SPS/IPC/Drives 2005 in motion

By Control Engineering Staff December 21, 2005

Success of the focused electric automation show SPS/IPC/Drives Exhibition and Conference (Nuremberg, Germany, Nov. 22-24) was measurable in all three categories of exhibiting companies (1,160), display area (73,000 sq m or 785,000 sq ft), and attendees (34,600)—respectively, rising 12.6%, 12.1%, and 8.7% over 2004. Besides statistics, this exhibition and conference brings together a gamut of electric drives, motion systems, and related software. Here are selected show highlights from ABB, Baumüller, B&R Industrial Automation, Elmo Motion Control, Emerson Control Techniques, Rockwell Automation, Schneider Electric, SEW-Eurodrive, Siemens, and Yaskawa Electric, along with links to company Web sites for more information.

For scalability, ABB’s DCS800 family consists of seven drive sizes overall, of which the four smaller unit sizes are shown here.

Among numerous drive, motion control, and related products on display by ABB , a major introduction was its new dc drive—DCS800. This “power converter” reportedly offers extra easy configuration, installation, and operator control. A cell-phone-like device with high-resolution display and context-sensitive function keys enable the operator features. DCS800 has a built-in PLC for handling local control and numerous add-on modules for scalability, added I/O points, and fieldbus connectivity. Intended for the 5-20,000 hp range, DCS800 works with 230-1,200 V ac supply, provides backward compatibility to prior DCS drives, and uses the same software and engineering tools as ACS800, its ac drive counterpart. North American availability is scheduled for 1Q06.

Other ABB offerings included Component Drives up to 4 kW output, featuring ACS50, ACS150, and other models, as well as larger ACS350. A patented feature of ACS150 and ACS350 is ability to do setup programming without energizing the drive, via the battery-powered operator interface. It means that users can program the drive literally out-of-the-box, explained Teemu Jalava, product ac drives sales manager at ABB. The configuration method also allows blocking out those parts of the extremely wide parameter set not needed for a specific application.

Also on display was new ACS800 04, a so-called “motion control drive” designed to mount inside a cabinet. It relies on two

A planetary-gear reducer is integrated smoothly into the housing of Baumüller’s DSD 56-IPG, three-phase synchronous servo (geared) motors to minimize dirt pickup. The housing has IP65-rated sealing.

Baumüller exhibited a wide range of rotary and linear servo, torque, and direct-drive motors and associated controls. Notable introductions include size expansion of high-performance servo motors with integrated planetary-gearing to obtain 98% efficiency and low noise level, explained Stephan Reiss, product manager for motors at Baumüller. Slated for 2006 production, DSD 56-IPG motor will increase the 1.37-kW rating of earlier motors in the DSD line.

Reiss also mentioned the increased output range for DA asynchronous (induction) motors from 260 to 450 kW. DA 280 will be available in air-cooled (IP23) and water-cooled (IP54) versions with production starting in early 2006. Meanwhile, the company’s direct-drive DST high-torque motors can obtain torques of up to 13,500 Nm in the 100-300 rpm speed range. Thrust bearings integrated into DST motors withstand the high axial forces developed in extrusion machines, a primeapplication area for these motors.

AcoposMulti power supply modules from B&R can regenerate power to the system and connect to the network for sharing operating data.

Introduction of AcoposMulti drive system was a major feature in B&R Industrial Automation ’s (B&R Industrie-Elektronik) redesigned exhibit, which was 39% larger than last year. This “logical progression” from Acopos Series drives consists of three major elements: backplane converter, power supply module, and axis modules serving 1 or 2 axes, each, according to Rainer Rück, B&R application engineer.

AcoposMulti integrates a 24-V auxiliary supply module, which saves cabinet space and provides a connection for drives, controllers, or peripheral devices (as an option) to the dc bus to obtain open/short circuit and overload protection. Three cooling methods are offered: conventional heat dissipation in the enclosure; feed-through heatsink with IP65 rating for dissipation outside the cabinet; and cold plate version that connects to a water or oil heat exchanger. Modular, scalable AcoposMulti uses Automation Studio, the same software tool as other company products, and is compatible with previous Acopos systems. The product is in field evaluation in Europe and is slated for U.S. availability in 3Q06.

Also shown by B&R were high-performance servo motors and backlash-free, direct-drive models that include hollow-shaft versions. Elmo Motion Control showed a musical melange of servo drives and controllers, among them its newest miniature digital servo drive—Whistle—and its analog counterpart, Ocarina. These matchbox-sized drives measure just 2 x 1.8 x 0.6 in., but deliver up to 0.5 kW continuous power (or 1 kW peak). Haim Monhait, Elmo’s general manager, referred to Whistle as a servo drive with the “highest power density and intelligence available in the market.” Emerson Control Techniques ’ sizable, redesigned booth showcased Unidrive, along with other ac and dc drive products. Unidrive SP caters to lower power ranges (0.55-132 kW), while Unidrive SPM C modular drive covers higher power needs up to 200 kW (or to 355 kW with dual units) and free-standing Unidrive cabinet units (SP6, 7, 8, and 9) handle 110-675 kW ratings.

Emerson’s Leroy-Somer brand (and business entity) was also prominent, for example, with Varmeca integrated variable-speed motors rated 0.25-11 kW and variable-speed drives (VSDs) in closed-loop vector and decentralized (Proxdrive) versions. Noteworthy was a VSD system for potentially explosive atmospheres (ATEX). FLSD drive, rated for 0.55-400 kW, is said to be qualified to operate in gas classification groups IIB or IIC Zone 1-Category 2. Rockwell Automation ’s exhibit was built around “twin circles” of automation systems and automation architectures . Kinetix integrated motion control system, CompactLogix, and PowerFlex drive technology were prominently featured. Products and components were emphasized rather than systems in this year’s exhibit, explained Dirk Weber, field business leader, power control and drives; however, “system solutions” such as batch were shown.

CompactLogix was presented from a price-point perspective intended for lower level automation, including OEM applications. A forward-looking view of PowerFlex showed Common Industrial Protocol (CIP) Motion application profiles coming in the 2006-07 timeframe to seamlesslyenchmark requirement set by ODVA to be able to coordinate a network of 100 motion axes with a 1 ms update rate.

Wide-ranging technologies displayed by Schneider Electric included variable-frequency drives (VFDs)—such as Altivar 71 and Altivar 61 for pump/fan applications—servo controllers (for example, low-cost Lexium 05 that offers the same form factor as a VFD), and various safety-oriented factory automation products.

Schneider’s Berger Lahr brand had a very large presence in the booth. Its intelligent, integrated motor and controller product (Icla) was highlighted in three motor versions: stepper; ac servo; and synchronous, three-phase electronically commutated motor. IclA—originally short for “integrated closed-loop actuator”—combines a motor, positioning control, power electronics, and feedback into a compact unit.

Movifit-MC, -SC, and -FC from SEW-Eurodrive each have a special version available to suit food industry applications.

A proponent of distributed automation architectures, SEW-Eurodrive has been evaluating the acceptance of distributed drives worldwide. Europe and North America were found most receptive to distributed drives, according Frank Höreth, global marketing & engineering manager at SEW. However, South America is currently not considered a viable market, he added.

Other developments at SEW include 2nd-generation Movimot decentralized motor-control unit that adds washdown capability, and the launch of Movifit—an integration of new power sections with variable-frequency drives (VFDs) and motor control switches, plus decentralized communication via Ethernet in a package that mounts near the motor. Movifit comes in three flavors. Movifit-MC controls up to three Movimot gear motors to 3 kW rating and provides power protection. Movifit-SC , “an electronic motor switch” (starter), provides two-directional rotation control to 4 kW (single-channel motor switch) or one direction of rotation for up to two 2.2-kW motors (dual-channel switch). Movift-FC integrates a VFD with 0.37-1.5 kW or 2.2-4 kW rating along with safety functions.

Höreth further mentioned progress on Movigear, a combination motor, gear reducer, and electronics in one package. Shown at Hannover Fair 2005 as a concept product, Movigear is moving toward test market phase in summer 2006, with mid-year buildup of products and full availability by year-end 2006 or early 2007. For more on Movigear, click here .

Here’s a bit of SEW-Eurodrive trivia: The company’s product lines are prefaced by the term “Movi,” which comes from the abbreviation of German words for Siemens showed the company’s wide cross-section of technologies. Exhibits ranged from motors, drives, and motion control to various sensor technologies and industrial safety systems. Sinamics drives family and Simotion integrated software received major emphasis, while industrial PC-based automation was another exhibit strong point.

Profinet, developed by Siemens, was also in the spotlight. Described as a single networking bus for real-time communication plus IT applications, Profinet is becoming increasingly integrated with more functions—for example, motion control capability through its associated IRT (isosynchronous real-time) chip. Profinet incorporates real-time (RT) as well as non-RT communication over Ethernet. Profinet also was shown integrated with safety functions. A new safety controller with Profinet interface has been added to the Simatic product line, which along with a Profibus interface permits connection to both networks at the same time. The controller’s new CPU complies with standards IEC 62061, IEC 6158 (to SIL 3), and NFPA 79-2002, according to Siemens. Yaskawa Electric Europe ’s (YEE) substantial exhibit was located in the Omron Electric booth, indicating the strong, long-term joint venture of the two companies in Europe. However, YEE has recently started pursuing parallel distribution of its Sigma II servo technology to select European customers, according to Jürgen Friedrich, section manager, motion & control engineering, at YEE.
He mentioned other developments. Explosion-proof, ATEX-conforming ac servo motors with 0.5-5 kW ratings being developed are only slightly larger than standard servo motors, but much smaller than competing ATEX-type servos. Certification by TÜV is expected to be completed by early 2006, according to Friedrich. Another Yaskawa development involves high-power servo motors up to around 500 kW rating. Commercialization for this longer range program is seen in the 2007 timeframe.

Further coverage of SPS/IPC/Drives 2005 will include technology trends and management views, later in Control Engineering . For previous coverage see

Daily News for Nov. 22, 2005

and an embedded controls’ view in Dec. 2005 Information Control Monthly E-Newsletter .

Frank J. Bartos, executive editor, Contol Engineering