CASES
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Explore real implementations across hydraulics, controls, and electrification. Engineered for reliability and easy service.
Case Studies
50+ projects delivered across mobile hydraulics, controls, and electrification.
Motor Grader
Case: Hydraulic Front Drive Integration (AWD Assist) for a Motor Grader
We engineered a hydraulic front-drive system for a motor grader to increase traction and productivity in low-grip and high-load conditions. The key challenge was synchronizing a mechanical rear drivetrain with a hydraulic front axle drive—so the front axle supports the machine without “pulling” the rear axle (overpowering it) or being “pushed” by it (acting like a brake). The solution enables both front-drive recovery mode and true 4×4 operation, with operator-adjustable traction support during demanding grading tasks.
What we engineered
Hydraulic front axle drive architecture
Two operating modes: Assist + AWD
Speed synchronization between mechanical rear and hydraulic front
Operator-adjustable traction split (joystick control)
Smooth gear / speed-range transitions for discrete motors
Commissioning + validation with service tooling
RESULT
KEY FIGURES
> Hydraulic front-axle assist + blended AWD sync (hydraulic front + mechanical rear) • operator-adjustable traction split
> Smooth step transitions for discrete motors • validated in field trials • baseline AWD delivered in ~3 months (benchmark ~12 months)
We engineered a hydraulic front-drive system for a motor grader to increase traction and productivity in low-grip and high-load conditions. The key challenge was synchronizing a mechanical rear drivetrain with a hydraulic front axle drive—so the front axle supports the machine without “pulling” the rear axle (overpowering it) or being “pushed” by it (acting like a brake). The solution enables both front-drive recovery mode and true 4×4 operation, with operator-adjustable traction support during demanding grading tasks.
What we engineered
Hydraulic front axle drive architecture
- Hydraulic wheel motors integrated into the front axle
- Pump driven from the grader’s engine
- Control concept designed to work alongside the existing mechanical rear drivetrain
Two operating modes: Assist + AWD
- Front-drive assist mode: rear drivetrain in neutral while the front axle moves the machine (recovery from mud/ice, low-traction scenarios)
- Blended AWD mode: synchronized front + rear drive to share traction effectively
Speed synchronization between mechanical rear and hydraulic front
- Control logic to match front axle speed to rear axle speed
- Prevents traction loss scenarios where:
- front axle “drags” the rear (rear becomes underutilized), or
- rear axle “pushes” the front (front becomes resistance)
Operator-adjustable traction split (joystick control)
- A dedicated joystick lets the operator increase/decrease front-drive contribution on demand
- Especially valuable when working with heavy blade load (e.g., front blade fully engaged) and rear wheels start to slip
Smooth gear / speed-range transitions for discrete motors
- Front drive uses discrete motor speed ranges (step change)
- We implemented pump/control compensation so transitions feel smooth—minimizing “jerk” during acceleration and speed changes
Commissioning + validation with service tooling
- Field commissioning and traction testing on an experimental site (including high-load pushing in sand)
- Used service diagnostics to correlate transient “shocks” and confirm they align with grader engine/gearbox shift events (identified as an improvement area for the customer’s drivetrain calibration)
RESULT
- Working baseline AWD functionality delivered in ~3 months (benchmark projects often take significantly longer)
- Meaningful traction increase with operator-controlled front assist under load
- Stable, synchronized motion without the front axle acting as a brake or overpowering the rear drivetrain
- Smoother speed-range switching for the hydraulic front drive (reduced operator-perceived “kicks”)
- Clear roadmap for final refinement tied to gearbox/engine interaction points, while the core functional system is already operational
KEY FIGURES
> Hydraulic front-axle assist + blended AWD sync (hydraulic front + mechanical rear) • operator-adjustable traction split
> Smooth step transitions for discrete motors • validated in field trials • baseline AWD delivered in ~3 months (benchmark ~12 months)
Electric Municipal Street Sweeper
Case: Electrification of the Hydraulic Powertrain for a Municipal Street Sweeper
We developed an electrified powertrain concept for a municipal street sweeper by replacing the diesel engine used to drive the hydraulic pump with a battery–inverter–electric motor system. The goal was to keep the machine’s hydraulic functionality and “operator feel” familiar, while meeting city-driven requirements for lower noise and reduced emissions. A key challenge was designing a battery system that fits the machine packaging and reliably supports up to an 8-hour shift without relying on mass-produced, off-the-shelf battery modules.
What we engineered
1) Energy sizing & duty-cycle modeling
2) Custom battery pack design (packaging + electronics)
3) Electric motor + inverter integration for pump drive
4) Hydraulic system alignment (function preservation)
5) Drivetrain notes for 4×4 municipal platforms (where part of the machine concept)
RESULT
The machine retains its familiar hydraulic functionality and operator workflow, while the diesel-driven pump power unit is replaced by a quiet, battery-electric system. This delivers a significant noise reduction and enables city-ready operation with modern electrification requirements—without redesigning the full machine around electric wheel drives. The solution provides a structured, engineering-based path to an 8-hour shift target through duty-cycle sizing, custom battery packaging, BMS-driven diagnostics, and controlled motor RPM behavior that feels consistent for the operator under varying hydraulic loads.
We developed an electrified powertrain concept for a municipal street sweeper by replacing the diesel engine used to drive the hydraulic pump with a battery–inverter–electric motor system. The goal was to keep the machine’s hydraulic functionality and “operator feel” familiar, while meeting city-driven requirements for lower noise and reduced emissions. A key challenge was designing a battery system that fits the machine packaging and reliably supports up to an 8-hour shift without relying on mass-produced, off-the-shelf battery modules.
What we engineered
1) Energy sizing & duty-cycle modeling
- Calculated required battery energy and power based on real operating cycles, load levels, and shift length targets (up to ~8 hours on a single charge).
- Defined the power envelope for the electric motor/inverter driving the hydraulic pump.
2) Custom battery pack design (packaging + electronics)
- Battery placement concept inside the machine (space/packaging driven).
- Mechanical enclosure + cell layout + internal wiring/harnessing.
- BMS (Battery Management System) integration: cell monitoring, diagnostics, and CAN communication.
- Support for both standard and fast charging strategies (where applicable).
3) Electric motor + inverter integration for pump drive
- Selected and integrated inverter + electric motor to drive the hydraulic pump as the new “heart” of the machine.
- Implemented speed-hold behavior so the operator experiences predictable “engine-like” response (set a speed → system maintains it under changing load).
- Two control paths depending on inverter capability:
- using built-in closed-loop speed regulation, or
- adding external control electronics to command the inverter (increase/decrease torque/current) to maintain target RPM.
4) Hydraulic system alignment (function preservation)
- Preserved conventional hydraulic architecture for working functions: brush drives, vacuum fan drive, and multiple cylinder functions (lift/lower, width adjustment, positioning).
- Control of multi-section valve blocks for auxiliary functions (multiple options/attachments typical for sweepers).
5) Drivetrain notes for 4×4 municipal platforms (where part of the machine concept)
- Support for typical sweeper mobility architecture with four driven wheels for curb climbing and traction on slippery surfaces.
- Speed management via pump control and motor speed-range switching to meet transport vs working requirements.
RESULT
The machine retains its familiar hydraulic functionality and operator workflow, while the diesel-driven pump power unit is replaced by a quiet, battery-electric system. This delivers a significant noise reduction and enables city-ready operation with modern electrification requirements—without redesigning the full machine around electric wheel drives. The solution provides a structured, engineering-based path to an 8-hour shift target through duty-cycle sizing, custom battery packaging, BMS-driven diagnostics, and controlled motor RPM behavior that feels consistent for the operator under varying hydraulic loads.
Self-Propelled Sprayer
Case: Smart Hydrostatic Drive Control for a High-Clearance Self-Propelled Sprayer
We developed control logic for high-clearance sprayers (U-frame, high center of gravity) to deliver smooth, predictable driving across transport and field modes. The project covered multiple drivetrain architectures used by different OEMs—from radial-piston wheel motors with discrete “gear” steps to axial-piston drives with continuously variable motor displacement—ensuring comfortable shifting, stable speed control, and traction protection under heavy loads.
What we engineered
1) Architecture support (2 drivetrain types)
2) Speed-command driving (not “pump lever control”)
3) Smooth two-step speed switching for radial-piston motors
4) Multi-mode operator control
5) Traction & driveline protection (load-aware control)
6) Pressure-sensor based implementation
RESULT
KEY FIGURES
> 2 drivetrain architectures • 4WD hydrostatic drive • full-tank load ~3.5–5.0 t • smooth “automatic-like” shifting
> Speed-command control (not pump lever) • transport + field modes • pressure-feedback traction / pull control • controlled downhill overrun
We developed control logic for high-clearance sprayers (U-frame, high center of gravity) to deliver smooth, predictable driving across transport and field modes. The project covered multiple drivetrain architectures used by different OEMs—from radial-piston wheel motors with discrete “gear” steps to axial-piston drives with continuously variable motor displacement—ensuring comfortable shifting, stable speed control, and traction protection under heavy loads.
What we engineered
1) Architecture support (2 drivetrain types)
- Radial-piston wheel motors (two-speed, discrete switching), with 1 or tandem pump options
- Axial-piston motors with gearboxes (continuous displacement control)
2) Speed-command driving (not “pump lever control”)
- The joystick/pedals set a target vehicle speed; the controller automatically calculates pump command based on engine RPM, motor state/displacement, and current conditions to hold that speed.
3) Smooth two-step speed switching for radial-piston motors
- Implemented coordinated front/rear motor switching with pump compensation so shifts feel like a refined automatic transmission (minimal jerk, no sudden acceleration “kick”).
4) Multi-mode operator control
- Transport mode: pedals for speed + joystick as FNR (Forward/Neutral/Reverse) selector
- Field mode: joystick as precise speed setpoint for low/working speeds
5) Traction & driveline protection (load-aware control)
- Uphill / heavy-tank assist: automatic “pull management” to prevent engine stall or relief valve events by adjusting motor displacement and reducing speed while maintaining tractive effort
- Downhill / overrun control: manages inertial push (motors acting as pumps) to prevent unintended acceleration by adapting motor displacement
6) Pressure-sensor based implementation
- Used pressure feedback to detect load changes and apply an electronic equivalent of traction/pressure-override behavior (PCOR-like functionality), tuned for real field conditions.
RESULT
- Smoother driving experience during discrete speed changes (no harsh jerks, no “jump” in speed)
- Stable, predictable speed holding in both transport and field work, independent of engine RPM variation
- Improved traction performance under heavy load (full tank) with automatic pull control on hills
- Safer downhill behavior with controlled overrun and reduced operator workload
- Controller logic adaptable across different OEM hydraulic drivetrain layouts (single/tandem pump, radial vs axial motor systems)
KEY FIGURES
> 2 drivetrain architectures • 4WD hydrostatic drive • full-tank load ~3.5–5.0 t • smooth “automatic-like” shifting
> Speed-command control (not pump lever) • transport + field modes • pressure-feedback traction / pull control • controlled downhill overrun
Mobile Drilling Rig
Case: Hydrostatic Travel Drive Control
We developed control logic for the hydrostatic travel drive of a heavy mobile drilling rig used in mining and underground operations. The machine combines a large, high-inertia chassis with a hydrostatic drivetrain (pump + motor) and multiple operating modes, including a transport/high-speed range. The key challenge was making the machine decelerate smoothly and predictably without oscillations caused by drivetrain inertia, and ensuring high-traction climbing performance without stalling the engine under sudden load spikes.
What we engineered
1) Stable hydrostatic drive behavior for a high-inertia machine
We tuned the interaction between engine RPM control, pump command, and motor displacement so the system remains stable during throttle-off events and transitions—avoiding the “hunting/oscillation” effect when vehicle inertia back-drives the hydraulic motor and disturbs engine speed control.
2) Predictable deceleration and braking feel
We implemented deceleration strategies so the rig slows down smoothly when the operator releases the pedal, and responds proportionally when braking input is applied—without pressure spikes and unpleasant drivetrain noises.
3) Anti-stall protection (“Anti-Stall”)
A protection layer compares commanded vs. actual engine RPM and reduces hydraulic load progressively when RPM drops toward a stall threshold—keeping the engine running and maintaining controllability in demanding conditions.
4) Electronic traction management / PCOR-like function (pressure-based)
We implemented an electronic equivalent of Pressure Compensator Override (PCOR) using pressure feedback in the travel circuit. When load increases (pressure rises), the control logic automatically adjusts motor displacement to increase tractive effort while reducing speed, helping the machine climb and push through resistance without stalling.
5) Transport-mode safeguards
Because high-speed / low-displacement motor range provides less tractive reserve, we added logic to prevent aggressive load events from causing sharp engine bog-down and unstable behavior during climbs or sudden resistance.
RESULT
The drilling rig’s travel drive became noticeably smoother and more predictable in real operation—especially during deceleration and load changes—while maintaining the ability to climb and work under heavy resistance without stalling. Pressure spikes during overrun/braking events were reduced to non-critical levels, oscillations tied to inertia and engine-speed feedback were stabilized, and traction performance improved through automatic load-aware motor displacement control. The outcome is a more controllable machine, with behavior that matches operator expectations in harsh mining conditions.
We developed control logic for the hydrostatic travel drive of a heavy mobile drilling rig used in mining and underground operations. The machine combines a large, high-inertia chassis with a hydrostatic drivetrain (pump + motor) and multiple operating modes, including a transport/high-speed range. The key challenge was making the machine decelerate smoothly and predictably without oscillations caused by drivetrain inertia, and ensuring high-traction climbing performance without stalling the engine under sudden load spikes.
What we engineered
1) Stable hydrostatic drive behavior for a high-inertia machine
We tuned the interaction between engine RPM control, pump command, and motor displacement so the system remains stable during throttle-off events and transitions—avoiding the “hunting/oscillation” effect when vehicle inertia back-drives the hydraulic motor and disturbs engine speed control.
2) Predictable deceleration and braking feel
We implemented deceleration strategies so the rig slows down smoothly when the operator releases the pedal, and responds proportionally when braking input is applied—without pressure spikes and unpleasant drivetrain noises.
3) Anti-stall protection (“Anti-Stall”)
A protection layer compares commanded vs. actual engine RPM and reduces hydraulic load progressively when RPM drops toward a stall threshold—keeping the engine running and maintaining controllability in demanding conditions.
4) Electronic traction management / PCOR-like function (pressure-based)
We implemented an electronic equivalent of Pressure Compensator Override (PCOR) using pressure feedback in the travel circuit. When load increases (pressure rises), the control logic automatically adjusts motor displacement to increase tractive effort while reducing speed, helping the machine climb and push through resistance without stalling.
5) Transport-mode safeguards
Because high-speed / low-displacement motor range provides less tractive reserve, we added logic to prevent aggressive load events from causing sharp engine bog-down and unstable behavior during climbs or sudden resistance.
RESULT
The drilling rig’s travel drive became noticeably smoother and more predictable in real operation—especially during deceleration and load changes—while maintaining the ability to climb and work under heavy resistance without stalling. Pressure spikes during overrun/braking events were reduced to non-critical levels, oscillations tied to inertia and engine-speed feedback were stabilized, and traction performance improved through automatic load-aware motor displacement control. The outcome is a more controllable machine, with behavior that matches operator expectations in harsh mining conditions.
Aircraft Deicing Truck
Case: Aircraft Deicing Truck — Fluid Mixing & Delivery Control
We developed the control system for an aircraft deicing truck that applies multiple deicing/anti-icing fluids from an elevated boom. The key challenge was accurate, stable mixing and dispensing of Type I fluid with water at operator-defined ratios, while maintaining consistent output under changing nozzle conditions — and generating a certified, auditable report for each aircraft treatment.
What we engineered
1) Dual-system control architecture
2) Operator interfaces (two HMIs)
3) Precise ratio control for Type I + water
4) Adaptive total flow regulation
5) Valves / pump actuation & hydraulic integration
6) Automated job reporting & traceability
RESULT
KEY FIGURES
> Type I + water closed-loop mixing (e.g., 20/80–50/50) • Type IV mode • audit-ready job tickets (print + stored)
> Dual HMI (basket + cab) with priority logic • flowmeter feedback + nozzle-pressure stabilization • Danfoss PLUS+1 (MC50/MC88)
We developed the control system for an aircraft deicing truck that applies multiple deicing/anti-icing fluids from an elevated boom. The key challenge was accurate, stable mixing and dispensing of Type I fluid with water at operator-defined ratios, while maintaining consistent output under changing nozzle conditions — and generating a certified, auditable report for each aircraft treatment.
What we engineered
1) Dual-system control architecture
- Separate controllers for the boom/lift functions and the fluid delivery & mixing system
- Implemented on Danfoss PLUS+1 (MC50 / MC88), with multiple controllers in the vehicle
2) Operator interfaces (two HMIs)
- HMI in the basket for operational visibility and process control
- Main HMI in the driver cab for setting fluid modes and target mixing ratios
- Priority logic to keep commands predictable across stations
3) Precise ratio control for Type I + water
- Operator-selectable ratios (e.g., 20/80, 40/60, 50/50) based on aircraft/pilot requirements
- Independent metering using high-accuracy flow meters on each line
- Closed-loop control to maintain ratio in real time, even when line dynamics tried to “push” one flow over the other
4) Adaptive total flow regulation
- Total delivery stabilized using feedback (including nozzle outlet pressure) when the operator partially closes the nozzle
- Output reduced/increased while preserving the target ratio
5) Valves / pump actuation & hydraulic integration
- Control of water supply valves and pump drives
- Signal shaping to valve coils / hydraulic motor-driven pumps to keep flows decoupled and stable
6) Automated job reporting & traceability
- Continuous logging of setpoint vs actual ratio and consumed volumes per tank
- Integrated receipt printer producing a job ticket used for billing/airport–airline reporting
- Stored history with ability to reprint tickets; configurable airport details via Danfoss Service Tool
RESULT
- Stable, repeatable mixing across a wide range of operator-set ratios and real hydraulic line behavior
- Consistent fluid delivery even with changing nozzle restrictions, without drifting from the required ratio
- Audit-ready documentation: per-job tickets with full volumes per fluid, enabling transparent reporting and commercial settlement
- A scalable solution deployable on different chassis platforms (e.g., Volvo, Scania, MAN, Mercedes-Benz, Iveco and similar) with the same control concept
KEY FIGURES
> Type I + water closed-loop mixing (e.g., 20/80–50/50) • Type IV mode • audit-ready job tickets (print + stored)
> Dual HMI (basket + cab) with priority logic • flowmeter feedback + nozzle-pressure stabilization • Danfoss PLUS+1 (MC50/MC88)
Well Logging Winch Control
Case: Geophysical Winch Control for Well Logging Units
We developed a control system for geophysical winches used in well logging operations—lowering and retrieving instrument strings on a cable to depths up to 5,000–7,000 m. The key challenge was achieving extreme speed range (from ~30 m/hour for precise measurements to up to ~8,000 m/hour for fast travel), while keeping speed and cable tension stable across changing drum radius and varying load conditions.
What we engineered
1) Hydrostatic drive control (pump + hydraulic motor + high-ratio gearbox) for a heavy-duty winch system (including support for modern single-speed gearbox configurations).
2) Closed-loop line speed stabilization using a line-speed sensor roller (compensating for changing drum radius as layers build up / unwind).
3) Constant tension mode via a dedicated hydraulic circuit + control logic, preventing slack while staying below cable break limits.
4) Multi-mode operation
5) Operator HMI + diagnostics (service-style interface)
6) Platform
RESULT
KEY FIGURES
> 5,000–7,000 m depth • ~30 m/h to ~8,000 m/h speed range • stable speed across drum layers
> Constant-tension mode • large HMI (~12") with calibration + diagnostics • Danfoss PLUS+1 (MC50 + DM1200)
We developed a control system for geophysical winches used in well logging operations—lowering and retrieving instrument strings on a cable to depths up to 5,000–7,000 m. The key challenge was achieving extreme speed range (from ~30 m/hour for precise measurements to up to ~8,000 m/hour for fast travel), while keeping speed and cable tension stable across changing drum radius and varying load conditions.
What we engineered
1) Hydrostatic drive control (pump + hydraulic motor + high-ratio gearbox) for a heavy-duty winch system (including support for modern single-speed gearbox configurations).
2) Closed-loop line speed stabilization using a line-speed sensor roller (compensating for changing drum radius as layers build up / unwind).
3) Constant tension mode via a dedicated hydraulic circuit + control logic, preventing slack while staying below cable break limits.
4) Multi-mode operation
- Manual joystick control
- Speed setpoint control from the screen (auto-hold)
- Tension control mode (separate operating state and valve logic)
5) Operator HMI + diagnostics (service-style interface)
- Large display (latest versions: ~12")
- Live visualization of key parameters: speed, tension, depth, status states and alarms
- Built-in calibration tools, I/O/joystick checks, parameter tuning (e.g., currents), and error decoding
6) Platform
- Danfoss PLUS+1, MC50 controller, DM1200 display (in the full solution)
RESULT
- Stable cable speed across drum layer changes and varying friction/load conditions
- Reliable tension control to prevent slack, improve cable handling, and protect tools/cable integrity
- Smooth switching between operating modes (manual / speed hold / tension mode) for different job phases
- Higher operator confidence and faster troubleshooting thanks to HMI-led diagnostics and calibration workflows
KEY FIGURES
> 5,000–7,000 m depth • ~30 m/h to ~8,000 m/h speed range • stable speed across drum layers
> Constant-tension mode • large HMI (~12") with calibration + diagnostics • Danfoss PLUS+1 (MC50 + DM1200)
Snow groomer (snowcat)
Case: High-Speed Snow Groomer (Snowcat/Ratrak) — Tracked Drive Control
A snow groomer needs a wide operating range: fast travel on flat sections, and slow, powerful, highly controllable motion while grooming. The challenge was to make a tracked, hydrostatic machine feel predictable and “vehicle-like” for the operator—both in straight driving and in turns—without the typical “bulldozer braking” behavior.
What we engineered
RESULT
KEY FIGURES
> 2 independent track circuits (1 pump + 1 motor per track) • stable straight tracking • “vehicle-like” turning feel
> Speed-compensated steering (one track slows, the other accelerates) • speed-dependent turning radius • Danfoss PLUS+1 (MC050)
A snow groomer needs a wide operating range: fast travel on flat sections, and slow, powerful, highly controllable motion while grooming. The challenge was to make a tracked, hydrostatic machine feel predictable and “vehicle-like” for the operator—both in straight driving and in turns—without the typical “bulldozer braking” behavior.
What we engineered
- Hydrostatic drivetrain control for tracked platform: one pump + one motor per track (two independent circuits)
- Custom track synchronization logic (built from scratch) to keep both tracks moving in sync for straight, stable driving
- Speed-compensated steering: one track decelerates while the other accelerates, helping preserve overall travel speed through turns
- Speed-dependent turning behavior: tight maneuvering at low speed (up to near pivot turns) and a larger, safer turning radius at higher speeds
- Implementation on Danfoss PLUS+1 with MC050 controller, including parameterization for tuning and commissioning
RESULT
- Predictable straight-line tracking and smoother operator control across the full speed range
- Turns without the “slowing down” feel typical for skid-steer/bulldozer logic—more comfortable transport behavior
- Improved stability at higher speeds via dynamic turning limits (reduced risk of aggressive high-speed maneuvers)
- Commissioning-friendly tuning thanks to structured, parameter-driven control logic
KEY FIGURES
> 2 independent track circuits (1 pump + 1 motor per track) • stable straight tracking • “vehicle-like” turning feel
> Speed-compensated steering (one track slows, the other accelerates) • speed-dependent turning radius • Danfoss PLUS+1 (MC050)
Fire Truck / Firefighting Vehicle
Case: Fire Truck / Firefighting Vehicle — Aerial Platform + Water Tank (Quint)
A specialized firefighting machine combining a water tanker with an articulating aerial platform (boom lift). We delivered an integrated hydraulics + controls + HMI safety (Human–Machine Interface) solution designed for fast deployment and safe operation under strict response-time requirements.
What we engineered
1) Outrigger automation & auto-leveling
2) Dual-station controls with prioritization
3) Motion envelope visualization & stability protection
RESULT
A highly integrated control system that enables:
KEY FIGURES
> 6-outrigger one-button auto-leveling • rapid deployment target ~20–30 sec • safe aerial envelope protection
> Dual-station controls with priority logic • pressure-sensor load balancing on outriggers • Danfoss PVG32 + MC50/MC38 + DP600
A specialized firefighting machine combining a water tanker with an articulating aerial platform (boom lift). We delivered an integrated hydraulics + controls + HMI safety (Human–Machine Interface) solution designed for fast deployment and safe operation under strict response-time requirements.
What we engineered
1) Outrigger automation & auto-leveling
- 6 outriggers controlled via chassis-mounted hydraulic valve manifolds
- One-button automatic deployment: the truck stabilizes and levels itself on uneven ground
- Pressure sensors on each outrigger circuit to balance load and achieve horizontal leveling (even if one outrigger lands in a pit)
- Time-critical logic aligned with firefighting deployment norms (rapid setup)
- Manual override mode available if auto-leveling can’t reach target conditions
2) Dual-station controls with prioritization
- Full aerial-platform control from:
- Ground operator station
- Basket controls (in the platform)
- A priority / arbitration logic prevents conflicting commands (e.g., basket up vs. ground down)
3) Motion envelope visualization & stability protection
- Sensors determine the boom position in space and feed the HMI
- On-screen working envelope visualization shows the operator where they are relative to safe operating limits
- Predictive safety interlocks: the system blocks commands that would move the boom outside the permitted stability zone, while still allowing safe corrective moves (e.g., stop extending, but allow lowering or retracting)
- PVG 32 electrohydraulic valve control (Danfoss)
- Controllers: MC50 and MC38
- HMI display: DP600
RESULT
A highly integrated control system that enables:
- Rapid, single-button stabilization
- Safe aerial operations with envelope-based protection
- Coordinated multi-station control without command conflicts
- Clear operator guidance via HMI visualization and smart interlocks
KEY FIGURES
> 6-outrigger one-button auto-leveling • rapid deployment target ~20–30 sec • safe aerial envelope protection
> Dual-station controls with priority logic • pressure-sensor load balancing on outriggers • Danfoss PVG32 + MC50/MC38 + DP600
Real machines. Real outcomes.
Explore what we built — and what we can deliver for your project
Explore what we built — and what we can deliver for your project
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