HF Motion 
1. Overview
A brushless DC motor/permanent magnet motor controller is an electronic device used to control the speed, torque, and direction of brushless DC motors/permanent magnet motors in ship applications.
These controllers serve as critical components in various ship systems, including electric vessels, underwater propulsion systems, thrusters, and other maritime equipment.
They play a crucial role in providing effective and precise control for propulsion systems, thrusters, and other electrical equipment on ships.
Furthermore, manufacturers classify brushless DC motors/permanent magnet motors for ships, ranging from 1kW to several hundred kW, into small, medium, and large categories.
Specifically, electric sailboats and small vessels typically utilize propulsion systems ranging from 1kW to 20kW, while mid-sized boats employ propulsion systems ranging from 20kW to 50kW. On the other hand, large cruise ships require propulsion systems ranging from 50kW to several hundred kW.
The following is an example of a marine controller developed by our company according to customer requirements:
2. Technical Parameters ：Environmental Conditions
Maximum operating altitude: 3000m
Working air ambient temperature: -25°C to +70°C
Working water ambient temperature: -2°C to +45°C
Working ambient humidity: Relative humidity not exceeding 95%, with potential for condensation
Storage ambient temperature: -20°C to +60°C
Storage ambient humidity: Relative humidity not exceeding 85%
Air pressure: 86kPa to 106kPa
Tilt angle: Transverse tilt 15 degrees, transverse roll 22.5 degrees; Longitudinal tilt 5 degrees, longitudinal roll 7.5 degrees. (Transverse and longitudinal tilts may occur simultaneously)
3. Technical Parameters: Driver Working Requirements
Driver rated working voltage: 48VDC;
Driver rated operating current: 250A;
Driver input voltage range: -25%~30% rated voltage;
Motor drive controller: FOC without position control;
Speed control accuracy: high speed (greater than 500rpm) index is 3%, low speed (less than 500rpm) index is 5%;
Motor and driver working system: S9 with non-periodic changes in load and speed;
Mounting base limit size: 160mm*110mm*40mm
4. Technical Parameters ：Driver Control Logic
The driver supports RS485/CAN communication. The driver needs to be able to receive commands such as speed and emergency stop from the main control board to control the motor’s motion.Additionally, it needs to transmit its own status, including faults and protection codes, to the main control board for displaying the current status.
After receiving a valid speed command, the electric drive requires a soft-start function, which involves speed curve planning for acceleration and deceleration. The soft-start function has acceleration and deceleration times set according to human comfort levels.Moreover, during the deceleration phase, the acceleration must not exceed the battery’s maximum regenerative voltage and current.
The driver supports instantaneous overload capability. During the acceleration phase of the soft-start function, the motor can temporarily exceed its rated torque. In this overload torque phase, the input power can exceed the rated power, but the maximum bus current or input power cannot exceed the battery parameters.
Furthermore, the driver supports input power limitation control. During the constant speed phase of the soft-start function, the input power needs to be limited within the rated power.
5. Technical Parameters: Driver Reliability Design
This product’s design incorporates mature technologies across all functional units, following a modular design principle. There are no risks associated with new technologies that could impact system reliability. The main factors affecting reliability are the quality grades of components and the operating environment.
In accordance with general principles of reliability design for products, appropriate design and management measures have been implemented during the product design phase to ensure the reliability of the motor drive product from a qualitative perspective. Specific measures tailored to the product’s characteristics have been taken in terms of design and management to guarantee reliability, including:
Using mature technologies and components, simplifying the system composition while meeting technical requirements, thereby improving basic reliability.
Applying derating during component selection. Derating resistors by power rating, capacitors by voltage rating, semiconductors by junction temperature, and electrical connectors by current rating, with main functional components meeting Grade I derating requirements.
- Coating printed circuit boards with conformal coating to enhance environmental protection.
Reinforcing mounted capacitors and heavier components with 704 silicone rubber to improve mechanical environmental adaptability.
- Conducting strength analysis on structural designs and improving weak points to increase safety margins.
- Enforcing strict process disciplines, following design and process documentation requirements to ensure controlled and traceable production processes.
6. Conclusion
Our company has rich project experience in the field of marine permanent magnet motor control. We can develop relevant controllers according to customer requirements. We can also combine our new E-Hybird solar technology to completely upgrade the original marine controller system.
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