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Customer’s challenge
Recent improvements in sensors and software allow autonomous robots to identify and avoid human workers or other obstacles and to travel to their destination by the shortest route, rather than being limited to defined robot pathways. These nimble robots are required to carry parts or finished goods 24/7 as a key contributor to the SMART factory, providing faster delivery and lower costs. This manufacturer of robots was looking to maximize time between recharges without impacting other performance factors. The key goals were:
- Maximize range between charges by reducing conversion losses
- Free up space for larger batteries and sensors by reducing size and weight
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The Vicor Solution
The power for the robot came from a 48V battery stack, which powered the motor drive directly. The power supply was required to convert the battery input to three rails of 6V and one of 12V to power the sensors, navigation interfaces and CPU. The solution was based on four arrays of Vicor PRM and VTM converters, one array for each output. Key benefits were:
Key benefits
Key benefits
Small footprint, low profile (6.7mm)
Lowest losses achieved by high efficiency conversion (>92.7%)
Lightweight
Power delivery network
Four PRM/VTM converter combinations provided the isolation and regulation for each output. The ability to parallel converters accommodated the output powers required (6V at 60W and 12V at 600W). Output rail power sequencing was easily achieved though configuration of the PRMs. To analyze this power chain go to the Vicor Whiteboard online tool.
PRM pre- and post-transformation regulators
Non-isolated regulated
Input: 48V (36 – 75V)
Output: 48V (5 – 55V)
Power: Up to 600W
Efficiency: Up to 97%
As small as 22.0 x 16.5 x 6.73mm
Isolated fixed-ratio
Input: 0 – 60V
Output: 0 – 55V
Current: Up to 115A
Peak efficiency: Up to 97%
As small as 22.83 x 8.52 x 4.9mm
Resources
Resources for the design engineer
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