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Tag Archives: Siemens General Motion Control

Enhanced SINAMICS Control Unit for Variable Speed Drives

New CU250S-2 control unit now in stock; supplements existing Siemens G120 drive with universal vector control and encoder feedback  

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Siemens Industry, Inc. announced today the availability of the new Sinamics CU250S-2 control unit for use with its popular Sinamics G120 variable speed drives.  The unit provides vector control with encoder feedback.  Additionally, the operation of single-axis applications with exact speed and torque control on induction motors, as well as positioning tasks with high demand on I/O, are supported, with different encoder interfaces provided on the module.  These new units complete the G120 product portfolio and replace the CU240S with encoder interface.

Typical applications for these new control units include single drives with a large number of I/O or those with high speed control requirements, including extruders, centrifuges, wire-drawing machines, basic fabric webs, conveyors, lifters and others in markets ranging from automotive assembly, textiles, printing and chemical processing to nearly all conveyors and material handling.

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The new Sinamics CU250S-2 control units can be combined with existing power modules to support all G120 drive applications, with or without encoder evaluation, for demanding applications requiring speed feedback.  Additionally, STO (Safe Torque Off), SBC (Safe Brake Control) and SS1 (Safe Stop 1) features are all integrated, enabling their application on basic safety requirements.  With the purchase of an optional software license, extended safety functions can be obtained, along with software for a single positioning function (EPos).

Comprehensive communications interfaces for general machine building are provided on this new Sinamics control from Siemens, including Profibus DP, Profinet (Ethernet I/P), RS485 (USS protocol, Modbus RTU) and CANopen, allowing convenient connection to other Siemens systems as well as external automation systems.  No external gateway is needed.

Other features include an integrated USB port, so users can simply go online to facilitate engineering set-up and maintenance, plus an integrated slot for an SD card to allow simple cloning and firmware updates or upgrades.

For more information about this line of Sinamics control units, please visit: www.usa.siemens.com/sinamics

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

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Precision Processing for Fast Bikes

To guarantee perfect workmanship and the highest possible product quality, BMW uses five-axis machining centers equipped with Sinumerik 840D sl and a range of new user interfaces for machining operations in its Berlin motorcycle plant.

B01a_Siemens_BMW-Berlin_M0910BMW motorcycles enjoy an outstanding reputation around the world for their reliability, quality, performance and safety. This is not achieved by chance, however. BMW’s motorcycle plant in Berlin uses around 50 machine tools to create numerous key components on-site, from frames and valve shafts to connecting rods and cylinder heads. Among these tools are Grob’s horizontal five-axis G550 machining centers equipped with Sinumerik 840D controllers, which are used in the manufacture of cylinder heads for flat and 4-cylinder engines. Prices are obtained from suppliers at regular intervals, especially when the company is investing in new machining centers. The aim is to ensure that BMW can manufacture its components more cost-effectively than external contractors, while at the same time comparing the prices offered by the various machine suppliers. One of the major reasons for choosing the G550 was because it was equipped with a Siemens CNC.

The horizontal design of the Grob five-axis G550 guarantees the highest levels of rigidity, which keeps axial deviations below 10 µm.

The horizontal design of the Grob five-axis G550 guarantees the highest levels of rigidity, which keeps axial deviations below 10 µm.

Thanks to previous positive experience with Siemens, the BMW manufacturing specialists in Berlin already employ technology from Europe’s market leader for 90 percent of their controllers. This allows both operators and tool setters the flexibility to work on almost all the machines in the plant. Other key requirements noted in the specification were adequate space for manufacturing all relevant components, the highest levels of precision and surface finish, compliance with pre-defined cycle times, and the ability to reuse all current tools and equipment.

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The highest levels of precision on even the hardest material

Before committing to the new investment, the responsible BMW production engineer worked with a colleague from process engineering to investigate the effectiveness of the Grob machines in cylinder head production. Initially, it was the G550’s near-identical sibling, the G350, that was under consideration. As a first traditional single-workplace machine tool, it already met almost all the main criteria, but the space available inside was deemed too small to accommodate all the required processing tasks. However, the G550 satisfied this requirement as well. Among other factors, the horizontal design of this five-axis machine, which has both rotary axes in the work area, contributes significantly to its outstanding rigidity. As a result, axial deviation remains process-compliant at values under 10 µm. The level of precision that can be achieved is correspondingly high, even when processing extremely hard materials, as with valve seat inserts, for example.

The machine also produces a high-quality surface finish, with roughness (Rz) of up to 2 µm. Christian Heiß, applications engineer at Grob, explains a further benefit of the horizontal design: “Tool life can be increased by approximately 30 percent compared with that of vertical machining centers. And the problem of jammed slivers is almost completely eliminated because they are not able to fall onto the workpiece in the first place, but instead fall right through to the ground.”

One of the G550’s strengths is its compact size, at only 3800 mm x 6300 mm. However, despite its size, it still features an extremely long z-axis stroke of 1020 mm, meaning that tools up to 500 mm long can be retracted completely out of the work area and into the so-called spindle tunnel. The swivel-mounted shuttle table is another feature that helps deliver high levels of productivity. While one workpiece is being processed, the next can be clamped and set, thus minimizing costly downtime. B09_Siemens_BMW-Berlin_0471

Programmed and set in no time at all
Employees find the new Sinumerik 840D sl CNC especially easy to operate because, in the production of BMW cylinder heads, only Siemens controllers are used. Despite this, the user interface presented on the Grob machines looks completely different from the others. Until now, operators and setters have been used to the DIN-based HMI Advanced user interface, but the new CNC on the G550 features the Sinumerik Operate animated graphical display. Siemens has integrated a new operation and programming structure, with practical functions such as copy and paste that are well known to users from their daily use of PCs. This allowed BMW employees to quickly adapt and master the new Sinumerik user interface in no time at all.

Thanks to its excellent usability and intuitive operation through various technology cycles, measurement cycles, and setting functionality, the new G550 machines can be set up for new batches much more quickly than before. As Heiß explains: “This means our customers are much faster than before. Previously, it might have taken several hours to set up the machine and the workpiece, now it can be done in just a few minutes.”

Highly trained employees and specialist suppliers help BMW motorcycles maintain their excellent reputation for reliability, quality, and safety.

Highly trained employees and specialist suppliers help BMW motorcycles maintain their excellent reputation for reliability, quality, and safety.

Quick and reliable with remote maintenance
Along with the tools and equipment from the current machines, the German motorcycle manufacturer was able to reuse all its existing programs as well. It took a single employee only two days to upgrade these programs to be compatible with the latest software, which can be loaded onto the relevant machine as required either over the network or from a USB stick. The modern Windows Explorer-style program manager means that complex programs can be managed either on the CF (Compact Flash) card or directly on the CNC.

If problems arise while the machine is operational, BMW production engineer Taner Ögretmen and his colleagues use the network-based remote maintenance functionality provided by Grob. This has rarely been required so far – but when it has, it proved to be extremely smooth and efficient, stresses Ögretmen. Grob can also perform minor optimizations together with Siemens using the teleservice. This is usually done automatically and without any disruption to ongoing production. The Sinumerik-controlled Grob machines have met every expectation in full, which is why BMW has already ordered an additional four G550s.

Programming and operation using Sinumerik Operate

sinumerik_cnc_op19_operateSinumerik Operate provides several different programming methods to let users program and set the workpieces: ShopMill graphical user interface, programGUIDE for G-code with cycle support, and pure DIN/ISO programming. If the user decides to use ShopMill, he or she receives an animated graphical work-step programming environment for simple dialog programming. The interface is designed to
be clear and self-explanatory, so  that even operators with no programming experience can learn the basics in no time at all. To write programs in programGUIDE, the operator will need some knowledge of G-code. The highlights here include new cycle support functionality and animated elements that can be used to represent the cycle graphically. Tooltip support is also provided.

For more information on this story:

SIEMENS INDUSTRY, INC.
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/cnc
Email:  SiemensMTBUMarCom.sea@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter:  www.twitter.com/siemens_cnc_us.

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Siemens Introduces North American Version of Sinamics S120 Cabinet Module Drives

North American users can now make full use of the benefits of a modular product, built to NEC (NFPA 70) standards, to configure common DC bus lineups and high horsepower drives, with optional UL/cUL listing

sinamics_s120_cmSiemens announces a new version of its popular Sinamics S120 Cabinet Module (CM) drive packages, compliant with North American standards and offered with optional UL/cUL listing. This unique product enables easy configuration of complex common DC bus lineups for multi-motor coordinated drive systems, as well as high horsepower (hp) stand-alone drives for a wide variety of industrial applications.

Key to the global growth of the Sinamics S120 CM range is its modularity and flexibility. Pre-designed, fully type-tested modules, including line side components, line infeeds (bus supplies) and motor inverters, all with a broad range of standard options, are selected and configured by the customer. Compared to the traditional approach of custom-engineered systems, this approach offers significant reduction in engineering and manufacturing lead times, which translates into reduced project costs and a compressed delivery schedule, while minimizing technical and commercial risk on even the most complex drive systems.

Individual cabinet modules from Siemens have a standardized power and control interface, which allows them to be freely positioned in a lineup that best suits the particular application and makes them easy to install and connect. The broad range of standard options including the DC bus current rating and enclosure type, for example, is available to tailor selections to best meet jobsite and environmental conditions. Despite standardization, this design offers a high degree of flexibility for both power and control circuits. For line side converters, there is a choice of non-regenerative Basic Line Module (diode rectifier) or fully regenerative Smart and Active Line Modules. Both of these are IGBT inverters, the Smart Line Module being a more basic six-pulse unit, while the Active Line Module offers low harmonics exceeding the demands of IEEE 519.  Unity or controllable power factor and DC bus voltage control allows stable operation of motors even on irregular power supply systems. Basic and Smart Line Modules can also be configured in 12-, 18- or 24-pulse systems for low harmonic operation. All these configurations are now compliant with the National Electrical Code (NFPA 70) and Short Circuit Current Ratings per UL508A supplement SB, up to 100 kA.

The SINAMICS S120 firmware, combined with Drive-CLiQ (the flexible backplane bus), allows users to assign control units multiple Line and Motor Modules, plus mount the control units and associated I/O and sensor modules anywhere within the line-up or even remotely in a centralized control cabinet or control room. Drive-CLiQ provides automatic electronic nameplate, real-time control data transfer, diagnostic and parameter value gathering and fault tolerant transfer protocols. For external control systems, high-speed industrial Ethernet communications can be parameterized for EtherNet/IP, PROFINET or Sinamics Link (peer-to-peer), while programming can be done via a dedicated port or Ethernet TCP on the Ethernet network simultaneously with Profinet or EtherNet /IP.

Sinamics S120 Cabinet Modules were designed to address the need for a complete, ready-to-connect-and-run drive system that enables customers to configure an enclosed drive lineup with a central line infeed (rectifier) and common DC bus, supplying power to multiple motor modules (inverters).  Typical uses for such systems requiring multi-motor coordinated drive systems include paper machines, steel rolling mills, test stands, cranes, mixers and oil/gas field equipment.  Very high horsepower single drive applications also benefit from this Siemens system.

The use of a common DC bus configuration with these new drive packages allows energy exchange between motors that are simply powering and others regenerating power back to the AC system, which can save up to 80% of the energy consumed when using standard installations.

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com

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Siemens Introduces Four-Week Lead Time on Generation II Simotics® 1FK7 Servomotors

1FK7042-2AF71-1QG0Field-replaceable 24-bit encoders in 10 styles and reduced lead times highlight new line of servomotors; three inertia versions, seven shaft heights on highly-configurable line

Siemens Industry, Inc. announces reduced lead times for its Generation II Simotics 1FK7 servomotors.  Highly-configurable to suit a wide variety of applications, this new line features seven shaft heights, Quick-Connect power connector and  high-accuracy 20- and 24-bit field replaceable encoders in 10 styles, all combined with a four-week lead time beginning July 1, 2013 — and ultimately reduced to three-weeks beginning January 1, 2014 on all models.

The Generation II servomotor offers three inertia versions — standard, high-dynamic for rapid acceleration jobs, and high-inertia for maximum smooth running.  These motors are designed for operation without external cooling and the heat is dissipated through the motor surface.  With 10 styles of field-replaceable encoders, the 1FK7 Generation II servomotors provide easy maintenance in the field, with reduced downtime and operating cost savings.  Further, a 10 percent improvement in continuous (S-1) power is achieved since the encoders are mechanically and thermally decoupled from the motor.  The mechanical decoupling also means the encoder is more resistant to vibration conditions on the machine.  In addition, there is no need for battery back-up on the absolute encoders.

1FK7042-2AF71-1QG0Generation II Simotics 1FK7 servomotors provide users with  3x overload, 2.5 percent torque ripple, cross profiling for easier mounting, Siemens Drive-Cliq interface for easier field commissioning and unit recognition with the Siemens Sinamics S120 drive family, plain shaft or keyway design, three IP ratings and are supplied with or without holding brake.

The full application of engineering assistance and service of the global Siemens network supports this new line of servomotors.

For more information on these new Siemens servomotors, please visit www.usa.siemens.com/simotics.

For product information and inquiries, call +1 800 879 8079 ext. Marketing Communications or e-mail SiemensMTBUMarCom.industry@siemens.com.

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Siemens Enhances Sinamics G120 Drive Platform with Industrial Ethernet Connectivity

siemens_sinamics_g120engSiemens announced that its versatile Sinamics G120 drive system has been enhanced to include EtherNet/IP connectivity, thus providing maximum flexibility for industrial Ethernet communication while offering innovative concepts for those wanting a single network for the entire plant.

“In many instances, plant managers have the requirement for a single-plant network, particularly with large automotive, packaging, plastics, metals, food and beverage as well as material handling companies,” says Robert Soré, Siemens product manager, Sinamics G drives.  “Our Sinamics G120 drive provides communications without limits to a specific network type.”

The Sinamics G120 drive platform supports, as standard, Profibus DP and Profinet to ensure seamless communications between every component involved in a typical automation solution, including HMI (operator control and visualization) and I/O.  Additional higher-level functions, including Safety Integrated telegrams and synchronized mechanisms for even the highest-level control applications, are
also included.

Profinet can transmit operating and diagnostics data simultaneously to enterprise-level systems using standard IT mechanisms (TCP/IP) for an integrated factory environment.  The new addition of an EtherNet/IP stack offers another option for Sinamics G120 users.  Having the flexibility to communicate with the most common automation systems via Profinet or EtherNet/IP makes the Sinamics G120 drive system easily adaptable to the current Industrial Ethernet boom.

With a wide power range (0.50 – 350 hp), highly scalable solutions, including safety integrated functionality and convenient start-up with Siemens Starter software, the Sinamics G120 drive is a powerful solution for a variety of applications, including packaging, plastics molding and extrusion, textile, printing and paper machines, handling and assembly systems, rolling mills and test stands.

See the SINAMICS Drives video on YouTube here.

For more information about the Sinamics G120 drive platform, visit www.usa.siemens.com/sinamics-g120.

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

 

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The Case for Regenerative AC Drives

A practical alternative to mechanical braking and non-regen drives systems in the converting, packaging, wireforming and printing industries

by William Gilbert, Industry Business Development Manager,
Converting and Cranes, Motion Control Solutions

The unwind brake operates much like the brake on a car, with disk, calipers and pads.  The tension is linked to a position controller.

The unwind brake operates much like the brake on a car, with disk, calipers and pads. The tension is linked to a position controller.

During the operation of any converting machine, whether for film, foil, wire, paper or board, plus most large printing presses, rolls of materials are handled by unwinds, often still driven by pneumatically operated braking systems.  The traditional tension control system for an unwind stand is a simple mechanical brake.  In principal, the unwind brake mechanically operates much like the braking system on your car, with a disk, caliper and pads, but is controlled by a tension sensor linked to a setpoint controller.  As the roll unwinds, the tension is maintained by the brake for smooth passage of the material through the dies or rollers, resulting in better package alignment, less wrinkling, better print registration, even more consistent wire dimensioning and other production positives.  These mechanical brake unwinds are effective in controlling the tension, but have inherent problems of heat and power loss, plus mechanical wear and constant maintenance needs, substantially impacting machine uptime.

The typical mechanical brake is pneumatically controlled and may utilize several sets of friction pads to control the web tension as the roll dimension decreases.  Plus, a reasonable pressure range in many applications might be from 15-90psi or a 6:1 drop, a range significantly less than the core to full roll ratio for most jobs, an obvious inefficiency in operation.

This schematic shows the typical driven unwind system in operation

This schematic shows the typical driven unwind system in operation

To affect good tension control on the brake, these friction pad sets need to be manually changed in an out of the brake assembly, depending on the desired operating tension and the roll diameter changes involved.  Often, the adjustments are several per roll during this manual changeover.  Because the mechanical brake creates the unwind tension through friction, it generates substantial heat and often requires a separately powered fan for cooling to operate effectively.  This friction also means the pads are subject to rapid wear, requiring frequent and time-consuming changes or maintenance checks.

For almost a decade now, this old technology has been gradually replaced, though usually in the lower power ranges, by newer precision technology, involving AC motors, drives and electronic loadcells.  On converting lines today, a further leap forward is being made with the onset of active front end technology.

With such technology, the operating principle is as follows.

Print

Conventional mechanical brake system

Since the unwind application is regenerative (regen) in nature, a driven unwind needs to return the energy that the mechanical the brake produced as heat back to the AC line.  In the past, regen DC drives have been successfully applied as driven unwinds, but DC drive systems are no longer common and even during their prime were very costly.  Early in the AC drive technology for these applications, the drives did not have the capability to regenerate the power back to the AC line and, when applied as unwind brakes, required regen resistors to dissipate the tension energy.  This was wasteful and costly.

Today’s AC drive systems now have the technology to regenerate the energy back to the AC line just as the DC drive did, but with added benefits to the user and machine designer alike.  Sending the tension energy back to the line means power that once was wasted can now be retained, instead of the system producing heat and worn parts.  When the drive is equipped with active front end technology, it will return the previously wasted energy with near unity power factors, something not possible for any DC drive system.

Even an open loop AC drive motor combination offers a tension control range far beyond the limits of a pneumatic braking system.  Synchronous AC motors can offer precision open loop torque control without a tension sensor, thereby saving further cost and inventory.  Today’s highly accurate tension control systems can be designed with high resolution (sin/cos) feedback encoders on both the unwind motor and dancer position feedback.  Additionally, in more advanced active front end designs, the regen capability of the drive can actually assist in the increase of stopping times and tension control regulation, owing to the four quadrant control, i.e., the motor can sink or supply current to the motor in both directions.

Driven unwind with AC regen motor, drive

Driven unwind with AC regen motor, drive

AC regen drive systems can also offer today’s machine designer software configurations with a wider range of control flexibility.  They can be configured to operate in the most basic mode with no motor encoder or with tension feedback to system configurations, utilizing either dancer position sensors or loadcells.  Alternatively, they can function as a programmable logic controller (PLC), controlling the machine functions on the unwind, while also connecting directly to a human-machine interface (HMI) panel.  In most converting, packaging and printing applications, the dancer position sensor can be used to calculate the starting diameter of a roll, eliminating additional diameter sensors and the possibility of operator error in the roll diameter input.  Further enhancements for unwind spindle motion such as jog for threading have also emerged for operator convenience through active front end technology.

Beyond the obvious cost savings of pad replacements on mechanical braking systems, AC motors are virtually maintenance free by comparison to DC motors, as AC motors have no brushes, do not require controller contactors to reverse direction of motor rotation or have commutators.  Fewer moving parts invariably means less motor maintenance, for additional cost and time savings.

In the most advanced systems, common DC bus regulation, energy-monitoring devices for near unity power and, through the use of mechatronic services often provided by the manufacturers, “turn off” parameters in vector drives are possible.  Mechatronic services can also be utilized for the proper tuning of these drives onsite or during machine build.  For designers, such services further assist in the proper sizing of motors, based on the mechanical and electrical forces generated by machine operation or computerized simulation of it.

This combination of improved operation, reduced maintenance, motor power savings and conservation of nearly all energy within the system make AC regen drives with active front end technology a decided advantage for machine designers and end users of converting, packaging, printing, wireforming and other roll-fed machinery, where driven unwinds can be implemented. 

For more information on regenerative drive motors and systems, please contact:

For product information and inquiries, call +1 800 879 8079 ext. Marketing Communications or e-mail SiemensMTBUMarCom.industry@siemens.com.

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Siemens Introduces Matched Motor/Drive Combination Package

Integrated drive system provides OEMs and end-users cost-effective Simotics motor and Sinamics drive packages from single source; backed by three-year warranty

siemens_motor_drive_combo_packageSiemens Industry, Inc. announces the release of combination motor/drive packages, allowing an OEM or end-user the option to select the optimum solution for a variety of heavy-duty industrial motion control applications from a single source, backed by a full three-year warranty.  Choosing from a predetermined list of motor/drive combinations, the customer simply makes the selection best suited to the application.  The motor and drive are packaged on a single pallet, shipped and invoiced together.

The motor and drive combinations are power-matched for 480V high-overload operation through a 20 hp range, with I2T  protection from thermal damage provided as a standard in both the motor and the drive components.  The Siemens Intelligent Operator Panel (IOP) is included with these packages, allowing easy step-by-step drive start-up.

Application macros are provided in the Sinamics G120C drive for easy installation and wiring; the terminals are pre-assigned at the factory and the parameters are automatically set.  The SIMOTICS SD100 motors are rugged cast-iron with inverter duty ratings in a 4:1 speed range for constant torque and 20:1 speed range for variable torque.  Simotics SD100 units are severe-duty TEFC motors that meet NEMA Premium® efficiency.

Communications selections on these matched motor/drive combinations include RS485 with USS and Modbus protocols.  A Profibus variant is also offered for a Totally Integrated Automation (TIA) solution.  TIA is the proprietary Siemens solution for achieving optimum performance, energy efficiency and sustainability within a machine or manufacturing environment.

Standard pricing has been established for a wide variety of motor/drive combinations from 1–20 hp and is included in the available literature on this new Siemens service.

For more information about these combination motor/drive packages, visit www.usa.siemens.com/drives.

For product information and inquiries, call +1 800 879 8079 ext. Marketing Communications or e-mail SiemensMTBUMarCom.industry@siemens.com.

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Jennerjahn Realizes Time Savings Up To Two-thirds on New Control Platform Implementation

Three-drum surface slitter rewinder outfitted with Siemens hardware and software achieves Category 4 safety standard with space savings and more flexibility in design

Jennerjahn JLS-120, a popular 120” wide format slitter rewinder, capable of producing 400-foot rolls in less than 30 seconds, was customized using a total package of Siemens controls and software.  The robust frame on this machine makes it ideal for construction grade materials, such as house wrap, roofing and flooring underlayment, billboard vinyl and landscaping rolls.

Jennerjahn JLS-120, a popular 120” wide format slitter rewinder, capable of producing 400-foot rolls in less than 30 seconds, was customized using a total package of Siemens controls and software. The robust frame on this machine makes it ideal for construction grade materials, such as house wrap, roofing and flooring underlayment, billboard vinyl and landscaping rolls.

Jennerjahn, located in Matthews, Indiana, is a manufacturer of assorted lines of narrow and wide web slitter rewinders and custom machinery used by converters of point-of-sale cash register rolls, ATM rolls, lottery rolls and a variety of tape rolls, as well as a wide range of paper and other products, including laminating film, plotter paper, house wrap, landscaping products, vinyl billboard sheeting, flexible packages, box tape, roofing underlayment and other construction materials.  Founded in 1978, the company also provides customer solutions for roll handling and roll packaging equipment.  Today, Jennerjahn equipment can be found in markets worldwide.

On a recent job for a building products company in Australia, the Jennerjahn engineering team, led by Roger Vogel and Will Adams, was confronted with a unique set of requirements on a 120-inch wide, three-drum surface slitter rewinder, a variation of the company’s standard Model JLS-120, to be used to wind a variety of non-woven web materials, used in the construction industry.  The machine required five axes of motion control.  The JLS line features an unwind with pneumatic braking, a driven surface winder and driven lay-on roll.  The machine typically slits a web into multiple sections and the surface winder winds a small diameter roll to a precise length.

100_2078-1rtThe customer required a Category 4, SIL 3 safety system, with components to support a local 415VAC, three-phase electrical power supply.  As Jennerjahn senior controls engineer Will Adams explains, “We discussed the job with the applications engineering team at our local distributor and the decision was made to utilize a total package of Siemens hardware and control software, including Simatic PLC, Sinamics drives, HMI and a Profibus DP communications network.”  While Jennerjahn had utilized Siemens products in the past, this machine requirement was a particular challenge, owing to the safety requirements, in particular.  The builder was seeking a solution that would not require adding large amounts of relays and other hardware to meet the customer needs, plus the Jennerjahn team wanted to utilize the standard controls enclosures on the JLS-120 for this job.  Adams continues, “The integrated safety features on the Siemens S7-300 PLC, plus the ability to execute a position move within the drive and also have those drives operate within a wide voltage range allowed us to meet the Category 4 safety level for our customer.”  He further notes that the compact “bookend” design of the drives enabled Jennerjahn to use the standard enclosure on their machine.  Previous JLS machines used AC/AC drives for all drive requirements.  On this machine, there were three additional ancillary axes, so the use of the Siemens S120 booksize drive platform enabled the machine design to run all driven axes in a single drive.  The use of the integrated E-POS positioning block in the S120 drive system and a high-resolution sin/cos feedback on the surface winder permitted very precise roll lengths, as well, on this application.

100_2048-1rtIn addition, many of the diagnostic features on the drive software helped the builder’s team with troubleshooting and start-up issues.  Finally, the I/O configuration of the Siemens platform “…allowed us to keep our existing distributed I/O layout with minimal system redesign,” said Adams.

The Jennerjahn team estimates that the implementation of the Siemens controls platform on this machine was achieved with a start-up time savings up to two-thirds, the result of various factors in the relationship between this builder, the controls vendor and the local distributor.  Will Adams explains, “Siemens provided us design assistance to verify the sizing information and specify the required drive hardware.  Our local distributor then provided a complete bill of materials to us, which saved us a great amount of time, owing to our lack of detailed knowledge about the Siemens products.” Adams also notes his company received several days of onsite engineering support provided by the controls supplier to help with drive set-up, network troubleshooting and the integrated safety program modifications required on this machine build.

100_2111-1rtRoger Vogel, engineering manager for Jennerjahn, adds, “This project went very smoothly for us, because the relatively few problems we had were quickly handled by the folks from Siemens and our local distributor, both in the hardware and software areas, plus overall automation integration scenario.  The training class we were offered was very well run and provided our team the extra information needed to successfully program the machine.”

Since 1978, Jennerjahn has been a leading supplier to the converting industry and today provides an international partner to the industry, offering the most efficient solutions to customer needs on a wide variety of end uses.  As a full line machine and ancillary equipment manufacturer, the company maintains a showroom of assorted automated slitter and rewind machinery, so any potential application can be tested, free of charge, according to the company’s website.

For more information on this story, please contact:

JENNERJAHN MACHINE, INC.
901 Massachusetts Avenue
Matthews, IN 46957
Phone:  765-998-2733
Fax:  765-998-2468
Web:  www.jennerjahn.com
Email:  sales@jennerjahn.com
Attention:  Chris Jennerjahn, Roger Vogel or Will Adams

or

SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL  60007
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

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Energy savings with “E-motion”

Servo-electric pump drive optimizes hydraulic presses — from a technical and energy efficiency perspective

The servo-electric pump control for presses, developed by Lasco Umformtechnik GmbH in Coburg, uses far less energy than conventional valve control systems, often well into the double-digit range, according to this press builder.

The servo-electric pump control for presses, developed by Lasco Umformtechnik GmbH in Coburg, uses far less energy than conventional valve control systems, often well into the double-digit range, according to this press builder.

A hydraulic pump directly coupled with a servomotor is an energy-efficient solution that delivers a highly dynamic performance with double-digit energy savings typical.  The press manufacturer Lasco uses this servo-electric pump drive for solid and sheet metal forming presses.  “This drive system provides us many performance advantages,” says Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik GmbH.

Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik: "The innovative servo technology that we have developed for hydraulic presses was previously not available on the market."

Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik:
“The innovative servo technology that we have developed for hydraulic presses was previously not available on the market.”

“Our new servo technology provides substantial energy savings for companies operating our presses,” says Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik GmbH, a machine tool builder in Coburg, Germany, in describing the significant advantages of this innovative forming press technology.  This well-known manufacturer of systems for solid forming and sheet metal forming produces screw presses, forging hammers, forging and cross wedge rolls, and even complete plants that are used by the building materials industry to produce sand-lime products.  When Lasco was first founded in 1863, the main focus was on the iron foundry.  However, just a few years later, it began producing water turbines, followed by forging machines in 1880. Since then, the company has concentrated on producing machines for forming technology, and has been active worldwide for many years.  “As a solution provider, we develop customized systems for optimized workpiece transport within the press as well as for feeding and removing workpieces,” Barnickel reports.  The company has a strong focus on continuous improvement in its processes and technology.  And the servo technology mentioned above is exactly this kind of technological milestone, as demonstrated through Lasco’s implementation in a recently delivered deep drawing press with a press force of 800 tons for up to 40 strokes per minute.

A fast controller at the core

At the core of this type of solution is a Simotics 1PH8 servomotor from Siemens, which directly drives the hydraulic pump.  This drive is controlled by the Sinamics S120 drive platform.  A Simotion D445 motion control system handles the complete path, velocity and position control of the axes —
the Simotion controller and Sinamics drive are both from the same manufacturer.  With a response time of 250 µs, up to 256 axes can be rapidly synchronized and precise axis motion and curve profiles are executed.  “The initial applications have demonstrated that this type of servo technology provides outstanding results,” says Barnickel.  This applies to the closed-loop control performance as well as to its energy efficiency and the application as a whole.

The challenge on the deep drawing press was to control the press force and press speed, based on a motion profile that could be set individually.  The hydraulic force and thus the press force can be adjusted at the servomotor by means of the torque.  The plunger speed is controlled by the motor speed and thus by the volumetric flow rate of the pump.  For the project described, axial reciprocating pumps with a fixed displacement per revolution were used.

Scalability of the pump systems is a significant advantage

Four such pump systems connected simultaneously for a maximum pressure of 250 bar supply the pressure line for the press stroke of the plunger; three additional pump systems are responsible for the return stroke of the press plunger. “The possibility of scaling, in other words adapting this kind of standard servo solution to the actual requirements, is another advantage of this new technology that certainly cannot be underestimated,” notes Barnickel.

The hydraulic oil tank of the deep drawing press holds about 2377 gallons (9,000 liters).  Because of the high flow rate of 16,000 l/min, filling valves are used for the fast downward motion of the plunger.  The servo pumps provide the required flow rate for the actual pressing operation, with a speed of up to 100 mm/s.  In the past, high-precision control valves with zero overlap were necessary to obtain the precise traversing profiles.  Today, this function is handled by the motion control system, in conjunction with the servo pumps.  Thanks to this new technology, the valve systems in the press can be reduced by up to 40 percent.  The remaining valve technology is mainly needed to comply with machine safety specifications.

Energy milestone

As a result of the new technology, expensive, traditional valve systems were eliminated, and energy efficiency has been significantly improved.  Electrical expert Barnickel knows this only too well.  “In the past, the large cooling systems for the hydraulic oil had to be installed before the first test run at Lasco.  But now, with servo technology, significantly smaller units can be used, and they are not required until the press is actually operational at the customer’s facility.”  One reason for this is that the oil is no longer forced through the narrow gaps at the control edges of the control valves, which means that these types of technology-related losses no longer occur in the first place.  The press manufacturer is seeing efficiency improvements well into the double-digit range depending on the application, significantly reducing users’ electricity costs, compared to older machines.

When comparing the new technology with very basic hydraulic presses using conventional technology, the amount of energy saved is certainly less than with presses equipped with complex control systems.  The energy-saving effect is especially apparent during the drawing operation, during which the drawing pressure is provided by a pump equipped with a servomotor, with the motor of the die cushion pump thereby operating as a generator.

Another advantage of the electrical system used here is that energy can actually be recovered when the hydraulic fluid decompresses.  This happens when the system is decompressed after the pressing operation and the main cylinder pressure must be reduced from 250 bar down to approximately 10 bar before the filling valve to the tank can be released.  This operation takes approximately 100 ms.  In the case of a compressibility of the hydraulic oil used of approximately 2.5 percent by volume, with a cylinder volume of approximately 800 liters of oil, the “spring energy” in the oil flows through the axial reciprocating pump and drives the servomotor.  This effect is amplified when the press mechanical system is relieved.  In this so-called generator or regenerative operation, the corresponding electrical energy is fed into the DC link of the S120 drive during each cycle.  “However, in addition to the energy recovered, the other advantage is that there are no additional power losses in the form of heat, as would be the case with conventional concepts,” Barnickel explains.

Straightforward optimization — and everything immediately documented

Although the Siemens Simotion controller has been specifically optimized to address motion control applications, Simotion can also control the complete system.  However, Lasco’s philosophy is to separate the various press tasks, and it therefore uses a separate PLC for the system control.  As a fail-safe control, this also addresses the safety technology requirements. Simotion can be programmed in various ways, for instance, with high-level-language, graphic programming, or Motion Control Chart (MCC) as well as a classic logic control.  The trace function with eight-channel plotter supports commissioning engineers and ensures detailed documentation of the press operation.  Control parameters are saved in the drive, which guarantees seamless documentation of the drive system.

The drive unit for the pump control consists of Simotics servomotors, Sinamics S120 drives and Simotion D445 motion control devices from Siemens.

The drive unit for the pump control consists of Simotics servomotors, Sinamics S120 drives and Simotion D445 motion control devices from Siemens.

Safety technology simply integrated

In addition, the fail-safe Simatic S7-319 F 3PN/DP PLC from Siemens, used here as the press system control, allows all safety technology to be implemented without any major additional expense.  The fail-safe signals are read via distributed Simatic ET200S I/O stations from the same manufacturer and transferred to the control via Profisafe.  This represents a simple yet complete solution for Lasco press engineer Harald Barnickel, who notes, “As a consequence, we obtain a clear machine structure.”

For instance, there are generally two monitored valves, which monitor the reduced traversing speed of the plunger, when setting up.  The new solution is far more precise, where the fail-safe S120 drive also monitors the reduced speed (Safely Limited Speed: SLS) as well as a safe stop (Safe Stop 1: SS1).

Simple parameterization through a seamless, integrated system

The press experts at Lasco also view the integrated, seamless nature of the Siemens systems as an additional benefit.  For example, the drive automatically identifies the servomotor and reads its parameters.  Another interesting feature of this servo solution is that the 1PH8 motors are available either as synchronous or asynchronous motors.  The application itself, or more specifically, the dynamic performance required, is the decisive element in selecting the appropriate motor type, according to Barnickel.

Both versions have the same mechanical mounting dimensions, the same wiring and the same encoder connection. Here, too, this state-of-the-art technology has some significant advantages.  For instance, instead of a typical 17-core cable, a single cable with RJ45 connector is sufficient.

And finally, this new drive concept for hydraulic presses, based on a servo-electric pump control, results in a significant overall improvement:  “In addition to the energy savings, its extremely precise controllability is far superior to that of a classic valve control,” says Harald Barnickel.  As he further noted, any defined motion profiles can be precisely implemented using this concept.

The motion control system has also proven itself to be extremely valuable in certain steps of the pressing process.  For instance, if the plunger moves to upper dead center, then the closed-loop position control in Simotion ensures that any leakages are compensated.  “A far higher precision is achieved when using servo technology than when using pure valve technology,” Barnickel summarizes.

Servo technology ensures dynamic performance of the press

The development of new servo technology for large hydraulic presses, based on the Simotion motion control system from Siemens, has already awakened significant interest among customers of Lasco Umformtechnik GmbH.  However, it is not only when building new machines that this dynamic company of 400 employees benefits from lower costs and improved quality; the drive concept described is also suitable for modernization and retrofit projects.

With the standard concept, comprising the Simotics 1PH8 servomotor, the Sinamics S120 drive platform and the motion control unit, Lasco Umformtechnik GmbH has clearly demonstrated that, when hydraulic presses are equipped with servo-electric pump drives instead of pure valve technology, the dynamic performance, precision and especially energy consumption on the press are improved.  This results in tangible press improvements that are decisive in the marketplace.  For Barnickel, it’s clear: “Anyone who addresses the challenges of press technology with E-motion (energy in motion) is creating innovation.”

For more information on this story, please contact:

Siemens Industry, Inc.
Drive Technologies — Motion Control Business
5300 Triangle Parkway, Suite 100
Norcross, GA  30092
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

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New Sinamics DC Master Base Drive for New Installations and Retrofits

Cost-efficiency and flexibility in one complete panel

sinamics_dc_master_base_driveSiemens Industry, Inc. introduced today its new Sinamics DC Master (DCM) Base Drive as a result of increasing demand for base drive panels using the Sinamics DC Master converter.

This pre-wired solution is offered complete and fully tested with all necessary components mounted onto a back panel. Sinamics DC Master Base Drives are an extremely flexible and cost-effective solution for new installations and retrofits where space is limited.  They are ideal for end-users and third-parties such as system integrators and Siemens solution partners.

Sinamics DC Master Base Drives offer more power per panel in the same footprint as compared to the previous two generations of base drives.  These base drives are rated from 15A–850A continuous current.

Standard features of the new SINAMICS DCM Base Drive include — input fuses, output DC fuses (regen only), control transformer, AC line contactors, PROFIBUS, BOP20, UL508A Certification and 65KA SCCR rating.  They are ready-to-order with deliveries available after February 2012.

For more information about the Sinamics DC Master Base Drive, visit our web page www.usa.siemens.com/motioncontrol.

Please forward all inquiries to:

Siemens Industry, Inc.
Motion Control Business
390 Kent Avenue
Elk Grove Village, IL  60007
Attn:  Marketing Communications

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to:  SiemensMTBUMarCom.industry@siemens.com.

 

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