

2) When the refrigerant pressure reaches 0.24 MPa or above—a pressure higher than the spring force of the switch—the spring deflects, causing the high- and low-pressure contacts to close (ON), and the compressor operates normally.

3) When the refrigerant pressure reaches 3.2 MPa or above, it exceeds the elastic force of the diaphragm and the disc spring; the disc spring reverses direction to disconnect the high- and low-pressure contacts, causing the compressor to stop and thereby providing high-pressure protection.

4) Medium-pressure switch. When the refrigerant pressure exceeds 1.6 MPa, the pressure overcomes the diaphragm’s spring force, causing the diaphragm to reverse and push the shaft upwards, thereby closing the speed-change contact for the condenser fan (or radiator fan). The fan then operates at high speed, providing medium-pressure protection. When the pressure drops to 1.25 MPa, the diaphragm returns to its original position, the shaft moves downwards, the contacts open, and the condenser fan operates at low speed.

Air-conditioning ductwork layout

Air conditioning pipework serves to transport refrigerant within an air conditioning system; therefore, a well-designed layout of air conditioning pipework should incorporate the following points:

① The pipework is highly reliable, ensuring that there are no refrigerant leaks.

② Does not affect the cooling performance of the air-conditioning system—keeping the refrigerant temperature rise, pressure drop and compressor oil return rate within appropriate limits.

③ Meets NVH requirements without introducing additional vibration or noise.

④ Meet the requirements for final assembly and after-sales maintenance.

⑤ Cost optimisation.

⑥ The overall appearance should be as aesthetically pleasing as possible.

Below, we shall discuss each of these features in detail from the perspective of pipework layout.

Pipeline reliability

Based on the failure modes observed in the pipework of earlier models, we have broadly identified several main causes of pipework damage:

① Aluminium tubing or rubber hoses are worn down by surrounding components

② Aluminium or rubber hoses break as a result of engine vibrations

③ Damage caused by excessive heat at the hose connection

1) To prevent the pipework from being worn down by surrounding components, a reasonable clearance should be allowed for when routing the pipework. As a motor vehicle is a moving machine when in use, this clearance must account for both static and dynamic clearances. Static clearance refers to the gap between two objects with minimal vibration (as virtually all components vibrate whilst the vehicle is in motion), such as between the headlights and the condenser–evaporator pipework, or between the bodywork and the condenser–evaporator pipework; it is recommended that this clearance be maintained at 15 mm or more. If the clearance is too small or zero and the routing cannot be avoided, the pipes in close proximity should be wrapped in foam, heat-shrink tubing or corrugated tubing.

As the engine vibrates whilst running, dynamic clearances must be taken into account for the two pipes connected to the compressor. For example, the clearance between the compressor’s inlet and outlet hoses and the fan and drive belt. If the clearance is too small, the engine’s forward vibration may cause the air-conditioning hoses to interfere with other components; consequently, the requirements for dynamic clearance are stricter than those for static clearance, and are generally specified as 20 mm or more. As the engine tends to vibrate primarily in a fore-and-aft direction relative to the vehicle, the hoses connected to the compressor should ideally be routed perpendicular to the XZ plane.

When routing the pipework, keep it as far away as possible from the high-temperature components (exhaust pipes) in the front compartment, maintaining a distance of at least 100 mm. If it is genuinely impossible to meet this requirement, the minimum distance must be greater than 40 mm, and the surface must be wrapped in heat-insulating aluminium foil.

Pipeline vibration and noise

Vibration in air-conditioning ductwork is mainly caused by the following factors:

Methods of securing pipework and associated components; 

Selection of hose types for pipework; 

Noise generated by pipework layout.

These three characteristics will be discussed in turn below:

Pipe supports must be fitted with rubber gaskets to prevent rigid connections. If plastic pipe clamps are used, it is also advisable to use gaskets.

All-rubber hoses may be selected for low-pressure piping; as they are relatively flexible, they can effectively absorb vibrations and reduce noise in the pipework.

To minimise noise generated by air-conditioning pipework, the pipework should be laid as short and straight as possible; this also reduces the amount of refrigerant required.

In addition, a silencer can be fitted to the pipework; this will buffer and absorb the pressure pulses generated within the system. The positioning of the silencer is crucial and requires several trials to determine the correct location. The silencer should be installed as close as possible to the compressor end, and there should be at least 25 mm of straight pipework on either side of the silencer.

1. The power steering feels heavy or lacks assistance

Symptoms:
Heavy steering, with brief loss of hydraulic power assistance

Causes of fault: 

① Loose V-belt on the oil pump 

② Oil level in the reservoir too low 

③ Insufficient oil pump pressure 

④ Pressure control valve sticking 

⑤ Excessive external leakage 

⑥ Excessive internal leakage 

⑦ Steering shaft bushing too tight 

⑧ Front suspension deformation 

⑨ Air in the hydraulic system

Troubleshooting: 

① Check the condition of the power steering pump drive assembly. Press down on the power steering pump drive belt by hand; if it compresses excessively, this indicates that the drive belt is too tight and needs adjusting. Start the engine and allow it to run at idle speed, then suddenly increase the engine speed to check whether the power steering pump drive belt slips. If slippage occurs, this indicates that the drive belt is too loose or excessively worn, and it should be adjusted or replaced.

② Check the level of the steering fluid in the reservoir. If the level is below the lower mark or the ‘MIN’ mark, this indicates that the steering fluid is low and should be topped up to the specified level.

③ Check the filter in the power steering fluid reservoir. Remove the filter and inspect the condition of the filter screen. If the filter screen is excessively dirty, this indicates that the filter is blocked and should be cleaned; if the filter screen is torn, it should be replaced.

④ Check for air in the system. First, start the engine and allow it to run at idle speed, then turn the steering wheel back and forth several times and observe the condition of the steering fluid. If the steering fluid is foamy or cloudy, this indicates that air has entered the steering system and must be bled out; check whether the steering oil pump’s inlet hose is cracked; if so, replace it; Check whether any of the pipe joints are loose; if so, tighten them; check whether the seal ring on the steering oil pump shaft is damaged; if there is an oil leak, replace it with a new part.

⑤ Check the oil pressure in the steering system. Connect a pressure gauge between the steering oil pump and the power steering unit, run the engine at idle, and close the pressure gauge valve. If the pressure does not reach the specified value within 10 seconds, this indicates insufficient pressure from the steering oil pump, which should be dismantled, inspected and repaired. Turn the steering wheel to its left or right limit position, open the pressure gauge valve; if the pressure does not reach the specified value, this indicates a fault with the power steering unit or that the valves are incorrectly adjusted, and it should be dismantled, inspected and adjusted.

2. The power steering system is making a noise

Symptoms:
A noise is heard coming from the power steering pump when the car is turned

Causes of failure:   

① Loose V-belt on the oil pump 

② Damaged oil pump bearings 

③ Damage to the pressure plate or rotor 

④ Excessive wear on the oil pump ring 

⑤ Insufficient oil in the reservoir 

⑥ Air in the hydraulic system or loose pressure hose connections 

⑦ Incorrect assembly of the oil pump 

⑧ Faulty relief valve

Troubleshooting: 

① Check the level of the steering fluid in the reservoir. If the level is below the lower mark or the ‘MIN’ mark, this indicates that the steering fluid level is too low; top up to the specified level. If the steering fluid is being consumed too quickly, this indicates a serious leak, which should be investigated and rectified.

② Check the condition of the power steering pump drive assembly. Press down on the power steering pump drive belt by hand; if it deflects too much, this indicates that the drive belt is too loose and should be adjusted.

③ Check for air in the power steering fluid. Open the reservoir cap, start the engine and let it run at idle speed, then turn the steering wheel back and forth several times to check for bubbles in the power steering fluid. If bubbles are present, this indicates that air has entered the power steering fluid and must be bled out.

④ Check whether the filter screen on the oil reservoir is blocked and whether the oil piping is correctly routed. Remove the filter screen from the oil reservoir; if it is excessively dirty, this indicates that the oil is not circulating properly and it should be cleaned; if the oil piping is kinked or dented, it should be replaced.

⑤ If all the above test results are correct, the steering oil pump should be dismantled and inspected to check for scratches on the vanes and the pump housing; replace the relevant parts as necessary based on the findings of the inspection.

3. The steering feels different on the left and right

Symptoms:
Whilst the vehicle is in motion, the steering effort required to turn left and right is not equal.

Causes of fault: 

① The spool (or slide valve) of the steering control valve is out of the centre position, or, although it is in the centre position, the clearance between it and the shoulder of the valve body is inconsistent;

② Debris inside the control valve is causing blockages, resulting in different levels of resistance when turning it to the left and right;

③ Air has entered one of the oil chambers of a power cylinder in the hydraulic system;

④ Oil leakage

Troubleshooting: 

This fault is usually caused by contaminated oil; replace the oil with fresh oil in accordance with the specifications before carrying out any checks.

① If the fault persists despite the oil being of good quality or having been replaced with fresh oil, the hydraulic system should be bled and checked for oil leaks. Should a leak be found in the hydraulic system, the components at the leak point should be replaced; 
 ② If the fault still cannot be rectified, it may be caused by poor centring of the control valve. Faults in spool-type steering control valves can be rectified externally to the power steering unit by adjusting the position of the valve body. If the fault persists after adjusting the spool position, the spool should be dismantled and inspected to measure its dimensions; if there is significant deviation, the spool should be replaced. For rotary-type steering control valves, the fault must be rectified by dismantling and inspecting the valve.

✈️Important Reminder – Coolworks is coming to the Russia Industrial Expo!
✨From July 6 to 9, you are welcome to visit Booth 1S15, Hall 1, at the Ekaterinburg-EXPO International Exhibition Center.

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✅No matter what type of filter you need, we can custom-produce it for you.
Our professional team will be on-site to answer your questions and tailor the right products and solutions for you.
We will also have our filter products on display – good quality you can see for yourself.

2026 International Industrial Trade Fair – see you there!

✨Thailand Expo is officially open! Coolworks is here waiting for you!
.
The long-awaited Manufacturing Expo 2026 in Thailand kicks off today!
Our professional team is ready to explain product details, discuss your filtration needs, and explore cooperation opportunities.
We're here on-site — looking forward to your visit!
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The expo runs through June 20.
✨Welcome to Booth 8C17, Hall 98, at BITEC Bangkok — come talk to us face to face!

Hello, everyone!

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Coolworks products provide reliable filtration results,

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If you are looking for a quality air compressor filter,

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Golf carts are used in outdoor environments all year round and need to cope with uneven terrain, heavy loads of passengers or daily transportation tasks. The complex and variable working conditions are highly likely to limit the vehicle's power output and range. To handle such demanding conditions and fully utilize the driving performance of the vehicle, in addition to improving the vehicle's basic body structure, it is also extremely important to equip it with a set of high-quality motors and controllers. By releasing the comprehensive performance of the golf cart from the power source, the vehicle can operate stably in various scenarios.

 

The motor, as the hardware foundation of vehicle power, can convert electrical energy into mechanical power, determining the load capacity, climbing ability and acceleration potential of the golf cart; while the controller is the brain of the electric drive power system, being the core of intelligent power control for the entire vehicle, responsible for power regulation, power distribution and other control tasks. The two work together, releasing the performance of the golf cart and achieving a balance among power, range and stability. 

 

Once an incompatible motor and controller are selected, the power and endurance of the golf cart will be reduced. Choosing an electric drive system that matches the vehicle will enable you to enjoy a smoother and more powerful driving experience. 

 

Our company's main product, this 96V flat wire permanent magnet synchronous motor control kit, offers a rated power of 6kW and a peak power of 12kW, with a peak torque of up to 65Nm - sufficient to handle the steepest fairways. For heavy-duty applications, we also offer 7.5kW/15kW versions. 

 

This golf cart motor and controller upgrade kit is specifically designed for golf carts. It can effectively avoid the losses and malfunctions caused by parameter mismatches, allowing the mini vehicles to achieve the best performance in operation.

 

In the current golf cart motor market, AC motors are gradually replacing DC motors and becoming the mainstream. 

 

Take the 96V flat-wire motor as an example. The flat-wire winding technology has further enhanced the advantages of AC motors compared to traditional round wires: higher slot filling rate, shorter heat dissipation path, and the ability to output higher power in the same volume, while reducing copper loss and temperature rise. More importantly, AC motors are inherently suitable for intelligent control. Their linear response characteristics enable the controller to precisely regulate torque, speed, and energy consumption. The Ac Golf Cart Motor achieves precise management of torque, speed, and energy consumption through the coordination of the controller, ensuring that each power output is just right. 

 

To promote the technological advancement of golf carts, an "Energy-Efficient Electric Golf Car Motor" is also of vital importance. Even in the case of frequent starting and stopping, it enables the vehicle to output more effective power and maximize energy recovery. According to numerous experimental data, high-efficiency motors can significantly extend the driving range of the vehicle under the same conditions.

 

Choosing a controller essentially means selecting an intelligent management unit that can protect the entire electric drive system. It needs to have computing capabilities and support real-time communication with the motor. These are very important for ensuring the smooth operation of the vehicle. The working environment of golf carts is quite harsh, with situations such as water immersion, mud, and high-temperature exposure being common. These working conditions place very high demands on the waterproof sealing performance, heat dissipation efficiency, and long-term operational stability of the controller. 

 

In response to the above situation, we have specially incorporated the VCU function into the controller. It receives motor encoder signals through the CAN2.0 bus, supports UDS diagnosis and OTA remote upgrade, and has an IP67 protection rating.

 

How to determine which solution is suitable for you? First, carefully assess your usage pattern of the vehicle. If you want the vehicle to achieve optimal performance and efficiency, then choosing our electric drive system specifically designed for small vehicles is undoubtedly a wise long-term choice. 

 

Treat the motor and the controller as a single unit. Carefully match the specifications of the vehicle and the electric drive system, and unleash the performance potential of the vehicle that has never been demonstrated before.

 

I believe you are already familiar with motors and controllers, and understand that a power system suitable for the specific conditions is the key to maximizing the performance of the vehicle.

If you are looking for an electric drive solution for your golf cart, you might want to visit our 【Electric Drive Series for Mini Vehicles】 to learn more about our products. 

 

For technical consultation, customized parameter adjustment, sample application or bulk order inquiry, please directly contact our engineering team: wisedrv@wiseelec.cn. We offer one-on-one professional services to help you select the best system configuration, confirm installation compatibility, and ensure a smooth upgrade experience. 

 

WISEDRV supports each project and is equipped with a tailor-made powertrain.

 

Commercial vehicles are comprehensively undergoing electrification transformation. High-voltage cab equipment has become a standard feature for vehicle production. These on-board devices require stable, safe and reliable DC power conversion equipment to support long-term and high-intensity outdoor working conditions. 

 

Outdoor workers in commercial environments have strict requirements for electrical protection. The Full Protection Automotive DC-DC Converter can prevent the chain reaction of faults from the source, ensuring the stable and safe operation of the entire vehicle's electronic control system. 

 

In the current market, the majority of ordinary non-isolated DCDC controllers are only suitable for light civilian equipment. When used in commercial vehicle conditions, they will expose a series of high-voltage safety hazards, CAN bus communication interference, short equipment service life and other defects. An inappropriate power conversion solution will cause frequent system failures of the entire vehicle, increase the later maintenance costs, and at the same time fail to meet the requirements of vehicle electrical safety standards. 

 

Equipment manufacturers are all seeking dedicated DC-DC solutions suitable for commercial vehicle operating conditions. The core issue that everyone is most concerned about remains unchanged: Which DC-DC controllers are compatible with commercial vehicles? In fact, in the industry, the isolated DC-DC converter for commercial vehicles is the mainstream compliant equipment that meets the selection requirements of commercial vehicle OEMs. 

 

To evaluate the quality of the isolated DC-DC controllers for commercial vehicle body equipment, the following four core standards are mainly considered: complete electrical isolation structure, IP67 environmental protection rating, liquid cooling heat dissipation architecture, and standard CAN2.0 on-board communication interface. 

The above design standards can ensure the high-voltage safety of the entire vehicle and its stable operation over a long period of time, and they are also fully compatible with the electronic control systems of commercial vehicles.

 

Analysis of the four core technical indicators:

（1）Isolated electrical architecture

A strict high-low voltage isolation design is adopted, completely separating the 48V low-voltage chassis circuit from the 200-400V high-voltage upper-mounted circuit. This structure can avoid problems such as high-voltage breakdown and current backflow caused by common ground potential difference, complies with the high-voltage electrical safety standards for commercial vehicles, and avoids a series of potential safety hazards that may arise in the vehicle's electrical system. 

 

（2）IP67 Dust and Water Resistance Protection

Commercial vehicles operate in harsh conditions such as mud, water, rain, snow, and dust all year round. The IP67 protection level can withstand short-term water immersion and full-range dust intrusion, ensuring the stable operation of the equipment under severe conditions and preventing hardware damage caused by environmental factors. 

 

（3）Liquid Cooling Cooling Solution

The on-board equipment of commercial vehicles operates continuously for a long time each day. Compared with traditional cooling methods, using a cooling solution consisting of 50% water and ethylene glycol can ensure uniform and efficient heat dissipation, suppress the temperature rise of the equipment under long-term heavy-load conditions, and be suitable for all-weather continuous operation scenarios. 

 

（4）CAN2.0 Vehicle Communication

This product is equipped with CAN2.0 communication technology, enabling real-time interaction of voltage, current, temperature, and fault information. It supports intelligent power scheduling for the entire vehicle and self-diagnosis of faults, meeting the intelligent control requirements of modern commercial vehicle electronic architectures.

 

Core pain points of the non-isolation solution:

Comparison of working conditions between isolation and non-isolation solutions：

Comparison Dimension	Isolated DCDC (Automotive Grade)	Non-Isolated DCDC (Standard Model)	Project Impact
Safety & Compliance	Complete isolation between high and low voltage, compliant with vehicle-level safety certification	Common ground loop, with risk of high-voltage breakdown	Non-isolated products are not recommended for mass production projects of commercial vehicles
Communication Performance	No bus signal interference	High-frequency noise interferes with CAN bus, causing frequent equipment failures	Non-isolated solutions will directly affect the operational reliability of vehicles
Fault Risk	Single-point fault only causes local disconnection, without affecting other modules	Local abnormalities are easily transmitted to the electronic control components of the entire vehicle	The frequency of replacement of after-sales parts for vehicles will increase

 

· Product Parameter Table

Item	Description	Parameter Specification
Electrical Input	Input Voltage Range	40~58Vdc, rated 48Vdc
Electrical Output	Output Voltage Range	200~400Vdc
Electrical Output	Output Current	Max 25A
Control Voltage	System Control Voltage	12Vdc
Communication Configuration	Vehicle Communication	CAN2.0, baud rate 500kbps
Heat Dissipation Solution	Cooling Method	Liquid cooling (50% water + ethylene glycol mixture), water flow rate 12-15L/min
Environmental Protection	Protection Class	IP67

 

· Application Scenario

DCDC Controller for Vehicle Body Systems in Commercial Vehicles 

 

· Core technical advantages of the product

As a mature high voltage DC-DC converter for automobiles, this 48V to high voltage DCDC converter adopts an independent isolated design, equipped with a constant current and constant voltage charging mode and a complete protection mechanism. The liquid-cooled IP67 body is combined with CAN communication, and is suitable for the cab system scenarios of commercial vehicles.

 

• It is strictly prohibited to omit the isolation architecture in order to control costs.

The non-isolation structure has a series of hidden dangers and cannot pass the commercial vehicle safety certification. Therefore, the isolation DCDC solution should be selected to avoid risks at the root. 

 

• It is recommended to standardize the vehicle-wide CAN communication protocol.

This will enable data exchange throughout the vehicle, facilitating unified scheduling and real-time reporting of faults, and saving costs for later modifications and debugging. 

 

• Equipped with multiple layers of comprehensive protection mechanisms.

Covering all scenarios of faults such as overvoltage, overcurrent, overheating, and short circuit, it automatically locks the output when an abnormality occurs, reducing the rate of after-sales faults.

 

Q1: What are the core differences between isolated and non-isolated DC-DC?

The core difference between the two lies in the electrical isolation structure. In isolated products, the high and low voltage circuits are independent of each other, eliminating the risk of interlock failures and having excellent anti-interference performance; non-isolated products are prone to cause safety accidents and communication failures, and are not suitable for mass production projects of commercial vehicles. 

 

Q2: Which commercial vehicles can the WISEDRV 48V to 320V isolated DCDC adapter be applied to?

This product is widely compatible with new energy dedicated commercial vehicles and can be matched with the high-voltage power supply scenarios of mainstream body systems. 

 

Q3: Compared with non-isolated DCDC products on the market, what advantages does the WISEDRV controller have?

Our products are based on isolated DCDC as the core component, eliminating potential safety hazards at the source. At the same time, it is equipped with the native constant current and constant voltage charging mode and a complete multi-layer protection mechanism. The synergy of these three core configurations is an integrated advantage that cannot be achieved by a single functional module.

 

If our commercial vehicle isolation DCDC solution meets your project requirements, please click here to view the complete technical manual of the 48V to 320V on-board DCDC controller platform, which includes all parameter tables, heat dissipation specifications and performance test reports. 

 

If you need to inquire about customized solutions, sample testing or bulk quotations, please send the detailed vehicle project information to the official email: wisedrv@wiseelec.cn. 

 

You can also directly submit your technical requirements by going to the Contact Us page. We offer one-on-one technical personnel who will quickly assess and provide customized support for you.

 

Before answering "What is an IGBT module?", let's first understand its function: The IGBT power module is the power "core" of industrial electric drives, frequency converters, UPS, and inverters and other equipment. It is responsible for converting direct current to alternating current to drive motors or grid-connected power generation, and can also rectify alternating current for energy storage and grid-connected power generation. 

 

Before making a selection, the following three points should be mainly considered: electrical parameters (which directly determine the overall operating loss of the machine), thermal performance parameters (which affect the heat dissipation design and the lifespan of components), and reliability parameters (short-circuit tolerance, power cycle life, ensuring the long-term stable operation of the equipment in the field). 

 

Its application scenarios include: frequency converters, motor drives, UPS systems, solar power generation, etc. 

 

This article will provide a comprehensive analysis of the working principle and application of IGBT power modules. Whether you are a purchasing manager, engineer, or manufacturer, this article will help you establish a decision-making framework.

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I. What is an IGBT Module? – Internal Analysis

The component behind the switch

IGBT (Insulated Gate Bipolar Transistor) is a three-terminal power semiconductor device that possesses two key characteristics:

Similar to MOSFETs, it has high input impedance - voltage-driven and easy to control

Similar to BJTs, it has low on-state loss - capable of handling large currents with a lower on-state voltage. 

 

From chips to modules

A single IGBT chip is merely the basic power unit. The IGBT power module integrates multiple IGBT chips with fast recovery diodes (FRED) in the same package. It is arranged according to mainstream topologies such as half-bridge, full-bridge, three-level, and chopper. Inverter operation modules are generally equipped with FRED current-limiting diodes. 

 

The typical module consists of a three-layer structure:

• Copper substrate - quickly conducts the heat from the chip to the heat sink
• DBC copper-clad ceramic substrate - electrical insulation and thermal conductivity
• Silicon chip (IGBT chip + diode chip) - actually performs the switching function
• Most industrial-grade modules also integrate NTC temperature sensors to monitor the junction temperature in real time, achieving precise over-temperature protection. The IGBT module we launched also adopts this temperature measurement design. 

 

The actual function of the module

The IGBT power module is essentially a high-speed electronic switch.

It can achieve:

• DC to AC conversion (inverter) - for driving motors, photovoltaic grid connection
• AC to DC conversion (rectification) - for power supply, charging equipment
• PWM pulse width modulation for voltage/current regulation

 

2. Core technologies within the module

The internal manufacturing techniques between IGBT modules determine the loss characteristics, switching behavior and reliability. 

 

Sag Channel/Gate-Off Field Stop Structure

Most of the current modern industrial IGBT modules, including those designed by us, adopt the sag channel/gate-off field stop technology. This design structure enables the module to withstand higher voltages under the same power loss, or generate lower power loss under the same voltage, ultimately achieving a dual improvement in system efficiency and reliability. 

 

Integrating NTC temperature detection

Heat management is a key factor affecting the lifespan of IGBT modules. Our IGBT module is equipped with an integrated NTC thermistor, which provides real-time temperature data feedback to the control system, enabling precise temperature control. 

 

Copper substrate + standard packaging

The thermal conductivity of copper is much higher than that of aluminum, allowing for faster and more uniform heat conduction. This directly shortens the cycle of power circulation.

Standard packaging ensures compatibility with existing system designs, reducing the cost and risks associated with module upgrades.

 

3. Selection Guide: Essential Information for Purchasers and Engineers

The key to choosing high-performance IGBTs for inverter drives lies in finding the module that best matches the actual working conditions.

The three crucial electrical parameters are as shown in the table:

Parameter	Definition	Impact on Component Selection
VCE(sat) — Saturation Voltage Drop	Tube voltage drop when the IGBT is fully turned on	Determines conduction loss
Eon/Eoff — Switching Energy	Energy lost during turn-on and turn-off processes	Determines switching loss
RthJC — Junction-to-Case Thermal Resistance	Thermal conduction resistance from chip junction to module case	Determines heat dissipation requirements

 

The three reliability dimensions of High-Reliability Industrial-Grade IGBT Modules 

Take our 1200V/600A IGBT module as an example:

① Voltage Margin

The bus voltage fluctuation and the peak of the turn-off voltage will increase the pressure on the device, thus requiring sufficient voltage margin to be reserved. This module has a 1200V rating and is compatible with 600-800V bus systems. Even when the stray inductance layout is not optimized, there is still sufficient peak resistance margin.

② Short-Circuit Tolerance

Short-circuit faults have a circuit protection response window period. The short-circuit capability determines whether the module can perform protection delay within microseconds without damaging itself. This module has excellent short-circuit tolerance performance, enhancing the overall fault tolerance capability.

③ Rated Maximum Junction Temperature (Tvj op = 150℃)

Junction temperature is the core factor determining the lifespan of an IGBT. For every 10°C exceeding the rated value, the device lifespan is halved. A rated junction temperature of 150°C can handle frequent startups, short-term overloads, and poor heat dissipation conditions. Moreover, in actual conditions, it is recommended to keep the long-term junction temperature within 120°C, leaving a 30°C thermal buffer to cope with transient high temperatures and device aging.

 

4. Where are IGBT modules applied?

For example, our IGBT modules can be applied in four typical areas:

Application Field	Core Function	Key Requirements for Modules
Frequency Converter	Convert DC bus into variable-frequency three-phase AC power to realize motor speed regulation	High reliability, long service life, resistance to frequent start-stop operations
Motor Drives	Deliver power drive for industrial equipment	High current capacity (600A), long power cycle lifetime
UPS Uninterruptible Power Supply	Rapidly switch to battery power supply once mains power cuts off	Fast response speed, high reliability
Solar Power Generation	Convert PV DC power into grid-tied AC power	High efficiency, excellent resistance to outdoor environments

 

5. Common Questions

Q1: What are the advantages of the trench gate/field stop structure?

The trench gate eliminates the JFET resistance in the planar design, significantly reducing the on-state voltage drop; the field stop layer optimizes the electric field distribution and simultaneously reduces the switching loss. It achieves a balanced optimization of on-state loss and switching loss. 

 

Q2: What is the purpose of integrating NTC?

The NTC thermistor provides real-time temperature data for the control system module. It enables precise over-temperature protection, preventing situations of delayed protection or failure. 

 

Q3: What are the most common failure modes of IGBT modules?

Mainly include: overcurrent damage, overvoltage breakdown, overheating failure, and fatigue of the solder layer caused by power cycling.

And the IGBT module we have launched provides sufficient engineering margin in all these aspects through a 1200V withstand voltage, high short-circuit capacity and 150°C junction temperature design. This enables the entire machine to maintain reliability during long-term operation.

 

6. Designed for real working conditions

Choosing the right IGBT module is like selecting a reliable "heart" for the drive system. As long as the correct and high-quality power module is chosen, it can largely prevent potential problems that may occur during the long-term operation of the system. 

 

We design our products based on actual working conditions, with the sole aim of achieving the following: parameters serve performance, and performance ensures stability. 

For more information on different types of IGBT modules, please visit our official website.

 

If you need detailed technical data of the products, sample applications or selection support, please contact our engineering technical team:wisedrv@wiseelec.cn

 

In electric two-wheelers, the motor controller is the core of the entire power system. It not only determines the acceleration response, climbing ability, and temperature rise performance under continuous load, but also directly affects how many kilometers each kilowatt-hour of electricity can cover. Many users or vehicle manufacturers are particularly confused and indecisive when considering the two dimensions of performance and efficiency and choosing which type of motor controller to use.

 

As WISEDRV, a supplier with three types and six models of dedicated controller platforms (48V-72V hybrid/pure electric, 48V-96V pure electric, and 48V-72V high-speed pure electric), has achieved diversified electronic control and full coverage in the models of electric two-wheelers. Today, we will further help you select the motor controller suitable for your electric two-wheeler based on performance and efficiency. Starting from your actual riding scenarios, voltage and current requirements.

 

• (1) Urban Commuting: Efficiency First

For the 60-80 km/h speed range during daily urban commuting, efficiency should be the top priority. Due to frequent starting and stopping during daily commutes, riders usually care about the vehicle's range. In such travel scenarios, a high current is not necessarily required. The focus should truly be on the algorithm of the controller, standby power consumption, and the lightweight design of the electronic control (which brings benefits to the weight reduction of the vehicle). 

 

This is precisely the advantage of our 48V-72V hybrid/pure electric platform. This platform offers two versions of motor controller and generator controller. The rated phase current is 60/110A, with a peak of 260A, ensuring low energy consumption during daily commuting. It also supports start-generate-assist functions and constant voltage and current generation functions, making the vehicle operation more efficient. The cooling can be selected from natural air cooling or external water cooling, with high flexibility.

 

• （2）Performance Riding: Current Power Output

For the sporty electric motorcycles that aim for speeds of 100-120 km/h, power output becomes the primary consideration for riders. Such models are typically used in long-distance high-speed cruising scenarios, where the vehicle needs to contend with strong wind resistance and road friction. This places even higher demands on the electronic control system. The power of the electronic control needs to support the vehicle in reaching high speeds and also meet dynamic riding requirements such as accelerating up slopes. Therefore, riders prioritize the performance of power output as the first priority in their decision-making. 

 

Our 48V - 72V high-speed platform is specifically designed for such scenarios. The rated phase current is 160/180A, with a peak value of up to 350/450A. Combined with the low-resistance MOSFET design, it minimizes energy loss. The natural air-cooling system is installed at the windward side of the vehicle to meet the heat dissipation requirements. Optional features include Bluetooth, UDS, and OTA, facilitating parameter adjustment and remote diagnosis.

 

• （3）Multi-purpose scenarios: Flexible adaptation

In real life, apart from the aforementioned two types of application scenarios, there are many users who hope that a vehicle can not only provide efficient commuting for weekdays but also meet the needs for weekend travel. 

 

For such mixed scenarios, our 48V-96V pure electric platform achieves an ultimate balance between performance and efficiency. The most distinctive feature of this platform is its wide voltage range: from 48V to 96V, covering a wide range of voltage adaptability. The rated phase current is 80/100A, and the peak current is 260/300A. It not only provides sufficient power energy but also does not consume additional energy for the vehicle. The electronic control is equipped with lightweight magnesium alloy material, which significantly reduces the weight of vehicle equipment and improves efficiency at the physical level. At the same time, it integrates wheel speed detection, Bluetooth, UDS and OTA, with high intelligence.

 

When making your choice, there are three product features that can assist you in making a better decision in terms of efficiency or efficiency direction. 

• (1) Lightweight Alloys

The overall weight of the vehicle has a direct impact on the riding resistance or energy consumption. If you prefer a lightweight travel experience and need to frequently shift positions, then every kilogram of control for the vehicle equipment becomes meaningful.

Our Lightweight Alloy Motor Drive Controller is made of magnesium alloy, which significantly reduces weight compared to conventional aluminum alloy. From a physical perspective, when the vehicle becomes lighter, the same amount of electricity can enable the vehicle to travel further, helping you improve efficiency without relying on algorithm optimization.

From the efficiency perspective: Reducing weight directly reduces energy consumption, and this effect is particularly noticeable in urban traffic conditions with frequent starts and stops. 

 

• (2) Low Internal Resistance Design

When you fully press the throttle, the internal resistance of the controller determines how much electrical energy actually turns into thrust.

Our Low Internal Resistance Electric Motorcycle Controller minimizes energy loss through low internal resistance MOSFETs.

In terms of performance: The lower the internal resistance, the less heat is generated, and the higher the efficiency of converting electrical energy into power, resulting in higher top speed and burst power of the vehicle. 

 

• (3) Constant Voltage and Constant Current

For hybrid two-wheel vehicles, the stability of the electric drive system is of particular importance.

Our Constant Voltage Current Automatic Generator Start And Stop Unit achieves power matching as needed, avoiding redundant power generation and waste. The generator only operates when truly necessary, saving fuel, reducing noise, and stabilizing the busbar voltage.

Precise control of the timing of generator start and stop avoids ineffective power generation and maximizes the overall efficiency of the hybrid system.

 

The electronic control of WISEDRV is equipped with: integrated start-generate-help, constant voltage and constant current power generation, low internal resistance MOSFET, magnesium alloy lightweight housing, integrated wheel speed detection, UDS diagnosis and OTA remote upgrade, optional MOSFET module and Bluetooth function. It also optimizes heat dissipation for high-speed conditions. 

 

Three models with electronic control, varying voltages. While ensuring performance, they also maintain the redundancy necessary for product safety without sacrificing it.

 

 

In the end, choosing the appropriate motor controller means precisely matching the electrical control parameters and specifications with the vehicle's voltage, current, and speed targets. For 60-80 km/h commuting or hybrid needs, the 48V-72V platform offers mature and reliable natural air-cooling or external water-cooling plate methods. For multi-purpose vehicles with a 48V-96V wide voltage and medium current, this platform brings flexibility, lightweight design, and intelligent connectivity. For electric motorcycles that aim for 100-120 km/h high-speed performance, the 48V-72V platform meets the requirements with peak power and low internal resistance characteristics. 

 

The one that truly suits you is the one that matches your actual riding style, is compatible with your voltage level, and meets the safety current threshold of the motor. Please assess your usage scenario and compare the motor specifications. Finally, select the controller that can achieve a perfect balance between performance and efficiency for your electric two-wheeler.

 

• If you are also interested in the electronic control systems of electric two-wheelers, you can bookmark our website. Maybe you want to know what types of motor controllers are compatible with your two-wheel electric vehicle. You can send your requirements to our email: wisedrv@wiseelec.cn.

 

• We have a mature technical team that can provide you with one-on-one dedicated technical support. 

 

• In the future, we will continue to share more engineering experiences related to the architecture and application of the electric drive system on our website. Let's walk hand in hand on the path of electric transportation.

 

 

 

In the design of eVTOL aircraft, the weight control of the generator controller is extremely strict and has the most significant impact. After all, every additional kilogram of equipment will have a certain effect on the flight range or payload capacity. Unlike ground power generators, eVTOL equipment must be able to achieve the most extreme reduction in weight without sacrificing performance.

 

Our combined generator and controller product adheres to this one-in-one concept. The direct connection assembly method eliminates the need for separate enclosures, wiring harnesses, and intermediate coupling components, freeing up a significant amount of cabin space and keeping the total system weight at 24kg. Within such a lightweight range, it achieves a rated power of 69kW, a peak power of 73kW, and a system efficiency of 94.5%. This integrated design is supported by the Weight Optimized Genset Controller, which intelligently balances power output and heat management, enabling the aircraft to achieve remarkable endurance performance without adding additional weight.

 

The silicon carbide (SiC) controller has redefined the performance boundaries of the electric drive system for aircraft. It enables low-altitude flight equipment to achieve higher switching frequencies, lower on-state and switching losses, as well as superior thermal performance, thereby achieving a higher power density for the equipment.

 

Our integrated controller has a wide voltage tolerance range and a silicon carbide power stage design. When applied to low-altitude flight, it becomes a "High Power Density SiC Generator Controller". Compared with traditional flight electric drive solutions, this controller achieves a comprehensive performance upgrade.

 

The eVTOL aircraft must maintain controllable operation even in the event of a failure. This requirement fundamentally determines the architecture design of the controller. 

 

Our platform has implemented highly secure control strategies. The controller communicates via CAN2.0 with the vehicle-level control unit for deterministic real-time data exchange; a rotary transformer is used to ensure the accuracy of rotor synchronization under all operating conditions; the IP67 protection level guarantees that the equipment can still operate reliably in various weather conditions. 

 

These functions are precisely where the High Safety Redundancy Drone Motors come into play. By having the generator controller act as part of the integrated safety system, it coordinates the overall operation of the powertrain, ensuring that the system operates under controlled conditions for flight.