Motors & Drives Information

In an increasingly competitive marketplace, Alias/Wavefront(TM), a Silicon Graphics (SGI) (NYSE:SGI) company, is playing a pivotal role in the evolution of the automotive industry.

Over the last 10 years, this industry has experienced significant change and with each manufacturer looking to gain even the smallest competitive edge, car companies are increasingly turning to technology to help shape both the future direction of their business, as well as the actual look and feel of the cars produced.

Alias/Wavefront, a leader in 3D software for the design and entertainment markets, has been at the forefront of this shift as the use of its AutoStudio(TM) software continues to revolutionize the automotive design and marketing processes with every major automotive manufacturer in the world, including General Motors(R), BMW(R), The Ford Motor Company(R), Honda(R), Toyota(R), and Daimler Chrysler, among others.

Speeding to Market through Team Integration

Alias(R) AutoStudio serves as the software tool kit for companies adopting a digital design process in the early stages of concept car development. Whereas companies once spent years using drawing boards and clay modeling to create and simulate auto prototypes, manufacturers now combine traditional tools with the use of advanced technology like AutoStudio software to speed up the process and funnel the ideation and creative design process from designer to modeler to engineer. With the average time-to-market rate (conception to production) dropping from between five to seven years to between 24-36 months over the last 10 years, automotive manufacturers are benefiting in many ways from a shortened production cycle.

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At the Solvay, N.Y., mill, the first new North American containerboard machine in three years is making 100% recycled corrugating medium at high efficiencies with little off-spec product

A new paper machine in North America is an increasingly rare occurrence, but the successful June startup of Solvay Paperboard's new corrugating medium machine serves as an example of what is possible with new technology, automation, and an innovative organizational structure. As high-cost, aging assets are retired in the region, this machine demonstrates a new, forward-looking direction in the North American industry.

Starting up six weeks ahead of schedule, the 200,000-tpy, 100% recycled corrugating medium machine already operates above design production levels at high efficiency with very low off-specification production. It is the first new NorthAmerican containerboard machine since Solvay started up its 250,000-tpy No. 2 linerboard machine in September 1999 (see Pulp & Paper, March 2000) and makes Solvay the tenth-largest containerboard producer in North America.

New tonnage can be a sensitive issue under current market conditions. However, the new medium machine simply represents the fulfillment of a corporate strategy conceived by the partnership that formed Solvay Paperboard, says James B. Porter, president of Solvay.

"We're a box company instead of a paper company, and that's an important distinction," describes Porter. "Solvay was started in 1993 with the goal of supplying high-quality containerboard to its partners-four independent producers of corrugated boxes. The model to be independent and to supply our own containerboard is the driving force behind our machines. It's not to produce a commodity in an attempt to increase market share."

Another feature initially envisioned for Solvay by its partners was adherence to a mini-mill concept at the Solvay, N.Y., site. Producing about 1,800 tpd, the mill would seem to have moved away from that feature, but organizational aspects have preserved the intent. "Our work team culture, the way we work with our suppliers and customers, and the way we utilize automation all ensure that our business works very much within the `mini-mill' concept we began back in 1993," explains Porter.

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In 1949 Nippondenso Co. Ltd. was spun off from Toyota Motor Co. Ltd. with a modest capital base of [yen] 15 million, something less than $150,000 at today's exchange rate. In late 2003, the company now known as Denso Corp. projected record sales of $22 billion for its fiscal year ending in March, putting it comfortably among the top five OE automotive suppliers in the world.

Denso's growth very much parallels Toyota's success. In the years from 1988 to 2000, Denso total sales actually doubled. Though separated from Toyota for more than 50 years, very nearly 50% of Denso's sales are still credited to Toyota.

Conversely, however, that means some $11 billion in sales is to other automakers and engine builders of the world, and Denso is certainly out to win more. It consistently wire accolades from its customers. General Motors, for example, has named Denso supplier of the year For 10 consecutive years.

Denso's engine products are its largest product sector, representing 37% of its business, with climate control at 30%, computer-related products at 14%, with information and communication systems, instruments and small motors accounting For die balance. Information Technology Systems (ITS) are expected to be the largest area of growth in years ahead. The use of pre-crash safety systems and adaptive front lighting systems are also evolving rapidly.

Japan accounts for 57% of Denso's sales volume, the Americas for 23%, Europe for 12%, with the balance going to Asia, Oceania and other lands.

Following the 2003 Tokyo Motor Show, we received an extensive tour of Denso's R&D center, several engineering and production facilities, and were able to interview key executives and engineering managers about Denso developments and directions.

Our deep dive into Denso revealed a richly textured organization of 90,000 employees all seemingly moving in the same direction to produce world class quality products at the lowest cost with the least possible environmental impact.

"Denso considers environmental protection in all of its activities," said Koichi Fukaya, president and CEO, "including planning, development design, manufacturing, marketing and services. We are developing technologies that will reduce the environmental burden of vehicles.

"We're also tackling higher fuel efficiency, exhaust gas purification and automotive air conditioning systems that have minimal impact on global warming."

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Chorus Motors plc (OTC: CHOMF) has signed an agreement with Magnetek Inc. (NYSE: MAG) to develop traction drive technology for the underground mining industry. The companies plan to offer complete motor and drive systems for customers who demand the highest performance and reliability in the smallest available package.

Chorus drive and control systems offer unequalled power density in a compact AC unit, together with the ability to switch between high and low torque applications without loss of efficiency, allowing the same system to be used as a generator as well as a traction motor.

Magnetek is a market leader for drives and controls to the underground mining market. It has over 30 years experience in designing and manufacturing industrial power controllers with a range of solutions for the most severe duty equipment as well as custom designs.

"Magnetek is an excellent partner for us," said Isaiah Cox, Chorus's President. "The underground mining market has very rigorous requirements in which reliability and performance are at a premium, and Magnetek will ensure that the products we make will meet and exceed the industry's expectations."

"The Chorus technology allows Magnetek to provide an AC motor and drive package with torque performance equal or greater than the existing Series DC controls," according to Ed Butte, Magnetek VP Product Management. "It also provides a level of redundancy that will allow greater up-time and throughput for our mining customers."

The agreement provides for the development of Chorus® motors for haulage equipment, shuttle cars, and regenerative traction drives, with further products envisaged over time. Marketing, integration, sales and ongoing service and repair contracts will be handled by Magnetek.

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MILWAUKEE, April 19 /PRNewswire/ -- Catalyst International, Inc. is pleased to announce that it has completed contracts with Shanghai General Motors, the leading Chinese Automotive Manufacturer, to implement its supply chain execution software suite in three new distribution centers and one new packaging plant in China.

"China is a significant growth opportunity for Shanghai General Motors and the automotive industry in general," says Wang Jun, Director of Service Parts Operations of Shanghai General Motors. "Service Parts Operations is, more than ever, critical for maintaining our growth and the WMS solution is a key element of our distribution strategy."

The project relies on the CatalystComplete(R) product suite including Warehouse Management, Labor Management, Slotting Optimization, Yard Management, Event Management and Enterprise Visibility. These components provide Shanghai General Motors with the most advanced supply chain execution software suite of any automotive company in the world. "Shanghai General Motors is a very exciting program for Catalyst and firmly establishes our company as one of the leading software suppliers in the hottest economy in the world," says Michael Eleftheriou, Catalyst Chief Executive Officer.

Less than ten years old, Shanghai General Motors is the largest and one of the fastest growing car manufacturers in China, assembling, distributing and servicing vehicles under the Buick, Chevrolet and Cadillac brands through over four hundred dealers in China. A leading innovator in operations and information technology and being one of the most respected corporations in China, Shanghai General Motors is a shining star in a country of many success stories.

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The automaker service information Web sites have been online since early 2003, and while they are not exactly what many thought they would be, they are in many cases much more. The major OEMs grumbled at the U.S. Environmental Protection Agency's (EPA) request that they each develop all Internet-accessible site that provided emissions-related service information as part of the 1990 Clean Air Act Amendments.

But, fortunately, EPA was adamant.

We say fortunately because it quickly became clear to most of the automakers that it would be an almost impossible task. If not an extremely expensive one, to filter out just their emissions-related diagnostic and service information from all other service system information they provide to their dealerships. The amendments state that independent service shops and technicians must have access to the same emissions-related service information, diagnostic tools and OEM training, that is available to the franchised dealership service departments. The aftermarket has long-maintained that this information is critical to independent service providers for the service and repair of 1996-and-newer vehicles, which are now subject to OBD emissions testing.

As a result, the OEMs decided to put virtually everything online. That includes service information, OEM training classes and OEM-dedicated tools and equipment.

The Automotive Management Institute (AMI), a member-benefit provided by the Automotive Service Association (ASA), recently began offering a three-hour, six-credit course called "You Have the Right to Repair." Over the last few months, this course--conducted by Bill Haas, ASA's vice president of Service and Collision Repair Activities--has been presented in a few markets around the nation. For service dealers who will be at this year's CARS convention, Haas will again present the course.

During this session, Haas does not touch on any of the reasons why ASA abruptly withdrew from a service industry coalition that had been seeking OEM support of the Motorist's Right to Repair Bill, H.R. 2735. That bill would assure that the flow of service information needed by the independent service aftermarket would continue unabated to both vehicle owners and service providers. However, background reference is provided in the workbook given to attendees at these sessions.

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Quality has been job 1 for top automakers for more than a decade, as Ford Motor Co., General Motors Corp. and DaimlerChrysler AG try to reduce outlays for warranties and improve customer satisfaction. Now those OEMs are making quality just as important for the component makers that supply auto parts.

Much of this effort is centered on APQP (Advanced Product Quality Planning), a process for documenting how suppliers design and deliver components. Software developers including Aras Corp. and Powerway Inc. have been rolling out applications to automate the gathering and distribution of that documentation.

The APQP process takes outsourcing beyond simply requiring a supplier to provide a component that matches a specification. It adds the monitoring of how and when a component is created and delivered to the OEM, thus speeding the supply chain and new-product introduction by ensuring that the OEM and supplier are working on the same schedules.

"Now, instead of delivering just to a specification, the OEM also tells [a supplier] how to design and tool up their factory," said Peter Schroer, chief technology officer at Aras, in Lawrence, Mass. "And they say, 'We're going to monitor you over three years so we know you are completing the project the way we want.' What's new is [the OEMs] are enforcing APQP."

Aras late last month began shipping its APQP Plus software, which automates the collection of APQP documents, provides a framework for managing APQP compliance projects and integrates with Aras' namesake PLM (product lifecycle management) software.

The new software includes templates for APQP and the Production Part Approval Process auto industry standard. An additional four applications in the suite enable users to manage production, sourcing, other quality issues and tooling. Together, these applications provide document management, engineering change management and cost accounting capabilities.

Indianapolis-based Powerway in March released Version 2.0 of its Powerway.com Web-based APQP software. The upgrade, which is being used by GM and DaimlerChrysler, features enhanced navigation capabilities, additional language support and a new activity log.

Freudenberg-NOK GP, which makes molded rubber components for automobiles, uses Aras' APQP Plus mainly for project management and design management, according to Tom Gill, director of CAE technology and support.

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While electronic data generation continues to grow at an 80% annual rate globally, according to IDC, the tape industry is keeping pace with the introduction of larger capacity, faster data transfers, and more scalable products that provide even better returns on investment that provides the protection of your business' data. Unlike their magnetic disk cousins (where the understood physical limits of the medium are continually being challenged and redefined) tape manufacturers have proven that there is at least another 16-fold capacity increase possible by using technologies and materials that are already being tested in their labs.

It is well established that tape is the most cost-effective media for storing large amounts of data. And even as disk capacities have dramatically increased over the past 10 years, the tape industry has continually maintained a capacity advantage over disk; a single tape cartridge can be used to backup the contents of a single hard drive. This has always been the case, and it continues to be the driving imperative behind tape drive and media development.

The science behind the improvements in tape technology is very impressive, and also very technically sophisticated. Over 40 researchers representing the major tape drive manufacturers, tape media suppliers and many of the leading research universities, collaborated (as part of the Information Storage Industry Consortium--INSIC) to analyze enterprise tape market requirements. The result was the development in 2001 of a 10-year projection for the future of magnetic tape storage. INSIC's work indicates that to remain an economically viable storage solution when compared to disk, tape capacity must grow at a rate comparable to future disk capacity growth on a cost-per-gigabyte basis.

Although disk densities are continuing to rise, the rate of growth is expected to slow as disk recording nears a superparamagnetic limitation. Due to a much lower areal recording density and much greater recording area, tape technology has the potential to grow at a faster rate and as a result improve its cost per gigabyte trends compared to disk. Therefore, when combined with disk in the enterprise storage environment, the tape industry roadmap currently maintains that tape capacity on a single cartridge must achieve 10 terabytes (TB) uncompressed per cartridge by 2011, and must reach 1TB uncompressed on a single cartridge by 2006 on its way to reaching the 10-year goal.

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Available for 200 or 400 V supplies, F700 series inverter features proprietary energy optimization software and can control up to 4 pump or fan motors. Programming is facilitated by jog dial, which provides access to 400 parameters. NEMA 1 structure allows for safe, secure installations in panel or as stand-alone module. Features include Optimum Excitation Control system, power dip ride-through and remote I/O capabilities, and independent RS-485 connections.

VERNON HILLS, ILLINOIS, October 12, 2004 - Mitsubishi Electric Automation, Inc., a global supplier of automation products to all major industries, has introduced its F700 series of variable frequency drives (VFDs) that can control motors ranging from one to 800 horsepower. The F700 inverter features the latest version of Mitsubishi Electric's proprietary energy optimization software that boosts motor efficiency to new levels and maximizes energy savings.

"This new drive is suitable for virtually any general purpose application that involves a motor, whether it's on the shop floor, air-handling unit or machine room," said Chris Cusick, marketing manager for Mitsubishi Electric Automation. "The unprecedented range of the F700 makes it one of the most versatile VFDs on the market. Available for either 200V or 400 V supplies, from 1-800HP, each VFD can control up to 4 pump or fan motors, resulting in significantly shorter payback times and reductions in maintenance costs in energy saving."

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Available for 200 or 400 V supplies, F700 series inverter features proprietary energy optimization software and can control up to 4 pump or fan motors. Programming is facilitated by jog dial, which provides access to 400 parameters. NEMA 1 structure allows for safe, secure installations in panel or as stand-alone module. Features include Optimum Excitation Control system, power dip ride-through and remote I/O capabilities, and independent RS-485 connections.

VERNON HILLS, ILLINOIS, October 12, 2004 - Mitsubishi Electric Automation, Inc., a global supplier of automation products to all major industries, has introduced its F700 series of variable frequency drives (VFDs) that can control motors ranging from one to 800 horsepower. The F700 inverter features the latest version of Mitsubishi Electric's proprietary energy optimization software that boosts motor efficiency to new levels and maximizes energy savings.

"This new drive is suitable for virtually any general purpose application that involves a motor, whether it's on the shop floor, air-handling unit or machine room," said Chris Cusick, marketing manager for Mitsubishi Electric Automation. "The unprecedented range of the F700 makes it one of the most versatile VFDs on the market. Available for either 200V or 400 V supplies, from 1-800HP, each VFD can control up to 4 pump or fan motors, resulting in significantly shorter payback times and reductions in maintenance costs in energy saving."

The F700 is a totally new design from Mitsubishi Electric, and features a new power module and hardware. Its NEMA 1 structure allows for safe, secure installations, whether in a panel or as a stand-alone module. Ease-of-programming is also a key benefit made possible by a jog dial that provides fast access to any of its 400 parameters. The F700 also incorporates an Optimum Excitation Control system that maximizes motor efficiency under all load conditions, and can even track and display energy and dollar savings in real time. Robust protective features help ensure that the drive will keep running despite fluctuations or interruptions in power.

The F700 VFD includes these new features:

* NEMA 1 enclosure designs: The drive can be mounted as a stand-alone unit where required.

* Ease-of-Programming: No more tedious scrolling to access parameters thanks to the new DU07 programming dial and FR-Configurator programming software.

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Utilizing digital networking technology based on IEEE-1394, ServoWire[R] Soft Motion 460 Vac Series drives provide 2,400-17,000 W of power with continuous output current from 5-35 A rms/phase. They are available for 24-96 Vdc, and 115, 230, or 460 Vac input power and provide output short circuit and overvoltage protection. All drives utilize IGBT-based intelligent power modules. Brushless ac servomotor H-Series includes 460 Vac models providing continuous stall torques from 25-700 lb-in.

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ORMEC has expanded the power and torque range of its popular family of ServoWire Soft Motion digital drives and H-Series motors. Five new 460 VAC-series drive models provide 2,400 to 17,000 watts of power, and offer continuous output current from 5 to 35 amps RMS/phase. The five, new 460 VAC ServoWire drives (5, 10, 17, 25 and 35 amps RMS/phase) provide excellent power density and enhance the ServoWire Soft Motion product offering by greatly expanding the number of applications that can benefit from ServoWire drive networking using IEEE-1394 (FireWire). ORMEC's H-series AC brushless servomotor product line has also been expanded to include 460 VAC models providing continuous stall torques from 25 to 700 lb.-in. and now covers the entire power range.

ServoWire SM digital drives provide high performance servo operation utilizing digital networking technology based on IEEE-1394. This network not only provides high speed, but also ease of use through cost-effective, industry-standard cabling. Each ServoWire drive supports a variety of high performance, quadrature and serial encoder and resolver-based servomotors. Consult ORMEC for OEM applications of user-supplied brushless rotary or linear motors---as well as DC brush-type & voice-coil motors.

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Suited for applications starting at 150 kW (200 hp), PowerFlex 7000 drives utilize Direct-to-Drive(TM) technology, which allows users to connect utility power directly to drive without isolation transformer. Symmetrical Gate Commutated Thyristor allows drive to be rated up to 6,600 V, while front end rectifier uses active switching and selective harmonic elimination that reduces harmonics to meet IEEE 519, EN61000-2-4, and G5/4 standards.

Allen-Bradley PowerFlex 7000 Medium-Voltage Drives with Direct-to-Drive technology deliver a transformerless option with improved efficiency, reduced size and weight, and lower total cost of ownership for applications starting at 150 kW (200 hp) and up

CAMBRIDGE, Ontario, Oct. 28, 2004 - Rockwell Automation introduces the Allen-Bradley PowerFlex 7000 Medium-Voltage AC drive with new Direct-to-Drive(tm) technology, which allows customers to connect utility power directly to the drive without an isolation transformer. Direct-to-Drive technology represents advanced technology, offering customers a transformerless medium- voltage drive option with improved efficiency, reduced size and weight, and lower total cost of ownership.

The Direct-to-Drive feature combines three innovations designed to eliminate isolation transformers on applications with either new or existing motors.

The Symmetrical Gate Commutated Thyristor (SGCT) semiconductor's high-voltage rating and ability to be connected in series allow the PowerFlex 7000 to be rated up to 6600V, without added complexity, reducing total component count and increasing reliability.

The active front end (AFE) rectifier uses active switching and Selective Harmonic Elimination to reduce harmonics.

The common-mode voltage protection is the current technology designed to mitigate common-mode voltage stress generated by variable frequency drives without using an isolation transformer.

The Direct-to-Drive technology brings a lower total cost of ownership by eliminating cost of the transformer and transformer protection relays, reducing cable costs and eliminating line and motor filtering purchases.

Eliminating the transformer on a medium-voltage drive helps:

improve efficiency by eliminating transformer heat losses

reduce drive system size by 30 to 50 percent

reduce drive system weight by 50 to 70 percent

eliminate the need for increased air conditioning capacity for transformer cooling

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Brushed-type, permanent magnet, dc servo motors are offered in 60, 90, and 110 mm dia with respective NEMA frame sizes of 23, 34, and 42. Winding voltages of 12, 24, 36, and 48 V ensure compatibility with industry-standard motor drives available to satisfy torque requirements from 40 to 2,100 oz-in. Applications include factory automation, packaging machines, robotics, coil winders, converting equipment, and laboratory instrumentation.

MOTORSOFT[R] INC., Lebanon, Ohio, has introduced a complete line of brushed-type DC servo motors for use in factory automation, packaging machines, medical devices, robotics, laboratory instrumentation, coil winders, labeling equipment, machine tool, converting equipment and numerous other applications. The robust design provides long life and rock sure reliability at extremely competitive costs for OEMs looking to provide their customers high quality at an affordable price.

Motorsoft's Arrow brand of permanent magnet DC motors are offered in diameters of 60mm, 90mm and 110mm corresponding to NEMA frame sizes 23, 34 and 42. Winding voltages of 12v, 24v, 36v and 48v, assure compatibility with all industry standard motor drives available to satisfy torque requirements from 40 oz-in (.3 N-m) up to 2100 oz-in (15.3 N-m).

Arrow Motor specifications, drawings, pricing and technical support are available on line at . Standard Arrow models are available for purchase direct at www.4quad.com, the on-line store for motion control design products and supplies. For special configurations such as unique windings, modified shaft lengths or custom flange dimensions, the Motorsoft Sales Department can be contacted for review of the specific application requirements.

Motorsoft is the world's leading electric motor and motion control design tool and resource supplier, offering custom designed high performance Switched Reluctance, Permanent Magnet and AC motors; Brushless DC Servo Motors; Electric Motor Drives and Controls; SPEED motor design simulation software; Motion Control Marketing Reports and Training Courses; and expert design, consulting and prototyping services.

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Series 130 utilizes zero-speed detect and solid state dynamic braking circuits that eliminate contact arcing and failed braking problems. Zero-speed detect circuit also eliminates motor plug reversing problems. In case of power loss or emergency stop condition, cULus-listed control drops into dynamic brake condition, safely bringing motor to stop until power is reapplied and run condition is recognized. Unit is suited for vertical or horizontal mounting.

The 130 Series reversing control from Dart Controls utilizes Dart's unique zero-speed detect and solid state dynamic braking circuits. These circuits eliminate the contact arcing and failed braking problems associated with other reversing and dynamic braking controls. Dart's zero-speed detect circuit also eliminates motor plug reversing problems.

In the event of a power loss or emergency stop condition, the 130 Series control will drop into a dynamic brake condition to safely and quickly bring the motor to a stop and remain there until power is reapplied and a run condition is recognized.

The 130 Series control comes in a compact package and fits the industry standard footprint for both vertical and horizontal mounting. The 130 Series is also now a cULus Listed control.

Dart Controls, Inc. is a ISO9001:2000 registered designer, manufacturer, and marketer of analog, and digital electronic variable speed drives, controls, and accessories for AC, DC, and DC brushless motor applications.

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