CUSTOM POWER CONTROL
Engineered For Your Application
For certain medium to higher volume applications, Control Concepts can tailor a controller to your specific electrical, mechanical, performance, size, and cost requirements. Our engineers work with you to design a solution that reduces cost, improves performance, consolidates function, and reduces footprint.
Overview
Custom solutions, designed together.
2-10x cost reduction compared to standard controllers.
Are you looking for a minimal cost and footprint, custom-branded controller with unique features and system-specific integration?
Control Concepts works directly with OEM engineering teams to develop application-specific power controllers based on thyristor (SCR), IGBT, or FET- power topologies.
We are the extension of your engineering team that specializes in power control.
Problems we solve…
Control Concepts develops custom controllers when process stability, integration requirements, or electrical demands exceed standard product capabilities.
Cost, Footprint, and Complexity from Unnecessary Features
Standard controllers may have unnecessary features that increase cost, enlarge footprint, or require complex configuration.
Non-standard Electrical Limits
The application exceeds electrical requirements for standard product voltage or current limits, demanding custom power stage design.
Specialized Firing Strategies
Processes require specialized firing strategies optimized for specific load behaviors and requirements.
Unique Mechanical Integration
Mechanical integration requires unique size and enclosure/mounting configurations to fit within OEM equipment architecture.
Proprietary Control Integration
OEM equipment requires proprietary control system integration for direct communication with machine control platforms.
Multi-Zone Coordination
Multi-zone industrial systems require coordinated power control across multiple zones within a single architecture.
High-Value Process Stability
The application involves high-value manufacturing processes where power stability directly affects yield and quality.
…and solutions we build.
Custom power controllers may incorporate a wide range of electrical, mechanical, and control modifications tailored to OEM requirements.
Controllers designed for nonstandard product ratings, including unusually high or low current levels (down to 1 amp).
Controllers designed to fit within OEM electrical cabinets or integrated equipment frames according to unique mounting, environmental, or safety requirements.
Power control architectures designed to manage multiple zones within a single system.
Control strategies optimized for specific industrial processes.
Electrical protection strategies tailored to the system’s operating environment.
Consolidate functions with integrated circuit breakers, mechanical contactors, and fusing
Custom SCR stacks and insulation designs for higher voltage applications.
Heat sink and airflow designs adapted to the machine environment.
Controllers designed to operate together across large furnace or processing systems.
Controllers designed to communicate directly with proprietary machine control systems via analog controls or digital communication protocols, including EtherCAT, EtherNet/IP, Modbus TCP, or PROFINET.
Controllers’ exteriors branded with customer-specific logos, colors, text fonts, and more.
Standard vs. Custom
Choose the right approach.
| Design Element | Standard SCR Controllers | Custom SCR Controllers |
|---|---|---|
| Electrical Design | Fixed electrical ratings | Tailored to the application |
| Enclosure & Mounting | Standard enclosure and mounting | Adapted to equipment architecture |
| Control Interface | Standard control interfaces | Custom OEM system integration |
| Application Scope | Standard processes | Specific processes |
| Deployment Time | Immediate deployment | Engineered in collaboration with OEM teams |
| Cost | Standard pricing | Minimized for the application, often 2-10x less |
| Size | Standard compact footprint | Minimized for the application |
Engineering Process
A Structured Path to Production
1
Technical Discovery
Engineers review electrical requirements and control system architecture.
2
Controller Architecture Design
Engineers define the power control topology, firing strategy, load types, and electrical configuration.
3
Mechanical & Electrical Integration
Controllers are designed to fit the physical and electrical environment of the equipment.
4
Engineering Validation
Controllers are tested to verify electrical performance and integration compatibility.
5
Production Support
Controllers are manufactured and supported as part of OEM equipment platforms.
Application review
Controller Design Elements
Every custom power controller begins with a specifications review. Control Concepts engineers evaluate the electrical, mechanical, software, and environmental requirements to design the best solution and ensure reliable performance.
System Architecture
How a Controller Integrates
An SCR power controller functions as a core subsystem within OEM equipment architecture.
Application Areas
Custom controllers in industrial environments.
Water Purification
Control Concepts assists CEDI water purification systems to deliver ultra-pure water to manufacturing processes.
Carbon Fiber & Composites
Achieve stable curing temperatures and better composite consistency with SCR power controllers built for advanced materials processing.
Advanced and Technical Ceramics
Maintain stable high-temperature processing with SCR power controllers built for kilns, ceramics, and advanced metal applications.
FAQ
Common Questions
An SCR power controller is a silicon controlled rectifier, a controllable diode with support electronics, heat management, and safety packaging. SCRs can be used in a variety of applications to control the power, current and voltage to your load.
SCR controllers offer infinite resolution and features such as voltage compensation, current limiting, and Overcurrent Trip. SCR controllers are often less expensive and don’t have inherent wear-out modes
Please visit our product selector or contact our team of experts. For fastest service, please have the following information available:
- Voltage
- Single or three phase
- Load current and type
- Command signal
- Other requested features
For more information, please visit our How to Order page.
Control Concepts recommends protecting the SCR with a class T fuse, an excellent compromise between protection and premature fuse failure.
Yes, SCR power controllers generate harmonics on power lines, which may cause overheating of inductive equipment, such as transformers, motors, etc. However, actual occurrences of this issue are essentially non-existent.
Zero Cross controllers generate most harmonics below 50/60 cycles.
Phase Angle controllers generate harmonics above 50/60 cycles. For single phase controllers, the largest distortions occur at 3rd, 5th, and 7th harmonics. For three phase controllers, all multiples of the 3rd harmonic are not created.
Your production line needs precision, reliability, and quick answers always.
When failure isn’t an option, work with engineers who understand what’s at stake and are ready to help.