Hannover Fair 2006 in motion

05/25/2006


Numerous technologies of "motors, drives, and motion control" were again in the spotlight at this year's running of Hannover Industrial Fair. Presentations ranged from standards announcements and technology discussions to products emphasizing innovation, energy efficiency, and mechatronic integration—even spanning to developments in high-temperature superconductivity. More details and links to additional information follow about ABB drives, Baldor motors and drives, Lenze gear motors, SERCOS III C2C profile specification, drive innovation perspectives from Siemens, VEM specialty motors, and the "Superconductivity City" exhibit.

Motors, Drives & Motion Control

SERCOS Controller-to-Controller (C2C) Synchronization and Communication Profile integrates communication and real-time links with mechanical connection of machine modules.

SERCOS trade organizations announced the release of Controller-to-Controller (C2C) Synchronization and Communication Profile, which defines mechanisms for interconnecting distributed control functions as well as synchronizing distributed motion controllers, using SERCOS III the new industrial Ethernet-based version of SERCOS interface. The spec addresses innovative SERCOS III features, such as hardware redundancy, hot-plug device capability, and cross communication, explained Peter Lutz, managing director of Interests Group SERCOS (IGS) interface.

Typical applications for the C2C profile are found in printing, packaging, processing machines, and machine tools with special control and synchronization needs, for example, in gantry axes or rotary transfer tables. Live demonstration of C2C profile with first device implementations took place at the joint IGS interface booth.

Release of the C2C profile represents a movement of SERCOS III to areas other than drives—the origins of SERCOS—to distributed control structures, said Lutz. Meanwhile, SERCOS also is active in the safety arena. Its safety concept for safe data transfer based on SERCOS interface was approved in December 2005 by TÜV Rheinland, an international technical service provider for safety certification. The protocol extension is said to allow use of SERCOS interface in safety integrity level (SIL) applications up to SIL 3, per IEC 61508.

Drives, motion systems perspective
Mechatronic innovation and the role of software were among trends in motion systems noted by Siemens . In comparing industrial motion control with CNC systems, Dipl.-Ing. Armin Huger, director of business development at Siemens AG Automation and Drives Div., sees CNCs in the lead technologically, in part, because of the need for higher accuracy. "Industrial motion systems need to come up in performance and sophistication to the level of CNCs," said Huger. Industrial systems are heading toward that higher ground, as "motion control becomes a more major, integrated part of the machine," he explained, but, it will take time to achieve the goal.
(Look for an article on " CNC Programming " in the June 2006 issue of CE .)

Relative to the performance evolution, Huger also commented on Siemens' major new generation of ac drives, Sinamics. With an extremely wide power range, including medium-voltage models, Sinamics is destined to replace the company's previous generation of drives, he explained. However, Huger was quick to point out this will take 10-15 years to accomplish. "It represents a huge effort and a large change for the company."

Machine Control & Discrete Sensors

Mechatronic innovation was definitely in the air at Hannover Fair. One example was Lenze AG's G-motion servo gear motor line. G-motion servo features power ranges of 0.25-10 kW using synchronous servo motors and 0.8-20.3 kW with asynchronous (induction) servos. A variety of gearing types is available. Size of the gearbox or "mecha" part is controlled by rules of physics as shown. The "tronic" part with the sleek servo motor is clearly in the lead for compactness. (Photo by Frank Bartos, Control Engineering.)

Two key attributes of Sinamics reside in its highly modular design and single software tool applicable to all drives in the family. The same software applies whether it's a variable-frequency unit or a servo drive. Modularity of Sinamics focuses on use of individual control units and a separate power module "for more flexibility in design and application," added Huger. The power module is identical across drive sizes and helps with inventory stocking.

Baldor Electric Co . exhibited innovations in ac drives as well as motors. The company has substantially widened the power range of its H2 drive family with 26 units extending the upper range from 45 to 93 kW. This broadens applications to include extruders, production machines, and other heavier duty machinery. For up to 7.5 kW ratings, other H2 drives now offer washdown-duty enclosures. Also, plug-in expansion boards are available for added drive connectivity, for example, electronic gearing. Baldor claims exceptional reliability for the H2 drive family, which includes several control variants: open-loop, encoderless vector, closed-loop vector, and servo control (for up to 18.5 kW output).

On the motors side, Baldor launched its Metric-E+ line—a range of IEC-frame ac motors with energy-efficiency up to 96.3% and 4-200 kW power ratings. Metric-E+ comes in two versions: "EFF1" to meet Europe's "high-efficiency" voluntary standard and a so-called "EFF1+" version, which is up to 2% more efficient than EFF1, according to the company. Indicating worldwide awareness of the cost of energy, these motors also comply with Australia's minimum efficiency performance standards (MEPS) per AS/NZS 1359.5-2—5/2006.

'Cool' drives
Besides emphasis on its new DCS800 dc drive, ABB showed liquid-cooling enhancements for other drives. Low-voltage ACS800 liquid-cooled ac drive in the 200-5,600 kW power range now features up to 50% less space requirement than a comparably rated air-cooled drive. "Compactness" definitely applies even at the higher power ratings. According to Roelof Timmer, ABB marketing manager for automation products, "Size reduction due to liquid cooling varies over the power range from 30% to 50% compared with an equivalent air-cooled drive."

Software

Rugged construction of this special electric motor from VEM Motors conveys its image of steel- and rolling-mill duty. The motor runs at 746 rpm with 178 kW output and offers an IP55 enclosure. (Photo by Frank Bartos, Control Engineering.)

Not to overlook air-cooling, ABB has meanwhile launched such a version of its medium-voltage ACS5000 ac drive to complement the existing water-cooled series—offering users an extra choice of cooling method. Air-cooled ACS5000 drive comes in a 2-7 MW power range at supply voltages up to 6.9 kV. It provides the option for either an integrated or separate input transformer.

VEM motors GmbH exhibited a variety of special industrial motors. One example was its "memory motor" with RFID technology, a modified conventional unit enabled for onboard data storage. A small RFID tag on the unit allows storage of large volumes of data, such as performance parameters, maintenance notes, and precise motor identification/tracking. A read-write unit enables data retrieval and adding user-specific data.


'Superconducting city'
Hannover Fair's Research & Technology sector included a special group exhibit entitled "SuperConducting City," where motor and drive innovations played an inherent part. Notable offerings included high-temperature superconducting (HTS) magnetic bearings from Siemens and Nexans Superconductors GmbH , destined for high-speed drives and rotating equipment. These contactless, low-loss, and wear-free bearings are projected to see service in high-speed motors and generators in the 2010 timeframe.

Dr. Wolfgang Nick, principal research scientist at Siemens Corporate Technology, also mentioned activity in development of a 4,000 kVA, 3,600 rpm HTS synchronous generator intended for ship propulsion. In part because of size limitations, the generator was shown through a video presentation. Development of the HTS generator follows Siemens' demonstration of Europe's first 400 kW HTS synchronous motor in 2001 ( see CE, Sept. 2001 ).

Oswald Elektromotoren GmbH displayed research projects in advanced motors, including a high-dynamic linear motor with a HTS stator. Two models are being developed with 10 kN and 120 kN linear thrust capability (2,248 lbf and 26,980 lbf, respectively) at up to 25 Hz actuation frequency.

American Superconductor Corp . (AMSC) exhibited its expertise in HTS wire production for first-generation (1G) and second-gen (2G) wire. Reliable quantity production of HTS wire is at the heart of developing actual superconducting machines. Physically, the wires look about the same, but 2G HTS wire has much higher performance, explained Rob Rouse, industry marketing manager for AMSC. Its 2G HTS material on exhibit was about 0.2 mm thick and 4.3 mm wide. "Presently, 2G wire is more costly than 1G," said Rouse. "We have to bring the price down—potentially through lower production costs, as 2G material has more manufacturing options and does not need to be extruded as does 1G wire."

First industrial usage of HTS motors is about five years away, Rouse suggested, with application of motors around 10,000 hp for ship propulsion of the non-naval type.

—Frank J. Bartos, Control Engineering,
executive editor, fbartos@reedbusiness.com





No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
Detecting security breaches: Forensic invenstigations depend on knowing your networks inside and out; Wireless workers; Opening robotic control; Product exclusive: Robust encoders
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide
 

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.