Overview
The Versa Drives Fitness & Sports PMSM Controller is a 24 V DC, 700 W class motor controller designed for high-performance fitness and sports training equipment. It provides precise, energy-efficient speed and torque control for 3-phase PMSM motors used in gym machines, disk throwing systems, ball launchers, and other motorised exercise rigs.
Positioned between basic hobby-level drives and heavy industrial systems, this controller targets professional gyms, sports academies, and high-end training setups that need advanced motor control without the complexity and cost of large automation platforms. It is built on an industrial-grade architecture with IEC 61800-3 and IEC 61800-5 based design practices, making it suitable for demanding commercial use.
Sample product reference
A complete in-house prototype based on this controller is showcased in the linked sample product page on this site. That implementation demonstrates how the 24 V, 700 W PMSM controller is integrated with the motor, mechanical system, safety interlocks, and user interface to deliver repeatable, programmable training cycles. OEMs can use this reference as a starting point for their own equipment architecture.
Key Features
- 24 V DC PMSM controller (20–30 V DC operating range) for fitness & sports automation
- Supports 3-phase PMSM motors up to around 700 W shaft power
- Sensorless PMSM control – no Hall sensors or encoders required, simplifying wiring and maintenance
- Field-oriented control (FOC) for smooth, efficient torque and speed regulation
- Closed-loop speed control enabling repeatable, programmable training profiles
- High drive efficiency (>90%) for battery-based or low-voltage DC systems
- Comprehensive protections: under-voltage, over-voltage, short-circuit, over-temperature
- IEC 61800-3 and IEC 61800-5 based design for industrial-grade safety and EMC
- IP44-rated design, suitable for indoor commercial environments with high humidity
- 1× digital input (enable/control) for simple system integration
- Firmware-tunable parameters (ramp times, overload behaviour, limits) for OEM-specific profiles
- Prototype units available for evaluation and integration in OEM machines
Applications
- Disk throwing machines and rotational training equipment
- Ball launchers for cricket, tennis, or other sports practice systems
- Motorised gym machines requiring controlled resistance or speed (treadmills, ergometers, etc.)
- Sports training rigs that demand programmable speed/load profiles for conditioning
- Other 24 V DC fitness and sports equipment using PMSM motors in the ~700 W power class
Technical Specifications
| Controller rated voltage | 24 V DC |
|---|---|
| Controller operating range | 20–30 V DC |
| Motor type | 3-phase PMSM |
| Shaft power | Up to 700 W |
| Input current | Up to 38 A (application-dependent) |
| Line current | Up to 45 Arms (application-dependent) |
| Position feedback | Sensorless PMSM |
| Control method | FOC (field-oriented control) |
| Drive efficiency | >90% |
| Overload capacity | 110% |
| Digital inputs | 1× digital input (enable / logic control) |
| Protection | Under-voltage, Over-voltage, Short-circuit, Over-temperature |
| Certification target | IEC 61800-3, IEC 61800-5 |
| IP rating | IP44 |
| Humidity | Up to 95% RH (non-condensing max.) |
| Operating temperature | -10 °C to 50 °C (controller; subject to enclosure and cooling) |
Next Steps
- Download technical overview (on request)
- Request prototype evaluation unit
Enquiry note
Please share details of your fitness or sports application – type of machine (disk thrower, ball launcher, gym equipment, etc.), motor rating and specifications, required speed/torque range, duty cycle, physical constraints, and input supply conditions (24 V battery / DC bus). Based on this information, we will confirm suitability of the 24 V, 700 W PMSM controller, propose firmware profiles, and outline any customisation options for your OEM platform.
