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Scalable Automation and Drive Technology Package for Tapping Centers

tapping_center_package_from_siemens

  • Package for tapping centers consisting of compact CNC, frequency converter with triple overload capability and high-speed electric motor
  • For ultra-fast tool changes: spindle start-up from 0 to 24,000 revolutions/minute in less than one second
  • Scalable functions and performance thanks to control hardware variants
  • High speed for high-speed cutting with small tools

Siemens has put together a scalable package of coordinated automation and drive components specifically for tapping centers. It consists of the Sinumerik 828D compact CNC with new panel processing units PPU2xx.3 of various performance classes as control hardware and the new variant of the Sinamics S120 Combi drive with triple overload capability. The package is completed with the new Simotics M-1PH8 Premium Performance main motor, which can achieve high speeds.

The productivity of tapping centers can be increased considerably due to the specially coordinated components, the powerful control system hardware, the converter with enhanced overload resilience and the high-speed main motor from Siemens. For example, the spindle can be started up from 0 to 24,000 revolutions per minute in less than one second. This saves considerable time, particularly with tapping center applications featuring frequent tool changes.

The Siemens range is also especially suitable for the increasing number of applications with freeform surfaces and high surface quality, for example cell phone components, which are manufactured with small high-speed cutting (HSC) tools and have short machining times. The tapping center’s maximum machine dynamics can be utilized to the fullest extent with the scalable performance spectrum, for example the different control hardware variants PPU 260.3 or 280.3 for the Sinumerik 828D compact CNC.

Background information

Tapping centers are designed as machine tools with small work spaces for milling, drilling and thread machining, and are frequently used to manufacture hard disk and mobile phone housings, for example. These are made out of lightweight materials using small tools and at high speeds.

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 Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly automation and drive technology, industrial software and technology-based services. The Sector’s comprehensive portfolio covers the entire industrial value chain, from product design, engineering and production to services. Siemens enhances its customers’ productivity, efficiency, and flexibility in a wide variety of different industries. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies.

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Siemens Offers New Sinamics S120M Decentralized Servo Drive

Siemens präsentiert dezentralen Servoantrieb Sinamics S120M / Siemens presents distributed Sinamics S120M servo drive

The new Sinamics S120M distributed servo drive system enables decentralized configuration of the drive and integration of the inverter power unit directly onto the driven axis of the motor. Less cabinet space, less cooling energy and shorter cable runs result for the machine builder or production line end-user.

Expanding on its popular Sinamics S120 multi-axis drive system, Siemens introduces the new Sinamics S120M, a compact, ready-to-connect motor with integrated drive that offers users the option of moving the motor inverter outside the control cabinet and directly onto the motor, thereby reducing both cabinet space and required cooling.

The addition of the Sinamics S120M distributed format into the S120 offering adds a high degree of flexibility for new and existing machines, as well as introducing innovative production line setups that can now be achieved.

Typical applications for the Sinamics S120M include packaging, printing, glass, textile and other processes, where machinery and production lines require multiple servo axes in a space-restricted environment.

The decentralized S120M axes are connected back to the central S120 components in the cabinet via a hybrid cable and the AM600 adapter module.  The pre-assembled hybrid cable contains all encoder and power cables and serves multiple S120M axes through a daisy chain connection.  This single-cable solution drastically reduces the number and length of cables and is easily expanded for additional axes.

s120m_schematic

 

As a fully integrated format of the Sinamics S120 drive system, all existing Safety Integrated functions and communication options are available, and the benefits of power sharing between axes across the DC bus are completely realized.  Additional design features of the S120M include a synchronous servomotor with multi-turn absolute encoder, optional holding brake and an integrated power unit (motor module) available in three shaft heights covering the power range of 0.25–1.5 kW.

For more information about the new Sinamics S120M distributed servo drive system, please visit:  www.usa.siemens.com/S120M-PR.

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 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 and Biglia Offer Full Flexibility in New “Quattro” Series of Turning Centers

Highlights include two-sided machining and servo drive technology

Recently, Northern Italian machine tool manufacturer Biglia introduced its multi-functional turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC. The mechanical concept, together with the scalable control, provides users with the most diverse standard turning and milling operations.  The result is increased flexibility and higher speeds for end users.  That quality machine tools are built in Northern Italy is nothing new.  And this fact is confirmed again by the “Quattro” series from the machine tool manufacturer Biglia.  These machines are multifunctional turning centers that are valued throughout Europe for their high reliability and performance power.  The machines are available in different versions from 11 to 15 CNC axes.  They are also intended for different turning diameters (45, 52, 65, 71 and 80 mm).

Biglia has equipped its turning centers of the Quattro series with the Sinumerik 840D sl CNC control.  The individual machines have 11 to 15 NC axes.

Biglia has equipped its turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC control. The individual machines have 11 to 15 NC axes.

The two opposing spindles form a special feature of the “Quattro” series. This allows the workpiece to be machined from two sides, which reduces the machining time. The second spindle can also be moved linearly in two directions (lengthwise and crosswise). This provides some leeway in the case of additional milling operations, but it can also be used for automatic workpiece unloading. Two turrets, mounted on the y-axis, ensure proper positioning of the necessary tools.

The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.

The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.

This innovative machining technology allows the creation of not only rotary but also prismatic workpieces – including polygons. Dealing with everything in one setup not only reduces cycle times, it also enhances accuracy.  The machines are developed on the basis of a modular concept that ensures flexible application options – from the universal CNC lathe, to complete machining of complex workpieces with powered tools (c- and y-axis).

Getting it right, from the start

By offering the Siemens Sinumerik 840D sl CNC control, Biglia now wants to expand its previous options and its own market by combining its technologies with that of the Siemens control.  “In this project, which is of personal significance to all of us who worked on it and of strategic significance for Biglia, we wanted to do everything perfect right from the start and to get the most out of it,” says Giovanni Delmondo, Business Development Manager for machine tools with Siemens Italy.  The result is an all-round successful machine series with a highly modern control that already includes the innovative system expansions of recent months – including increased energy efficiency options offered by the control and drive systems from Siemens.

To illustrate this, Giovanni Delmondo points out that “the fans on the spindles are shut down automatically when they are not required, or certain services such as hydraulics, lubricant supply, or compressed air are deactivated during machine standstill times. This is handled via special screen forms on the control and is extremely simple, using the Run MyScreens function.”

Also notable is the standard energy efficiency solution from Siemens in the Sinamics S120 drives onboard this machine series. This includes automatic power factor correction or regenerative feedback of the energy generated in braking operations, a substantial factor in energy savings.

Performance and scalability

The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.

The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.

The centerpiece of the automation concept of these Biglia turning centers is the Sinumerik 840D sl control. This is a universal and flexible CNC system, implemented in the Sinamics S120 design (see Fig. 3). It is suitable for up to 31 NC axes. Whether you are turning, drilling, milling, grinding, laser-machining, nibbling or punching, the Sinumerik 840D sl is suitable for use in the most diverse machining technologies. The CNC control also has PLC (programmable logic controller) functionalities, so that a special PLC can be eliminated, if applicable.

This high-end control from Siemens is ideally suited to medium and complex tasks and production and can be adapted to the task, thanks to scalable hardware. The CNC is also characterized by openness, so the operator interface and also the software present few limits to specific job adaptability. This applies all the way to supplementing the NC core of the control; however, a special license is required for this adaptation.

On the Biglia turning centers, the control was equipped with the Sinumerik Operate user interface, making operation simple and intuitive. Three different methods of parts programming are possible: Classic ISO code programming, programming with the help of the integrated ProgramGuide with graphical support of the selected cycles, and the new two-channel ShopTurn with graphical 3D simulation. The user is led step-by-step through the cycles, whether for simple metal removal, drilling, thread cutting, pocket milling, groove milling or engraving. Complex programming cycles for complex contours are also possible. The “ProgramSync” function for automatic synchronization of the machining programs via two channels ensures a significant increase in machine productivity. The control is equipped with a 15″ monitor and integral keyboard.

Siemens CNC in metalcutting applications.

Siemens CNC in metalcutting applications.

The Quattro series from Biglia also uses the highly effective personnel and machine protection system provided by the Sinumerik control concept with the Sinumerik Safety Integrated package.

Biglia is also breaking new ground with servo drives. Thus, the new servo motor generation 1PH8 from Siemens is used for the main spindle motors in this series.  The linear axes are further equipped with the new 1FK 7 G2 series of permanent-magnet synchronous motors. These motor types from Siemens enable onsite replacement of the encoders without having to dismantle the complete motor.  This combination of machine and CNC control in the Quattro turning centers from Biglia provides users with greater flexibility.

For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.

For more information on the this story, contact:

SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
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 Communication

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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.

 

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Siemens at PackExpo 2012

Engineering TV is now featuring Siemens from PackExpo 2012!

Click here to check it out.

Lee Teschler of Machine Design talks to Bill Henderson, Business Development Manager at Siemens about industrial ethernet connectivity solutions and networks used in several manufacturing environments.

Hosted by: Lee Teschler Videography by: Terry Knight Edited by: Terry Knight

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

Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.

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Sinamics S120 Drive Platform with Industrial Ethernet Connectivity

The Sinamics S120 drive platform from Siemens provides users maximum flexibility with industrial Ethernet connectivity.

ATLANTA — Siemens announced today that its versatile Sinamics S120 drive system has been expanded to include Profinet, Ethernet TCP/IP and 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.

Whether a greenfield project with multiple vendors or an OEM supporting different platforms on their machines the importance of industrial Ethernet connectivity for drive systems is today’s top requirement.

“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 Craig Nelson, Siemens product manager, Sinamics S drives.  “Our Sinamics drives platform provides communications without limits to a specific network type.”

Sinamics S120 drives support, as standard, Profibus DP and Profinet to ensure seamless communications between all the components 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 motion applications are also included in these innovative solutions.

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 users.  Having the flexibility to communicate with the most common automation systems via Profinet, EtherNet/IP or basic Ethernet TCP/IP makes the Sinamics drive system easily adaptable to the current Industrial Ethernet boom.

 

Sinamics S120 drives are designed to handle virtually any drive requirement and facilitate vector, servo and variable-frequency drive (V/Hz) applications with the choice of single- or multi-axis offerings.  The modular design and system architecture, combined with new communication connectivity features, makes Sinamics S120 a truly advanced drive offering in today’s market.

With a wide power range (0.25 – 1,600 hp), highly scalable solutions, including safety integrated functionality and convenient start-up with automatic configuration of the drive system, through the innovative Drive-CLiQ interface, Sinamics S120 is a powerful solution for a host of applications, including packaging, plastics molding and extrusion, textile, printing and paper machines, handling and assembly systems, machine tools, rolling mills and test stands.

For more information about EtherNet/IP connectivity to Sinamics S120 drives, visit our website: www.usa.siemens.com/eip.

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 Drives, Motors Breathe New Life into Aging Extrusion Lines

Production boost of 20% reported by Amgraph on food packages

At 30 years old and approximately 75-feet long, the Black-Clawson two station Extrusion Laminator dominates Amgraph’s (Versaille, Conn.) production floor like a dinosaur lining up at a bone yard. As customer requirements surpassed the capabilities of this aging behemoth, Amgraph, which supplies flexible packaging solutions for the food industry, had several choices. It could spend millions on a new machine, settle for lower productivity and product diversity or retrofit the equipment for the 21st century. Instead of scrapping their investment and spending millions on new machines to meet new product, productivity, and customer requirements, Amgraph’s Senior Management decided to prepare their equipment for the needs of tomorrow by upgrading the analog control system to high-efficiency Siemens motors, Sinamics S120 digital drives and newer control systems.

As a result of the retrofit, Amgraph can now produce a wider variety of coated plastic and foil flexible food packages, cut material expenditures and improve throughput, while boosting productivity.

Improved Web Tension

Siemens Solutions Partner, Circonix, located in Ringwood, N.J., knew that by upgrading the machine’s analog drives and discrete controls to the latest Siemens motors and Sinamics S120 digital drives, Amgraph could accommodate new materials, manufacture packages with thicker coatings, achieve uptime of 95 percent or better, and increase throughput by 20 percent or more.

“Initially, the machine had four different motors with analog drives and controls, each with their own wiring harness and relay logic, which really made the machines a challenge to maintain,” explained Circonix Vice President of Engineering Andrew Alaya. “Only one of the sections was capable of tension control, which forced Amgraph to operate the extrusion machine in draw mode. This meant that the machine could only handle certain types of coatings without breaking the web and going down. Improving that uptime through better tension control was the main goal of the project.”

Circonix engineers decided to retrofit the Extruder’s four existing analog drives with Siemens motors and Sinamics S120 drives, while adding four load cells inline, and a new Fulton Machinery dancer to the machine’s two unwind spindles.  Also, two Vetaphone treaters were added inline as part of the retrofit.  These effectively eliminated the need for the primer coater, and served as pull stations for the machine, which were driven by Siemens motors and drives. These modifications allowed the machine to work in closed-loop tension control mode. By changing values on the HMI and PLC, Amgraph’s Production Manager, David Rand, could now precisely control the speed and thickness of the web, turn various systems such as treaters, laminators, and tension control systems on or off, and apply either thinner coatings to package materials without worrying about additional web breaks and downtime, or thicker coatings to meet special customer needs.

“Now that we have more control of the system, we’re looking at replacing thicker films that we used to purchase from other vendors with extruded materials we make ourselves, which saves us money,” says Amgraph’s Rand. “Our initial trials have been successful.”

The new motors, upgraded digital drives and new controls also increased the extrusion machine’s uptime, throughput and productivity.  The high bandwidth of the Sinamics S120 digital drives allows for improved speed regulation and  faster response, both of which are key to improving tension control.  Amgraph set aggressive goals of 95 percent uptime for the retrofitted extrusion machine. “We’ve had some success since the machine was installed in January,” says Amgraph’s Rand. “We spent a few months fine-tuning operations, [but] recently, we’re starting to see [uptime] benefits. We should have some firm numbers in the next few months.”

In addition to increasing uptime and the number of products the machine can handle, Rand says the retrofit has increased throughput by up to 20 percent, depending on the product line. “We’ve definitely increased production speeds,” he said. “We’re happy where we are now, but we still have opportunities to improve throughput.”

On time, Within Budget

Retrofitting large production machinery like Amgraph’s Black-Clawson extrusion laminator machine rarely comes in as scheduled because changing a machine from discrete analog to digital control systems with the latest energy-saving AC induction motors presents significant electronic and mechanical engineering challenges.

Customers may also want to use specific equipment providers for certain systems. In this case, Amgraph was familiar with third-party HMI and PLC technology, which meant Circonix needed to interface the Sinamics S120 drives with third-party systems. However, thanks to Circonix’s close partnership with Siemens as an official Siemens Solutions Provider, Siemens’ STARTER drive engineering/commissioning software and the easy integration of the Sinamics S120 drives using the electronic name plate capabilities of Drive-Cliq for the motors and drive components, the project was delivered to Amgraph on time and within budget.

“We used Profibus to tie the drives together and an SST module in the PLC to talk to the Siemens drives,” Alaya explains. “It was easy to meet Amgraph’s development schedule. With Siemens DC bus line up, all the drives fit in a single cabinet that was smaller than the space of one of the previous motor control systems. We were able to eliminate the wiring mess and relay logic that came with the older analog controls, which significantly simplified maintenance and troubleshooting for the customer while improving performance and uptime.”

Circonix started engineering development for the system in July of 2008, and just six months later, installed and commissioned the retrofits.

“We gave them a pretty intense schedule,” says Amgraph’s Rand. “What’s remarkable about this project is that it was done on-time. We have some machines that came in before we did this project and they’re still not up and running.”

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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Honing a Competitive Advantage: Sunnen’s Growth Rises from Innovative Motion Control Ideas from Siemens

Using market insight coupled with new technology, Sunnen has been able to grow in a downward economy. The company expanded its platform of high production, high precision bore sizing and finishing systems to include maintenance and repair operations honing. The deeper secret to this 85-year-old OEM’s success is its ability to adopt simpler, yet more advanced and cost-effective motion control.

Problem and Opportunity

It was an evolutionary decision, says Carl Mik, Product Design Engineer. Traditionally, the company’s bore sizing and finishing systems have been customized, high-end designs. Having identified a new market segment opportunity, the immediate problem was system cost versus the market’s willingness to pay. But the larger and longer-term problem was how to evolve the company’s technology platform while maintaining its competitive advantages in systems design, manufacturing and service efficiency.

“When we went into this, the costs were not in line with the envisioned spec,” Mik recalls. “The stroker would be an AC motor and the spindle would be an AC motor. We wanted some sort of encoder on the AC motor for the stroker to hold relative position; and then we wanted a touch screen display. The costs were becoming prohibitive.”

An early breakthrough came when Sunnen learned that Siemens could offer a basic performance servomotor with resolver feedback for the price of an AC motor. But Sunnen still faced the challenge of developing an all-new system design for low-cost honing that would be consistent with the company’s established product platform, supported by the multi-axis high-performance Sinamics S120 drive line and Simatic automation platform from Siemens.

This need for platform consistency is an industry-wide challenge, as OEMs and their end-customers evaluate the cost-performance advantages of emerging motion control solutions versus traditional hydraulic, mechanical and electro-mechanical machine system designs. For Sunnen, this evaluation has been facilitated by Siemens mutual interest in the possibilities of new servo-based systems design.

Synchronized Innovation

“I have been on the motion control side from the beginning,” says Product Engineer Mike Nikrant. “Back in 2002-2003, we did a lot of research on different communication bus structures and what people had to offer. We chose Profibus because of component availability and cost, along with its high acceptance in the market. Then we began using Siemens drives because they were the most flexible and configurable. We went with them on our KGM product line, which required extreme accuracy for all axes of motion when finishing cylinders. Then, we used a lot of the same components when we introduced our SV vertical honing machines.”

Sunnen’s product platform evolution soon fell into step with the evolution of the Siemens drives technology platform, Nikrant recalls.

“When we first started the SV vertical honing line, we were attempting to use ball screws. At the time there was only one company that had a motor that could handle the load we were doing, because of the reciprocation. Then Siemens designed a motor that fit our application requirements and assisted us in our initial synchronization and tuning. We established a common DC bus drive structure with the Siemens drive platform, which made it possible to have all the same drives in the system for servo or vector applications. It is a very clean and proficient design because there are no mixes and matches of drive types. Everything just flowed a lot better with that solution and our customers like this common approach and service efficiency.”

Advanced Yet Simple Positioning

As Sunnen’s attention moved last year to the development of a basic large bore horizontal honing system called the HTA, both Nikrant and Mik were on the same page regarding product platform evolution. Joining them were other engineering team members, including Russ Jacobsmeyer, the company’s chief technology officer, who oversees technology adoption in support of the company’s global growth.

According to Jacobsmeyer, Siemens brings a global support capability that is becoming increasingly important to Sunnen’s growth strategy. He says the relationship is based on more than just meeting a spec. It is based on system performance exploration. “One reason why we like working with Siemens,” Jacobsmeyer adds, “is we have built a partnership with them and they understand what is required of our products. They can make suggestions in an intelligent manner, helping us solve problems that add value for our customers. Precision bore sizing and finishing is a very niche capability that requires significant engineering content and resultant product performance. Our customers value what we have to offer with our systems and our ability to solve their difficult bore sizing and finishing applications.”

Jacobsmeyer recalls that when the engineering team first looked into developing a new basic bore sizing and finishing system to fill a gap in the Sunnen product line, Siemens was the logical resource.

In regard to control system design, “We didn’t have anything at that point,” Jacobsmeyer says. “We heard from our customers and engineers in the field that there was a need for a basic economical system. However, we were not sure if we could satisfy the product requirements and meet the market price point.”

Mik agreed about the scope of the engineering problem. “Remember, this was August and September of last year,” Mik says. “So I started programming and put a prototype system together and the biggest issue I found was spindle response time, due to delays in signals between the display, PLC, and a servo and general purpose drive. We had 300 milliseconds altogether, which may be acceptable from the standpoint of introducing a basic system at a basic system cost, but it was unacceptable for our application, so we decided to go back to Siemens.”

This was in January, with production of the new basic system to occur in May or June, Mik explains. “That is when Siemens told me that they had this new Sinamics S110 basic performance servo drive coming out, along with their new MP177 six-inch touch display, which allows soft PLC capability with the WinAC MP software. The direct connection between Sinamics S110 servo drive and MP177 display over Profibus made the system very cost effective and responsive. Not only did this reduce components, but also made it possible for us to stay in line with our migration to a single platform on the Sinamics family of drives because we could use the same Step 7 software already being used to program our S7 automation on other machines.

According to Mik, the new basic servo positioning package gave Sunnen an unexpected level of performance for basic machine development.

“If you think about trying to stop an AC induction motor to do stroking back and forth, it’s pretty difficult. Even when applying dynamic braking and braking resistors, traditionally acceptable reversals on a tube-hone machine are around a quarter-inch repeatability. But our tests show the new system is achieving under 15/1,000 of an inch, and this is a low-cost system.”

Mik explained that the key components of the new system, are an easily programmable soft PLC at a low-cost point and a low-cost distributed motion control – solutions brought about by the new Siemens Sinamics S110 drive and 1FK7 servomotor. This also accomplished a new level of simplicity for this basic machine because the Drive-Cliq cable between the Sinamics S110 drive and motor provides automatic configuration as well as the feedback of the servo system. Additionally, the MP177 with WinAC software made the configuration and communication simple and straightforward.

“We have a color TFT display, we are programming everything with ease, and we can even automate the machine. It’s not in the original spec, but we could do this to add even more value to our offering. And spindle response time is down in the 25-millisecond range, instead of 300,” adds Mik. “For such a low-cost machine, I cannot believe we have such a capable system.”

Platforms for Growth

Mike Nikrant believes alignment between the Sunnen and Siemens product platforms is helping to drive Sunnen’s business forward. The decision to develop new, more basic systems was facilitated by the product range of Siemens Motion Control solutions. The two companies are already talking about performance improvements for Sunnen’s next generation of high-end PC-based systems with integrated safety functions.

“Siemens is coming out with motion control ideas that fit what we want to do,” Nikrant observes. “For our high-end PC line, we are trying to come up with a common circuit for multiple machines. Siemens drives, bus structures and components fit really well in that respect because of the way some of the logic can be split up as far as the controllers go. Their Sinamics drives are easy to use and highly configurable. The same piece of hardware can be used for multiple functions. Some systems can be configured to use any functionality the user can conceive. On other systems, where there is no need for all that functionality, a product like the Sinamics S110 servo system provides a simple and efficient solution. And control, programming and communication are all the same. The Siemens platform works well for us, for both the higher and entry level.” Jacobsmeyer adds, “Building upon common platforms from Siemens, which are stable and high performance, serves our customers and entire Sunnen organization quite well – around the globe, enabling us to more efficiently use our global resources to engineer, construct, service and sell product.”

According to Sunnen’s David Moehn, Manager of Engineered Machines and Custom Systems, the adoption of the Siemens Sinamics S110 servo drive is just part of the story for Sunnen.

“The bigger story is Siemens ability to work with us, standing with us and helping us find solutions,” Moehn says. “This relationship continues to improve our market success by getting us to market faster and ahead of competitors.”

Phil Hanna, Sunnen’s Global Product Manager for Machines agrees: “The goal of partnering with Siemens has been to standardize control systems across all of our machine platforms – horizontal, vertical, and tube hones of which the new HTA machine is the latest edition as an entry level market machine. This is part of an ongoing effort at Sunnen to produce modular designs that can easily be modified to new configurations. The SV machines are a perfect example of this concept. The modular columns with integral Siemens controls can be easily configured on a custom basis to optimize the customer’s process. One, two, three, etc. columns depend on the customer’s stock removal and geometry requirements. This lends great flexibility to the product line. And with component standardization and Siemens global presence, the machines are much more supportable globally because of Siemens technical expertise and resources.

See the Sunnen/Siemens video HERE.

For more information, contact:

Sunnen Products Company http://www.sunnen.com

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

Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.

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