Drive Systems
HighTechCOM designs and tunes complete electric drive systems – from the first system architecture to series-ready hardware and firmware. We focus on applications where torque density, robustness and safety matter: handheld tools, light electric vehicles, fans and pumps, robotics and industrial machines.
What we mean by a “drive system”
A drive system is more than a motor and an inverter. We look at the full chain:
- Electric motor (PMSM / BLDC / induction) and mechanical interface
- Inverter / motor controller hardware and STM32-based control firmware
- Power supply and battery, contactors, fusing and wiring harness
- Safety and protection concepts for overcurrent, overtemperature and faults
- Thermal design, cooling strategy and NVH (noise & vibration) behaviour
- HMI and telemetry (Android apps, displays, service tools)
- Enclosure, mounting and environmental protection (IP rating, drop and shock)
By treating the drive as one system, we can trade off efficiency, performance, cost and robustness – instead of only “fixing” one component in isolation.
What we optimise for
- High torque and power density for a given package and weight
- Stable start-up and low-speed behaviour under varying load
- High efficiency over the relevant duty cycle and speed ranges
- Predictable protection behaviour in fault and abuse cases
- Acceptable noise, vibration and thermal behaviour in the real product
- Manufacturability and testability at your chosen suppliers
Typical drive-system applications
- High-power cordless tools and outdoor equipment
- Light EV and mobility (scooters, motorbikes, utility vehicles)
- Fans, pumps and blowers for HVAC and industrial use
- Robotics and AGV drives, wheel hubs and joints
- Precision drives for measurement and laboratory equipment
How we work on drive systems
Our drive-system projects combine several of our core services. Depending on your starting point we may:
- Define or refine the system architecture, including power stage, control concept and safety strategy.
-
Tune and stabilise the motor controller firmware on STM32, including
FOC start-up, low-speed behaviour and timing integrity.
See engineering & firmware overview, FOC start-up & low-speed tuning, real-time optimisation and motor-drive protection. -
Design or update mechanical parts such as housings, mounts and brackets,
including FEA-based optimisation and drop-test simulation.
Related pages: mechanical CAD design, drop-test simulation, topology optimisation. -
Support complete product development from concept to SOP, where the
drive system is the core of the product.
See complete product development services.
Example project patterns
- “Stabilise our existing drive” – your hardware is mostly fixed, but the tool or vehicle shows unstable start-up, noise or thermal issues. We review timing, FOC tuning and protection, then propose and implement firmware and small hardware changes.
- “New high-performance drive platform” – you are creating a new platform (e.g. light EV or tool family). We support architecture, control strategy, mechanical design around the drive and validation, then hand over a documented baseline to your internal team.
- “Cost down an existing drive” – we keep the functional performance but reduce material, complexity or test effort via topology-optimised structures, simplified PCB and smarter test strategy.
Deliverables for drive-system projects
- Drive-system architecture document and block diagrams
- Motor and inverter requirements, including safety and protection
- STM32 firmware repositories and configuration, with documentation
- Mechanical CAD and drawings, FEA and drop-test reports where applicable
- Test plans and results (lab and, if relevant, field tests)
- Supplier-ready manufacturing and test documentation
How to engage with us
Most drive-system engagements start with a short, free consulting call to understand your current hardware, challenges and timeline. Afterwards, we propose either a small assessment package or a larger implementation sprint.
- Book a free 1h session via our motor-controller consulting packages.
- Or contact us directly with a short description of your application and target industry.