berger lahr icla intelligent compact drives. 2 contents motion control with berger lahr what is...
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Berger Lahr IclAIntelligent compact drives
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Contents
Motion Control with Berger Lahr
What is IclA? – Integrated Intelligence
Market trends (demands)
Keyfactors: Compactness and Flexibility
BL Answer: IclA - Product range
Applications - References
Questions and Conclusion
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Motion Control with Berger Lahr
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What’s IclA? – The concept of Integrated Intelligence
Intelligence close to the application Electronic and Motor form a unit Reduction of components,
reduced space in control cabinet, wiring and installation effort
Flexible Integration to customer systems by: 3 different motor characteristics Manifold options as standard
(variance) Fast Track Solution for
individual demands
Intelligent compact-line Actuator
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IclA - Intelligent compact-line actuator
Communication interface:
Profibus DP CANopen RS485 Pulse/Direction
Motor: AC Servomotor, Stepper Motor, DC brushless
Electronic: Positioning control Power stage Motor Feedback Internal Power Supply
> I/Os Power Removal
Additional options: gearboxes Holding brakes Industrial connectors PCB-connectors
24-V signal interface Programmable I/Os Power Removal interface DIP-switches
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Berger Lahr Experience
1999 20032000 20102001 2002 2004 20062005
D0xx – EC Motor
IFS6x Stepper
IFA6x AC-Servo
IFE EC-Motor
IFS9x Stepper
IclA Ixx:
IclA D/N0xx:
N065 – EC-Motor
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Market Trends
Application demands: Decentralization
Continuously Miniaturisation Optimisation of production (flexible product changes)
Increasing Individuality Easy Integration
IclA-Characteristic: Flexibility – easy and fast integration
Compactness – size and integration of motor, electronics and functionalities Modularity – Project Planning, Installation, Set Up and operation
Safety – integration and controlled
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Increasing Individuality
Flexible production of small series requests for new solutions in positioning and drive
technology
Trend in Cost per unit
Batch size
Co
st p
er u
nit
Trend
= kconventionel produktion
= automated produktion
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Optimisation of production (flexible product changes)
Increasing Process reliability by elimination of manual adjustments, >> ristk of wrong adjustments in machine change over
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Fieldbus - Communication
DC-Power 18-36 V
De-Centralized solution:
IclA – Decentralized Intelligence
- Machine - Application
Motion
Controller
Centralized solution:
Electronic
Control Cabinet: Motor Power
Feedback
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IclA Ixx - Product Portfolio
The fantastic four: Motor Characteristics
IFA
AC Servo-Motor
IFE
EC-Motor (BL-DC)
IFS
Stepper-Motor(Fieldbus)
IDS
Stepper-Motor(Pulse/Direction)
Common features:Various power ranges by different motor sizes and supply ranges
Operating modes
Communication interfaces
Programmable signal interface
Connection technologies
Integrated Power Removal
Holding brakes
Gearbox options
Commissioning Tool IclAeasy
Accessory
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IclA Ixx = Integrate it!
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Flexibility – Communication Interfaces
Field Bus interfaces:-
CANopen Profibus DP RS 485
IDS (Stepper): Pulse/Direction interface
Motion Controller or PLC
Ethernet
Pulse/Direction interfaces
RS 485
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Flexibility – Functionalities
Application >> e.g. Pick and Place
500 mm
1.200 mm
Absolut positioning
0
500 mm
Relative positioning
0 700 mm
Positioning mode (Point-to-Point)
v
t
v1v2
v3
Speed profile
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Flexibility – Functionalities
Application >> e.g. cutting material on a conveyor
Electronic gear mode:
NC:200 Incr.
200 Incr.
300 Incr.
600 Incr.
1 : 1
3 : 2
3 : 1
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IclA Ixx - Internal Power Supply
Supply of max. four 24 V-Outputs by the power supply of the IclA (Standard from week 44!) Supply V DC: 24 +- 10% Switching current mA < 200 Energy recovery safe
Alternative (Option) as known – Supplied by an external (separate) Power supply unit
24V - I/0s (4x)
Signal interface:
24V DC
power amplifiercontrol electronics
24V... 36V DC
Power Supply Unit
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IclA Ixx – Integrated Power Removal
Standard in all IclA Ixx Power Removal (=Safe Standstill) integrated safety function Emergency Stop
(EN 60204-1) for Category 0 stop and Category 1 stop
Safety levels in accordance with the standards of functional safety:
SIL 2; IEC 61508 (Functional safety of electrical/electronic/programmable electronic safety-related systems.)
SIL 2; pr IEC 62061 Category 3; EN 954-1 Category 3; pr EN 13849-1
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IclA Ixx – Category 0 Stop
Category 0 stop (EN60204-1) Standstill by immediate power shutdown to the machine drive elements (i.e. an
uncontrolled stop).
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IclA Ixx – Category 1 Stop
Category 1 stop (EN60204-1) A controlled stop in which the machine drive elements are retained to effect the
standstill. Power feed is only interrupted when everything has come to a standstill.
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Integrated Power Removal Benefits
Emergency safety Control function acc. EN 60204-1 Continuous connection to positioning electronic Control over position Reduced Costs for safety components (external power contractors) less space required in the machine
24V..35V DC
24V
24V..35V DC
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Flexibility – Software Tool IclA Easy
Field bus interface for software update & diagnostics Commissioning-Software: Look & Feel
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Flexibility – Connection Technologies
Two different connection technologies are available:
Industrial Connectors:
Generally used in specialised machines and small production runs
Wire to Board Connector:
Generally used in serial machines in with cable harnesses
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IclA® IFA – The Dynamic AC-servo
AC Servo Motor based Closed-Loop controlled drive system High dynamic characteristics High resolution encoder Options:
Holding brake Planetary gearbox
For processes which require dynamicaccelerations, high speed and exact resolution
Max. Torque: 0.40 ... 0.72 Nm Max. Speed: 6000 – 11.000 rpm
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IFA News 2005: new winding variants: /... 3D
IFA61:
IFA62:
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IclA® IFE – The Reliable Format Adjuster
Electronically commutated – EC Motor Closed-Loop controlled drive system Absolute position feedback High detent torque Options:
Spurwheel gearboxes or Planetary gearboxes
For automatic format adjustment –with minimum setup times
Max. Torque: 0,24 Nm Max. Speed: 4.800 rpm Detent Torque: 0,08 Nm
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IclA® IFS – The Strong, Precise Stepper
Stepper Motor based High torque - no need for gearbox Excellent constant velocity characteristics High-resolution positioning Options:
Planetary gearboxes Encoder with index pulse Holding Brake
For short range positioningIFS6x: Max. Torque: 0.45 ... 1.5
Nm Max. Speed: 2000 rpm
IFS9x: Max. Torque: 2 ... 6 NmMax. Speed: 1000 rpm
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IxS9x news: Optional Holding brake
Technical Data:
Protection Class (unit) IP54 EMC Cl. B acc. EN55022
Holding Torque MH: 6Nm Electrical pick-up power: 22W Make Time (release brake): 40ms Break Time (close brake): 20 ms Moment of inertia: 0.2
(kgcm²) Weight: 1,8kg
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IclA N065
New Format setting IclA (Update of IclA D065)
Fieldbus: CANopen DS 402 Planed Market Launch:
1. Quarter 2006 Replacement of D065 ASAP 4 gearbox option:
Spurwheel Wormgearbox Planetary gearbox Angular planetary gearbox
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Application – CD/DVD production cell
Application Requirements: dynamic acceleration, speed, easy integration
Solution: IclA IFA with AC-Servo Benefits with IclA:
Reduced production space (approx. 10%) Increased productivity (approx. 20%)
Field bus: CANopen
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Application – CNC furniture machine
Application requirements: Replacement of manual settings (hand wheels) Fast product changes Save position after switching
Solution: IclA IFE with EC-Motor Benefits with IclA:
Reduction of change over time High detent torque – no brake or gearbox required No referencing required
Field bus: CANopen
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Application – PCB Machines
Application Requirement: Automated Precision Positioning (camera) Repeatable printing quality Field bus communication (8 different drives) Easy integration
Solution: IclA IFS - Stepper Benefits with IclA:
Reduction in size (footprint) “Plug and Play” – no tuning required Precise positioning
Field bus: CANopen
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Applications – References
Printing Wood and Furniture Paper Handling Labelling Textile Electronics Medical technology Material Working:
Rubber, PlasticMetal, Wood,Paper ...
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Perspective IclA® - Product Range (1)
IclA Ixx: Safety Functionality „Power Removal“
>> released in 2005 Internal Power Supply
>> released in 2005 Fieldbus –
CANopen DS402 >> Next Generation IclA Ixx – Beginn of 2008DeviceNet on demand!
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Perspective IclA® - Product Range (2)
IFA – AC-Servo Medium Power:
>> Beginn of 2007 Absolute multiturn encoder
>> Mid 2006IFE/N06x – DC-Brushless Power Extension for IFE
>> in 2006 Wormgear for IFE
>> in 2006 Power Extension for N06x
>> on FTS-Basis from todayIFS - Stepper ATEX certification for IFS 6x
>> 2. Quarter 2006
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Conclusion: Main benefits of Berger Lahr IclA®
Integrated Intelligence at the application: Positioning Electronics, Power Electronics, Safety Function, Internal Power
Supply High Flexibility and Availability by modular variant configuration
for easy integration and individual demands Interference Resistance by internal motor wiring and
high failure detection field bus Little wiring(field bus + power supply). Significant
reduction in costs and installation Significant reduction in control cabinet space No climatisation of control cabinet Significant reduction in floor space
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for your attentionThanks