Drive has full quota of decentralised intelligence

With more than 100 integrated technology functions, the Rexroth IndraDrive sets new standards for decentralised intelligence

All the drive devices, with power outputs ranging between 1.5 and 120kW, use open interfaces. Due to the consistent decoupling of performance and functions, the new drive series provides both hardware-based servo drive and frequency convertor functions. At the same time, Rexroth has significantly increased its range of direct drives, with newly developed high-speed motors, torque motors and linear motors.
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One module offers full logic integration
Rexroth IndraMotion offers full motion logic integration in one piece of hardware

Drives improve safety for paper companies
The drives installed in Rexroth's Synax 200 system solution are setting a clear standard when it comes to integrated safety

In addition to a drive-integrated motion logic according to IEC61131-3, IndraDrive offers the most advanced integrated safety functions for 'safe standstill' and 'safe motion'.

This technology, which is certified according to EN954-1, Category 3, permits the drive to satisfy safety regulations throughout Europe without additional hardware and without taking another detour over the control.

The basic software packages for servo drive operation already contain all required basic functions such as positioning batch processing, position control, speed control and torque control.

Standardised expansion packages include axis error correction, main spindle functions, axis synchronisation, electronic camshaft gears and technology packages based on the integrated motion logic.

One of the new functions is the productivity agent for early fault detection for machine mechanics through intelligent drives.
Further reading

PLC supports open standards
With cycle times down to 30us, the new IndraLogic open PLC from Rexroth offers considerable potential for increasing productivity

Machine building subassemblies on show
At EMO 2005, the world's leading metalworking trade fair, Rexroth will be presenting ready-to-install subassemblies put together from different technologies

Rexroth wins motor drive vendor award
IMS Research presented the result of its annual benchmark survey of electrical drive producers at the Hanover Fair 2005

To build-up an efficient system for preventive maintenance is not a complex challenge anymore.

It is reduced to the simplified use of intelligent drive functions.

IndraDrive supports all common command interfaces, such as SERCOS interface, Profibus, Profinet, CANopen, DeviceNet, analogue and parallel interfaces.

Further development of the Drivetop commissioning tool allows commissioning to be interactive and fast.

The autotuning function quickly adapts control parameters by automatically optimising the control loops.

In addition to a broad range of rotary motors, Rexroth provides high-performance motors with direct drive technology.

The latest developments are the Rexroth IndraDyn H high-speed synchronous motors.

IndraDyn H motors provide the highest torque of their class, reaching speeds of 30,000rev/min.

Due to the very wide range of constant output, the short run-up times and the low rotor temperature, these motors are suitable not only for use in motor spindles.

The novel cooling system, which is already enclosed within the motor, reduces the amount of work for the mechanical engineer and increases the cooling efficiency.

Rexroth IndraDyn T torque motors offer a maximum torque of up to 13,700Nm at maximum speeds of up to 1200rev/min and run with an extremely low torque ripple.

The new Rexroth IndraDyn L synchronous linear motors can be supplied in various sizes and lengths, for simple applications also with the field-proven standard encapsulation.

For high temperature stability requirements, the entire motor range is available with thermal encapsulation.

The motors are characterised by very high continuous and maximum forces and a very compact design, as well as a low force ripple.

Software speeds drive-based automation tasks

The IndraWorks engineering suite was developed from the ground up to speed up and simplify engineering tasks across the entire range of Rexroth drive and control technologies

The all new Rexroth IndraWorks engineering suite was developed from the ground up to speed up and simplify engineering tasks across the entire range of Rexroth drive and control technologies. This modular system draws a clear line between the open framework infrastructure and the actual commissioning, programming, parameterisation and diagnostic tools.
Related stories

One module offers full logic integration
Rexroth IndraMotion offers full motion logic integration in one piece of hardware

Drives improve safety for paper companies
The drives installed in Rexroth's Synax 200 system solution are setting a clear standard when it comes to integrated safety

Users now have access to comprehensive data management and open communication mechanisms that span the entire spectrum of engineering tasks and tools.

When it designed IndraWorks, Rexroth made a clear distinction between the infrastructure, the framework, and the actual tools.

The advantage of this approach is that Rexroth can develop the two in parallel independently of each other.
Further reading

PLC supports open standards
With cycle times down to 30us, the new IndraLogic open PLC from Rexroth offers considerable potential for increasing productivity

IndraWorks users always work with only the tools that they need for the task at hand, and the tools can be used separately.

The suite features scalable integration of the various engineering tools into the framework, and the level of integration is aimed exclusively at the concrete automation task.

Rexroth, the drive and control supplier, has succeeded in reducing complexity and simplifying the engineering workflow.

The Microsoft.NET framework offers stability, proven high productivity during development and extensive COM and ActiveX support for migration of existing software components.

The framework also supports key automation engineering standards such as OPC, and it facilitates integration of 3rd party software, for example visualisation systems or configuration software supplied by field device manufacturers.

As a Microsoft development partner, Rexroth has been using this technology for more than two years.

The use of XML as a standardised data exchange format guarantees the modules can be integrated across different platforms and technology boundaries.

A common project database manages any number of internal and external automation components.

SCP (Scaleable Communication Platform) offers a comprehensive communication topology for all devices.

A large number of basic components, which are used by all engineering tools, standardise many common functions, for example printing system data or programs or configuring user administration.

Intelligent online aids and 'wizards' bundle Rexroth's industry-specific knowhow and make it easier to implement entire automation projects.

Appropriate engineering tools are supplied with all Rexroth components and systems.

Transformer is ideal for high-efficiency welding

Rexroth has added the new, certified PSG 6130 medium frequency transformer to its successful PSI 6000 medium frequency welding inverter system

The system components, which are perfectly matched, provide optimal power transfer and offer extra monitoring functions between the inverter and the transformer. Users enjoy the benefit of greater efficiency and higher precision in a wide range of welding applications. The compact design of the Rexroth PSG 6130 and weight reduction of up to 30% make it an ideal solution for high-efficiency welding, robotic and manual gun applications up to 130kVA.
Related stories

One module offers full logic integration
Rexroth IndraMotion offers full motion logic integration in one piece of hardware

Drives improve safety for paper companies
The drives installed in Rexroth's Synax 200 system solution are setting a clear standard when it comes to integrated safety

High power density and significantly higher welding performance set this product apart from conventional medium frequency transformers in its class.

The transformer has plug-in type connectors which can be used to detect voltage and current levels and monitor the temperature.

Depending on requirements, the primary connection can be made with or without a junction box.

A removable plastic cover protects the integrated rectifier pack from spatter and other contamination.

Controller powers up smaller electric vehicles

The Model 1234 is a mid-power range AC induction motor controller designed for smaller industrial vehicles and larger pallet movers

At CeMat 2005 in Germany, Curtis Instruments introduced the latest addition to its line of AC induction motor controllers. The Model 1234, a mid-power range controller designed for smaller industrial vehicles and larger pallet movers. With 24-48V battery systems, 200-350A 2min current ratings, the Model 1234 is targeted for a wide range of battery powered vehicles.
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AC motor controller set for show debut
The Model 1234 AC motor controllers is aimed at light industrial vehicles and larger pallet movers, and is available in three basic models

Battery monitoring improves productivity
Curtis Instruments' gauges include intelligent technology which warns of predetermined low voltage

The Curtis AC product line now covers all power ranges: the Model 1230 is a lower power controller with features and price points that satisfy the requirements of smaller EVs, such as pallet movers and floor maintenance equipment - 24V up to 150A and 24V up to 200A with optional CAN bus.

Models 1236 and 1238 are fully featured CANbus-compatible controllers for mid range and larger EVs, from counterbalance lift trucks to aerial platforms, and people carriers.

Both models are suitable for single/dual drive and pump control systems.

Model 1236 power ranges are 24-36V up to 500A, 48V up to 350A and 80V up to 300A.

Model 1238 Power ranges are 24-36V up to 600A, 48V up to 650A and 80V up to 550A.
Further reading

Motor controllers take charge of plant watering
Southern Glasshouse Produce asked Curtis Instruments to modify a custom-designed automated watering system imported from the Netherlands at considerable expense

MOSFET controllers are gentle on motors
Small PM motors or linear actuators need careful control in order to give long life and reliability

Tiny controllers take on PM motors and actuators
Two tiny microprocessor-based MOSFET units offer precision control of small permanent-magnet motors and linear actuators

The new Model 1234 offers high frequency and silent operation with a powerful operating system allowing parallel processing of vehicle control tasks, motor control tasks and user configurable programmable logic.

Advanced pulsewidth modulation technology provides efficient use of battery voltage, low motor harmonics, low torque ripple and minimised switching losses.

Key to the flexibility and power of Models 1234, 1236 and 1238 is their incorporation of Vehicle Control Language (VCL), a programming language developed by Curtis specifically for industrial EVs.

A first in the industry and a hallmark of optimal design, VCL combines a best-in-class AC motor controller with a powerful programmable logic controller (PLC).

VCL is designed for industrial vehicle control and comes with predefined functions, such as PID, battery monitoring, I/O control and CANbus communications.

This high level, easy-to-use language provides unique input and output features, integrates functions and controls the overall operation of the vehicle.

Both OEM designers and Curtis engineers can write VCL programs to customise and create that critical market differentiation for the product.

To allow upgrades in the field or at the OEM manufacturing site, Models 1234, 1236 and 1238 employ Flash programmable memory.

This memory can be erased and re-written without opening the controller, for modification at any stage of development, from quick prototypes to field updates at the customer site.

These models also feature field oriented motor control, allowing greater control at lower speeds and maximised torque efficiency across a wider speed range.

AC controllers can be matched to most AC induction motors for optimal response, feel and performance.

All Curtis AC controllers are designed to operate with the Curtis Model 1311 handheld programmer, which features intuitive menus, an ergonomic design and a large LCD graphic screen.

For real time information on the vehicle, the controllers can connect to the Curtis Model 840 LCD, which provides a cost effective means to communicate battery status, vehicle use time, maintenance scheduling and error codes.

Variable speed drive saves dough at bakery

Northern Foods is saving nearly £2500 annually on its compressed air system since installing an ABB variable speed drive at its Riverside Bakery in Nottingham

Northern Foods is saving nearly £2500 annually on its compressed air system since installing an ABB variable speed drive at its Riverside Bakery in Nottingham. The 45kW drive was supplied by inverter drives Systems (IDS), an ABB Drives Alliance member. Compressed air is used in many of the bakery's processes.
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Drives save paper manufacturer GBP20,000 a year
ABB variable speed drives used at James Cropper automatically vary the speed of the pump motors to match the changing demand for water

Service prevents drive downtime
Three levels of ABB variable speed drive servicing enable each customer to choose from a range of services that can be tailored to suit their needs and budget precisely

As part of the company's efforts to cut energy costs, Northern Foods investigated its compressed air system and asked IDS to carry out an energy appraisal and make recommendations.

James Whieldon, Maintenance Analyst for Northern Foods, said: 'Our monitoring and targeting software gives us profiles of the compressors and indicated that there were definite opportunities to improve the amount of energy they were using'.

IDS confirmed the energy use figures recorded by Northern Foods and recommended the use of a 45kW ABB standard drive.
Further reading

ABB organisation expands in UK
IDS South is a new branch of long-standing ABB Drives Alliance member, Inverter Drive Systems of Nottingham (IDS East Midlands)

There are three compressors in total, two 30kW fixed-speed assist compressors and a 45kW duty compressor.

The drive was fitted on this compressor, which is in operation all the time.

One of the fixed speed 30kW compressors is used to top up the pressure when demand increases, while the other is on standby in case one of the others goes down.

Zac Dorn of IDS said: 'There are always two out of three compressors running so we had to ensure that the fixed-speed assist compressor only came online when the duty compressor with variable speed drive could provide no more air, that is when it is running at full-speed'.

This was achieved by installing a pressure sensor to provide accurate system pressure feedback for the drive's built-in PID controller.

Whieldon said: 'The drive is now operational and we calculate the actual payback time of the project is 1.5 years, achieving an annual saving of £2450'.

Module adds remote monitoring to relay

With the launch of a Devicenet module for the Allen-Bradley E1 Plus electronic overload relay, Rockwell Automation reduces the cost of remote motor management

With the launch of a devicenet module for the Allen-Bradley E1 Plus electronic overload relay, Rockwell Automation has reduced the cost of remote motor management. The E1 Plus, part of the MCS modular control system range, is a compact, self-powered electronic overload relay. The Devicenet module is an optional accessory that adds intelligent motor protection to industrial networks.
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Safety controller reduces installation costs
Rockwell Automation's Allen-Bradley SmartGuard 600 safety controller helps manufacturers integrate their standard and safety systems for increased productivity

Vision sensor simplifies assembly line inspection
The 48MS MultiSight from Rockwell Automation is a fully self-contained, multi-function vision sensor, which can handle up to ten different inspections simultaneously

Designed to mount directly onto the E1 Plus, the module adds 18mm to the overall width.

All control circuit connections are made via the E1 Plus terminals.

Parameters such as motor current and percentage of thermal capacity can be continually monitored over a network and displayed on a PC or HMI, as can information such as device status, trip-warning identification and trip history.
Further reading

Cable pull switch resists corrosion
Rockwell Automation's Allen-Bradley Guardmaster Lifeline 4 cable pull switch provides users with emergency stop access along exposed conveyors and around awkward machinery

It also allows network access to E1 Plus features such as jam protection and over and underload warnings.

Its two discrete inputs and one relay output let it monitor and control a starter over the network.

Wide trip current adjustment means that a current range of 0.1 to 800A is covered by five overload relays and one Devicenet module.

Using thermal models of motor performance, motor loading can be accurately monitored without using heating elements, meaning the E1 Plus generates less than 2.5% of the heat of a traditional bimetal thermal overload relay.

A dedicated phase loss detection circuit improves protection by reacting to a phase loss condition in less than 3s.

Torque control optimises hoisting applications

Lifting and hoisting applications can be both simplified and optimised thanks to TorqProve, a new and unique torque control feature on the Allen-Bradley PowerFlex 700 range of AC drives

Lifting and hoisting applications can be both simplified and optimised thanks to TorqProve, a new and unique torque control feature on the Allen-Bradley PowerFlex 700 range of AC drives from Rockwell Automation. TorqProve offers both torque control and mechanical brake redundancy, providing users with more onboard functionality - simplifying applications and reducing installation times and costs.
Related stories

Safety controller reduces installation costs
Rockwell Automation's Allen-Bradley SmartGuard 600 safety controller helps manufacturers integrate their standard and safety systems for increased productivity

Vision sensor simplifies assembly line inspection
The 48MS MultiSight from Rockwell Automation is a fully self-contained, multi-function vision sensor, which can handle up to ten different inspections simultaneously

TorqProve is a product of the PowerFlex 700's flux vector control (FVC) architecture, which provides excellent torque and speed regulation, in combination with fast update times of torque inputs, enabling the drive to cope with occurrences such as torque shocks.

It can be used for many kinds of lifting, hoisting or elevator-type applications and simplifies them by automatically co-ordinating the stopping and starting actions of the PowerFlex 700 drive with the setting and releasing actions of a mechanical brake.

This co-ordination is achieved by checking the current flow though all three motor phases.

Only if enough torque is available to assume control of the load does it allow the mechanical brake to be released.

TorqProve works in conjunction with other integrated PowerFlex features.
Further reading

Cable pull switch resists corrosion
Rockwell Automation's Allen-Bradley Guardmaster Lifeline 4 cable pull switch provides users with emergency stop access along exposed conveyors and around awkward machinery

Partnership focuses on network integration
Rockwell Automation and Cisco are collaborating on their common technology view, building reference architectures using standard networking technologies such as EtherNet/IP

Integrated automation aids modern factories
Rockwell Automation's RSLogix 5000 version 16 software contains comprehensive PowerFlex AC drive profiles

One such feature, brake proving, is activated when the speed of the motor reaches zero.

The PowerFlex 700 sets the mechanical brake and then monitors motor movement to ensure the brakes ability to hold the load before releasing drive control.

If movement exceeds a set limit, an alarm is set and the drive will start a brake slip procedure.

This allows the motor to travel a set distance (brake alarm travel) before a second slip test is performed and this will be repeated continuously until the brake holds and the load stops slipping, or the load reaches the ground.

Control of the load is maintained at all times, ensuring that it descends to the ground in a controlled manner, should the mechanical brake fail.

In addition to brake proving, the PowerFlex 700 also offers: speed band limit, a function designed to ensure that, when a certain speed is commanded for the load, it actually travels at that speed; float, the condition when the drive is holding the load at zero speed without the need for the brake to engage; micro precision, which allows for slower, more precise (creep speed) operation; and, finally, fast stop, a feature that ensures ramp deceleration time is forced down to just 0.1s, and that the mechanical brake is applied immediately.

In applications not requiring the float or brake slip functions, the advanced features of PowerFlex 700 allow it to be used in encoder-less hoisting applications while still benefiting from the remaining TorqProve features.

The tight integration of torque control and mechanical brake control is just one example of how the advanced features of the PowerFlex range of AC drives from Rockwell Automation can simplify load management and provide cost-effective yet sophisticated motor control in a wide variety of applications.

Drive maker surpasses WEEE directive

With established recycling scheme, drive maker is ahead of European WEEE directive that will oblige manufacturers to take back and recycle certain types of electrical and electronic equipment

ABB recycled more than 11tonne of electrical and electronic waste from its variable speed drives last year. The company's collection in 2005 was up by 57% on 2004 and by 100% on 2003. As an environmentally conscious manufacturer, ABB collects old drives that have been replaced by newer ABB models, or even those produced by other manufacturers, and dismantles them.
Related stories

Drives save paper manufacturer GBP20,000 a year
ABB variable speed drives used at James Cropper automatically vary the speed of the pump motors to match the changing demand for water

Service prevents drive downtime
Three levels of ABB variable speed drive servicing enable each customer to choose from a range of services that can be tailored to suit their needs and budget precisely

The drives are recycled in accordance with the Environment Act of 1990 in the UK, which stipulates how different materials should be disposed of.

Recyclable materials such as copper and aluminium are recovered, with hazardous waste such as electrolytic capacitors being sent to specialist disposal facilities.

Up to 90% by weight of ABB's drives can be reused or recycled.
Further reading

ABB organisation expands in UK
IDS South is a new branch of long-standing ABB Drives Alliance member, Inverter Drive Systems of Nottingham (IDS East Midlands)

In the UK, ABB has an agreement with recycling company and approved waste carrier, RID, to transport and recycle the drives.

The company collects from the premises of ABB Drives Alliance partners, which have designated recycling bins for drives.

For large drives or large quantities of smaller drives, RID collects direct from the user.

Once the drive has been removed for recycling, ABB issues a certificate that can be used for environmental audits by users complying with ISO 14001.

With its established recycling scheme, ABB is ahead of new legislation.

Under the European directive on Waste Electrical and Electronic Equipment (WEEE), manufacturers will become obliged to take back and recycle certain types of electrical and electronic equipment.

Although the directive will not cover drives, ABB provides the service as an added benefit.

AC drives help cut cheese into portions

Bespoke cheese cutting machine provide precision portioning of blocks of cheese that weigh up to 85kg thanks to quick stop ability of AC drives

The latest bespoke cheese cutting machine from Northwood Food Machinery of Stoke-on-Trent provides precision portioning of blocks of cheese that weigh up to 85kg. This has drastically cut the time for the task and gives accurate and repeatable results every time. The control and accuracy of movement of the blocks of cheese through the machine is attributed to the choice of Commander SK AC drives from Control Techniques.
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Servo motors handle a range of applications
Unimotor FM is a unified 200V/400V servo motor range in six frame sizes from 55 to 190mm and spanning powers from 0.75 up to 73.2Nm

AC drives keep Chinese cranes working
Control Techniques is supplying 160 AC variable speed drives for cranes in Xiamen Haicang Port in Fujian Province in the south of China

The machine is installed at Tippagral's Dijon plant from where it supplies cheeses for the wholesale and food manufacturing markets in France and central Europe.

'We were faced with the task of stopping these huge blocks of cheese instantly', said Northwood Food Machinery Director Mike Southwick.

'A lack of friction in the gearboxes meant the blocks were over-running the target position by some 100mm'.

'We brought in Control Techniques, which was confident it could give the degree of position control required, using the smallest of its general industrial drives, the Commander SK'.

'On the first trial, these drives stopped the motors on target and without any additional cost of braking resistors'.
Further reading

New frame size extends drive range
Control Techniques' frame size D drive is approximately 30% smaller than its predecessor and offers ratings from 200V, 1 phase at 3kW up to 400V, 3 phase at 7.5kW

Servo drives aid football game
A total of 28 Control Techniques Unidrive SP drives in servo mode are used for target control and the ball retrieval system in the Soccer Circus, 10 minutes from Glasgow city centre

Compact drive collects series of awards
Control Techniques' Commander SK drive range won the Industrial Product Design Award at the DBA's Design Effectiveness Awards 2006

The machine is divided into four conveyor sections, each driven by a 0.37kW AC drive.

The incoming conveyor's role is to ensure a fixed pitch between the cheeses as they move through the machine.

The second conveyor section moves the cheese into the machine and, when the way is clear, into the third section.
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This conveyor has optical sensors that feed back to the controlling PLC which initiates a rapid stop exactly between two pneumatically controlled pusher-plates.

This is to ensure that the cheese is absolutely central on the conveyor.

After being centralised, the cheese is moved by the next drive onto the lift section of the conveyor and is stopped at the required position.

It is then elevated by scissor-lift to in front of the cutter section, where a heavy duty pneumatic ram pushes the cheese through the grille of cutting blades, and a guillotine at the reverse side cuts the cheese to the required length.

Director of Tippagral, Neil McAuley, said: 'We portion some 7000tonne of cheese per year, mainly Emmental, but also Cheddar, Gouda, Edam and Mozzarella'.

'Some 75% of our throughput is grated, but many customers, particularly wholesalers and manufacturers of pizza, sandwich and baguette producers, require the cheese to be cut into specific sizes and shapes, for example 9 by 9cm, 7.2 by 7cm and 12 by 5cm'.

'This machine will dramatically streamline this aspect of our operation and cut our labour costs'.

This order follows the success of a similar machine in use at parent company, the Tipperary Co-op in Ireland.

Commander SK is a high specification, general purpose AC drive.

Featuring integral dynamic braking as standard, the drive can absorb the energy created by fast stops, as in this case, while giving smooth, precise control of off-the-shelf motors.

The drives on this cheese cutting machine are hard-wired into the PLC controller to give a fast digital link and are simply programmed to give smooth acceleration and instant stop, when they individually receive instructions to do so.

'We are delighted with the results', said Southwick.

'The Commander SK drives have exceeded our expectations'.

'We simply could not have achieved these results with any other drive, and we're very pleased with the support we've received from Control Techniques, who helped us set it up and provided us with the programming'.

Northwood Food Machinery is an established family-run business with its origins in the bakery business.

It has considerable expertise in the dairy industry and has developed a range of specialist cheese cutters, from simple single-stage cutters to multi-stage machines that give the operator precise portion control and which are able to cut the blocks in two axes.

Motor starters are designed for long life

Enclosed motor starters combine exceptional reliability with compact dimensions and very competitive pricing

Based on the latest xStart DILM contactors, which have mechanical lives in excess of ten million operations and are fitted with durable RMQ Titan pushbuttons, Moeller Electric's new enclosed motor starters combine exceptional reliability with compact dimensions and very competitive pricing. In addition, because the starters are designed and built in the UK, they fully address the specific needs of UK users, and excellent availability is guaranteed.
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Units offer 12 digital inputs
Moeller Electric's EC4P keeps costs down while handling projects where the requirements go beyond simple interlocking and sequencing

Power supplies offer versatile automation
Moeller Electric's new SN3 switch-mode power supplies offer a versatile, convenient and cost-effective choice for automation applications of all types

Standard products in the new Moeller Electric enclosed motor starter range include direct-on-line types with ratings from 4 to 11kW, direct-on-line reversing types with ratings of 4 and 5.5kW and star-delta types with ratings from 5.5 to 15kW.

The starters are available in 230 and 400V versions for use on 50Hz supplies.

The starters come complete with or without an isolator and are supplied fully wired, requiring only the addition of an overload relay - which mounts directly on the contactor - to be ready for immediate use.
Further reading

Vacuum contactors offer AC3 ratings
The DIL M vacuum contactor range now includes products with AC3 ratings from 580A to 1,600A, and is an ideal choice for controlling large motors

All models are offered in insulating or stainless steel enclosures with an IP65 ingress protection rating, or in sheet-steel enclosures which have an IP55 rating.

Moeller Electric's new enclosed motor starters are designed to provide long maintenance-free service lives.
Customised versions to meet requirements which are not covered by the standard models are available on fast deliveries and at attractive prices.

Drive cleans up in bearings washing operation

A Japanese bearings manufacturer benefited from Yaskawa's engineering expertise by chance recently when two engineers stepped in to assist with a malfunctioning bearings washing machine

The UK factory of a large Japanese bearings manufacturer benefited from Yaskawa's engineering expertise by chance recently when two EEU engineers stepped in to assist with a malfunctioning bearings washing machine. The engineers were at the Sheffield site of bearings maker Koyo installing some new re-engineered Servopack drives on a grinding machine that was being upgraded.
Related stories

Woodworking company seeks CNC solution
Three existing Yaskawa Servopack servo drives were replaced a Ferrari CNC machine's panel

Machine tool company offers training
Yaskawa Engineering Europe (EEU) is offering its customers training for every Yaskawa machine tool product, as well as all Yaskawa Mechatronic products such as servo drives and frequency converters

One of Koyo's maintenance engineers asked them if they could take a look at the washing machine whose aging drive was now faulty.

It transpired that the manufacturer of the drive was unable to repair it and unwilling to offer assistance.

The cleaning process involves the bearings entering the washer by sliding down a ramp.
Further reading

Systems keeps customers informed
Yaskawa Engineering Europe has employed a new, automated system by TNT for keeping customers up to date at all times with their orders

They are then dipped in an oil to remove any swarf.

The bearings then slide down into a slot in a holder, which then spins to remove the oil from the bearings.

The clean bearings are then pushed back up top eject them after which they roll away for the next manufacturing process.

The faulty drive controlled the rotation of the bearing holder within the machine.

After spending some time considering the problem and thoroughly checking the application, EEU's engineers offered to develop a solution.

The resultant drive arrangement took some time and expertise to develop, but the new design using a Yaskawa Sigma II drive and motor system has proved successful.

There is also an MP940 machine controller in the new system to interface between the PLC and the drive.

The machine has been running for some time now with no problems.

Koyo Bearings is so satisfied with the new drive and control system that the company's engineers wanted to upgrade eight further washing machines with Yaskawa technology of which four have already been installed and running smoothly.

Koyo Bearings lays claim to being the third largest bearings manufacturer in the world.

The company makes ranges of rolling element bearings and accessories, as well as specialised units for the automotive industry.

Follett to lead sales and marketing initiatives

Fairford's sales and marketing team has been strengthened by the recruitment of Nigel Follett who is leading a number of new initiatives

Follett has a high technology background and has many years experience in the sales and marketing of electronic products and solutions. His most recent position was as Chief Operating Officer for a Bracknell based company developing Internet solutions. Mark Shepherd, Director of Fairford comments: 'We are delighted that Nigel has decided to join us'.
Related stories

Soft starter fitted to hydro power system
A turbine system at the Mill House using a DFE soft starter will provide basically free electricity for between three and four decades

Soft starter cuts food industry carbon emissions
Fitting SPOSS soft starters to the electric motors used on refrigerators, freezers, chillers, and compressors allows energy demand to be reduced immediately by 10-18% per unit

'With the recent acquisition of Fairford by Crown Graphic Group, we need a fresh approach to our customers both in terms of marketing and sales'.

'Nigel's background gives us the ability to bring more added value to existing customers as well as attracting new business'.

Follett adds: 'Having led the development of the soft starter since the late seventies, Fairford has gained a great reputation for technical innovation'.

'We'd like to build on that reputation whilst focusing on a future, which will see us developing a strong applications and solutions-led approach'.

'Customers tell us that our unique experience is a direct benefit to them, especially in vital areas such as cost saving on peak electricity demand'.

Over the next 12 months Fairford is developing innovative new products and solutions that will continue to benefit customers, VARs and distributors alike.

New specialist UK drive integrators announced

Four companies across the UK have been appointed as Lenze Engineering Partners to build and commission new drive and automation equipment

Lenze has created a new UK team of specialist integrators for drive and automation products. Four companies across the UK have been appointed as Lenze Engineering Partners, all with experience and knowledge of Lenze products, plus general experience of machinery and process lines. These Engineering Partners offer a service that includes on-site evaluation and proposal of the optimum package to meet customer specifications.
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Frequency inverter cuts cost and complexity
Sensorless vector operation allows Lenze's SMV frequency inverter to provide fast dynamic torque response and low-speed operation

Drives catalogue goes online
The Lenze DSC Drive Solution catalogue generates 2D and 3D CAD drawings from the virtually infinite possibilities with Lenze motors and geared motors, and is available online

They can build and commission new drive and automation equipment including HMIs, PLCs, IPCs and I/O, plus the networking communications.

The service available covers panel building and operator training.

Lenze Business Development Manager, Geoff Janes, comments 'customers sometimes need a resource beyond our standard capabilities, but they need to be assured of technical ability and reliability'.

'That is where our Engineering Partners fit in'.

Lenze/AC Technology creates new strategic position

AC Technology, a member of the Lenze Group, announces the creation of a new strategic position, Distribution Sales Manager

Company officials describe the new role as responsible for building the relationship between factory and distribution channel. 'As we work to grow our Lenze/AC Tech product lines, we need to develop an enhanced business rapport with the executive management of our distribution partners', says Danny McDonald, Director of Sales for Lenze/AC Technology.
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Facility expands to cover all technologies
Due to double-digit growth over the last 10 years, Lenze/AC Tech, just recently moved from an 7900m2 plant to a brand new facility that spans over 11,600m2

Vector drive gains choice of comms
Plug-in communication modules increase the flexibility of the SMVector drive

To fulfill this new key position, AC Technology has recruited Eric Klein, a graduate of Cornell University with a BS in Engineering and a plethora of business experience, including 16 years at Toshiba and four years with Reliance Electric.

Most recently, Klein was a Northeast Regional Manager for Toshiba where he landed a $4 million motor and drives order and was awarded the 'Shark Award' for obtaining business through enhanced customer relationships.

Soft starters are key to green energy generation

Fairford is demonstrating the ongoing relevance of well established soft starter technology to a newer and greener form of energy generation

The company is supplying its QFE range of soft starters for use in wind turbines, providing the means to synchronise operation of the turbines to distribution networks, obviating the problems of direct-on-line starting. The QFE soft starters are delivering a cost effective and highly reliable solution for bringing wind turbine generators on line smoothly.
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They provide the means to synchronise the output of the turbine generator to power networks without massive inrush currents on the supply, and without the harsh shocks that can damage and break mechanical equipment such as bearings, couplings and gears.

The QFE soft starter comes into operation when the wind generator, under the action of its aerodynamic rotor, reaches a point just below synchronous speed (approximately 93 percent).

Working in reverse mode, the QFE unit is used to put the generator on line.
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It ramps the generator voltage up to the system voltage, and as the generator accelerates further to synchronous speed, a by-pass contactor is closed by the wind turbine controller (WTC), once it has received a top of ramp signal from the soft starter unit.

When the by pass contactor is closed, the wind turbine's power factor capacitors are connected and the turbine rotor then accelerates the generator up to a greater than synchronous speed, allowing generation to begin.

The QFE Soft Starter units that perform this operation are Fairford Electronics standard 690V range.

They are designed to reduce the magnetic inrush currents, which are an order of ten times rated line current when starting the generator direct-on-line, to about one times rated line current.

This current is held as an acceleration current during progression from 93 percent to full synchronous speed and, finally, freewheeling current.

This is load current not drawn by the generator while it is at synchronous speed: it is handled by the QFE controller until the by-pass contactor is switched in.

'Having led the development of the soft starter since the late seventies, its appropriate that Fairford is taking the technology to new and developing industry sectors', said Nigel Follett, Fairford's Sales and Marketing Manager.

'With our involvement in wind energy systems, we are demonstrating the relevance of our soft starters to a still evolving method of power generation, proving that existing technology can still provide answers even in today's fast developing markets'.

Servomotors improve energy efficiency

Direct drive motors are fitted directly to the load, dispensing with the need for additional components such as gearboxes, couplings, belts, chains and sprockets

A new range of direct drive servomotors has been launched by Motor Technology to provide a solution for machine builders looking for increases in energy efficiency and a reduction in drive components. direct drive motors are fitted directly to the load, dispensing with the need for additional components such as gearboxes, couplings, belts, chains and sprockets.
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Replacement components keep old servos running
Replacement servo drive components are compatible with originals from a range of manufacturers that date back, in some cases, more than 20 years

Servomotors are highly efficient, typically 90 to 95%, and direct drive servos can result in energy savings of up to 50% in some cases.

Not only is the motor more efficient, but driving the load directly removes the inefficiencies inherent in a power train with more components.

Driving the load directly has the additional advantage of eliminating backlash from gearboxes, couplings and rack-and-pinions.

It also eliminates the problems associated with expansion in belt drives or the play in chain, all of which translate into efficiency losses and a requirement for increased maintenance.

Direct drives also reduce design-in time, installation time and cut maintenance and down time.
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Servo controllers are flexible about interfacing
Single and three phase servo positioning controllers can be connected to a wide range of encoder systems and motor types

Intelligent servo drives gain UK support
Metronix has appointed Motor Technology of Stockport to act as its UK agent in a move to make its intelligent servo drives more readily available to the UK market

Direct mounting cuts costs for servo drive
Decentralised 24 and 48V DC servo drive can be mounted directly onto brushless or permanent magnet DC servomotors and has a universal encoder interface to operate with various feedback devices

The new SKA direct-drive linear motors are synchronous, linear, permanent magnet motors designed with iron-core technology.

The mobile part is formed by the winding while the static part is formed by the track to which the permanent magnets are fixed.

The motors are offered as ready-assembled units with integrated linear guide rails and feedback, or as frameless units comprising a part-set of track and carriage.

They are available up to 3m long and are capable of producing up to 7200N of peak force.

Amongst the range of linear motors is a compact model designed as a plug and play solution.

It has an extruded aluminium body with integrated track, carriage, linear guides and feedback device, and is as simple to fit as a conventional linear actuator.

The SKA direct drive rotary motors, capable of producing up to 800Nm of torque, are essentially brushless servomotors with an increased number of poles.

This spreads current more evenly through the windings and allows for a much higher torque density and smooth operation.

The motors are available as ready-to-fit power pack units with solid or hollow shafts, motor flange and casing, feedback device and holding brake if required.

Alternatively they can be supplied as frameless part-sets consisting of a rotor and stator.

Positioning stages offer long lifetimes

The ATS115 is Aerotech's smallest side-sealed, hard cover positioning stage and is based upon a tried and tested protection system

Aerotech's new low-cost ATS115 and ATS165 positioning stages feature linear motion guide bearings, precision ball screws and durable hard cover/side-seal protection for high-performance, medium-precision positioning applications. The servomotor driven-stages have nominal widths of 115 or 165mm, a choice of travel range from 50 to 600mm and a low-profile height of just 60mm.
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LMA/LMAC actuators include dual sealed linear motion guide bearings and robust chain type cable management for a complete positioning solution

They are suited for long and trouble-free use in medium-duty manufacturing production and research automation where less than 45kg direct loading, 300mm/s speed and bidirectional repeatability above +/- 1.0um per-axis is required.

The ATS115 is Aerotech's smallest side-sealed, hard cover positioning stage and is based upon a tried and tested protection system designed for hostile application areas such as laser welding and ultrasonic machining.

Unlike traditional bellows or sliding top-seal designs, the one-piece hard cover and vertical side-seal arrangement deflects debris away from the internal stage mechanics.

Working life is extended, downtime and maintenance schedules are drastically reduced and production time is maximised.

The design can include optional brush cleaning strips, fitted to the moving carriage, to help remove machining waste and prevent debris from accumulating on the hard cover.
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Webcasts explain motion control concepts
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Drives combine linear and PWM amplifier technology
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Brochure highlights motion options
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As standard, ATS115 and ATS165 linear stages are fitted with Aerotech's BMS series cog-free, brushless motors with 2500-line rotary encoders for 0.5um resolution with excellent smoothness and acceleration performance.

Motor mounting is made through a NEMA 23 flange and alternative motors from Aerotech or third-party suppliers include stepper motors or brushed servomotors to allow the widest choice of price and performance alternatives.

A side motor mounting option is also available to reduce overall stage length for restricted space applications.
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The wider ATS165 shares a similar protection, bearing and drive design with the increased width allowing a heavier payload and offset loading capability over the ATS115.

Common interfacing dimensions allow both ranges to be assembled for optimal X-Y and X-Y-Z mounting configuration.

A mounting bracket is available to support vertical orientation where a brake option can be provided to prevent back-driving.

A complete selection of mounting configurations is available both with and without precision orthogonality alignment.

Both stage designs are available in a wide choice of travel ranges covering 50, 100, 150, 200, 250, 300, 400, 500 and 600mm.

An optional table top is available with a useful array of holes for mounting customer fixtures or with mounting holes to suit a choice of Aerotech rotary stages.

As with all Aerotech mechanical stages, the ATS115 and ATS165 can be supplied complete with accuracy and repeatability performance plots.

ATS115 and ATS165 stages are typically supplied as part of complete 'ready to run' systems configured to the customer's requirements with Aerotech motion controllers and servo amplifiers.

A wide choice of motion controllers available includes the A3200 Automation Platform - a PC-based, software-only motion and machine control system with deterministic Firewire networking; the Soloist stand-alone single-axis intelligent drive; or the Ensemble range of intelligent drives with deterministic Ethernet for tightly synchronised multi-axis motion and I/O control.

Aerotech systems are supplied complete with interconnecting cables, motor parameter set-up data, performance documents and assembly information to speed commissioning and help integrators with their own system documentation.

Servomotor controller allows I/O sharing

QuickSilver Controls' SilverDust IGC makes it easy and inexpensive to create a scalable, multi-axis network

QuickSilver Controls' SilverDust IGC is its lowest cost CANopen servomotor controller. This single-axis controller includes serial communications (RS-232, RS-485), CANopen and 7 I/O. CANopen can be configured for peer-to-peer, master or slave which allows the controllers to share I/O with other CANopen enabled SilverDust controllers or third party CANopen devices.
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The RS-232/RS-485 serial network runs in parallel to CANopen for supervisory control from a host.

For a multi-axis system, users can connect several IGCs, making one the master and letting the others receive motion commands over CANopen.

If more I/O or Ethernet are needed the user can upgrade the master to one the more powerful controllers.

With the IGC it is easy and inexpensive to create a scalable, multi-axis network.

The IGC is designed to servo QuickSilver's NEMA 17 and NEMA 23 frame I-Grade servomotors and includes breakouts for power and communications.

The 7 bi-directional I/O can be broken out using one of the company's basic breakouts

Custom products kill surface bacteria

Elesa now has products that actively kill bacteria on their surface; a whole new type of soft touch products which are more comfortable to hold - each of these required major technological advances

Today we are so habitualised to the use of standard machine elements - knobs, handles, clamps, handwheels, that we could be forgiven for ignoring the possibility of developments in this area. But - one company who have made it their business to specialise in these items is increasingly applying materials and production technologies in a way that is changing the way we interact with manually operated equipment.
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Market leaders Elesa now have products that actively kill bacteria on their surface; a whole new type of soft touch products which are more comfortable to hold - each of these required major technological advances.

The first to incorporate active silver ions into the plastic without destroying their bacteria-busting action in the moulding process, and the second in development of a complete new moulding methodology with a new configuration of moulds and special injection machinery to operate them.

'Whatever you want so long as it is black' used to be the mantra of machinery accessory suppliers.
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Elesa has changed all that with lean, flexible manufacturing processes that deliver multiple colours as standard; logos, warnings and instructional markings to order and fixing systems by selection from plain bore to clip-fix.

These same processes can also handle high impact thermo plastics and increasing requirements for stainless steel - ultimately providing quality and choice to OEMs and end users.

Simply by extending this philosophy into the supply chain, minimum quantity deliveries can be scheduled over 12 months, thus spreading the cost and effectively dealing with stock and cash flow issues.

By pushing forward the boundaries of their standard products, Elesa can now also offer that same novel (often patented) technology in the development of custom products, thus adding definition to a customer's own niche equipment.

Digital measuring made for dynamic balancing

An extremely accurate, lower priced digital measuring system for virtually any manual one- or two-plane dynamic balancer is simple to operate

The UNI-25 is simple to operate and extremely accurate digital measuring system for virtually any manual one- or two-plane dynamic balancer. The UNI-25 system has been developed to accommodate the lower end market where Universal Balancing's famous super advanced UNI-44 windows based system cannot compete on price.
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The UNI-25 is technically just as accurate as its 'big daddy' - the UNI-44 - but without the 'bells and whistles'.

The UNI-25 accuracy is one of its best selling points because many competitors entry-level systems just don't provide high-level accuracy.

The UNI-25 can be purchased with most of Universal Balancing's standard range of manual dynamic balancers instead of the UNI-44, thus saving cost for low volume users.

Or you can use it to upgrade old balancing machines.

The UNI-25 can be retrofitted on most makes and types of balancers.

You can even install the UNI-25 yourself using an easy to follow 'step by step''nstallation manual.

Other key features of the UNI-25 are Job Store, Tooling Compensation, Encoder angle tracking, IO for interlocking, Various units of operation, 125mm large backlit LCD display.

The base price of the UNI-25 is GBP 2,999.

Pickups, encoder, photocell, leads, etc, are all available as additional packaged solutions to provide a complete modern measuring system upgrade.

Precise rotary indexer takes large workpieces

Indexing/rotary table system provides users with rapid part positioning and enables a diverse range of milling operations (spiral, linear, arc, etc) on large, complex workpieces

Market-leading milling, turning, grinding and workholding specialist - Hardinge Machine Tools - has introduced its new 16C indexing/rotary table system into the UK. The 16C system is an extension of the highly-popular and successful 5C system launched by Hardinge last year - and is designed to provide the same performance and capabilities as the 5C - but on larger and heavier workpieces.
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The 16C system provides users with rapid part positioning and enables a diverse range of milling operations (spiral, linear, arc etc) on large, complex components to be undertaken - and has been aimed at customers machining, amongst other components, higher-precision medical and aerospace parts.

The system enables common and standard spindle tooling to be shared - from indexer to lathe - and can be mounted directly and quickly in or on the (A2-5) spindle without the use of an adapter.

Collet, expanding collets, step chucks and three-jaw power chucks automatically centre the part and, because the collet spindle design means that gripping is in the spindle - closer to the spindle bearings - superior gripping force required for heavy cutting is produced.

The 16C system has a 152.4mm centreline to base capacity - and a 41.2mm through-hole-capability (for longer parts).

A pneumatic collet closer provides 2068kg draw bar pull.
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And the 16C's 15.87mm stroke allows the use of 'power' chucks.

The system also features a compact brushless motor that can be specified for either left- or right-hand setup and the spindle has a rolling element design - with dual angular contact spindle bearings - to accommodate heavy workpiece weights and high tailstock thrusts.

Speeds can be reached up to 50 rev/min.

The 16C model will accept 'round stock' capacities up to (41.27mm), hex capacities up to (35.71mm) and square capacities up to (28.97mm) - using standard collets.

Hardinge manufactures and stocks a large array of spindle tooling to hold larger parts.

These include - step chucks for up to 6in (152.4mm) outside diameters or customised shapes; Sure-Grip expanding collets for up to 4in (101.6mm) internal diameter gripping; three-jaw power chucks and 10in fixture plates.

Emergency collets and step chucks can also be bored-to-size on location for JIT (Just-in-Time) machining and tailstocks are also available to provide support for parts that exceed the 3:1 length-to-diameter ratio.

Hardinge indexing/rotary table systems are compatible with most brands of vertical machining centers and knee mills.

Hardinge's unique servo control stores up to 50 programs with up to 1000 steps in each program.

The multiple line display means that viewing all critical data (at one time) is optimised - with less time spent on scrolling up and down and/or referring to the operator's manual.

Infrared data transmission capabilities allow upload and download of programs from a pocket PC.

16C indexer/rotary table systems can be used with a Hardinge servo control actuated by 'M' functions; or interfaced using an RS-232 interface cable; or as a true 4th-axis on many/most VMCs - including Hardinge Bridgeport machining centres or knee mills.

* Super-Precision Direct-Drive technology from Hardinge - the advantages - Hardinge's new Direct-Drive, Quick-Change Rotary Systems (as in the 16C system) incorporates a direct-drive, rare-earth permanent magnet torque motor with no mechanical gearing.

This frameless motor wraps around the spindle, eliminating the need for a separate motor extension - resulting in a much smaller footprint.

Liquid-cooling wraps around the motor stator housing to increase continuous torque output by 38% to 100% when utilized for rigorous duty cycles and heavy cutting.

Thermal isolation mounting arms and a cast iron base enable uniform heat dissipation, which holds the centre line of the spindle constant in the Super-Precision A2-5 spindle mount design.

The direct-drive design eliminates backlash, which results in high servo stiffness and extremely rapid and accurate bi-directional response and exceptional repeatability.

When the command is given to stop at a certain angular location - it absolutely stops at that precise location with no overshoot and will repeat exactly.

When operated as an integrated axis on a high speed VMC utilizing look-ahead programming, the Hardinge Direct Drive system's combination of zero backlash, high servo gain, and rapid acceleration will enable the user to operate at the maximum capability of the machine.

Hardinge's new direct-drive systems require little maintenance and have fewer parts to wear than traditional gear-driven systems.

A rugged cross roller bearing is used for high-moment loads with super rigidity.

The bearing is permanently lubricated, and there are no brushes to wear or to create dust, providing a smooth, quiet operation and a longer life.

The inherent high servo stiffness eliminates the need for a clamp for most applications, however a spindle clamp/brake is available if necessary for particular applications.

Said David Andrew, sales and marketing director at Hardinge: 'The 16C indexing system is a hi-tech solution which, with our Super-Precision positioning and repeatability - increases part accuracy and customer productivity.

Our high-performance rotary indexing technology makes everything possible.'

Lighting withstands machine tool chips

Although acrylic can be ideal in many machinery lighting applications, it does tend to scratch if hit by flying machine tool chips, so borosilicate glass tubes are recommended

When Cincinnati wanted to upgrade the lighting specification of its UK-built CFV and FTV vertical machining centres it chose powerful RL fluorescent tube lights from Waldmann Lighting. As Cincinnati's electrical design manager Martyn Robinson explained, 'We reviewed our specification and decided that we wanted to upgrade our current machine tool lights.
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We knew of Waldmann Lighting's reputation, and that they supplied many of the world's other leading machine tool manufacturers, so we approached them for their suggestions.

They were able to offer a fluorescent lamp in a borosilicate glass tube that gave us a number of advantages over our previous lights that had an acrylic housing.' Although acrylic can be an ideal solution in for many applications - and indeed Waldmann can supply its tube lights in high quality 5mm thick acrylic housings - it does tend to scratch if hit by flying chips.

In these cases Waldmann recommends that the lights are housed in borosilicate glass tubes.
Further reading

Compatible lighting products for machine tools
As an independent manufacturer, Waldmann Lighting may well be able to offer compatible machine tool lighting products with much better performance

Waldmann's RL fluorescent tube lights offer a greatly enhanced service life because of their ability to withstand the harsh environment of coolant splashes and chip impacts in the machining zone.

As well as using robust borosilicate glass tubes they are sealed using special twist-off end caps that are easy to open, yet provide protection against moisture and dust ingress to IP67.

As Rodger Henderson of Waldmann Lighting explained, 'All machine tools have to meet the obligations of the European machinery directive by providing appropriate lighting exactly where it is needed for safe and error-free setup and operation.

Waldmann Lighting has 4000 different variants of tube lighting available and can tailor the lighting system to provide exactly the right illumination for a specific machine tool with an off-the-shelf product - in Cincinnati's case this actually meant that it could use a less powerful light and avoid unnecessary heat.' Waldmann lights are now being fitted as standard original equipment on all new CFV and FTV machining centres and retrofit kits are also offered to upgrade machines that are already in the field if their lights break or wear out.

'We have been very happy with the quality of the lights and the service offered by Waldmann Lighting and are always glad to find ways to make our products even better,' said Robinson