Controllers are widely used in industries such as manufacturing, logistics handling, and medical equipment. Statistics show that the global automation market has an annual growth rate of 8%. Using controllers in logistics automation equipment can increase efficiency by 30%, significantly reducing labor costs and operational errors.
Medical Mobility Devices
Companies specializing in this kind of technology, such as Rotontek, invest considerable effort in increasing response speed and precision to secure the best driving experience for users. In the design of an electric wheelchair, its motor controller should have high power density with low power consumption to meet user demands for continuous outdoor use. The power of motor controllers falls between 200W and 500W, but some high-end product power supports higher power outputs to handle even more complex terrain or heavier loads.
The battery life directly influences the reliability and safety of devices for electric wheelchair users. Most electric wheelchairs on the market use 24V or 36V lithium batteries and operate up to 8 to 12 hours of runtime. The motor controllers optimize current consumption, dynamically adjusting power output, which seriously extends the battery life and maximizes travel distance. For users in an emergency to stop or make a sharp turn, response times by the controller mean everything in terms of operational safety and precision. The Industry-leading response time of leading motor controllers can be as low as 5 milliseconds. That way, it will be easy for users to maneuver in tight spaces to avoid collisions and other accidents.
The controllers also provide several modes of operation, such as low-speed mode, high-speed mode, and energy-saving mode. The controller regulates output power and speed upon user selection to suit different scenarios. Motor controllers provide higher torque output on steep slopes, allowing the wheelchair to climb gradients above 15 degrees safely, especially for users who often spend time outdoors. High-quality motor controllers boast an average lifespan of over 10 years, are extremely durable, have great weather resistance, and operate reliably in a wide temperature range from -20°C to 50°C.
Cleaning Equipment
Modern electric cleaning vehicles require a higher power output, usually within the range of 500W to 1500W, depending on the cleaning power needed. These vehicles are normally used in large centers like shopping malls, airports, and industrial parks. The motor controllers should be efficient enough to allow at least 8 hours of continuous operation to meet cleaning cycles. More noticeably, Rotontek came up with controllers that were more efficient and capable of intelligently partitioning power to reduce power waste by increasing the battery life by as much as 20% and greatly reducing daily operational costs.
Electric cleaning vehicles have to negotiate several smooth surfaces. With correct torque control, these can drive up ramps or over obstacles without stalling. A standard electric cleaning vehicle controller usually handles slopes of about 15 degrees, hence smoothing its application on diverse grounds such as urban roads to parking ramps. Most cleaning vehicles have speeds that range from 3 to 8 km/h, where controllers adjust the speed automatically to different tasks in cleaning for efficiency. For example, in narrow corridors or crowded areas, motor controllers provide slower speeds with which their safety and accuracy can be improved; in open areas, they speed up to increase efficiency.
Since the environment in which cleaning vehicles are used provides for long exposure to dust and moisture, motor controllers should be highly protected. Most of the mainstream cleaning vehicle controllers can achieve IP65 or more water and dust resistance, thus guaranteeing reliability in bad working conditions. For daily outdoor use or in a humid environment, this feature is essential. In general, electric cleaning vehicles work uninterruptedly for 3 to 5 years, while annual operating hours are well over 2,000. High-quality motor controllers ensure reliable work under heavy workloads; on the other hand, low-quality controllers lead to frequent downtime and maintenance.
AGV & AMR
The most common applications of the AGV and AMR in warehousing and manufacturing are represented by processes like automatic transport and material handling. As a rule, their motor controllers come with power outputs within the range of 300W to 1000W to guarantee reliable and uninterruptible operation at full load. In automated warehouses, travel speeds of 0.5 to 1.5 meters per second are quite enough to ensure efficient goods transport by AGVs. Motor controllers automatically adjust speed according to load to further facilitate transport effectively.
Controllers are used by the AMRs for real-time route adjustment, avoidance of obstacles, and replanning of paths. The employment of high-efficiency motor controllers can limit an AMR path deviation within 1 centimeter, and agile movement in tight spaces is enabled. It enables the work of the AMRs to adapt to complicated scenarios, such as sorting and transporting commodities in an e-commerce logistics warehouse. For example, a warehouse with 500 AGVs operating on an average of 2,000 hours a year will save several hundreds of thousands of dollars in electricity annually due to the energy efficiency provided by motor controllers like Rotontek.
Motor controllers must ensure that stable speed is provided in AGVs carrying a load of 500 kg or more and support quick start-stop operation. If this is greater than 1 second, it may impact the overall efficiency of a warehouse system. However, with good-quality controllers, the start response times could be reduced to below 0.5 seconds for speed and efficiency in operation. Motor controllers also usually achieve protection standards higher than or equal to IP65 to guarantee stable performances against changes in temperature and humidity. The controllers also monitor the battery level and health, while optimizing power consumption for extended runtime. With advanced controllers, AGVs can continue to work without stopping for 8 to 10 hours with just a single charge.
Logistics Handling Equipment
The torque output of an electric forklift should be large enough to guarantee smooth starts and operation under heavy loads. Most of the electric forklifts available on the market can have a load capacity ranging from 1.5 to 5 tons, needing controllers with power support ranging from 1000W to 3000W to support such heavy cargo. Under full load conditions, the controller keeps the vehicle’s driving speed constant, usually between 6 and 10 km/h, thereby assuring operation efficiency along with safety.
Most electric forklifts have less than 1.6 meters of turning radius. Their high-precision controller provides less than ±1-centimeter movement control error; positioning in crowded spaces is accurately controlled to avoid collision. Companies like Rotontek provide motor controllers for electric forklifts that raise the standard not only for the overall operational experience but also reduce the frequency of maintenance. With high-quality motor controllers installed, electric forklifts have an average annual failure rate of less than 3%, compared with more than 10% for traditional internal combustion forklifts.
The motor controller is integrated into the electric forklift, together with the battery management system, which allows for real-time monitoring and maximizes the capacity, health, and discharge rate of the batteries. Electric forklifts fitted with efficient controllers can also operate for about 6 to 8 hours on a single charge, therefore satisfying the requirements of routine handling of logistics. It also sends out warnings in case power reaches low levels to prevent the sudden shutdown of the operating machine, hence ensuring workflow continuity. Typically, the life cycle of a forklift controller is 8 to 10 years, and it can be maintained 30% more cheaply than its traditional internal combustion counterpart. Since the investment is higher upfront, the savings from reduced maintenance and energy costs during operation are considered considerable by businesses.
