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Controllers are probably 99% efficient. If you think of the batteries as a huge water storage tank, and you open up the pipe for the water to start pouring in as fast as possible, if you are at a stop light, the water is filling up. If you want to do some hard accelerations, the tank drains some. If you are happy to keep the batteries at 50% or whatever, I think you could eliminate the controller. It could simplify the system a little bit, but you would be forced into unforgiving eco mode, rather than having it as an optional "average eco" sort of thing.
The parts for the 0-192v 0-50amp charger are around $400, excluding the 50amp 2mH inductor. I have no idea what one of those costs.
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