Saturday, October 14, 2006
Drive range expanded
Variable speed drive range for electric motors expanded with 15 larger sizes to take it from 0.7kW up to 530kW.
Mitsubishi Electric has expanded its F700 series of variable speed drives for electric motors with 15 larger sizes up to 530kW. At the launch last year, the range ran from 0.7 to 55kW, the most popular sizes for OEM and end-user applications. The full range now covers drives in fields as diverse as manufacturing, HVAC, utilities, wind tunnels and commercial kitchen appliances.
The FR-F700 has excitation control and torque patterns to improve drive performance and efficiency to the load.
It can automatically optimise energy usage for each load profile.
For instance some materials, such as batter, can change their viscosity when being mixed and the F700 can detect this and constantly reoptimise its settings to follow the changing conditions.
Other features include ease of commissioning, predictive maintenance monitor, high level connectivity to control systems and tripless reliability.
A flux vector option is available for applications requiring high levels of dynamic control.
Energy savings can be monitored via the front panel, which can display the power, percentage or cumulative energy saving in kW/hr or local currency.
This information, along with other performance measures, can be downloaded via the communication network to a central location.
The removable terminal block means that if a unit has to be exchanged, say during a system reconfiguration project, rewiring is not necessary.
Instead, the terminal block is removed from the old drive and inserted into the new one.
The terminal block is compatible with Mitsubishi' s previous generation inverters, the 500 series.
The on-board EMC filter ensures compliance with European EMC legislation for industrial environments.
The cooling fan uses larger than normal bearings for an operating life expectancy longer than 10 years.
This can be improved if the fan is switched off when not required.
The F700 monitors its own key components, such as capacitors and protection circuits, and flags up if or when they are coming towards the end of their operational life.
A timer highlights when specified maintenance procedures are due, reducing unplanned downtime.
An RS485 communication port is fitted as standard and connection to all the major networks and protocols is covered, including CC-Link, Devicenet, Profibus, Modbus and, for HVAC and building automation, Lonworks.
Mitsubishi Electric has expanded its F700 series of variable speed drives for electric motors with 15 larger sizes up to 530kW. At the launch last year, the range ran from 0.7 to 55kW, the most popular sizes for OEM and end-user applications. The full range now covers drives in fields as diverse as manufacturing, HVAC, utilities, wind tunnels and commercial kitchen appliances.
The FR-F700 has excitation control and torque patterns to improve drive performance and efficiency to the load.
It can automatically optimise energy usage for each load profile.
For instance some materials, such as batter, can change their viscosity when being mixed and the F700 can detect this and constantly reoptimise its settings to follow the changing conditions.
Other features include ease of commissioning, predictive maintenance monitor, high level connectivity to control systems and tripless reliability.
A flux vector option is available for applications requiring high levels of dynamic control.
Energy savings can be monitored via the front panel, which can display the power, percentage or cumulative energy saving in kW/hr or local currency.
This information, along with other performance measures, can be downloaded via the communication network to a central location.
The removable terminal block means that if a unit has to be exchanged, say during a system reconfiguration project, rewiring is not necessary.
Instead, the terminal block is removed from the old drive and inserted into the new one.
The terminal block is compatible with Mitsubishi' s previous generation inverters, the 500 series.
The on-board EMC filter ensures compliance with European EMC legislation for industrial environments.
The cooling fan uses larger than normal bearings for an operating life expectancy longer than 10 years.
This can be improved if the fan is switched off when not required.
The F700 monitors its own key components, such as capacitors and protection circuits, and flags up if or when they are coming towards the end of their operational life.
A timer highlights when specified maintenance procedures are due, reducing unplanned downtime.
An RS485 communication port is fitted as standard and connection to all the major networks and protocols is covered, including CC-Link, Devicenet, Profibus, Modbus and, for HVAC and building automation, Lonworks.
Direct drive motors offer attractive servo choice
Direct drive motors are becoming more common because they offer a number of advantages over conventional rotary servomotors. The absence of a gearbox means that the resulting servo system is much quieter, and also requires less maintenance than existing configurations. Most servo systems use a conventional rotary servomotor that is coupled to the driven load through a gearbox or belt drive.
Although conventional servo systems in and of themselves are maintenance-free, performance issues such as position inaccuracy or difficult tuning problems can be introduced by the backlash or compliance from the gearbox or belt drive.
In fact, even systems that do not employ gearboxes or belt drives can have excessive compliance issues from the couplings used to connect the servomotor to the load.
These coupling methods will take a maintenance-free servomotor and introduce new maintenance requirements, such as gearbox lubrication and belt adjustment/replacement.
Gearheads are typically required to improve the torque and improve the inertial match of the servomotor to the load, but new technological developments make direct motors drives a viable alternative.
Direct drive rotary (DDR) systems provide the benefits of a brushless servomotor solution, while eliminating the drawbacks created by couplings, gearbox backlash and gearbox/belt maintenance.
By coupling the motor directly to the load, all mechanical transmission components are eliminated.
In addition to solving the maintenance headaches, DDR systems do not require inertia matching, position and velocity accuracies can be increased up to 50 times, and audible noise is reduced by up to 20dB.
For designers who need to reduce machine size, the elimination of the mechanical transmission components results in a smaller machine that boasts higher performance, quieter operation and zero maintenance of the motion control system.
Frameless DDR systems comprise a separate rotor and stator without bearings.
These components are designed into the machine and become an integral part of the machine.
The feedback device (such as a resolver, encoder, hall sensors etc) must also be designed into the machine.
Frameless DDR systems were Danaher Motion's original DDR technology.
Most frameless DDR motors are custom designs, which make them good candidates for applications where space is limited or weight is critical.
There are standard catalogue versions of frameless DDR motors available.
These are less common but offer the benefits of ready availability, UL approved design and pre-engineered feedback designs.
Frameless DDR motors are ideal for aerospace/defence applications such as aircraft or ground vehicle radar and weapons systems.
They also make sense in high performance industrial applications, robotics and precision grinding being good examples.
When the lowest size and weight must also deliver optimum performance, frameless DDR systems are an excellent solution.
Housed DDR systems, also referred to as 'full frame' systems, integrate the rotor, stator, and factory aligned feedback within a housing that includes precision bearings.
Although such systems still require the selection of a compatible drive amplifier, they represent a standard solution that is much easier to select, integrate and service than a frameless solution.
Housed DDR systems are best suited to applications where the load is designed to ride on the motor's bearings.
Where a machine already has bearings the motor must be coupled to the load or multiple sets of bearings must be aligned, a complex and time-consuming task.
Housed DDR motors are generally used in applications without existing machine bearings, such as indexing and rate tables.
For applications suited to the housed DDR design, they offer fast and easy installation, a pre-aligned feedback device, built-in bearings, and significantly lower cost than a frameless design.
Cartridge DDR motors represent a completely new category of direct drive technology that combines all the performance benefits of frameless DDR motors with the ease of installation of a full frame motor, and at a significantly reduced price point than conventional DDR technology.
Their unique 'bearing-less' design facilitates mount-and-run operation in less than 30 minutes.
Cartridge DDR motors can be used in a wide variety of applications in the converting, factory automation, packaging, printing, and semiconductor industries.
The cartridge technology can be adapted to nearly any application that has existing bearings, providing all of the benefits of direct drive at the lowest cost, and with fast, easy installation.
All DDR systems provide a common set of benefits that include zero maintenance, reduced downtime, zero backlash, improved repeatability, zero compliance, improved accuracy, more compact mechanical design, quiet operation, and improved velocity regulation.
Many DDR designs are also available in 'hollow shaft' configurations that permit electrical lines, pneumatic lines or other machine components to pass through the motor for optimised space utilisation.
Not all direct drive systems are available from all manufacturers.
Moreover, different electromagnetic designs will result in different levels of performance, different cost points (cost per torque available), and different top speed capabilities.
Variable reluctance motor designs do not offer the performance, torque or speed capabilities available from brushless, high-energy permanent magnetic motors.
Also, variable reluctance motors often require that the drive amplifier be specifically matched to the motor.
This limits flexibility in drive selection and makes service more difficult.
Some machines can benefit from the use of different DDR designs on different machine axes.
Ideally the motors should come from a single manufacturer that can provide a common drive amplifier design to run all the different motors.
This provides a common platform and eliminates the need to learn and support multiple designs.
Direct drive systems will have higher initial costs than conventional servo systems.
The degree of difference can vary from as little 30% more for a cartridge system, to as much as four times more for a frameless system (total cost including design and integration).
This cost picture changes quickly when the lifecycle costs are examined.
Over a typical five-year life the conventional system will cost from three to ten times the direct drive system costs due to maintenance and downtime.
On a final note, the benefits of direct drive technology are not limited to just rotary motion applications.
Direct drive linear (DDL) systems eliminate mechanical translation devices such as ball/lead screws or rack and pinions, offering the equivalent performance and maintenance-free operation improvements to linear systems that DDR systems offer to rotary systems.
Machines that combine DDR and DDL systems provide the ultimate in performance and zero maintenance operation.
Although conventional servo systems in and of themselves are maintenance-free, performance issues such as position inaccuracy or difficult tuning problems can be introduced by the backlash or compliance from the gearbox or belt drive.
In fact, even systems that do not employ gearboxes or belt drives can have excessive compliance issues from the couplings used to connect the servomotor to the load.
These coupling methods will take a maintenance-free servomotor and introduce new maintenance requirements, such as gearbox lubrication and belt adjustment/replacement.
Gearheads are typically required to improve the torque and improve the inertial match of the servomotor to the load, but new technological developments make direct motors drives a viable alternative.
Direct drive rotary (DDR) systems provide the benefits of a brushless servomotor solution, while eliminating the drawbacks created by couplings, gearbox backlash and gearbox/belt maintenance.
By coupling the motor directly to the load, all mechanical transmission components are eliminated.
In addition to solving the maintenance headaches, DDR systems do not require inertia matching, position and velocity accuracies can be increased up to 50 times, and audible noise is reduced by up to 20dB.
For designers who need to reduce machine size, the elimination of the mechanical transmission components results in a smaller machine that boasts higher performance, quieter operation and zero maintenance of the motion control system.
Frameless DDR systems comprise a separate rotor and stator without bearings.
These components are designed into the machine and become an integral part of the machine.
The feedback device (such as a resolver, encoder, hall sensors etc) must also be designed into the machine.
Frameless DDR systems were Danaher Motion's original DDR technology.
Most frameless DDR motors are custom designs, which make them good candidates for applications where space is limited or weight is critical.
There are standard catalogue versions of frameless DDR motors available.
These are less common but offer the benefits of ready availability, UL approved design and pre-engineered feedback designs.
Frameless DDR motors are ideal for aerospace/defence applications such as aircraft or ground vehicle radar and weapons systems.
They also make sense in high performance industrial applications, robotics and precision grinding being good examples.
When the lowest size and weight must also deliver optimum performance, frameless DDR systems are an excellent solution.
Housed DDR systems, also referred to as 'full frame' systems, integrate the rotor, stator, and factory aligned feedback within a housing that includes precision bearings.
Although such systems still require the selection of a compatible drive amplifier, they represent a standard solution that is much easier to select, integrate and service than a frameless solution.
Housed DDR systems are best suited to applications where the load is designed to ride on the motor's bearings.
Where a machine already has bearings the motor must be coupled to the load or multiple sets of bearings must be aligned, a complex and time-consuming task.
Housed DDR motors are generally used in applications without existing machine bearings, such as indexing and rate tables.
For applications suited to the housed DDR design, they offer fast and easy installation, a pre-aligned feedback device, built-in bearings, and significantly lower cost than a frameless design.
Cartridge DDR motors represent a completely new category of direct drive technology that combines all the performance benefits of frameless DDR motors with the ease of installation of a full frame motor, and at a significantly reduced price point than conventional DDR technology.
Their unique 'bearing-less' design facilitates mount-and-run operation in less than 30 minutes.
Cartridge DDR motors can be used in a wide variety of applications in the converting, factory automation, packaging, printing, and semiconductor industries.
The cartridge technology can be adapted to nearly any application that has existing bearings, providing all of the benefits of direct drive at the lowest cost, and with fast, easy installation.
All DDR systems provide a common set of benefits that include zero maintenance, reduced downtime, zero backlash, improved repeatability, zero compliance, improved accuracy, more compact mechanical design, quiet operation, and improved velocity regulation.
Many DDR designs are also available in 'hollow shaft' configurations that permit electrical lines, pneumatic lines or other machine components to pass through the motor for optimised space utilisation.
Not all direct drive systems are available from all manufacturers.
Moreover, different electromagnetic designs will result in different levels of performance, different cost points (cost per torque available), and different top speed capabilities.
Variable reluctance motor designs do not offer the performance, torque or speed capabilities available from brushless, high-energy permanent magnetic motors.
Also, variable reluctance motors often require that the drive amplifier be specifically matched to the motor.
This limits flexibility in drive selection and makes service more difficult.
Some machines can benefit from the use of different DDR designs on different machine axes.
Ideally the motors should come from a single manufacturer that can provide a common drive amplifier design to run all the different motors.
This provides a common platform and eliminates the need to learn and support multiple designs.
Direct drive systems will have higher initial costs than conventional servo systems.
The degree of difference can vary from as little 30% more for a cartridge system, to as much as four times more for a frameless system (total cost including design and integration).
This cost picture changes quickly when the lifecycle costs are examined.
Over a typical five-year life the conventional system will cost from three to ten times the direct drive system costs due to maintenance and downtime.
On a final note, the benefits of direct drive technology are not limited to just rotary motion applications.
Direct drive linear (DDL) systems eliminate mechanical translation devices such as ball/lead screws or rack and pinions, offering the equivalent performance and maintenance-free operation improvements to linear systems that DDR systems offer to rotary systems.
Machines that combine DDR and DDL systems provide the ultimate in performance and zero maintenance operation.
New digital servo drives cut cost of installation
The new Allen-Bradley Ultra-3000 family of high performance, digital servo drives from Rockwell Automation offers a wide choice of easy to install, easy to commission motion control solutions. A typical servo drive has in the order of 120 wiring points and at 5 minutes per connection, the cost of installation can be £300 or more. Five years ago, this would only have represented 5 or 6% of the cost of the drive, but with today's lower hardware costs, it is more like 30%.
So a reduction in installation cost was one of the key goals given to the Rockwell automation engineers when they set out to design the Ultra 3000.
They identified three key areas where these savings could be made: * Connection of the servo drive to the controller, where they chose to use Sercos, a single fibre optic connection.
* Connection of the servo drive to the motor by using pre-configured power and feedback cables.
* A drive that automatically configures itself with the help of a smart feedback facility.
With Sercos, command signal and all position feedback information is routed over the fibre optic network, enabling the user to control, commission and monitor the drive.
The 20 wires that would previously have been required between the controller and servo drive are reduced to a single fibre optic cable.
The pre-configured power and feedback cables are designed to connect the servo drive to all current Allen-Bradley motors.
They are available in various lengths and take only seconds to plug in, compared to several hours needed to connect a conventional system.
With smart feedback technology, the drive can not only read the motor part number and so automatically configure itself, but also support absolute and high-resolution encoders.
This ensures that position is not lost if the power is cut, eliminating time-consuming machine homing cycles.
It delivers resolution down to millionths of a revolution, providing extreme accuracy.
For simple applications where complex multi-axis control is not required, the Ultra 3000 has a built in indexing function, allowing it to carry out a series of moves without an external controller.
This makes it perfect for applications such as pneumatic or clutch/brake replacement.
However, when connected to a modern controller such as the Allen-Bradley ControlLogix, it is capable of handling the most sophisticated requirements.
The power range is 0.5 to 22kW, 100 to 240V single phase or 380 to 500V three-phase AC.
There are eight general-purpose digital inputs assignable to multiple functions, four general-purpose digital and one relay output and a choice of multiple operating modes.
Such versatility is truly amazing, and with easy connectivity and commissioning it can be up and running and saving money in less time than it takes your accountant to do the sums.
So a reduction in installation cost was one of the key goals given to the Rockwell automation engineers when they set out to design the Ultra 3000.
They identified three key areas where these savings could be made: * Connection of the servo drive to the controller, where they chose to use Sercos, a single fibre optic connection.
* Connection of the servo drive to the motor by using pre-configured power and feedback cables.
* A drive that automatically configures itself with the help of a smart feedback facility.
With Sercos, command signal and all position feedback information is routed over the fibre optic network, enabling the user to control, commission and monitor the drive.
The 20 wires that would previously have been required between the controller and servo drive are reduced to a single fibre optic cable.
The pre-configured power and feedback cables are designed to connect the servo drive to all current Allen-Bradley motors.
They are available in various lengths and take only seconds to plug in, compared to several hours needed to connect a conventional system.
With smart feedback technology, the drive can not only read the motor part number and so automatically configure itself, but also support absolute and high-resolution encoders.
This ensures that position is not lost if the power is cut, eliminating time-consuming machine homing cycles.
It delivers resolution down to millionths of a revolution, providing extreme accuracy.
For simple applications where complex multi-axis control is not required, the Ultra 3000 has a built in indexing function, allowing it to carry out a series of moves without an external controller.
This makes it perfect for applications such as pneumatic or clutch/brake replacement.
However, when connected to a modern controller such as the Allen-Bradley ControlLogix, it is capable of handling the most sophisticated requirements.
The power range is 0.5 to 22kW, 100 to 240V single phase or 380 to 500V three-phase AC.
There are eight general-purpose digital inputs assignable to multiple functions, four general-purpose digital and one relay output and a choice of multiple operating modes.
Such versatility is truly amazing, and with easy connectivity and commissioning it can be up and running and saving money in less time than it takes your accountant to do the sums.
Friday, October 13, 2006
Drives feature speed profiling
Rockwell Automation has added three important new features to its Allen-Bradley 1336 IMPACTTM AC drive. The inclusion of speed profiling, encoder/encoderless switchover and an encoderless-with-deadband option, considerably broadens the applications for this market leading drive. Speed profiling allows users to define 16 speed-step changes for greater control.
Previously, drives required an external controller (such as a programmable controller), to change the speed command.
The new, embedded speed profiling feature gives users the flexibility to run applications at a specified speed.
This can be based on time, encoder counters, or hardware inputs through the L-option card, saving panel space and costs associated with an external controller.
For applications requiring repeatable speed-step changes, such as turntables, gantries, run-out tables, transfer shuttles, palletisers and station gates, the 1336 IMPACT with speed profiling can be programmed for a series of up to 16 speed-step changes.
These are based on either an encoder pulse count, a specific time interval or by toggling a digital input in the drive.
The sequence of the profile can be a single cycle with a 'return-to- home' or a continuous loop with a 'return-to-step-one' routine.
For added application flexibility, each speed step has three parameters for configuration, including the step RPM speed, units of travel and the type of index or move needed to perform.
The Allen-Bradley 1336 IMPACT AC drive features Force TechnologyTM, a patented, field-oriented control technology developed by Rockwell Automation.
This permits the independent control of speed and torque, providing high-performance control of standard AC induction motors.
Speed profiling brings the added flexibility of defining speed- step changes to demanding motor control applications.
The encoder/encoderless switchover function automatically switches from encoder feedback to encoderless operation without disrupting the drive.
This is achieved by running the drive in encoderless mode and using the process trim loop as an outer speed trim loop.
This feature is intended for continuous casters and similar applications.
The encoderless-with-deadband option is effective when the drive is operating below 1 hertz in encoderless mode.
For low-speed applications, such as extruders, this eliminates cogging at low speeds by generating a zero-speed command while operating below 1 hertz.
The introduction of these new features further increases the flexibility and versatility of the Allen-Bradley 1336 IMPACTTM drive, making it suitable for a wide range of demanding industrial applications.
Linear drives speed up sliding head automatic
Using linear motors to remove any likelihood of deflection and backlash from the power transmission system a very compact sliding head automatic offers super precision with high speed.
By using linear motor technology to remove any likelihood of deflection and backlash from the power transmission system and to optimise the structure of the slideway, Citizen has been able to create a very compact machine able to capitalise on combining super precision with high speed one-hit machining cycles and short cycle times on components up to 7mm diameter by 40mm long. As a result, the new Citizen R07 Type VI CNC sliding head auto is reckoned to be significantly faster than a traditional cam auto when machining parts in single cycles using the main and subspindle and up to 13 tools while maintaining a very compact footprint when installed on the shopfloor. The Citizen R07, launched in the UK by NC Engineering of Watford, UK, has no hydraulics or pneumatics and is totally electric and electronic in operation.
It has six axes, a 16,000 rev/min, 1.1kW built-in main spindle with ceramic bearings for optimised machining of small diameter parts and a 0.5kW secondary spindle with an 8,000 rev/min capability.
Having two independent toolposts able to hold 13 tools, of which two are driven by 0.2kW, 8.000 rev/min spindle, two tools are able to simultaneously machine a component.
An important development with the RO7, that significantly increases machine utilisation, is the ability to open and close the collet at normal machining revolutions without having to slow the spindle.
Accuracy is high with increments of 0.0001mm in each axis and repeatability of one micron is possible.
By combining linear drive technology to both tool posts, high productivity is guaranteed with rapid acceleration to maximum traverse rates of 20m/min.
The maximum machining length is 40mm and with the two slide arrangement, five turning tools can be mounted on the gang tool post with two cross-driven tool positions.
In addition, three end working tools can be applied to each of the main and secondary spindles to high orders of positioning accuracy through the use of glass scale encoders.
Drilling and tapping capacity at the main spindle is 4mm and M3 respectively with 2mm and M2.6 for the secondary spindle.
Driven tool a capacity is 2mm.
The main spindle has 1 deg indexing and both spindles have rotational synchronisation for part transfer.
By using linear motor technology to remove any likelihood of deflection and backlash from the power transmission system and to optimise the structure of the slideway, Citizen has been able to create a very compact machine able to capitalise on combining super precision with high speed one-hit machining cycles and short cycle times on components up to 7mm diameter by 40mm long. As a result, the new Citizen R07 Type VI CNC sliding head auto is reckoned to be significantly faster than a traditional cam auto when machining parts in single cycles using the main and subspindle and up to 13 tools while maintaining a very compact footprint when installed on the shopfloor. The Citizen R07, launched in the UK by NC Engineering of Watford, UK, has no hydraulics or pneumatics and is totally electric and electronic in operation.
It has six axes, a 16,000 rev/min, 1.1kW built-in main spindle with ceramic bearings for optimised machining of small diameter parts and a 0.5kW secondary spindle with an 8,000 rev/min capability.
Having two independent toolposts able to hold 13 tools, of which two are driven by 0.2kW, 8.000 rev/min spindle, two tools are able to simultaneously machine a component.
An important development with the RO7, that significantly increases machine utilisation, is the ability to open and close the collet at normal machining revolutions without having to slow the spindle.
Accuracy is high with increments of 0.0001mm in each axis and repeatability of one micron is possible.
By combining linear drive technology to both tool posts, high productivity is guaranteed with rapid acceleration to maximum traverse rates of 20m/min.
The maximum machining length is 40mm and with the two slide arrangement, five turning tools can be mounted on the gang tool post with two cross-driven tool positions.
In addition, three end working tools can be applied to each of the main and secondary spindles to high orders of positioning accuracy through the use of glass scale encoders.
Drilling and tapping capacity at the main spindle is 4mm and M3 respectively with 2mm and M2.6 for the secondary spindle.
Driven tool a capacity is 2mm.
The main spindle has 1 deg indexing and both spindles have rotational synchronisation for part transfer.
This Russian bear gets its teeth into service!
Yaskawa Engineering (EEU) has an agreement with the Russian automation and systems integrator Rakurs to deliver service to the Russian market. The Rakurs Certified Diagnostic and Repair Centre in St Petersburg, was set up to service Omron and Yaskawa equipment in Russia. The centre services and repairs the entire range of inverters.
Rakurs is extremely well qualified not only to effective repairs and refurbishment of motors and drives to the exacting Yaskawa quality standards, but can also take on re-engineering projects and process improvements on behalf of Yaskawa users in the country.
Rakurs is a well respected and highly competent systems house that undertakes major automation projects in the likes of the paper and board industry, chemical processing and many other manufacturing sectors.
Started in 1991 by a team of engineers rooted in the automation and electronic engineering fields.
From the beginning the company specialised in designing control systems used in industrial processes.
There are now over 150 engineers and office staff based at Rakurs headquarters in St Petersburg, and in regional branches of Rakurs all over Russia.
According to Alexander Tikhomirov, Service Manager at Rakurs, his company believes in 'performing quickly and efficiently, giving customers the highest quality achievable, delivering a turnkey product'.
At the same time, he explained, 'we also must be ready to provide long-term support, maintenance and diagnostic services.
In short, solving our customer's problems'.
In September 2002 Rakurs passed a certified audit, which attested that its quality management System fully conformed to the requirements of the ISO 9001:2000 standard.
Apart from its systems ands service operations, since 1992 Rakurs has also been a distributor for Omron products in the region, including, of course the Omron Yaskawa Motion Control drives and motors.
Established in 1994, the Rakurs Authorised Training Centre trains specialists who will be operating and maintaining control systems and automation equipment, based on Omron products.
The centre is a joint venture with Saint Petersburg Electrotechnical University.
Rakurs staff trained by Omron as well as University personnel provide instruction.
Rakurs is extremely well qualified not only to effective repairs and refurbishment of motors and drives to the exacting Yaskawa quality standards, but can also take on re-engineering projects and process improvements on behalf of Yaskawa users in the country.
Rakurs is a well respected and highly competent systems house that undertakes major automation projects in the likes of the paper and board industry, chemical processing and many other manufacturing sectors.
Started in 1991 by a team of engineers rooted in the automation and electronic engineering fields.
From the beginning the company specialised in designing control systems used in industrial processes.
There are now over 150 engineers and office staff based at Rakurs headquarters in St Petersburg, and in regional branches of Rakurs all over Russia.
According to Alexander Tikhomirov, Service Manager at Rakurs, his company believes in 'performing quickly and efficiently, giving customers the highest quality achievable, delivering a turnkey product'.
At the same time, he explained, 'we also must be ready to provide long-term support, maintenance and diagnostic services.
In short, solving our customer's problems'.
In September 2002 Rakurs passed a certified audit, which attested that its quality management System fully conformed to the requirements of the ISO 9001:2000 standard.
Apart from its systems ands service operations, since 1992 Rakurs has also been a distributor for Omron products in the region, including, of course the Omron Yaskawa Motion Control drives and motors.
Established in 1994, the Rakurs Authorised Training Centre trains specialists who will be operating and maintaining control systems and automation equipment, based on Omron products.
The centre is a joint venture with Saint Petersburg Electrotechnical University.
Rakurs staff trained by Omron as well as University personnel provide instruction.
Thursday, October 12, 2006
Motors provide open-loop speed control
Ideal choice in an even wider variety of open-loop speed control applications, the Allen-Bradley PowerFlex 700H power range has been extended to 500kW.
Rockwell Automation has extended the Allen-Bradley PowerFlex 700H power range to 500kW, and now offers the popular IP21 enclosure drive in two additional versions of IP54 dust tight enclosure and open-frame IP00 option. More flexible than ever, the PowerFlex 700H is the ideal choice in an even wider variety of open-loop speed control applications. Since its introduction last year, the PowerFlex 700H has proved a popular choice in applications requiring accurate open-loop speed regulation and excellent low-speed torque, such as fans, pumps, conveyors, mixers, crushers, bark strippers, centrifuges, stamping presses and extruders.
With the addition of the new IP54 enclosure option, it can now be employed in an even wider range of applications, in all but the harshest industrial environments.
Along with the existing IP21 enclosure and new IP54 enclosure, Rockwell Automation has also added an IP00 option to the PowerFlex 700H.
The open frame design makes the PowerFlex 700H more accessible than ever to OEMs and machine builders requiring precise, reliable and cost-effective motor control for their high-power applications.
Open frame access and 'pull-apart' control terminal blocks simplify the task of wiring, and the optimised global voltage settings make the drive quick and easy to configure for applications anywhere in the world.
The power range of PowerFlex 700H has now been extended to offer 160kW to 500kW at voltages from 380 to 690V.
Users can configure the PowerFlex 700H for either V/Hz or sensorless vector control.
Standard I/O options include 24V or 115V digital I/O plus analogue I/O for added flexibility.
The extensive communications options available allow the user to easily integrate the drive into a manufacturing process or machine application using Rockwell Automation NetLinxTM, DeviceNetTM, ControlNetTM and EtherNet/IP networks as well as other industrial networks such as Profibus.
The built-in LCD display is multi-line and multi-lingual, and the on-board start and assisted start routines allow for easy configuration and tuning of the drive.
Naturally, PowerFlex 700H is also fully compatible with Allen-Bradley DriveExplorer, DriveExecutive and DriveTools SP software tools, making complex programming and system configuration easy and quick.
The new PowerFlex 700H IP54 enclosure and IP00 open-frame options are just the latest additions to the comprehensive PowerFlex range of AC drives, available from 0.25kW to 6700kW.
Like all products within the PowerFlex family, the 700H meets worldwide power ratings, packaging requirements and electromagnetic compatibility (EMC) criteria.
All the drives include AC-chokes and EMC filters compliant with EN 61800-3, and are CSA/cUL Certified, UL-listed and CE-marked.
The modular design and worldwide availability of spares makes the PowerFlex range easy to maintain in the field.
With the power range extension and addition of IP54 and IP00 variants, PowerFlex 700H is the ideal choice for both OEMs and end-users requiring the best possible combination of features and cost-effectiveness.
Rockwell Automation has extended the Allen-Bradley PowerFlex 700H power range to 500kW, and now offers the popular IP21 enclosure drive in two additional versions of IP54 dust tight enclosure and open-frame IP00 option. More flexible than ever, the PowerFlex 700H is the ideal choice in an even wider variety of open-loop speed control applications. Since its introduction last year, the PowerFlex 700H has proved a popular choice in applications requiring accurate open-loop speed regulation and excellent low-speed torque, such as fans, pumps, conveyors, mixers, crushers, bark strippers, centrifuges, stamping presses and extruders.
With the addition of the new IP54 enclosure option, it can now be employed in an even wider range of applications, in all but the harshest industrial environments.
Along with the existing IP21 enclosure and new IP54 enclosure, Rockwell Automation has also added an IP00 option to the PowerFlex 700H.
The open frame design makes the PowerFlex 700H more accessible than ever to OEMs and machine builders requiring precise, reliable and cost-effective motor control for their high-power applications.
Open frame access and 'pull-apart' control terminal blocks simplify the task of wiring, and the optimised global voltage settings make the drive quick and easy to configure for applications anywhere in the world.
The power range of PowerFlex 700H has now been extended to offer 160kW to 500kW at voltages from 380 to 690V.
Users can configure the PowerFlex 700H for either V/Hz or sensorless vector control.
Standard I/O options include 24V or 115V digital I/O plus analogue I/O for added flexibility.
The extensive communications options available allow the user to easily integrate the drive into a manufacturing process or machine application using Rockwell Automation NetLinxTM, DeviceNetTM, ControlNetTM and EtherNet/IP networks as well as other industrial networks such as Profibus.
The built-in LCD display is multi-line and multi-lingual, and the on-board start and assisted start routines allow for easy configuration and tuning of the drive.
Naturally, PowerFlex 700H is also fully compatible with Allen-Bradley DriveExplorer, DriveExecutive and DriveTools SP software tools, making complex programming and system configuration easy and quick.
The new PowerFlex 700H IP54 enclosure and IP00 open-frame options are just the latest additions to the comprehensive PowerFlex range of AC drives, available from 0.25kW to 6700kW.
Like all products within the PowerFlex family, the 700H meets worldwide power ratings, packaging requirements and electromagnetic compatibility (EMC) criteria.
All the drives include AC-chokes and EMC filters compliant with EN 61800-3, and are CSA/cUL Certified, UL-listed and CE-marked.
The modular design and worldwide availability of spares makes the PowerFlex range easy to maintain in the field.
With the power range extension and addition of IP54 and IP00 variants, PowerFlex 700H is the ideal choice for both OEMs and end-users requiring the best possible combination of features and cost-effectiveness.
Shorter payback now drives included on ECA list
The long-awaited publication of the UK Government's Energy Technology Product List (products that qualify for Enhanced Capital Allowance) includes all three of the Moeller's ranges of drives
The long-awaited publication of the Government's Energy Technology Product List - better known as the list of products that qualify for enhanced capital allowance - finally took place today, 28th March 2001, with good news for Moeller customers: all three of the company's ranges of drives - Optidrive, DV4 and DF4 are included on it. From 1st April 2001 the climate change Levy comes into effect. This is an attempt by the Government to reduce energy and thus curb the harmful emission of greenhouse gases by making major industrial users pay 0.43p more for every kWh of electricity that they consume.
In order to lessen the blow and to ensure that companies are using more energy-efficient equipment, the Government has introduced Enhanced Capital Allowances that allow companies to write off 100% of the cost of AC drives and high efficiency motors in the year that they buy the equipment.
Commenting on the company's inclusion on the list, Jerry Stokes general manager of Moeller Electric's industrial automation Division, said: "The Energy Technology Product List is a very important document, both for manufacturers and users alike.
It shows which products have been certified as meeting the appropriate energy saving criteria, in other words on which ones businesses will be able to claim the 100% capital allowance.
We are delighted that all three of our popular AC drives have been included on the list, a move which reinforces our commitment to providing the highest levels of energy efficiency."
There are approximately 10 million motors being used in Britain today.
With a combined capacity of around 70GW, these motors consume more than 130TWh of energy, at a cost of around œ6,600m.
Nearly half of this energy is used to power motors driving pumps and fans.
Most of these run at constant speed, using inefficient mechanical devices such as valves or throttles to vary the rate.
Reducing the speed of the fan or pump using an AC drive is a much more efficient way of achieving the same result.
For example, an AC drive such as Optidrive used to reduce a fan motor speed by 15% can cut energy costs by as much as 40%, enabling the drive to pay for itself within two years - and that is before considering the new Enhanced Capital Allowance! .
The long-awaited publication of the Government's Energy Technology Product List - better known as the list of products that qualify for enhanced capital allowance - finally took place today, 28th March 2001, with good news for Moeller customers: all three of the company's ranges of drives - Optidrive, DV4 and DF4 are included on it. From 1st April 2001 the climate change Levy comes into effect. This is an attempt by the Government to reduce energy and thus curb the harmful emission of greenhouse gases by making major industrial users pay 0.43p more for every kWh of electricity that they consume.
In order to lessen the blow and to ensure that companies are using more energy-efficient equipment, the Government has introduced Enhanced Capital Allowances that allow companies to write off 100% of the cost of AC drives and high efficiency motors in the year that they buy the equipment.
Commenting on the company's inclusion on the list, Jerry Stokes general manager of Moeller Electric's industrial automation Division, said: "The Energy Technology Product List is a very important document, both for manufacturers and users alike.
It shows which products have been certified as meeting the appropriate energy saving criteria, in other words on which ones businesses will be able to claim the 100% capital allowance.
We are delighted that all three of our popular AC drives have been included on the list, a move which reinforces our commitment to providing the highest levels of energy efficiency."
There are approximately 10 million motors being used in Britain today.
With a combined capacity of around 70GW, these motors consume more than 130TWh of energy, at a cost of around œ6,600m.
Nearly half of this energy is used to power motors driving pumps and fans.
Most of these run at constant speed, using inefficient mechanical devices such as valves or throttles to vary the rate.
Reducing the speed of the fan or pump using an AC drive is a much more efficient way of achieving the same result.
For example, an AC drive such as Optidrive used to reduce a fan motor speed by 15% can cut energy costs by as much as 40%, enabling the drive to pay for itself within two years - and that is before considering the new Enhanced Capital Allowance! .
Long travelling column machine has linear motors
A longer travelling column, vertical machining centre equipped with linear motor drives is ideal for machining aerospace components and larger dies and moulding tools.
The Super Velocity Centre (SVC) 2000L travelling column, longer vertical machining centre is now equipped with linear drives. Recognising that larger production machining centres benefit from the speed and maintained accuracy achievable by linear drive motors, Mazak's new SVC 2000L will complement the existing (shorter) VTC machines but take advantage of linear drive technology for its 3-metre capacity. The new Super Velocity Centre 2000L is a machine ideal for use in the aerospace industry where its 3.4 metre long machining table can accommodate workpieces such as air frame components.
It is also ideally suited to the machining of larger dies and mould tools.
W ith a rapid traverse of 120m/min in the X axis and 50m/min on the Y and Z-axes, the table is capable of accelerating at 0.5G in all axes.
The maximum spindle speed is 12,000 rev/min driven by a 22kW spindle motor.
The higher operational speeds of linear machines have the advantage of reducing both idle and cutting times, giving increased productivity with the fewer number of components in linear drive motors and machine tools, further increasing the overall reliability.
The Super Velocity Centre (SVC) 2000L travelling column, longer vertical machining centre is now equipped with linear drives. Recognising that larger production machining centres benefit from the speed and maintained accuracy achievable by linear drive motors, Mazak's new SVC 2000L will complement the existing (shorter) VTC machines but take advantage of linear drive technology for its 3-metre capacity. The new Super Velocity Centre 2000L is a machine ideal for use in the aerospace industry where its 3.4 metre long machining table can accommodate workpieces such as air frame components.
It is also ideally suited to the machining of larger dies and mould tools.
W ith a rapid traverse of 120m/min in the X axis and 50m/min on the Y and Z-axes, the table is capable of accelerating at 0.5G in all axes.
The maximum spindle speed is 12,000 rev/min driven by a 22kW spindle motor.
The higher operational speeds of linear machines have the advantage of reducing both idle and cutting times, giving increased productivity with the fewer number of components in linear drive motors and machine tools, further increasing the overall reliability.
Wednesday, October 11, 2006
Drum motors protect against salmonella poisoning
Drum motor drives on conveyors eliminate the risk of bacterial contamination since the entire drive mechanism is located in a sealed unit.
Chris Middleton, Managing Director of BDL Drum Motors (UK) warnsagainst using conventional conveyor belt drives in the food,beverage and pharmaceutical industries. Distributing contaminatedfood, knowingly or unknowingly, can spell disaster formanufacturers. In addition to the lost value of batches returned,a producers reputation could be irretrievably shattered withbuyers moving acquisitions to other competitor sources.
However,time and technology has moved on and it is now possible to usemodern and competitively priced production equipment that canvirtually eliminate contamination in processing.
The food,beverage and pharmaceutical industries make special demandsregarding hygiene and cleaning in production areas and, that iswhy machinery design looks to be crevice free to prevent dirttraps and are often manufactured from non-corrosive materials.Contamination is a major issue in the food and dairy sectors,including the soft cheese industry.
Here, manufacturers areconfronted with clostridia (spindle shaped bacterial cells).Various strategies exist such as UHT heating, adding salts,pre-melting, or introducing repressive substances such as nisin.But if the raw products used to produce these cheeses arecontaminated themselves, even these measures can proveineffective.
Such highly resilient bacteria can then easilyaccumulate in production equipment.
Conventional conveyor drivesa source of contamination However, traditional conveyor beltdrives comprising of the classic geared motor, chain and pulleyare still in widespread use in the food, beverage andpharmaceutical process and packaging industries, but they do posea potential contamination risk to products transported by them.Where guarding and obstacles create limited access to standardgeared motors on production lines cleaning cannot be thoroughlyundertaken and as a result, it is not uncommon to see coolingribs completely clogged with product residues or belt lubricants.Even the fan cowling attract process dust and needs frequentremoval for effective cleaning.
A recent report from UdoEigenfeld, CEO of BDL Maschinenbau GmbH remarked that a foodmanufacturer recently became aware of this fact during a recall.Although chain motors are often placed under a protective guardand cover, fine dust particles can still accumulate on the chain.Unfortunately, most covers leave the undersides of the mechanismsexposed and are a far cry from complying with stringentprotection standards such as IP65 or IP66.
It was found that thesource of contamination was actually the grease used to lubricatethe chain.
Although this substance is physiologically harmless,it can nevertheless accumulate dust.
Dust containing protein isthe basic foodstuff for germs, bacteria and salmonellae, whichoccasionally break free from the chain due to normal processvibration and can end up in food.
Drum motor drives eliminate therisk of contamination since the entire drive mechanism is locatedin a sealed unit.
The easy to access, space saving and compactdrum motor drives, eliminate the risk of contamination, since theelectric drive motor and integrated precision gearbox are allcombined and enclosed in a crevice free, sealed rotating drum.With maintenance free bearings there is no need to lubricate thedrive elements and the absence of chains and cooling fan, hasalso removed further possible sources for dirt, dust and germs toaccumulate.
The obvious consequence is that drum motor drives arethus able to comply with the highest standards of hygiene andeliminate the risk of food contamination due to dustaccumulation.
Drum motor drives offering IP66 protectionclassification can be cleaned using high pressure hosing withoutthe need for subsequent lubrication or maintenance.
This not onlyreduces the risk of contamination but also the total cost ofownership.
Independent study confirms lack of hygiene - a studyconducted by the _Frauenhofer Institute for ProductionEngineering and Automation_ confirmed problems with levels ofhygiene in food production.
More than half (52%) of foodmanufacturers found hygiene to be inappropriate duringproduction.
The main cause for concern was traced back toconveyor belt drives.
It was found that older external gearboxdrive mechanisms in particular, often had areas that were hardlyaccessible and were thus difficult to clean.
( A copy of thestudy can be obtained from the Frauenhofer IPA in Stuttgart,Germany.
Source: open automation 2/2002, p.54f).
A further optionprovided in particular for the food, pharmaceutical and cleanroom industries is 'burnt-in' identification plates onthe end of drum motor covers.
These new identification plates areformed by electrolysis.
This procedure enriches carbon moleculesnear the surface of the stainless steel housing, causing a changein colour - similar to the process used on some knife blades.
Incomparison to the traditional method of attaching a separatestainless steel identification plate to the motor, this methodprovides considerable greater degree of hygiene.
It's nowimpossible for capillaries to form behind the plate and avoidsthe plate being ripped off, as can be the case with adhesiveidentification plates.
BDL Drum Motors (UK) located at Corby haveundertaken various trials in conjunction with customers and OEMsto demonstrate energy saving claims of between 32% (loaded) and47% (unloaded) in comparison to conventional geared motor drives;clean hygienic profile features of drums with quick changeoverand no maintenance requirements; developing new drive solutionsfor new belting materials, etc.
Working closely with industry,BDL have evolved the drum motor to be a serious contender toreplace geared motor drives.
Chris Middleton, Managing Director of BDL Drum Motors (UK) warnsagainst using conventional conveyor belt drives in the food,beverage and pharmaceutical industries. Distributing contaminatedfood, knowingly or unknowingly, can spell disaster formanufacturers. In addition to the lost value of batches returned,a producers reputation could be irretrievably shattered withbuyers moving acquisitions to other competitor sources.
However,time and technology has moved on and it is now possible to usemodern and competitively priced production equipment that canvirtually eliminate contamination in processing.
The food,beverage and pharmaceutical industries make special demandsregarding hygiene and cleaning in production areas and, that iswhy machinery design looks to be crevice free to prevent dirttraps and are often manufactured from non-corrosive materials.Contamination is a major issue in the food and dairy sectors,including the soft cheese industry.
Here, manufacturers areconfronted with clostridia (spindle shaped bacterial cells).Various strategies exist such as UHT heating, adding salts,pre-melting, or introducing repressive substances such as nisin.But if the raw products used to produce these cheeses arecontaminated themselves, even these measures can proveineffective.
Such highly resilient bacteria can then easilyaccumulate in production equipment.
Conventional conveyor drivesa source of contamination However, traditional conveyor beltdrives comprising of the classic geared motor, chain and pulleyare still in widespread use in the food, beverage andpharmaceutical process and packaging industries, but they do posea potential contamination risk to products transported by them.Where guarding and obstacles create limited access to standardgeared motors on production lines cleaning cannot be thoroughlyundertaken and as a result, it is not uncommon to see coolingribs completely clogged with product residues or belt lubricants.Even the fan cowling attract process dust and needs frequentremoval for effective cleaning.
A recent report from UdoEigenfeld, CEO of BDL Maschinenbau GmbH remarked that a foodmanufacturer recently became aware of this fact during a recall.Although chain motors are often placed under a protective guardand cover, fine dust particles can still accumulate on the chain.Unfortunately, most covers leave the undersides of the mechanismsexposed and are a far cry from complying with stringentprotection standards such as IP65 or IP66.
It was found that thesource of contamination was actually the grease used to lubricatethe chain.
Although this substance is physiologically harmless,it can nevertheless accumulate dust.
Dust containing protein isthe basic foodstuff for germs, bacteria and salmonellae, whichoccasionally break free from the chain due to normal processvibration and can end up in food.
Drum motor drives eliminate therisk of contamination since the entire drive mechanism is locatedin a sealed unit.
The easy to access, space saving and compactdrum motor drives, eliminate the risk of contamination, since theelectric drive motor and integrated precision gearbox are allcombined and enclosed in a crevice free, sealed rotating drum.With maintenance free bearings there is no need to lubricate thedrive elements and the absence of chains and cooling fan, hasalso removed further possible sources for dirt, dust and germs toaccumulate.
The obvious consequence is that drum motor drives arethus able to comply with the highest standards of hygiene andeliminate the risk of food contamination due to dustaccumulation.
Drum motor drives offering IP66 protectionclassification can be cleaned using high pressure hosing withoutthe need for subsequent lubrication or maintenance.
This not onlyreduces the risk of contamination but also the total cost ofownership.
Independent study confirms lack of hygiene - a studyconducted by the _Frauenhofer Institute for ProductionEngineering and Automation_ confirmed problems with levels ofhygiene in food production.
More than half (52%) of foodmanufacturers found hygiene to be inappropriate duringproduction.
The main cause for concern was traced back toconveyor belt drives.
It was found that older external gearboxdrive mechanisms in particular, often had areas that were hardlyaccessible and were thus difficult to clean.
( A copy of thestudy can be obtained from the Frauenhofer IPA in Stuttgart,Germany.
Source: open automation 2/2002, p.54f).
A further optionprovided in particular for the food, pharmaceutical and cleanroom industries is 'burnt-in' identification plates onthe end of drum motor covers.
These new identification plates areformed by electrolysis.
This procedure enriches carbon moleculesnear the surface of the stainless steel housing, causing a changein colour - similar to the process used on some knife blades.
Incomparison to the traditional method of attaching a separatestainless steel identification plate to the motor, this methodprovides considerable greater degree of hygiene.
It's nowimpossible for capillaries to form behind the plate and avoidsthe plate being ripped off, as can be the case with adhesiveidentification plates.
BDL Drum Motors (UK) located at Corby haveundertaken various trials in conjunction with customers and OEMsto demonstrate energy saving claims of between 32% (loaded) and47% (unloaded) in comparison to conventional geared motor drives;clean hygienic profile features of drums with quick changeoverand no maintenance requirements; developing new drive solutionsfor new belting materials, etc.
Working closely with industry,BDL have evolved the drum motor to be a serious contender toreplace geared motor drives.
New European Electric Drives information service
Industry analysts Frost and Sullivan are announcing the launch of a new wide-reaching market research service, the European Electric Drives Market Service.
The electric variable speed drives market is one of the most dynamic in the mature motors and drives industry. Changing customer demands, widening applications, a large total of competitors and the need for constant product development means that regular and reliable information is critical in order for companies to remain or become key players in the market. As a means to provide a fundamental analysis of the market, industry analysts Frost and Sullivan - http://motors.frost.com - announce the launch of a new wide-reaching market research service, the European electric drives Market Service.
The service offers market participants a definitive overview of the industry, providing detailed breakdowns by product, power rating, region and application enabling subscribers to identify and track the key developments in the industry over the course of the year.
The Low Power Rated Drives: Power Rating Analysis is the first Deliverable available to be completed within the service.
The low power rated electric drives market has been defined to include all electric drives with a power rating under 75kW which are used in industrial applications.
The market includes both alternating current (AC) and direct current (DC) drives.
The low power rated electric drives market - valued at $1.09 billion in 2000 - has faced a number of challenges in the last few years, and these will continue to affect the market.
One of the key challenges has been continued fierce price competition.
"All manufacturers are facing greater pressures with regards to their price levels and this trend is most significant at the lowest power rating levels," explains Mik Sabiers, European Research Manager, Motors, Drives and Controls.
"Although it had long been expected that price levels had reached a low point and there was no scope for further reductions, manufacturers are continuing to lower price levels on a regular basis."
"This has been led by the desire to build the customer base as well as gain increased orders from actual and potential customers.
However, the fact that prices are continuing to fall means manufacturers must improve their overall production facilities and sales strategies to take account not only the increased demand, but also the need to offer ever more competitively priced technology."
The AC drives segment has been advancing strongly despite the challenges it has faced.
Total revenues for AC drives increased by 4.7 percent to $955.8 million in 2000, while total shipments increased by a higher 9.4 percent to 1.1 million.
Competitive prices, wider penetration of drive technology across multiple applications, interest in advanced speed control and the positive economic environment in core European regions saw growth in all power rating segments, with power ratings below 2.2kW experiencing the greatest rise in demand growth.
Frost and Sullivan forecasts that growth should moderate with AC drives revenues projected to reach $1.26 billion and shipments forecast to rise to 1.8 million units in 2007.
The AC market will be driven by technological advancements and the greater simplicity of drive operation.
"Drive technology does remain complex, and the wide variety of operations and options that drives can offer have in the past limited user demand as the complexity of the technology was seen as a negative for wider usage," Mr Sabiers explains.
"Drive manufacturers have been focusing on simplifying the use and operation of drives, and this can be expected to widen overall demand.
Easier programming and operation are projected to support rising usage of AC drive technology, expanding total penetration across the broad range of applications, and increasingly supporting their use in basic applications where a drive was considered too complex a solution in prior years."
The results for the DC drives market were mixed with revenues and shipments falling to $134.1 million and 127,4000 units respectively in 2000.
The continued move to AC technology combined with poor demand across all power rating levels contributed to the decline.
Frost and Sullivan forecasts demand and revenues will slow over the remainder of the forecast period, although the market should also benefit to a degree from a gradual rise in price levels as well as focused interest in some core industry areas.
Revenues are projected to fall slightly to $124.5 million in 2007.
Other deliverables due out during the course of the year include: #6400 High Power Rated Drives: Power Rating Analysis (Publication in June), #6401 Low Power Rated Drives: Regional Analysis (Publication in July) #6402 High Power Rated Drives: Regional Analysis (Publication in July) #6403 Low Power Rated Drives: Competitive Analysis (Publication in September) #6404 High Power Rated Drives: Competitive Analysis (Publication in September) #6405 Electric Drives: End-User Analysis (Publication in December) #6406 Electric Drives Market Engineering Awards (Publication in December)
The electric variable speed drives market is one of the most dynamic in the mature motors and drives industry. Changing customer demands, widening applications, a large total of competitors and the need for constant product development means that regular and reliable information is critical in order for companies to remain or become key players in the market. As a means to provide a fundamental analysis of the market, industry analysts Frost and Sullivan - http://motors.frost.com - announce the launch of a new wide-reaching market research service, the European electric drives Market Service.
The service offers market participants a definitive overview of the industry, providing detailed breakdowns by product, power rating, region and application enabling subscribers to identify and track the key developments in the industry over the course of the year.
The Low Power Rated Drives: Power Rating Analysis is the first Deliverable available to be completed within the service.
The low power rated electric drives market has been defined to include all electric drives with a power rating under 75kW which are used in industrial applications.
The market includes both alternating current (AC) and direct current (DC) drives.
The low power rated electric drives market - valued at $1.09 billion in 2000 - has faced a number of challenges in the last few years, and these will continue to affect the market.
One of the key challenges has been continued fierce price competition.
"All manufacturers are facing greater pressures with regards to their price levels and this trend is most significant at the lowest power rating levels," explains Mik Sabiers, European Research Manager, Motors, Drives and Controls.
"Although it had long been expected that price levels had reached a low point and there was no scope for further reductions, manufacturers are continuing to lower price levels on a regular basis."
"This has been led by the desire to build the customer base as well as gain increased orders from actual and potential customers.
However, the fact that prices are continuing to fall means manufacturers must improve their overall production facilities and sales strategies to take account not only the increased demand, but also the need to offer ever more competitively priced technology."
The AC drives segment has been advancing strongly despite the challenges it has faced.
Total revenues for AC drives increased by 4.7 percent to $955.8 million in 2000, while total shipments increased by a higher 9.4 percent to 1.1 million.
Competitive prices, wider penetration of drive technology across multiple applications, interest in advanced speed control and the positive economic environment in core European regions saw growth in all power rating segments, with power ratings below 2.2kW experiencing the greatest rise in demand growth.
Frost and Sullivan forecasts that growth should moderate with AC drives revenues projected to reach $1.26 billion and shipments forecast to rise to 1.8 million units in 2007.
The AC market will be driven by technological advancements and the greater simplicity of drive operation.
"Drive technology does remain complex, and the wide variety of operations and options that drives can offer have in the past limited user demand as the complexity of the technology was seen as a negative for wider usage," Mr Sabiers explains.
"Drive manufacturers have been focusing on simplifying the use and operation of drives, and this can be expected to widen overall demand.
Easier programming and operation are projected to support rising usage of AC drive technology, expanding total penetration across the broad range of applications, and increasingly supporting their use in basic applications where a drive was considered too complex a solution in prior years."
The results for the DC drives market were mixed with revenues and shipments falling to $134.1 million and 127,4000 units respectively in 2000.
The continued move to AC technology combined with poor demand across all power rating levels contributed to the decline.
Frost and Sullivan forecasts demand and revenues will slow over the remainder of the forecast period, although the market should also benefit to a degree from a gradual rise in price levels as well as focused interest in some core industry areas.
Revenues are projected to fall slightly to $124.5 million in 2007.
Other deliverables due out during the course of the year include: #6400 High Power Rated Drives: Power Rating Analysis (Publication in June), #6401 Low Power Rated Drives: Regional Analysis (Publication in July) #6402 High Power Rated Drives: Regional Analysis (Publication in July) #6403 Low Power Rated Drives: Competitive Analysis (Publication in September) #6404 High Power Rated Drives: Competitive Analysis (Publication in September) #6405 Electric Drives: End-User Analysis (Publication in December) #6406 Electric Drives Market Engineering Awards (Publication in December)
Hazardous area motors benefit from end shield
ABB is introducing a new motor design for hazardous area air-cooled heat exchanger applications.
ABB is introducing a new motor design for hazardous area air-cooled heat exchanger applications. The motors are fitted with a specially designed end shield and a maintenance-free, non-contacting labyrinth seal to prevent damage caused by water ingress. Air-cooled heat exchangers are used as process coolers in gas processing, petroleum refining and similar applications within the chemical, oil and gas and petrochemical industries.
Motors in this application are positioned vertically, shaft-up, in very demanding site conditions such as high humidity, rain and dust.
It is extremely important to prevent any damage caused by water entering the motors.
This puts high demands on the sealing, particularly to ensure the bearings are protected.
An air-cooled heat exchanger is used to reject heat from fluid directly to the ambient air without using water as a cooling medium.
This enables plant with a high cooling requirement to be placed in locations without a water supply.
The new design can be used for both foot- and flange-mounted, low-voltage,
ABB is introducing a new motor design for hazardous area air-cooled heat exchanger applications. The motors are fitted with a specially designed end shield and a maintenance-free, non-contacting labyrinth seal to prevent damage caused by water ingress. Air-cooled heat exchangers are used as process coolers in gas processing, petroleum refining and similar applications within the chemical, oil and gas and petrochemical industries.
Motors in this application are positioned vertically, shaft-up, in very demanding site conditions such as high humidity, rain and dust.
It is extremely important to prevent any damage caused by water entering the motors.
This puts high demands on the sealing, particularly to ensure the bearings are protected.
An air-cooled heat exchanger is used to reject heat from fluid directly to the ambient air without using water as a cooling medium.
This enables plant with a high cooling requirement to be placed in locations without a water supply.
The new design can be used for both foot- and flange-mounted, low-voltage,
Tuesday, October 10, 2006
Extensive range of geared motors launched
New geared motors from Siemens Automation and Drives include spur, mitre, flat and worm types, supplied with outputs from 90W to 7.5kW, with shaft heights from 63mm to 132mm
Four new geared motors have been added to the range of drives available from Siemens Automation and Drives. The spur, mitre, flat and worm gears are supplied with outputs from 90W to 7.5kW, with shaft heights from 63mm to 132mm. Outputs of these two, four, six and eight pole motors are graded in accordance with the IEC.
Pole-changing versions are available for all of the models.
The modular design of the geared motors allows the flexible connection of encoders, braking units and external fans, and can be adapted to individual requirements.
As these motors are embedded in the concepts of Totally Integrated Automation (TIA) and Ecofast, the system for distributed interface technology, they enable integrated system solutions to be implemented at a reasonable price.
In addition, they are compatible with all Siemens converters and are harmonized with one another.
The spur gears are concentrically designed and offer two housing design options: flange or foot mounting.
The housing of the smaller sizes is made from die-cast or permanent-mould aluminium alloy, while the larger units have a grey cast iron housing.
The spur gears are available in two-stage version, and the range of ratios can be increased by means of a flanged-on preliminary stage.
The mitre gears allow users to attach output flanges, baseplates or torque brackets.
For small sizes, the angle stage is a hypoid gear pair that ensures very quiet running and greater gear ratios.
The geared motors have a housing made of aluminium alloy permanent-mould casting and have two stages in the basic version.
The larger, three-stage gears are equipped with a bevel-gear stage and are manufactured from grey cast iron.
The range of ratios for the mitre gears can also be increased by means of a preliminary stage.
The compact construction and low-profile design of the flat gears means they are particularly well suited to space-saving applications.
They can be ordered with either solid or hollow shafts and with various attachment options.
The smaller series have a dimensionally stable, vertically split housing made from die-cast aluminium alloy, whilst the larger gear units have a grey cast iron housing.
The flat gear units are available in both two-stage and three-stage versions.
Helical worm gears also offer the advantage of a variety of attachment options due to their universal design or with a combination of flanges, baseplates and torque brackets.
Solid and hollow shafts in various dimensions and versions are available as input shafts.
The efficiency depends on the gear ratio and thanks to the spur gear input stage, values of up to 90 percent are achieved.
The smaller gear units have a housing of aluminium alloy permanent-mould casting, while the larger ones have a grey cast iron housing.
The worm gear units have two stages in their basic version.
The range of ratios in the larger gear units can be increased by means of a preliminary stage.
Four new geared motors have been added to the range of drives available from Siemens Automation and Drives. The spur, mitre, flat and worm gears are supplied with outputs from 90W to 7.5kW, with shaft heights from 63mm to 132mm. Outputs of these two, four, six and eight pole motors are graded in accordance with the IEC.
Pole-changing versions are available for all of the models.
The modular design of the geared motors allows the flexible connection of encoders, braking units and external fans, and can be adapted to individual requirements.
As these motors are embedded in the concepts of Totally Integrated Automation (TIA) and Ecofast, the system for distributed interface technology, they enable integrated system solutions to be implemented at a reasonable price.
In addition, they are compatible with all Siemens converters and are harmonized with one another.
The spur gears are concentrically designed and offer two housing design options: flange or foot mounting.
The housing of the smaller sizes is made from die-cast or permanent-mould aluminium alloy, while the larger units have a grey cast iron housing.
The spur gears are available in two-stage version, and the range of ratios can be increased by means of a flanged-on preliminary stage.
The mitre gears allow users to attach output flanges, baseplates or torque brackets.
For small sizes, the angle stage is a hypoid gear pair that ensures very quiet running and greater gear ratios.
The geared motors have a housing made of aluminium alloy permanent-mould casting and have two stages in the basic version.
The larger, three-stage gears are equipped with a bevel-gear stage and are manufactured from grey cast iron.
The range of ratios for the mitre gears can also be increased by means of a preliminary stage.
The compact construction and low-profile design of the flat gears means they are particularly well suited to space-saving applications.
They can be ordered with either solid or hollow shafts and with various attachment options.
The smaller series have a dimensionally stable, vertically split housing made from die-cast aluminium alloy, whilst the larger gear units have a grey cast iron housing.
The flat gear units are available in both two-stage and three-stage versions.
Helical worm gears also offer the advantage of a variety of attachment options due to their universal design or with a combination of flanges, baseplates and torque brackets.
Solid and hollow shafts in various dimensions and versions are available as input shafts.
The efficiency depends on the gear ratio and thanks to the spur gear input stage, values of up to 90 percent are achieved.
The smaller gear units have a housing of aluminium alloy permanent-mould casting, while the larger ones have a grey cast iron housing.
The worm gear units have two stages in their basic version.
The range of ratios in the larger gear units can be increased by means of a preliminary stage.
Motors have integrated servo drives
With the drive integrated into the back of a range of servo motors, which can deliver rated torques down to zero speed, machine builders benefit with reduced panel and installation costs.
The Lenze fluxxtorque range of servo motors with integrated servo drives are available in three sizes for powers up to 500W. With the drive integrated into the back of the motor, machine builders benefit with reduced panel and installation costs. Nominal output torques range from 0.45 to 1.6Nm with highly dynamic peak torques up to 14Nm.
Motors are rated at 3000 rev/min and can deliver rated torques down to zero speed.
Taking the drive out of the panel and integrating it with the motor allows the panel to be smaller.
Only one component needs to be installed saving time.
Further savings can be found by creating loop or spur connections from motor to motor, so reducing cable length, and there is no need for the cable to be shielded for EMC.
This new product line has been developed for applications in packaging, wood processing, warehousing and medical technology.
So for example, limit stops can be reset quickly and precisely in the event of product changes, or food dosed precisely to the gram.
Further advantages come from the compact and smooth bodied design with IP54 enclosure.
Control communications can be by PROFBUS or CAN.
The Lenze fluxxtorque range of servo motors with integrated servo drives are available in three sizes for powers up to 500W. With the drive integrated into the back of the motor, machine builders benefit with reduced panel and installation costs. Nominal output torques range from 0.45 to 1.6Nm with highly dynamic peak torques up to 14Nm.
Motors are rated at 3000 rev/min and can deliver rated torques down to zero speed.
Taking the drive out of the panel and integrating it with the motor allows the panel to be smaller.
Only one component needs to be installed saving time.
Further savings can be found by creating loop or spur connections from motor to motor, so reducing cable length, and there is no need for the cable to be shielded for EMC.
This new product line has been developed for applications in packaging, wood processing, warehousing and medical technology.
So for example, limit stops can be reset quickly and precisely in the event of product changes, or food dosed precisely to the gram.
Further advantages come from the compact and smooth bodied design with IP54 enclosure.
Control communications can be by PROFBUS or CAN.
Drives and motors 'Overview' is down-loadable
Technosoft presents a new, comprehensive Product Overview for its intelligent drives and motors, which are software configurable to drive brushless, step, DC or linear motors.
Free to download, this catalogue presents the Technosoft embedded intelligence products based on the latest MotionChipTM DSP Control Technology. These drives and motors are software configurable to drive brushless, step, DC or linear motors from 25W to 640W and they embed motion control, drive, PLC functionalities, motor (with intelligent motors) in a single compact unit. Designed to help users select among different products, the catalogue is clear and easy to use.
Engineers will find here short illustrated descriptions of each drive, links to technical documentation and software available, as well as ordering information.
For an easier comparison between different items, the users can utilize the Product Selector, which covers information regarding: types of motors, bus voltages, currents, communication networks, control functions, inputs/outputs, accepted sensors, sizes, weights, etc Also, this Product Overview includes brief presentations for software platforms, motion libraries and starter kits available.
The catalogue content will show that these products are the ideal cost-effective choice for distributed control applications, and, it will illustrate the flexibility and versatility of Technosoft drives and motors.
Free to download, this catalogue presents the Technosoft embedded intelligence products based on the latest MotionChipTM DSP Control Technology. These drives and motors are software configurable to drive brushless, step, DC or linear motors from 25W to 640W and they embed motion control, drive, PLC functionalities, motor (with intelligent motors) in a single compact unit. Designed to help users select among different products, the catalogue is clear and easy to use.
Engineers will find here short illustrated descriptions of each drive, links to technical documentation and software available, as well as ordering information.
For an easier comparison between different items, the users can utilize the Product Selector, which covers information regarding: types of motors, bus voltages, currents, communication networks, control functions, inputs/outputs, accepted sensors, sizes, weights, etc Also, this Product Overview includes brief presentations for software platforms, motion libraries and starter kits available.
The catalogue content will show that these products are the ideal cost-effective choice for distributed control applications, and, it will illustrate the flexibility and versatility of Technosoft drives and motors.
Monday, October 09, 2006
Read all about intelligent drives and motors
Technosoft has published a new, comprehensive product overview for its intelligent drives and motors.
Technosoft has published a new, comprehensive product overview for its intelligent drives and motors. Free to download, this catalogue presents the Technosoft embedded intelligence products based on the latest MotionChip DSP control technology. These drives and motors are software configurable to drive brushless, step, DC or linear motors from 25 to 640W and they embed motion control, drive, PLC functionalities, motor (with intelligent motors) in a single compact unit.
Designed to help users select among different products, the catalogue is clear and easy to use.
Engineers will find here short illustrated descriptions of each drive, links to technical documentation and software available, as well as ordering information.
For an easier comparison between different items, the users can use the product selector, which covers information regarding: types of motors, bus voltages, currents, communication networks, control functions, inputs/outputs, accepted sensors, sizes, weights etc.
Also, this product overview includes brief presentations for software platforms, motion libraries and starter kits available.
The catalogue content will show that these products are the ideal cost-effective choice for distributed control applications, and, it will illustrate the flexibility and versatility of Technosoft drives and motors.
Technosoft has published a new, comprehensive product overview for its intelligent drives and motors. Free to download, this catalogue presents the Technosoft embedded intelligence products based on the latest MotionChip DSP control technology. These drives and motors are software configurable to drive brushless, step, DC or linear motors from 25 to 640W and they embed motion control, drive, PLC functionalities, motor (with intelligent motors) in a single compact unit.
Designed to help users select among different products, the catalogue is clear and easy to use.
Engineers will find here short illustrated descriptions of each drive, links to technical documentation and software available, as well as ordering information.
For an easier comparison between different items, the users can use the product selector, which covers information regarding: types of motors, bus voltages, currents, communication networks, control functions, inputs/outputs, accepted sensors, sizes, weights etc.
Also, this product overview includes brief presentations for software platforms, motion libraries and starter kits available.
The catalogue content will show that these products are the ideal cost-effective choice for distributed control applications, and, it will illustrate the flexibility and versatility of Technosoft drives and motors.
Variable-speed drives promise easy installation
Variable speed can be quickly and easily installed anywhere thanks to the Leroy Somer Varmeca.
Variable speed can be quickly and easily installed anywhere thanks to the Leroy Somer Varmeca. Using an oversize terminal box to house the inverter allows the Varmeca to replace mechanical variators without the extra cost and space requirements of an inverter panel. A high protection index (IP65) also allows the unit to operate in very wet or dusty environments without detriment to its operation.
Surface mounted controls or remote control can be used for controlled stopping, starting and speed making the Varmeca one of the most flexible drives on the market.
Controls range from simple speed variation to control via fieldbus - Profibus DP, Interbus S, Devicenet, CANopen etc.
Units are available ex-stock from Industrial Motors and Gears, which can also fit the Varmeca to inline or right-angled gearheads to match specific requirements.
Variable speed can be quickly and easily installed anywhere thanks to the Leroy Somer Varmeca. Using an oversize terminal box to house the inverter allows the Varmeca to replace mechanical variators without the extra cost and space requirements of an inverter panel. A high protection index (IP65) also allows the unit to operate in very wet or dusty environments without detriment to its operation.
Surface mounted controls or remote control can be used for controlled stopping, starting and speed making the Varmeca one of the most flexible drives on the market.
Controls range from simple speed variation to control via fieldbus - Profibus DP, Interbus S, Devicenet, CANopen etc.
Units are available ex-stock from Industrial Motors and Gears, which can also fit the Varmeca to inline or right-angled gearheads to match specific requirements.
AC drives oust DC servos to improve gantry loader
AC geared motors and smd micro drives have replaced DC servo control systems to improve cost and performance on a pick and place gantry used in casting operation.
DC servo control systems on a pick and place gantry used in the Cosworth Technology casting operation in Worcester have been replaced by AC geared motors and SMD micro drives from Lenze. The decision to ditch the 'higher' technology DC system was taken by Maintenance Manager Joe Reeves based on cost and performance, the original system having been deemed overcomplicated and costly to replace like-for-like when compared to the levels of accuracy and ease of integration offered by the new generation of small AC drives. Cosworth Technology produces high quality aluminium alloy castings predominantly for the automotive industry, complementing the powertrain and diagnostic engineering services provided by the company.
The casting facilities at Worcester are flexible enough to make 3 or 300,000 items per year of any design using the patented Cosworth Technology Casting Process.
Central to the casting operation is the accurate and reliable transfer of crucibles containing molten aluminium from the furnace to the moulds.
The working environment is tough, with a sometimes heavy work load and 50 degree heat, hence the replacement system had to be tough as well as reliable.
The original system had reached the end of it's operating life and was due for replacement.
Advances in power handling and reduction in size (a 2.2kW smd inverter has a panel size of just 146x114x140mm) meant that four smd drives would fit comfortably into the existing control cabinet, while the units offered levels of accuracy and reliability that were not easily achieved with AC control when the original system was specified.
The cost differential between a new replacement servo system and the AC solution using standard Lenze geared motors, de-rated to handle the high ambient temperature is an order of magnitude lower, reducing both the initial purchase cost and limiting the cost of any future replacements.
Ease of control was also a factor in the selection, Glyn Fisher, the Lenze Sales Engineer who specified the gearmotors and 2.2kW smd drives, 'the set-up takes a few minutes on a lap-top with a simple to use Windows based software application which means the user is perfectly able to set the drive up and can fine tune it from the PC or on the drive itself.
Even if the drive needs re-setting or replacing, the program is held on a removable chip that can be transferred in seconds.
The parameters can be copied to a spare chip and kept just in case.
The result is a fast set-up, good flexibility and downtime kept to an absolute minimum.' Joe Reeves, Cosworth Technology Casting Maintenance Manager comments, 'it makes perfect sense to use a simpler technology for this application; not only on the cost advantages, but it makes any changes for operational and the maintenance reasons faster and less of a headache.
Controlling the crucible gantry is central to the operation because we run a highly flexible casting system in order to handle what might be a very short run of bespoke engine parts or long runs for road cars such as Aston Martin for example.
About Cosworth Technology Cosworth Technology is an independent consultant and major supplier of powertrain and diagnostic engineering services to the global automotive industry.
It employs around 1000 people at its operations in Northampton, Wellingborough and Worcester in the UK and at Cosworth Technology in Detroit, USA.
DC servo control systems on a pick and place gantry used in the Cosworth Technology casting operation in Worcester have been replaced by AC geared motors and SMD micro drives from Lenze. The decision to ditch the 'higher' technology DC system was taken by Maintenance Manager Joe Reeves based on cost and performance, the original system having been deemed overcomplicated and costly to replace like-for-like when compared to the levels of accuracy and ease of integration offered by the new generation of small AC drives. Cosworth Technology produces high quality aluminium alloy castings predominantly for the automotive industry, complementing the powertrain and diagnostic engineering services provided by the company.
The casting facilities at Worcester are flexible enough to make 3 or 300,000 items per year of any design using the patented Cosworth Technology Casting Process.
Central to the casting operation is the accurate and reliable transfer of crucibles containing molten aluminium from the furnace to the moulds.
The working environment is tough, with a sometimes heavy work load and 50 degree heat, hence the replacement system had to be tough as well as reliable.
The original system had reached the end of it's operating life and was due for replacement.
Advances in power handling and reduction in size (a 2.2kW smd inverter has a panel size of just 146x114x140mm) meant that four smd drives would fit comfortably into the existing control cabinet, while the units offered levels of accuracy and reliability that were not easily achieved with AC control when the original system was specified.
The cost differential between a new replacement servo system and the AC solution using standard Lenze geared motors, de-rated to handle the high ambient temperature is an order of magnitude lower, reducing both the initial purchase cost and limiting the cost of any future replacements.
Ease of control was also a factor in the selection, Glyn Fisher, the Lenze Sales Engineer who specified the gearmotors and 2.2kW smd drives, 'the set-up takes a few minutes on a lap-top with a simple to use Windows based software application which means the user is perfectly able to set the drive up and can fine tune it from the PC or on the drive itself.
Even if the drive needs re-setting or replacing, the program is held on a removable chip that can be transferred in seconds.
The parameters can be copied to a spare chip and kept just in case.
The result is a fast set-up, good flexibility and downtime kept to an absolute minimum.' Joe Reeves, Cosworth Technology Casting Maintenance Manager comments, 'it makes perfect sense to use a simpler technology for this application; not only on the cost advantages, but it makes any changes for operational and the maintenance reasons faster and less of a headache.
Controlling the crucible gantry is central to the operation because we run a highly flexible casting system in order to handle what might be a very short run of bespoke engine parts or long runs for road cars such as Aston Martin for example.
About Cosworth Technology Cosworth Technology is an independent consultant and major supplier of powertrain and diagnostic engineering services to the global automotive industry.
It employs around 1000 people at its operations in Northampton, Wellingborough and Worcester in the UK and at Cosworth Technology in Detroit, USA.
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