Motors & Drives Information

Submersible series stainless-steel step motors are uniquely designed to provide maximum operational reliability in marine and submarine applications. Their internally sealed design eliminates the corrosion and motor failure problems common to conventional steppers in fluid processing, washdown and complete submersion environments. Standard submersible motors feature air fittings that allow the motors to be pressurised for protection against external fluids, from simple mist to complete submersion.

An oil-filled version with pressure equalising diaphragm is available for more aggressive deep submersion applications.

Waterproofing measures for both motor versions include o-ring body seals and a double shaft seal.

The motors are available with feedback resolvers and conversion electronics, providing quadrature or binary motor position information.

Submersible motors are available in standard 23, 34 and 42 frame sises, with static torque ranging from 60 to 1600os-in.

Round mounting flanges are standard to simplify face sealing, while square flanges are available for compliance with NEMA mounting specifications.

These motors are compatible with most bipolar full step and microstepping motor drives.

Rockwell Automation introduces the new Allen-Bradley 1394 SERCOS drive for high speed, flexible, easy to use motion control. With single point programming, reduced wiring requirements, and the elimination of analogue offsets and EMI effects, it is perfect for OEMs and end users. Sercos (SErial Real time COmmunication System interface) is a digital interface that provides improved system performance and increased speed.

It communicates information between the controller and servo drive via a fibre optic, real-time, deterministic network.

The network replaces the complex bundle of wiring associated with traditional drives and is used to send and receive information about the status of the drive.

This includes the demand position and axis position together with many drive parameters.

The benefits of using Sercos, include ease of commissioning, higher accuracy, and improved system performance.

Originated as a solution for the machine tool industry, Sercos network speed has advanced significantly in recent years, allowing more axes of control and faster update rates.

Claimed to far outperform any traditional single spindle cam machines in both flexibility and profitability, a linear motor drive CNC automatic makes simultaneous use of several tools. For those who were unable to attend the last EMO, DMG is staging a British re-run, complete with several machines never before demonstrated publicly in the UK. In total, eleven machines will feature showing a wide range of machining solutions and four of those are brand new.

The star performer for turning is undoubtedly the new Sprint 32 linear, aptly named as it far outperforms any traditional single spindle cam machines in both flexibility and profitability.

One of the key features of this new CNC automatic turning machine is its motor spindle and the linear arrangement of the tool holders, which allow the simultaneous use of several tools.

These features, combined with the unique configuration of up to 8 axes, make it possible to process turned parts, inexpensively and at reduced cycle times.

The next universal turning newcomer is the CTX410, one of the latest additions to the CTX 10-Series whose hallmark is low capital cost; a CTX210 model with Fanuc control will also feature on the stand.
In addition to the standard configuration, the design may be specified with fixed or driven tools.

The use of high-tech components such as the integrated spindle motor and fast servo-turret ensure up to 25% idle time reduction resulting in greater productivity and cost efficiency.

With the introduction of the new GMX 200 linear, DMG extends it turn-mill capabilities up to 560mm diameter, making this product line the most comprehensive for complete 6-sided machining with linear technology.

A linear drive, compound slides with a Y- and B-axis and the highly dynamic turning and milling spindle with 100Nm and a maximum 12,000 rpm are just some of the features that make this machine both a high-end lathe and a high-tech machining centre.

Speed and angle-synchronous workpiece transfers as well as integrated spindle motors provide the shortest cycle times, both for the counter spindle and the tail stock versions.

Thanks to linear drive technology, the CTX 320 linear universal lathe has been rewarding several UK companies with significant productivity increases and at MACH its abilities will be demonstrated on 65mm bar.

DMG's twin spindle range is to be represented by the Twin 65.

The large frame size of this lathe has created space for a CNC-controlled B-axis in the area of the upper turret.

In combination with the Y-axis and driven tools, it is therefore able to machine slanted bores, planes and even complicated milling contours.

Danfoss Drives and Pilz have announced that they will be working together on the development of combined drives and safety controls in the new Danfoss Drives' series, AutomationDrive. The partnership meets market demands for intelligent networking of safety technology and standard automation systems. Special safety implementations for drives ensure that people operating production equipment in, for example, the food, beverage and automotive industries, are not exposed to danger if faults develop in the drive control unit.

Danfoss Drives' new AutomationDrive series already has additional, integrated safety functions; however, when combined with Pilz safety technology, more functions can be added - such as safe speed and standstill monitoring.

Pilz and Danfoss Drives are both leading suppliers within their respective fields, and both are experts in jointly developing optimal safety systems for their customers.

Pilz is viewed by many as the world-leading manufacturer of safety equipment and a company of high standing within machine safety.

Its headquarters are located in Germany and the company has more than 1000 employees all over the world.

Danfoss Drives produces and markets frequency converters for the speed control of motors, and is a global business with sales and service activities throughout the world.

The hospital development, currently taking shape in the heart of London, has been designed and built with energy conservation very much in mind. The new generation of HVAC specific Alldales compact inverter drives have been specified as part of an integrated approach designed to provide responsive, local climate control while delivering significant energy savings in an area (HVAC) which traditionally accounts for the lion's share of building energy consumption. The commissioning of the drives follows on from a full harmonics analysis carried out by Alldales in conjunction with M and E Consultants for the project, DSSR The new UCLH development situated on the busy Euston Road is being carried out in two phases.

Phase One - the main wing, consisting of a 97m high tower and podium, which will be completed in 2005.

Over 200 inverter drives ranging from 5Kw to 75Kw units have already been fitted to air handling units throughout the site in plant rooms serving administration blocks, wards and theatres.

One of the country's busiest Trusts, the new UCLH hospital will have 669 beds and will also act as a key centre for clinical, research and teaching activities.

By varying the speed of the motor to automatically adjust airflow to match changing occupancy and usage requirements, inverter drives can reduce energy consumption by as much as 50%, compared with traditional control vane and throttle control methods where motors are kept running at full speed.

Linked to a building management system as part of an integrated solution, inverter drives provide detailed data to help track and control energy performance.

With initial investment costs recoverable under DETR's Enhanced Capital Allowances Scheme, inverter drives are proving to be a cost-effective option for specifiers looking at long term solutions for applications with large-scale energy requirements, such as the new University College Hospital.

The LEM Series is an epoxy core brushless motor with an overall width of 28mm. It is one of the smallest motors available that produces 75 Ibs of peak force. The LEM Series features an epoxy coil core which provides ultra smooth motion, since there are no cogging forces.

The LEM Series, because of its compact size and high force, is an ideal choice for high performance applications where space is limited.

Air-cooling and watercooling options are available for use in extremelly high duty cycle applications.

The LEM Series is available in four different model sizes to match force and duty cycle requirements as well as satisfy price v performance considerations.

The LEM Series can come equipped with a full range of options to take advantage of Anorad's complete line of linear encoder and motion control products.

Linear servo motors, with their simplistic two-part design, are increasingly proving to be the preferred drive mechanism over ball screws and belt drives.

A new market study from IMS Research shows that linear motors have not impacted the electromechanical linear motion market to the extent that some suppliers had feared. Linear motors offer many performance benefits over traditional electro-mechanical linear motion systems based on ball screws and belt drives. Not only do they offer higher levels of acceleration and deceleration, but higher combined levels of speed and accuracy can be achieved.

Despite this, very few machine builders use them.

Those that have made the transition to linear motors have usually replaced pneumatic or hydraulic actuators rather than electro-mechanical types.

The research found that the main barrier preventing companies from using linear motors is the higher initial cost when compared with electro-mechanical products.

Whilst prices of linear motors have fallen in recent years, a like for like comparison still favours ball screw and belt drive linear actuators.

IMS Research forecasts that the European market for industrial linear actuators will remain fairly flat this year due to the general slowdown in global economic growth.

However, the longer term outlook for the market is good, with double digit annual growth rates forecast for 2004 and 2005.

LG Motion's inaugural UK exhibition following its launch last year is set to show its range and diversity of motion control and positioning systems. Visitors to stand D37 at Drives and Controls 2006 from 16th to 18th May at Birmingham's NEC will see the launch of a breakthrough hybrid technology for stepper motor drives from Agile Systems along with positioning systems from the Unislide and Bislide ranges as well as LG Motion's own range of LG series precision tables. Details of an agreement with Schneeberger for a rapid turnaround cutting service for linear motion guide bearings systems will also be announced.

The Silentstep stepper motor drive from Canadian designer and manufacturer Agile Systems brings servo motor performance to conventional stepper motor systems.

A technique derives position feedback from back-EMF and phase current sampling without encoder feedback and eliminates motor stalling, reduces audible noise and increases motor speed.

LG Motion will demonstrate how the drive technology can be applied to new and existing position control applications improving performance while maintaining the simplicity of a conventional stepper motor drive system.

Other products on display from Agile will include the DPDLite sensorless motor commutation system for brushless DC motors and the uMaxB series, Firewire networked, DSP based single-axis motion controller with integrated servo amplifier.

Aimed at medium precision positioning applications and available with manual and motorised versions, the Unislide is a simple, strong and durable design based on a rigid dovetail bearing system in a lightweight aluminium construction.
The Bislide is aimed at heavier duty motorised applications and based on an extruded I-beam aluminium profile with dual 45-degree opposing guideways that provide rigidity regardless of the load direction.

Both ranges are available in single and multi-axis configurations with various options and accessories.

LG Motion designs and makes its own range of linear and rotary positioning tables for high precision applications and a selection from the forthcoming catalogue will be on display at the show.

The firm will also show a selection of products from Schneeberger Linear Technology, the Swiss manufacturer of linear cross roller bearings and slides and Monorail profiled linear guideways.

While LG Motion has been building Schneeberger's linear bearings into its custom engineered positioning systems for some time, the agreement will allow a stocking and a rapid turnaround cutting service for linear guideways where customers can order custom lengths and be assured of delivery within two working days.

Building on the success of its popular DF5 and DV5 families of inverter drives, Moeller Electric has launched two new models. The DF51 is designed specifically to provide energy-efficient speed control for fans, pumps and similar variable torque loads, and the DV51 combines high starting torque with accurate sensorless speed control for constant torque applications such as mechanical handling and hoists. Both of the new drives, which are available with ratings up to 7.5kW, have integral Modbus communication facilities, making them easy to integrate with factory or building automation systems.

Requiring up to 40% less space in the control panel than its immediate predecessor in the Moeller Electric range, the new DF51 V/f drive has built-in PID functionality, making it particularly easy to use in applications requiring flow control.

Its integrated keypad provides straightforward set-up options, as well as keys for manually increasing and decreasing speed.

A 0-10V analogue output is available to allow easy external monitoring of either motor speed or current.

To maximise cost-effectiveness in multi-drive applications, the DV51 sensorless vector drives in the new range have removable keypads, which means that a single keypad can be used to set up many drives.

Removing the keypad also protects the drive very effectively against unauthorised tampering.
Capable of providing starting torque in excess of 200% at 1Hz, DV51 drives feature a completely new auto-tuning system which means that it is no longer necessary to enter detailed motor parameters during set up.

Dynamic current limit and overvoltage stop functions provide enhanced protection for the drive and motor under fault conditions.

To ensure compatibility with modern automation systems, DV51 drives can be fitted with optional cards which supplement the built-in Modbus connectivity by providing facilities for direct connection to Profibus and CANopen fieldbus systems.

The drives also have five programmable inputs and two programmable outputs, allowing simple local control functions to be implemented without the use of additional components.

For applications needing drives with higher power ratings than the 7.5kW offered by the new DF51 and DV51 units, Moeller Electric's established DF6 and DV6 ranges are available.

Between them, these ranges provide efficient and cost-effective V/f and sensorless vector drive solutions for motors up to 132kW.

WEG has extended its ATEX range of high efficiency electric motors for hazardous applications with the introduction of dust ignition proof (DIP) motors for use in ATEX Zones 21 and 22. The motors are designed to operate safely and save energy in environments where explosions can occur due to combustible dust. Typically these environments are found in sugar refining plants, breweries, cement works, textiles, and pharmaceutical, chemical and agricultural process industries.

The WEG high efficiency DIP ranges are designed in accordance with the requirements of IEC and CENELEC Standards, and with the ATEX Directive 94/9/EC: Categories Ex II 2 D T125oC (Zone 21) and Ex II 3 D T125oC (Zone 22).

In addition, the Zone 22 motors offer the added benefit of operation in gas Zone 2 (Ex II 3 G EEx nA II T3).

This means that that one motor will suffice in atmospheres containing both combustible gas and nonconductive combustible dust.

Offering the highest level of safeguarding of the new introductions, the Zone 21 DIP motors are third party certified and offer the highest level of ingress protection on the market: IP66.

These motors are designed to operate in areas where flammable dust can be released, or atmospheres where explosions can occur due to a mixture of air and dust being present.
Complementing the Zone 21 motors for less critical applications, the Zone 22 range is IP55 rated - upgradeable by WEG to IP66, where required.

It is designed for environments, where nonconductive flammable dusts may occur frequently and be present for short periods of time.

Constructed with robust cast iron housings in frame sises 63 to 355M/L, the new DIP motors are rated for three-phase operation at both 50 and 60Hz, in output ranges up to 355kW.

Both ranges are available in two-, four-, six- and eight-pole configurations, benefit from Class F insulation with Class H winding wire as standard, and are suitable for use with variable speed drives (VSD).

As regards inverter use, the insulation system of all WEG's range of hazardous area motors - gas or dust - is highly efficient in dealing with the higher peak voltages and faster voltage rise times generated by the IGBTs (high dV/dt) used in the latest generation of VSD.

However, as an added safeguard to diminish the risk of excessive surface temperatures, thermal protection of DIP motors is incorporated as standard in the form of PTC thermistors in the motor windings.

In cases of over-temperature, the output from the thermistor initiates a relay, which removes the power supply to the motor, effectively turning it off.

In addition to the high levels of safeguarding they provide, WEG's new DIP range incorporates high efficiency machines that either meet or exceed CEMEP/WIMES requirements.

Premium Efficiency types meet the requirements of CEMEP's/WIMES Eff1 level, and the Top Premium Efficiency Eff1+ units comfortably exceed these requirements.

In addition, WEG also offers EExd/EEx de high efficiency motors in premium efficiency ratings up to 400kW for use in general hazardous environments.

All of these motor types are registered with DEFRA to enable users to claim Enhanced Capital Allowances (ECAs) on the motor purchase - a substantial contribution to reducing payback times.

WEG offers the market the most comprehensive and graduated range of ATEX Compliant electric motors for use in the widest variety of dust laden or gaseous atmospheres.

In addition to the dust ignition proof ranges described above, the following gas compliant classifications are included in the WEG low voltage product range: EEx d/EEx de IIA, IIB and IIC (explosion proof), EEx nA, (non sparking) and EEx e (increased safety), which offer the user and OEM the ultimate flexibility in both application specification and cost.

Complementing this flexibility is the wide range available: ratings up to 1120kW and frame size 500 - in standard two-, four-, six- and eight-pole configurations.

Completing the WEG Hazardous Area offering is a comprehensive range of MV/HV machines in EEx d/EEx de, EEx p and EEx nA variants in multiple polarities and power ratings.

When it came to replacing worn-out fans fitted to the air supply units in premises at London's Thomas More Square, resident HVAC contractors TAC took the opportunity to install energy-efficient Alldales inverter drives. With a small foot print and the potential to link to existing BMS systems using serial communications, Alldales drives offer new opportunities for existing buildings to reduce energy consumption without the need for a total refit or additional space. The Thomas More Square complex, adjacent to Tower Bridge, comprises six buildings housing up to 5,000 people.

The site is occupied by a number of tenants with different operating needs, among them a global financial institution trading worldwide, 24 hours, seven days a week.

Building occupancy patterns also vary considerably throughout the day.

The buildings are served by 2 11kV chillers, with the condenser water cooled by air from 4 160 Kw fans.

Historically, airflow has been regulated by means of soft starters and variable pitch of the fan blades to achieve the desired settings.

Where a building is operating around the clock with fluctuating demand, this can place a heavy load on the motors.

TAC took the opportunity in replacing a burnt-out motor to adopt a different strategy, aimed at providing both an economical replacement solution and switching to a more energy efficient approach.

TAC approached Alldales as a supplier with whom they had worked before and who could provide the necessary consultancy and installation expertise.

Incorporating variable speed drive technology into HVAC systems can make a huge difference in energy consumption, an important consideration given that HVAC systems account for up to 1/3 of all energy consumed in a typical office building.

Inverter drives work by regulating the speed of the motor to adjust flow, with the blades maintained in a fixed position.

The secret lies in the 'law of the cube': any reduction in centrifugal load results in a threefold decrease in power input.

This means a reduction of 20% in motor speed could halve energy requirements.

Savings in energy costs, have anywhere up to £14,000 worth of electricity every year, based on a typical 75kW motor are not unrealistic.

In addition, by reducing wear and tear, the life of plant components is extended.

With the first inverter drive installed and already delivering operational benefits and energy savings, TAC plans to replace the soft starters to the remaining fans as and when they reach the end of their operating life.

Looking to the future, TAC hopes exploit the serial comms facility of the inverter drives to integrate air handling and delivery with a new BMS system, which has been recently installed on site.