rightsizing for material handling

© 2014 MHI®

Copyright claimed as to audiovisual works of seminar sessions and

sound recordings of seminar sessions. All rights reserved.

Sponsored by: Presented by:

Robert Gradischnig

Rightsizing for

Material

Handling

NOTE: The use of

the following opening

title slide is

MANDATORY in

each PowerPoint

presentation for in-

show continuity and

post-show on-

demand web

viewing. Please

include seminar title,

sponsor logo and

speaker names/titles.

Contents – Current state

– Problems with the current state

– Goals - What do we want?

– Recent Innovations

• Mechatronic Technicians

• Drive sizing Software

• Efficient Gearing

• Motors

• Drives

• DO and Starter Replacements

Contents (Continued)

– Special Notes - Standards

– Performance and Profitability

– Conclusion

• OEMs

• No re-evaluation of geared motors

• Not focused on efficiency

• Price Pressure

• End User

• Risk averse = Change averse

• Downtime is a career ender

• Focused on brands, not standards or performance

Current State

• OEMs -

• Standards (Machine Efficiency, IES2, Safety)

• Profitability

• Competitive differentiation

• Cost, Performance, Quality

• End User

• Part variants

• Electrical infrastructure for large systems (cabinet

reduction)

• Troubleshooting (diagnostics with DO and Starters)

• Lifecycle costs

Problems with the Current State

• White Sheet Design – Rightsized

• OEM –

• Embrace standards

• Improve competitive advantage (Innovation)

• Profitability

• End User

• Less part variants

• Less infrastructure

• Easy to support with diagnostics

• Low overall costs

• Performance

Goals - What do we want?

These industry-wide innovations will take us from the

current state to our goals…

• It starts with people that understand…

mechatronic graduates

• Rightsizing software

• More efficient gearing

• Efficient motors (eg:120Hz, permanent magnet)

• Motor mounted drives (troubleshooting and support)

• Soft start and contactor replacements

Technology Advances

In the last 5 years, colleges and universities have added

pure mechatronic programs. The expectation is that

graduates know…

• Mechanical

• Electrical

• Software

Mechatronic Technicians

Mechatronic Technicians

What does it do for you?

• It helps mechatronic engineers properly

size and select the right components for

a task. Conversely, it will tell them when

a design concept is not feasible (like

CAD software can).

Rightsizing Software

Features

• Entire system (load through drive)

• Motion profiles and advanced motion

• Solutions comparison

• Energy costs

• Payback time

Rightsizing Software

Helical gear

1-stage: eff= 98%

2-stage: eff= 96%

3-stage: eff= 94%

Helical gear

2-stage: eff= 96%

3-stage: eff= 94%

Helical bevel gear

2-stage: eff= 96%

Helical Bevel gear

3-stage: eff= 95%

4-stage: eff= 93%

Helical bevel gear Hypoid Gear

(= 43-89%)

Worm gear

(= 60%)

Efficient Gearing

Helical bevel gear

(= 96 - 98%) Worm gear

(= 60%)

Efficient Gearing

Motors

• IE2 and IE3

• 120Hz Motor

• Permanent magnet (IE4)

IE2 IE3

120Hz Motor

Permanent magnet (IE4)

Motors

120Hz Motor

• Up to 2 sizes smaller than a

conventional IE2 motor

Drives

• Eco Mode

0 10 20 30 40 50 60 70 80 90 100

20

40

60

Wirk

ungs

grad

[%]

Messung an einem 2,2kW-Norm-ASM bei 600 rpm

etaVFCplus

etaVFCplus ECO

0 10 20 30 40 50 60 70 80 90 1000

50

100

150

Mot

orsp

annu

ng [V

]

UVFCplus

UVFCplus ECO

0 10 20 30 40 50 60 70 80 90 1000

500

1000

1500

normiertes Drehmoment [%]

el. L

eist

ung

[W]

PVFCplus

PVFCplus ECO

0 10 20 30 40 50 60 70 80 90 1000

0.5

1

Leis

tung

sfak

tor [

-]

cos phiVFCplus

cos phiVFCplus ECO

Drives – Eco mode result

DO* and Starter Replacements

*Direct Online

• Standard AC motor Starting torque 2 – 2.5 : 1

• Electronically controlled motor Starting torque 4:1

5

M [Nm]

t [s]

20

n [m/s]

10

5

15

1 2 3 4

Mmax [Nm]

Mcontinuous [Nm] > 4:1

DO and Starter Replacements


5

M [Nm]

t [s]

MMax

MN

MMax

MN

DO motor: size 90

Electronically controlled motor: size 80

20

n [m/s]

10

5

15

1 2 3 4

• Oversized with Direct Online Motor

• Poor efficiency


Size Comparison:

120Hz vs. 60Hz

Induction Motor


• Up to 70% less variance

Motor Gearbox

i=7.5

i=10

i=5

Starter

Electronically controlled motor

IEC 60034-30

• International Efficiency Regulation

Special Note - Standards

• There are new efficiency standards for power drive systems

(PDS) in the pipeline:

New efficiency classes

for PDS

Special Note - Standards

Special Note - Standards • LCC – Life Cycle Costs

Special Note - Standards • Break Even / Payback

1. Using electrical energy intelligently

2. Converting energy with high degree of efficiency

3. Using the recovered braking energy

Performance and Profitability

Rightsizing drives is easier than ever:

• The software tools exist.

• There are more efficient motors and gear trains available.

• Drive technology is less expensive and more powerful.

• The time required to review and create drive systems has

been reduced because of all the tools in combination.

Rightsizing saves end users power money and saves the

environment.

Rightsizing can really save OEM’s money and add

differentiation to machine offering.

As easy as that.

Conclusion

For More Information:

Speaker email: [email protected]

Website: www.Lenze.com

Or visit MODEX 2014 Booth 5131

NOTE: This ending slide is OPTIONAL. Items that can be included are your

speaker’s email address/home page, the Exhibiting Member Company’s name,

home page and Booth Number.

Thank You

rightsizing for material handling

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