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© 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
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
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
DO and Starter Replacements
Size Comparison:
120Hz vs. 60Hz
Induction Motor
DO and Starter Replacements
• 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
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