Modified Motor Controllers and PDUs
A modified standard product starts from an existing Redler product, such as a Rayon motor controller (servo drive), a Power Rider power distribution unit (PDU) or a Power Rider solid-state circuit breaker, and adapts it to your platform instead of designing new hardware from scratch.
This is the shorter route when a standard product is close to what you need and the gap is in interfaces, configuration, firmware, connectors or finish.
When to choose this path
Choose modified standard products when:
- a Rayon motor controller, Power Rider PDU or solid-state circuit breaker already covers your power level and the difference is limited;
- the change you need is to the communication interface, channel or protection configuration, firmware behaviour, operating range, connectors or finish;
- you want to use an existing product and its published specifications as the baseline for the requirement.
If your requirement changes the power stage, form factor or architecture, or no standard product is close, see full custom design.
What can be modified
These examples come from options and configuration points already described on our product pages. Whether a specific change is feasible on a given product is settled in the consultation and feasibility analysis.
Motor controllers and servo drives
- Supply voltage: the Rayon 135 is specified at 12–58 VDC with an optional extension to 96 VDC.
- Temperature: −40 °C to +85 °C across the Rayon family; the Micro Rayon lists an optional extension to −55 °C, and the Rayon 70 and Rayon 135 list extended-temperature or ruggedized options.
- Communication: RS-232, RS-422, CAN bus and optional CANopen on the Rayon 70, Rayon 135 and Rayon Single Board; CAN bus, CANopen and J1939 on the EV Rider 200.
- Motor feedback: Hall sensors, incremental encoders and absolute or SSI encoders, depending on the product.
- Firmware and parameters: the EV Rider 200 offers customizable driving profiles with adjustable acceleration and torque curves.
Base products: Rayon 70 Motor Controller, Rayon 135 Motor Controller, Micro Rayon Motor Controller, EV Rider 200 Motor Controller, Rayon Single Board Motor Controller, TMC III. See the Motor Controllers & Servo Drives overview.
Power distribution units
- Channel configuration: 12-channel and 16-channel units with up to 25 A per channel, and 50 A with parallel operation on the 16-channel models.
- Channel behaviour: over 20 adjustable parameters per channel on the 12 Channel Military Grade PDU, covering logic control, trip recovery and fault response.
- Interfaces: CAN bus (J1939), Ethernet (UDP) and RS-422/485, with some of these listed as optional depending on the model.
- Connectors and finish: MIL-standard connectors on the 12 Channel Military Grade PDU and chemical conversion coating per MIL-DTL-5541F on the 16 Channel Military Grade PDU.
- Input range: the 12-channel family exists as a 9–48 VDC unit and as a −48 V unit.
Base products: Power Rider 12 Channel PDU, Power Rider 12 Channel -48V PDU, Power Rider 12 Channel Military Grade PDU, Power Rider 16 Channel PDU, Power Rider 16 Channel PDU Military Grade. See the Power Distribution Units overview.
Solid-state circuit breakers
- Protection settings: user-defined trip points, timing and recovery behavior.
- Communication: CAN bus and RS485.
Base products: Power Rider 25A, Power Rider 80A, Power Rider 150A, Power Rider High Voltage. See the Solid-State Circuit Breakers (SSPC) overview.
How a modification project runs
The same four stages as a full custom design apply, with the design stage focused on what changes from the base product.
1.Consultation
We analyze your requirements, constraints and goals, identify the base product and run a feasibility analysis of the changes.
2.Design of the modification
Design work is limited to the areas that change from the base product, for example firmware and software, mechanical integration and thermal design, or component selection.
3.Prototyping and testing
We build and test prototypes under real-world conditions, with environmental and stress testing, performance validation and EMI/RFI compliance checks.
4.Production and support
Quality-controlled production (ISO 9001), assembly and integration, final acceptance testing (ATP), and long-term maintenance and support.
The standards listed in each product's published data are on the Quality & Compliance page.
What to send us to start
A first message does not need to be complete. These inputs let our engineers judge fit quickly:
- Base product: the Redler part number or product you want to start from, if you know it.
- The change: what must differ from the standard unit, and why.
- Supply voltage: nominal, minimum and maximum DC bus voltage, and any transients you expect.
- Current and power: continuous and peak current, per channel and in total, or motor power and peak torque demand.
- Interfaces: communication (CAN bus, CANopen, J1939, Ethernet, RS-232/422/485), I/O, motor feedback type, connectors.
- Environment: operating temperature range, shock and vibration, ingress protection, and corrosion or coating needs.
- Standards: the standards and revisions your program requires, for example MIL-STD-1275F, MIL-STD-461G or MIL-STD-810F, and any acceptance test (ATP) criteria.
- Size and weight: mounting envelope, weight limit and cooling method.
- Quantities: prototype and production quantities and the timeline you are working to.
Start your project
Describe your requirements in the Project Planner, or contact us to talk to an engineer first.
full custom design · Build to Spec overview · Quality & Compliance