media newsletter dt january 2012 - home - english ... · dt media newsletter january 2012 1 ......

Drive Technologies Division

DT Media Newsletter January 2012

1

Integrated efficiency – Cost-saving potential is in the complete drive trainDrive technology is the key to energy-efficient

operation in the industrial environment. This re-

presents a large percentage of the energy costs.

The energy-saving potential is thus correspondin-

gly high. According to an analysis conducted by

ZVEI this is 10% by using high efficiency motors,

30% by using frequency converters and 60% by

optimizing the drive system. Depending on the

particular application, an individual combination

of various measures results in the maximum

effect.

When viewing the individual components of the drive

system, the efficiency of motors can be significantly

increased by using design measures and certain materi-

al combinations. Within the range of the Simotics

motor family Siemens offers both High Efficiency (IE2)

and Premium Efficiency (IE3) motors for various

applications. The former group has an efficiency that is

up to seven percent higher than conventional motors.

While IE2 motors are already stipulated by law in the

European Economic area, IE3 motors, too, might be-

come obligatory within the next years. Their efficiency

is up to ten percent higher than conventional motors.

The maximum system efficiency can be achieved when all of the components of the drive train interact with one another in an optimized fashion.



2

When it comes to frequency converters, the closed-

speed control is of special significance. It allows the

power drawn in partial-load operation to exactly adapt

to the actual demand. As a consequence, energy is no

longer simply wasted; this allows energy consumption

to be slashed by 60 percent, in extreme cases even by

70 percent. Energy recovery, too, is important. The

Sinamics G and S converters capable of energy reco-

very do not require a braking resistor and feed the

braking energy back into the line supply where it can

be used at another location in the plant or system. As a

consequence, energy costs can be slashed by up to 60

percent, for instance in hoisting applications.

There are, however, more aspects to integrated

efficiency along the drive train. Liquid cooling of

motors and frequency converters, for example, is the

more efficient alternative because the temperature

of the water used for cooling increases and can be

used as pre-heated service and process water. Further

savings potential can be realized by energy exchange

between generating and motoring axes. If some of the

axes, at least in specific process phases, operate in the

regenerative mode as following drives, the energy that

is taken from the process can be recovered and used.

This is done by using frequency converters, as is the

case for the Sinamics S120 drive family for example.

The state of the plant and the drives also play a crucial

role when it comes to energy efficiency. Leakage might

cause particular drives to be switched on more fre-

quently and for longer periods of time without anyone

knowing. Specific maintenance and optimization

measures can resolve this issue. In this case, a diag-

nostics device, as for example the motorstarter M200D,

sends a diagnostics status message when a drive is

worn or when load levels increase – which can be cen-

trally monitored by a higher-level maintenance station.

Excessive energy demand and increased costs can thus

be prevented.

All in all, it is obvious that the maximum possible ener-

gy efficiency and cost effectiveness according to state-

of-the-art technology can only be achieved by taking

a holistic approach. This means taking into account

possible interactions and synergies of the individual

measures and combining them on an application-

specific basis.

Within the range of the Simotics motor family, Siemens offers motors with a high efficiency. They form the basis of an efficient drive system.



3

The main thread through automationTotally Integrated Automation, or "TIA" for short, is

the holistic view of automation. The benefits that it

brings are clearly demonstrated in the construction

of thread handling machines. As the thread must

run through such machines accurately, so must all

the automation components perfectly interact with

each other. The safety technology also blends into

the TIA concept which runs like the main thread

through the plant.

Threads made of polyester, fiberglass or polyamide

frequently form the basis for rugged tires, tubes and

seals. To achieve the required stability of the threads,

they must be pretreated individually. The Mehler

Engineering + Service GmbH (MES) in Fulda/Germa-

ny specializes in planning and constructing thread

handling machines required for this purpose. A thread

handling system was recently delivered that comprised

tensioning mechanisms, immersion system and redirec-

ting rollers to ensure even tension. The servo motors

required for this purpose were driven via Sinamics S120

frequency converters from Siemens.

Regardless of whether the threads had to run through

at a variable or constant production speed, the modular

construction of the S120 converter comprising Power

Module and Control Unit made it easy to combine indi-

vidual drive performance values for power and control.

It can be used to control synchronous and induction

motors as well as torque and linear motors. Thanks to

the regenerative feedback capability of the converters

via so-called Line Modules, a constant DC-link voltage

and high degree of supply system compatibility can be

achieved.

In addition to the purely technical aspects, operation of

the equipment is noticeably user friendly. This applies,

in particular, to the easy programming and parame-

terization of the frequency converters which can be

implemented using the "Sizer" and "Starter" programs

included in the scope of supply. Starter is used by the

MES planning engineers at the control level, because

the settings can be saved and archived with the program.

Solutions from the modular system, such as the pre-assembled load feeders shown here, are used for the direct drives in the thread handling machines.



4

The advantages of the system concept of TIA are also

clear in the safety technology. The drives of thread

handling machines, for example, must always rotate

slowly when the new threads are being drawn in on

setting up. The safety function SLS (Safely Limited

Speed) is particularly useful here which, in addition to

other safety functions, is integrated into the Sinamics

S120 converter. On top of this, the Simatic S7-300 con-

troller ensures fail-safe communication on the Profinet

connection using the Profisafe protocol.

It is also important to remember that the thread hand-

ling machines contain a number of additional drives,

such as fans and pumps, that are started directly. Load

feeders comprising Sirius contactors and Sirius circuit

breakers of the new generation are implemented for

this purpose for switching and protection. Thanks to

innovative link modules, the units can be combined

quickly, reliably and without the normal wiring costs.

It is demonstrated here, once again, that the advanta-

ges of Totally Integrated Automation with its modern,

perfectly interacting solutions pay off and it acts as the

main thread running through the automation.

MES equips its thread handling machines with Sinamics S120 frequency converters from Siemens. The concept of Totally Integrated Automation enables the devices to be programmed and parameterized extremely easily.



5

The snow conditions are a major factor in the success

of a ski season. The right technology is essential for

those whose job it is to make winter sports an unfor-

gettable experience whatever the weather. Schmitten

AG at Zell am See in Austria is well aware of this, and

has proved once again with its latest artificial snow

project that the white stuff does not necessarily have

to fall from the sky. With the energy-efficient drive

technology for the snowmaking machines, extending

the season will be even more lucrative.

In the Schmittenhöhe ski area in Zell am See, 100 per-

cent of the pistes can be covered with artificial snow.

The best conditions for snowmaking are found at tempe-

ratures between -5 and -10 degrees Centigrade. Climate

change has resulted in fewer cold days, so winter sports

operators must constantly invest in the performance of

their snowmaking machines. The latest Schmitten AG

expansion stage was commissioned towards the end of

2010 and comprises three plant expansions and new

constructions. Pumping systems equipped with efficient

drive technology from Siemens form the central core.

Simotics three-phase induction motors, that are charac-

terized by high availability and a long service life, are

used to drive the massive high-pressure water pumps for

producing the artificial snow. Up to 375 kW, the upper

limit of applicability of the new international efficiency

standard, motors are also available off-the-shelf in the

high energy efficiency class IE3 which was a decisive

factor in acceptance of the drive solution. This was due

to the operator's insistence on energy-saving systems,

and as a result they are already endorsing these electric

motors.

Constantly good conditions with artificial snow production

In Zell am See, Schmitten AG ensures that the snow on the pistes is of a constantly high quality using 298 snow guns and 86 propeller systems.



6

The Sinamics G150 frequency converters used also have

a positive effect on the energy balance. In comparison to

plants with valve control of the water supply, which are

still common in many other winter sports areas, electronic

pressure and speed control saves a considerable amount

of energy and also reduces the wear in the pumping

stations. The devices are supplied in the form of "turnkey"

cabinets and, thanks to their high control accuracy, they

enable precisely synchronized operation of the water

pumps.

The more frequency converters there are in the network,

however, the more harmonics there are that require

compensation. Schmitten AG has chosen suitable line

filters to enable it to comply with the THD (Total Harmonic

Distortion) values prescribed by the energy supplier. Their

matching and integration in the drive solution has just

become easier. Since 2010, Sinamics converters have

been available with the option L01, the so-called line

harmonics filter. This complete unit is called Sinamics

G150 Clean Power and contains the compensation filter

as a fully integrated cabinet unit connected between the

control section and power section of the converter.

Finally, the safety technology also plays an important part.

To produce fine granular snow, the water must shoot

through the gun nozzles at high pressure, which means

that the pumps have to generate a pressure of up to 100

bar due to the difference in altitude between the station

and the mountain peak. If a fault occurs in the equipment

unit, rapid shutdown is essential to prevent damage. It is

easy to implement the shutdown of individual machines

without loss of the complete pumping system, thanks

to the fail-safe shutdown feature that is available as an

option in Sinamics G150. This enhances the availability

of the snowmaking machines and secures artificial snow

production at Zell am See for the future.

Simotics three-phase induction motors from Siemens provide a reliable drive system in the new high-pressure pumping stations on the Plettsau peak.



7

Siemens uses Sinamics SL150 cycloconverters for first time in an ore mill for copper producer Quadra FNX

Quadra FNX Mining Ltd., a Canadian mining company,

commissioned Siemens to modernize the drive in a

SAG mill at its Robinson open-cast copper mine in Ne-

vada, USA. This was the first time that an ore mill had

been equipped with a Sinamics SL150 cycloconverter.

The modernization concept developed by Siemens

allowed for most of the existing electrical equipment

to be retained, thus reducing downtimes during con-

version to a minimum. A new diagnostics system is en-

suring an immediate increase in operational reliability

and availability of the plant.

The Sinamics SL150 cycloconverters in operation at the

Robinson mine since the fall of 2011 are the first to be

used in an ore mine. Two air-cooled inverters circulate

the air in a closed circuit inside the container module

(e-house). This prevents ingress of dust particles or

copper powder from the ambient air into the frequency

converter. The standardized solution concept for mo-

dernizing ore mills means that it is not necessary to re-

place the motor or transformers. The software is based

on the standard Simine Mill GD for gearless mill drives

and was adapted for Robinson, where operation is via a

twin-pinion drive. A Sinamics DCM inverter handles the

excitation unit.

The Sinamics SL150 cycloconverter was pre-assembled

in a container module (e-house) and installed in paral-

lel with existing components. This made it possible to

install all the internal cabling and perform all the inter-

nal testing procedures prior to shutdown of the plant.

Downtime during conversion could therefore be limited

to only three days. Siemens' scope of supply also inclu-

ded new protection devices, a new diagnostics system,

as well as operating data acquisition systems and a

remote service feature. These provide maintenance

personnel with an immediate, up-to-date overview of

the relevant plant parameters and allow them to avoid

or quickly remedy unscheduled shutdowns. In addition

to hardware and software engineering and adaptati-

on of the automation equipment, Siemens was also

responsible for installation supervision and commis-

sioning. Siemens Industry Inc. was closely involved in

project handling.

Quadra FNX Mining Ltd. was created in May 2010 by

the merger of Quadra and FNX Mining and is one of

North America's leading copper producers. The com-

pany runs a number of ore mines in Chile, Canada and

the USA, as well as development projects in Chile and

Greenland. The Robinson open-cast copper and gold

mine in Nevada was bought by Quadra from BHP Billi-

ton in 2004.

Further information about solutions for the mining

industry can be found at

http://www.siemens.com/mining

The installation of the new container module (e-house) in parallel with the existing components helped to reduce downtimes of the ore mill to a minimum.

http://www.siemens.com/mining



Media Contact:

The Siemens Industry Sector (Erlangen, Germany) is

the world’s leading supplier of innovative and environ-

mentally friendly products and solutions 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 Divisions Industry

Automation, Drive Technologies and Customer Services

as well as the Business Unit Metals Technologies. For

more information, visit

www.siemens.com/industry

The Siemens Drive Technologies Division (Nurem-

berg, Germany) 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 mar-

kets in the production and process industries as well as

the infrastructure/energy segment. With its products

and solutions, the Division fulfills the key requirements

of its customers for productivity, energy efficiency, and

reliability. For more information, visit

www.siemens.com/drives

Siemens Industry Sector

Drive Technologies

Julia Kauppert

Phone +49 (0)911 - 895 7952

[email protected]

The Industry Sector and Drive Technologies Division in brief

Siemens Industry Sector

Drive Technologies

Franz-Ferdinand Friese

Phone +49 (0)911 - 895 7946

[email protected]

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