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Compact and High Torque
New servomotor series from Baumüller:
DST 45-100
Nuremberg. The DSTorque motors of frame
sizes 135-315 from Baumüller have been
use din applications with great success
for the past three years. They are a typical
example for consistent implementation of
state-of-the-art application-specific drive
engineering. With this technological experience,
Baumüller has now complemented the
product range of its powerful servomotors
in a practical way.
A development towards application-specific
drive engineering is increasingly identifiable
in the area of servomotors. This means that
in the future, a single motor design with
respect to device volume, torque density
or even acceleration capacity will no longer
be sufficient for different applications.
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Rather, the market is already demanding a perfect
dimensioning for the specific requirements in
different sector of industries.
With the new DST servo series, Baumüller
renders the torque motor servo-ready. The development
concentrated on increasing the performance data
in favor of a higher torque density while drastically
reducing the volume of the device at the same
time. Nevertheless, the usual speed range up to
4500 rpm remains covered for servomotors. Compared
to conventional servomotors, the new DSTs built
more compact by up to 30 percent.
Concerning mechanics, the proven properties were
adopted. The DST 45-100 also demonstrate the successful
core features of their dynamic counterparts, the
DSD series. Examples are the smooth surface of
the housing design protecting against dirt and
the high degree of assembly friendliness, including
the high degree of enclosure. As a result, the
motors are perfectly suited for application in
sensitive industrial environments, such as in
the textile, robotics or packaging industry. Based
on their electromechanical properties, they are
also suited as direct drives, for example, to
be able to replace small gear graduations.
EtherCAT Master
Available in the Drive
New option card for b maXX
Nuremberg. Modular drive systems will feature
an additional advantage in the future: The servo
controllers b maXX 4000 from Baumüller can
optionally be equipped with an EtherCAT Master.
This allows mechanical engineers to implement
machine architectures that are modular and networked
with EtherCAT.
Baumüller provides an EtherCAT Master, which
can be operated together with the b maXX drivePLC,
as an option card for the b maXX 4000 drive series.
The EtherCAT Master is configured and operated
via the Engineering Framework ProMaster. The modular
automation system from Baumüller also allows
for integrating third-party devices via ProMaster.
The mechanical engineer can now implement his
machine architectures with EtherCAT in a flexible
way.
EtherCAT joins and connects the IT networks and
the Internet with a fast real-time Ethernet solution
for machine communication. This allows for achieving
a universal communication structure across all
levels of the machine which is designed and parameterized
in ProMaster.
The Engineering Framework ProMaster from Baumüller
enables the user to cerate projects and applications
in a simple way via intuitive drag & drop.
The low-level programming is replaced by simple
parameter setting and configuring throughout all
levels of the machine from the perspective of
the mechanical engineer. The complexity of engineering
as well as the time-to-market are reduced by ProMaster.
Increased safety
b maXX inverters take safety certification to
the next level
Nuremberg. In mechanical engineering, the subject
of safety is an increasingly hot topic. The Baumüller
Group is playing its part in pushing forward developments
in this area. Baumüller b maXX 4400 servo
controllers, frame sizes 1 to 6, now feature a
Safe Stop function certified in accordance with
Category 3 (single-channel stop) as defined by
standard EN 954-1. Baumüller achieved certification
for the Safe Stop function in accordance with
Category 4 (two-channel stop) as defined by standard
EN 954-1 for frame sizes 3 to 6 of its b maXX
4400 range back in July 2005.
It has already been three years since the Baumüller
Group started to increase its focus on safety
in the context of development. The automation
solution supplier, which is based in the German
city of Nuremberg, presented the Safe Stop function
at SPS/IPC/Drives 2003. Since then, requirements
from customers in the plastics sector have been
pushing forward developments in respect of safety:
Back in July 2005, Baumüller achieved certification
for its Safe Stop function in accordance with
Category 4 (two-channel stop) as defined by standard
EN 954-1 for frame sizes 3 to 6 of its b maXX
4400 range; this has been followed, in 2006, by
certification for the Safe Stop function in accordance
with Category 3 (single-channel stop) as defined
by standard EN 954-1 for frame sizes 1 to 6 of
the same range. The obvious benefit for customers
is that they now have access to a cost-effective
route to implementing safe solutions in accordance
with Categories 3 and 4 as defined by EN 954-1.
Custom-configuration of drive systems is made
possible by the modular structure of Baumüller’s
b maXX range. Plug-in modules mean that users
can add new functions to their loop controllers
as they please – new control functions,
for example, or additional interfaces. Thanks
to a universal hardware and software platform,
drives can easily be customized to meet prevailing
needs at any time. The b maXX also supports access
to numerous bus systems in the automation sector,
including, for example, EtherCAT, CANopen, CANsync,
PROFIBUS-DP and Sercos. All controllers in the
b maXX range are parameterized using WinBASS II.
EtherCAT fully
integrated in Engineering Framework ProMaster
Application runs on application level
Nuremberg. The Baumüller group presents
an application at the Hanover Fair based on EtherCAT
that corresponds to the real application level.
Consistently configured with ProMaster, the application
connects a controller-based PLC as the EtherCAT
master with three EtherCAT slaves. An external
device is also integrated in the system in addition
to two drives.
The Engineering Framework ProMaster from Baumüller
makes it possible for the user to easily create
projects and applications using intuitive drag
& drop functionality. Simple parameterization
and configuration takes the place of complicated
programming universally through all levels of
the machine from the perspective of the engineer.
ProMaster reduces engineering complexity and time-to-market.
For the first time, EtherCAT is now fully integrated
in ProMaster in addition to CANopen. EtherCAT
integrates and connects the IT network and the
Internet with a fast real-time Ethernet solution
for machine communication, thereby achieving a
universal communication structure over all levels
of the machine. ProMaster supports the EtherCAT
communication structure.
In the system presented by Baumüller at
the Hanover Fair, a modular controller-based PLC
functions as an EtherCAT master. It is also conceivable
that a drive-based PLC be used as a master. Three
EtherCAT slaves (could also be drive- or controller-based
variants) are connected: one b maXX 4000, one
I/O bus coupler and one position sensor from TR-Elektronik.
The drive maps a cam disc motion that has been
generated in ProMaster with Motion Control. The
interaction between the components via EtherCAT
becomes clear with changes to the sensor.
The application demonstrates that external devices
can also be easily integrated in an EtherCAT system
with ProMaster. The integration uses the standard
defined by the EtherCAT Technology Group and runs
trouble-free.
EtherCAT can emulate the already well-known CANopen
device profile via CANopen over EtherCAT (CoE).
The interface makes changing over the field bus
quick and easy. The Servo over EtherCAT (SoE)
protocol is also available as a slave.
With its EtherCAT solution, Baumüller presents
an application on a real application level at
the Hanover Fair: An EtherCAT system with ProMaster
is currently being field tested at the customer.
The highly complex and remarkably dynamic machines
are easily configured with the universal Engineering
Framework ProMaster by plug & play.
Visit Baumüller at the Hanover Fair.
Find us in Hall 14, stand H07. The EtherCAT Technology
Group (ETG) booth can be found in Hall 9, stand
F13.
Automation
Solution for Bag Forming, Filling, and Sealing
Machines
Software template for the packaging industry
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Group developed a completely structured,
well-organized and ready-to-run application
software for typical bag forming, filling,
and sealing machines. The machine mechanics
and its function are mapped in the controller.
The mechanical design as well as the software
distinguish themselves through their modularity.
It consists of basic functionalities that
can be joined upon demand. The finished
basic functionalities only require a few
parameters to be adjusted to the mechanics.
The software template for bag forming,
filling, and sealing machines is based on
a system concept by Baumüller that
does not require in-depth knowledge in the
area of drive and control technology. The
user simply specifies the necessary machine-based
parameters. The application software for
bag forming, filling, and sealing machines
allows performing changes and expansions
of the machine functionality – quickly
and well organized.
The automation solution is bundled as a
software package that is based on modules
such as winder, dancer control, and flying
“up synchronization”. Baumüller
offers axes and technology functions for
the various types of machines: For horizontally
continuous and intermittent as well as vertically
continuous and intermittent bag forming,
filling, and sealing machines.
The entire system solution comes from one
source: The Baumüller Group offers
in-house manufacture of controllers, inverters,
motors, visualization hardware, and control
cabinets. The user does not have to become
involved in the machine architecture –
instead, he receives a system of perfectly
matched software and hardware components.
Communication and interface problems never
occur.
The modularity of the template allows for
effortless adaptation of the prefabricated
hardware and software architecture to the
machine concept. The user’s engineering
costs are reduced to a minimum, thereby
significantly increasing the time-to-market.
The use of highly dynamic and inertia-minimized
servomotors from Baumüller increases
the number of cycles of the bag forming,
filling, and sealing machine as well as
its output. This results in competitive
advantages on the international market.
With more than 40 subsidiaries worldwide,
the automation expert Baumüller has
an extensive support and spare parts network
at its disposal. In case of an emergency,
the standstill times of a system are reduced
to a minimum.
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Engineering
Framework ProMaster
Continuous engineering, continuous communication
and continuous parameterization
Nuremberg. Reducing the complexity of automation
solutions, simplifying software updating
and maintenance, significantly reducing
the cost of software initialization, updating
and maintenance and having an extremely
short time-to-market are the demands that
machine manufacturers make of their automation
partners.
The Baumüller group meets these demands
with the ProMaster Engineering Framework,
which is based upon Microsoft’s .NET
technology. In a ProMaster project, the
entire machine structure is topologically
depicted in machine modules that consist
of devices and components. The communication
topology of the machine modules and the
individual components is also displayed,
e.g. via real-time Ethernet EtherCAT or
field bus systems such as CANopen. The data
and programs of the individual devices and
components exist in an XML structure in
a project-oriented (and therefore machine-oriented)
way.
The ProMaster Engineering Framework has
a library concept that simplifies the configuration
of the machine. The devices, components
and entire machine modules are available
in catalogues and libraries. Devices, components
and entire machine modules belonging to
the user can be stored in self-created libraries,
including configurations, IEC programs and
entire applications.
ProMaster is used in all areas of industry.
It is an open concept and can be expanded
accordingly. Each field bus is managed independently,
and ProMaster has export and import functions
for external devices.
Continuous field bus communication is achieved
using real-time Ethernet EtherCAT, for example.
The system extends to all levels of the
automation platform, drives, displays and
sensors, right through to the inputs and
outputs. Data throughput with real-time
capability provides reliable cross-communication
between individual machine elements. The
field bus is no longer a communication bottleneck.
The openness of real-time Ethernet EtherCAT
is an important factor. The protocol has
a completely open design and the slave controller
is available to any user, making the system
compatible.
The ProMaster Engineering Framework reduces
the time-to-market by speeding up continuous
engineering considerably by making it extremely
easy to create machine structures, and because
of its partially automated configuration
and programming facilities. The use of catalogues,
libraries and motion control also makes
life considerably easier for the user.
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Successful
concept expanded
Expansion of geared motors in servo area
Nuremberg. A compact unit consisting of a dynamic
servo motor for direct connection in combination
with a powerful planetary drive: This concept
has exceeded all of the Baumüller group’s
expectations. The initial steps in the shape of
the DSD 45…IPG about two years ago are regarded
as a major success. The concept is now being expanded
upwards accordingly: The DSD 56…IPG is the
consistent continuance of this successful product.
Like the DSD 45…IPG, the DSD 56…IPG
is extremely suitable for applications with maximum
torque and dynamics requirements because of its
integrated planetary drive. Unlike comparable
conventional combinations, terminal connections
and additional bearings are not required. This
makes the drive package much more compact, gives
it less inertia and makes it stiffer for direct
torque transfer.
The DSD 56…IPG will be supplied as a self-cooling
version with a fully encapsulated motor. A continuous
housing design was also selected for both components.
The smooth, slim housing surface does not attract
soiling. A high protection class has also been
achieved for use in harsh industrial environments
(IP65). The motor can still be mounted from the
rear in order to make it easier to fit in situations
where little room is available. The transmission
ratios of i=4 and i=8 and appropriate peak torques
for dynamic deployment have been perfectly matched
to each other.
The integrated planetary drive is outstanding
because of its low circumferential backlash, high
tilting resistance and high efficiency. It is
also extremely quiet.
The DSD 56…IPG is currently being tested
at customer sites. Additional in-house testing
under tightened-up conditions is also currently
in progress. Series production of the motor is
due to start in 2006.
Next stage
ignited
Performance range of the DA motor series
moves upwards
Nuremberg. The Baumüller group has increased
the performance range of its DA asynchronous motor
series in the form of the DA 280 model. With power
of up to 450 kW, this now represents a competitive
alternative to standard IEC motors.
From 260 to 450 kW: This performance increase
has been made possible by specifically expanding
the range of DA motors. The new DA 280 is an outstanding
dynamic drive with high power density. With rated
output of up to 450 kW, it represents a real alternative
to the standard IEC motors that are currently
in use. Compared to these motors, the design of
the DA 280 is much more compact and robust. This
is an important factor in helping to reduce the
dimensions of the drive components in customer
applications.
The three-phase motor that was previously top
of the range, the DA 225, generated up to 260
kW. In future the DA 280 will mainly be used in
the plastics industry and the general motion area
(e.g. with flying cutters).
Air cooled and water cooled versions of the DA
main drives are available. The former version
is available with protection class IP23, and the
latter is available with IP54. This means that
the existing concept of cooling and protection
class variants has been consistently continued
in this new size.
Customer demand for a continuous Baumüller
product range in the three-phase current area
was the motivation for the upwards expansion of
the DA motor series. The DA 280 is currently undergoing
trials at customer sites. Series production of
the motors is due to commence in early 2006.
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Overview
