3T designs cutting-edge control and power module for cordless hydraulic rescue tools
3T specializes in developing bespoke power and motor control systems that satisfy exceptionally challenging specifications. In collaboration with a prominent manufacturer of hydraulic equipment, 3T designed a module that governs the control and power provision of cordless rescue tools' hydraulic drives.
Since the rescue equipment is cordless, our team had to ensure that the hydraulic system and the battery-powered system are synchronized and work in harmony. In addition, controlling the hydraulic pumps requires a sophisticated algorithm to handle the high pressures and flow rates. And, of course, these tools must also function reliably underwater and in rugged applications.
Together with the customer, 3T was facing the challenge of finding a cost-efficient solution to power and control their complete product, which required seamless functioning between hydraulic and battery-powered components, and a demanding control algorithm for the hydraulic pump. Additionally, the tool had to be robust and reliable, able to operate underwater, and withstand high peak currents caused by mechanics.
3T makes the difference using their motor control platform VIPER
3T proved to be the perfect partner for this project, utilizing their VIPER platform, a PMSM motor control solution, which can be flexibly adapted to customer-specific requirements. Based on this, the 3T team developed a reliable customer-specific solution for a seamless BLDC motor including robust electronics capable of operating underwater.
The resulting solution is highly convincing in its application, offering high performance, robustness, and the ability to withstand high ambient temperatures. The dedicated control algorithms were developed in close cooperation with the customer and can auto-detect the tool type, matching its performance and control strategy.
Power integrity simulation to meet high-performance requirements
To guarantee an efficient power supply during all operating modes of the rescue tools, the solutions have been proven by power integrity simulations.
Many function and interfaces included
The solution boasts several relevant features, including its 48 Arms - 18-28V - 1KW power output. It also offers settings memory, code upgradability, communication interface with the battery, LED string driver, HMI, and faulty wiring detection on control inputs. Autonomous tool detection, a 2nd motor channel for a small BLDC/stepper motor, a battery charger interface, and an interface for digital and analog pressure/motor temperature sensors are also included. Diagnostics, statistics, and error logging are also provided, making it ideal for the service department.
Features of the motor control system for hydraulic rescue tools
| Controller | sensorless BLDC/PMSM control |
|---|---|
| Power output |
48 Arms – 18-28 V – 1 kW 2nd motor channel for a small BLDC/stepper motor ~3Arms |
| Diagnostics |
live data statistical data error logging settings memory faulty wiring detection on control inputs |
| Software | customer specific control algorithms for multiple tools (option for customer to add functionality) |
| Special feature |
works under water code upgradable |
| Interfaces |
communication interface with battery interface for battery charger interface for digital and analog pressure sensor interface for motor temperature sensor |
| HMI | LEDs, button, control switches |
Flexible Motor Control: VIPER
VIPER is a building block for flexible motor control solutions.
VIPER is a motor control solution perfectly suited for any kind of motors with permanent magnets. With its powerful processor, intelligent FET driver, and discrete power stage, VIPER can supply up to an impressive 1kW (in its basic version) to a range of motors, including BLDC, PMSM, IPM, and steppermotors, with a supply voltage of up to 28V (40V peak).
VIPER is fully scalable and adaptable, making it the perfect choice for any application requiring different voltages and powers. Just look at how the Motor Control Unit (MCU) of Solarteam Twente has already benefited from VIPER's versatility and adaptability!
The powerful processor enables the addition of customer-specific functions, such as motion control, usage and fault logging, setting storage, and software updates. This means that VIPER can be fully customized to create a unique solution that perfectly meets the requirements of any customer.
Learn more about VIPER and Power and Motion Control
