SOLO-PRO-400-160

BLDC Motor FOC Controller & Driver, 160A/450V, USB/UART/CANopen/EtherCAT

High-performance liquid-cooled servo drive with integrated power stage, Field-Oriented Control, EtherCAT, CANopen, and up to 160 A output current.

The SOLO-PRO-400-160 from SOLO Motor Controllers is a powerful, ready-to-use high-voltage motor drive designed for demanding industrial and mobile applications. Combining advanced motion control, high-performance power electronics, and industrial communication interfaces in a robust, liquid-cooled IP67 housing, it delivers up to 45 kW of continuous output power.

Designed for DC bus voltages from 150 to 450 VDC, the drive provides up to 160 A DC (100 Arms) continuous output current. Its integrated power stage, gate drivers, current and voltage sensing, pre-charge circuit, and protection functions eliminate the need for custom power electronics or motor control firmware development.

The sealed aluminium housing with integrated liquid cooling makes the SOLO-PRO-400-160 particularly suitable for industrial automation, electric traction systems, robotics, mobile machinery, and high-performance servo applications operating in challenging environmental conditions.

Advanced Motor Control with Dual-Core Architecture

At the heart of the SOLO-PRO-400-160 is the SOLO-SOM, featuring a Texas Instruments TMS320F28388D dual-core DSP with two independent 200 MHz processor cores.

The first processor handles all motor control tasks using SOLO’s integrated firmware. Field-Oriented Control (FOC) provides precise torque, speed, and position regulation with a current control loop execution time of just 7 µs, corresponding to a control loop rate of approximately 140 kHz.

The second processor is reserved for application-specific functions and can be programmed by SOLO on request. This enables customized control functionality to be integrated directly into the drive without affecting the motor control loops.

The drive supports brushed DC motors, BLDC motors, Permanent Magnet Synchronous Motors (PMSM), and coreless EC motors. Automatic motor parameter identification and self-tuning simplify commissioning and optimize control performance.

High-Power Drive Technology and Industrial Connectivity

The SOLO-PRO-400-160 combines a powerful high-voltage inverter with a comprehensive range of industrial communication and position feedback interfaces.

EtherCAT and CANopen (CiA 402 / DS402) enable integration into industrial automation systems, while USB-C provides convenient configuration, monitoring, and digital control. Analogue 0–5 V and PWM command inputs allow straightforward integration with PLCs, embedded controllers, and other control electronics.

Multiple position feedback interfaces support Hall sensors, differential incremental encoders, BiSS-C absolute encoders, and Sin/Cos sensors. Dedicated temperature monitoring interfaces, including an isolated motor PT1000 input and an internal base-plate temperature sensor, provide additional protection against thermal overload.

The integrated dual-channel Safe Torque Off (STO) function provides a hardware-level interface for machine safety systems. Galvanic isolation between the high-voltage power stage and the control electronics enables safe integration of external communication and control equipment when used with the required isolated logic supply.

Four-quadrant regenerative operation allows energy to be returned to the DC bus during braking. Depending on the application, an external energy absorption system may be required.

The robust IP67-rated aluminium enclosure features an integrated liquid-cooled base plate for efficient thermal management. This enables operation in dusty, wet, and demanding industrial environments where conventional air-cooled drives may not be suitable.

Commissioning, configuration, and control-loop tuning are performed using the browser-based SOLO Motion Terminal, eliminating the need for custom motor control software.

Typical Applications

The SOLO-PRO-400-160 is particularly suitable for high-power industrial servo drives, electric traction systems, industrial automation, robotics, automated guided vehicles (AGVs), autonomous mobile robots (AMRs), electric mobility applications, heavy machinery, pumps, compressors, and high-performance motor control systems.

Its liquid-cooled IP67 enclosure also makes it an excellent choice for demanding mobile and industrial environments where high power density, reliable thermal management, and protection against dust and moisture are essential.

By combining a powerful 45 kW inverter with advanced motion control, industrial connectivity, galvanic isolation, and robust environmental protection, the SOLO-PRO-400-160 simplifies system integration, reduces development effort, and accelerates time to market.

Key  Features

• Continuous output power: up to 45,000 W (45 kW)
• DC bus voltage: 150–450 VDC
• Continuous output current: 160 A DC / 100 Arms
• Separate 11–28 VDC isolated logic supply
• Robust aluminium housing with IP67 protection
• Integrated liquid-cooled base plate
• Dimensions: 316 × 220.5 × 107 mm
• Four-point wall or frame mounting
• Texas Instruments TMS320F28388D dual-core DSP with 2 × 200 MHz
• Field-Oriented Control (FOC) with torque, speed, and position regulation
• Current control loop execution time: 7 µs
• Adjustable PWM switching frequency: 8–80 kHz
• Automatic motor identification and self-tuning
• Integrated S-curve motion profiling
• Four-quadrant regenerative operation
• EtherCAT, CANopen (CiA 402 / DS402), and USB-C
• Analogue 0–5 V and PWM command inputs
• Two general-purpose I/O
• Support for Hall sensors, differential incremental encoders, BiSS-C, and Sin/Cos position sensors
• Integrated dual-channel Safe Torque Off (STO) with feedback output
• Galvanic isolation between control electronics and power stage
• Hardware over-current, over-voltage, under-voltage, and over-temperature protection
• Isolated motor PT1000 temperature sensor input
• Additional PT1000 input and internal base-plate NTC
• Integrated DC bus pre-charge circuit
• Second processor core available for customer-specific programming by SOLO
• Configuration via SOLO Motion Terminal