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DEPRAG SCREWDRIVERS
 

          Our customer DEPRAG manufactures a large range of electronic and pneumatic screwdrivers. For the electronic screwdrivers we have done most of the hardware design and all of the real-time control software. The screw tightening process can be freely programmed through a web-interface. Statistics, error checking, graphical analyzes  and other features provide perfect monitoring of the process and a high level of quality control. Our motor controller design was optimized for precision, all engineering decision were taken in favor of minimal torque fluctuations and maximum speed.
          The torque measurement is performed indirectly by measuring the phase currents of the 3 phase synchronous motor and applying a mathematical model for the torque at the spindle. The model was also designed by us and optimized in close cooperation with DEPRAG. As a result these screwdriver products provide high precision at moderate costs, sparing the need of an external torque sensor.
 
          For further information please refer to the DEPRAG web-site. 




 HIGH PRECISION SYNCHRONOUS MOTOR CONTROLLER

Brief facts:

  • 3-phase motor controller with 24V supply
  • 10 A maximum motor current, no heat sink necessary 
  • pure sine wave generation, with LC-filter (off board)
  • motor cables up to 20 meters
  • minimal motor losses due to high precision sine-wave control
  • 40 KHz current measurement and control
  • direct phase current measurement
  • overload and short-circuit protected
  • overvoltage protected with brake resistor
  • ultra-low response time to torque/speed commands (less than 1 ms)
  • precise torque control between 0 and 25000 RPM
  • MR or optical incremental sensor feedback, differential signaling for high noise immunity
  • Linux operating system for application programming on 400 MHz AT91SAM9G20 platform
  • 2 GB micro-SD memory
  • 100 Mbit network interface
  • Interface for touch-screen display
  • High performance Ti DSP controller TMS320F2802-60
  • bootloader for web-based upgrade of all software

 
This controller has been designed for fast, high precision industrial screw driving applications. The unit is capable to control very small torque values required for miniature screws used for instance in mobile phone mounting. Process monitoring and control is implemented through a user-supplied web-site. 

 


LOW-COST, HIGH POWER MOTOR CONTROLLER

Brief facts:

  • PWM control of 3 DC-motors
  • 24 V battery supply
  • integrated charge controller, (charger requires external power supply only)
  • up to 40 A maximum motor current (70 A total of all motors, 90 A short term)
  • special safety features to inhibit uncommanded motor start
  • text-mode display with 18 languages
  • serial interface with bootloader for software upgrades
  • integrated 70 A high power relay
  • several low-power I/O for auxiliary functions
  • high side current measurement for short circuit protection of the motors
  • MSP430F247 processor, 1 Mbit external flash
  • ESD hardened design up to 16 KV

 
We engineered this unit for cleaning applications to control brushes, a drive motor and a vacuum cleaner in one unit. The device is very compact and low-cost. The user can take full advantage of the PWM capabilities for silent and ECO operation modes on all loads.

 


ULTRA LOW-COST, HIGH POWER MOTOR CONTROLLER

Brief facts:

  • control of 2 DC-motors, (one with PWM capability)
  • 24 V battery supply
  • integrated charge controller, (charger requires external power supply only)
  • up to 40 A maximum motor current (70 A total of the 2 motors)
  • 2 LED display, multicolor for charge status, red for error
  • serial interface for diagnosis
  • 2 integrated 40 A high power relays
  • low-power I/O for auxiliary functions
  • high side current measurement for short circuit protection of the motors
  • Low-cost MSP430F133 processor

 
We engineered this unit for cleaning applications to control a brush, and a vacuum cleaner in one unit. The device is very compact and ultra low-cost for an entry level cleaning machine.

 


ULTRA HIGH PRECISION SYNCHRONOUS MOTOR  CONTROLLER

Brief facts:

  • 3-phase motor controller with 48V supply
  • 20 A maximum motor current, no heat sink necessary 
  • pure sine wave generation, with LC-filter (on board)
  • motor cables up to 20 meters
  • minimal motor losses due to high precision sine-wave control
  • 40 KHz current measurement and control
  • direct high precision phase current measurement
  • overload and short-circuit protected
  • overvoltage protected with brake resistor
  • high speed 3 Mbit serial data interface for real time process monitoring
  • RS485 interface for external control
  • ultra-low response time to torque/speed commands (less than 1 ms)
  • precise torque control between 0 and 25000 RPM
  • MR or optical incremental sensor feedback, differential signaling for high noise immunity
  • High performance Ti DSP controller TMS320LF2406
  • serial bootloader for software upgrade via RS485

 
This controller has been designed for fast, high precision industrial screw driving applications. The unit is capable to control a wide range of torque values between 0.05 – 4.5 Nm required for either miniature or larger screws. Process monitoring and control is implemented by an external Linux board and through a user-supplied web-site.

 


AUTOMOTIVE LIGHTING AND MAGNETIC VALVE CONTROLLER

Brief facts:

  • 17 – 50 V input
  • complete automotive lighting for front and rear lamps as well as the blinkers
  • high power work-light
  • PWM modulation on all outputs, with effective voltage and current calculation
  • Programmable RMS output voltages, between 12 – 24 V
  • RS485 bus-interface
  • all outputs fully short circuit and overload protected
  • 5 ESD protected universal inputs
  • 6 universal programmable outputs 12-24 V/1A for magnetic loads (relais, valves)
  • uses low-cost MSP430F133

 
This unit was designed as an add-on module for cleaning machines that require road-worthy lightning. The module is universal so that 12 V lamps and valves can be used for all system voltages. All loads can be controlled through the RS485 interface, the applicable current limits can be arbitrarily set.



UNIVERSAL MOTOR-CONTROLLER FOR 3 MOTORS

Brief facts:

  • 17 – 50 V input
  • 2 independent full bridge (bidirectional) PWM motor outputs up to 10 A each
  • precise torque and speed control for all motors
  • 1 PWM motor output up to 20 A
  • RS485 bus-interface
  • all outputs fully short circuit and overload protected
  • uses low-cost MSP430F135
  • compact design

 
We designed this module for performing independent lift operations for parts of a cleaning machine. An additional motor output is provided for an auxiliary brush. All functions can be commanded through the RS485 interface.




HIGH POWER MOTOR CONTROLLER

Brief facts:

  • 17 – 50 V input
  • full-bridge motor output up to 180A
  • cooling through the board with SMD MOSFETs
  • high security design with independent supervisor micro controller (PIC16F684)
  • PWM output for a magnetic emergency brake. Standard 12V brakes can be used independent of the system voltage
  • output for a car type horn
  • RS485 bus-interface
  • Flexible accelerator pedal input, for all passive or active pedal designs
  • MSP430F133 processor

 
This is a high power motor controller for electric drive applications. Machines up to 2 tons gross weight are being controlled with this device. Because of the inherent danger of such machines, all critical control paths are 2-way redundant. Speed, drive direction and current limits can be freely programmed through the RS485 interface.




UNIVERSAL HIGH POWER MOTOR CONTROLLER

Brief facts:

  • 17-35 V input
  • 3 configurable half bridge PWM outputs, max. 100A each
  • Auxiliary PWM output 30 A
  • on-board DC/DC converter 13V /1 A output
  • cooling through the board with SMD MOSFETs
  • coolers also used for supply voltage
  • 4 valve or relay outputs, 2 of them PWM controlled
  • LCD-display interface, textmode, 18 languages
  • Button and switch inputs
  • numerous sensor/switch inputs
  • uses Ti DSP TMS320F2802-60
  • RS485 interface
  • 1 Mbit external flash

 
This a low-cost, compact master- and power-controller for a cleaning machine. This all in one solution is very flexible. The output bridges can be configured in different ways:

  • 3 independent DC motors 100 A each
  • One DC motor 100 A, one reversible drive motor (H-bridge)
  • One 3 phase asynchronous motor
  • 2 drive motors in an electronic differential configuration

 
There are two extension connectors provided to control further equipment if necessary.
 
Highlight:
 
High cost-efficiency:  One high-side current measurement is shared between the three main outputs. The current sensor is multiplexed through intelligent software design. The three currents are precisely measured and offset calibrated every millisecond. 


 

 


 






MZ ELECTRIC SCOOTER CHARLY

        The scooter shown is one example of the many DC-motor control projects we have worked on. The scooter's motor current is up to 70 amps. The design includes a battery charger with a switching power supply. The motor and charger current are precisely controlled by a Microchip PIC micro controller.

        The controller algorithm maintains a battery charge status and communicates that to the user by means of an LED display. Comprehensive error analysis and fault tolerance is incorporated. Our product is much more compact in its physical dimensions (See photo) as its predecessor designed by a competitor. Also lower component count provides higher reliability and lower manufacturing costs.

        Through the cooperation with us, our customer MZ improved its competitive strength with a better product and better profit margins.

        For further information on Microchip micro controllers that are highly versatile for a variety of applications while consuming only minimal quiescent power, check the Microchip home page.

 

PLAY AND MASTER CONTROLLER MODULE

Brief facts

 


LOGIC-INTERFACE BOARD

Brief facts
 

  • 3 channel differential converter for high speed signaling
  • EEPROM and flash permanent storage
  • uses PIC18F1320
  • ultra-compact design to fit into a 15 pin canon connector
  • RS485 interface

This unit is being used as an id-tag of an electronic screwdriver. Calibration information specific to the load attached is stored in EEPROM and Flash. Our motor-controllers can read the information and control the motor with optimum performance.


DISPLAY AND MASTER CONTROLLER MODULE

Brief facts
 

  • DC/DC converter 17-50 V input, 13 V/1.3 A output, realized in software on low-cost Freescale HC08
  • PIC18F6820 as central processor for application software
  • 512 Kbyte external serial EEPROM
  • LCD display interface
  • encoder and push-button for user-interface
  • up to 16 LED
  • 1 A PWM output for main relay
  • ESD-protected I/O interfaces
  • RS485 bus-Interface

We designed this unit as a master controller of a cleaning machine. The DC/DC converter is a pure software solution that also implements the power-cycling and the reset of the main controller. In sleep mode the DC/DC converter consumes minimum power before being waken up by a user action.