Overview
On-board hydraulic power pack controller for EV and utility vehicles, designed to drive 3-phase AC induction hydraulic pump motors from a high-voltage DC bus.
The controller operates from a 200–500 V DC supply derived from the vehicle battery or an auxiliary DC source and delivers variable-frequency 3-phase 230 V output for hydraulic pumps in the approximately 1–5 HP range. It is intended for truck-mounted and vehicle-mounted hydraulic power packs such as tipping bodies, refuse compactors, aerial work platforms and water pressure pumps, with control signals typically coming from a PLC or vehicle controller.
Built on Versa’s EV & Mobility motor controller platform, this on-board hydraulic drive combines high efficiency (>96% inverter efficiency), robust protection and IEC 61000-6-3 EMC compliance with an IP66 enclosure suited for continuous operation on moving vehicles.
Key Features
- On-board hydraulic pump drive for vehicles – dedicated controller for truck-mounted and utility-vehicle hydraulic power packs, powered directly from the vehicle DC bus.
- Wide DC bus input – operates from a 200–500 V DC input derived from the traction battery or a separate DC supply, suitable for a range of EV and hybrid vehicle architectures.
- 3-phase ACIM pump motor drive – drives a 3-phase 230 V AC induction motor for hydraulic duty; platform can be adapted for PMSM hydraulic pumps in new programmes.
- 1–5 HP hydraulic range – sized for typical hydraulic power pack applications in the approximately 1–5 HP pump power range, supporting lifting, tipping and boom functions.
- V/F control for hydraulic applications – V/F control tuned for hydraulic pump characteristics, with an output frequency range of 10–50 Hz for controlled acceleration and speed.
- High inverter efficiency – inverter efficiency >96% helps minimise losses and thermal stress in continuous and intermittent hydraulic operation.
- PLC-friendly interfaces – digital input for motor enable and a second digital input for PLC slow-speed command, making it straightforward to integrate with existing PLC or vehicle control logic.
- Status and diagnostics – on-board display of motor on/off status, DC input current and voltage, AC output current and voltage, operating frequency and fault conditions to assist commissioning and service.
- Comprehensive protection – protection features include door open/close interlock, phase loss, accidental output short circuit, over- and under-voltage, reverse polarity, overcurrent, motor overload and drive over-temperature.
- Designed for harsh mobile environments – operates from 0 to 50 °C and up to 95% non-condensing humidity, with an IP66 enclosure suitable for continuous operation on truck-mounted equipment.
Applications
- Tipper trucks – hydraulic power packs for lifting and lowering tipper bodies
- Refuse-compactor and waste-collection vehicles – hydraulic pump drives for compaction and bin-lift mechanisms
- Aerial work platforms and man-lifts – boom and platform elevation using DC-powered hydraulic packs
- Cable-maintenance and utility trucks – hydraulic lifting systems to access overhead cables and infrastructure
- Truck-mounted water pressure pumps – DC-driven hydraulic or water-pressure systems on service vehicles
- Other DC-supplied hydraulic power packs on EVs, hybrids and speciality vehicles within the 1–5 HP pump range
Technical Specifications
Representative values for a typical on-board hydraulic power pack implementation.
| DC bus / input voltage | 200 to 500 V DC |
|---|---|
| Motor type | 3-phase AC induction motor (PMSM-compatible variants possible in future programmes) |
| Motor input voltage | 230 V AC (3-phase) |
| Motor input current | Up to 15 A (typical) |
| Pump power range | Approximately 1–5 HP hydraulic pump applications |
| Control method | V/F control for hydraulic duty |
| Motor output frequency | 10 to 50 Hz |
| Inverter efficiency | >96% |
| Interfaces | Digital input 1: motor enable |
| Interfaces (continued) | Digital input 2: PLC interface for slow-speed command |
| Display parameters | Motor on/off status, DC input voltage and current, AC output voltage and current, operating frequency, fault conditions |
| Protection functions | Door open/close interlock, open circuit / phase loss, accidental output short circuit, over-voltage, under-voltage, reverse polarity, overcurrent, motor overload, drive over-temperature |
| Standards / compliance | IEC 61000-6-3:2006 (EMC), other relevant standards as per application |
| Enclosure | IP66-rated design for vehicle-mounted environments |
| Ambient temperature | 0 to 50 °C |
| Humidity | Up to 95% RH, non-condensing (max.) |
Enquiry Note
If you are interested, please share a few lines about your product, motor rating and supply voltage. We will review your requirement, map it to the closest Versa motor–drive platform and get back to you with next steps.
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