Just in time for SPS in Nuremberg, automation specialist Lenze presents its new compact IE5/IE7 engine drive system. The drive system operates sensorlessly even in dynamic applications. The combination consists of the motor M550/M650, the G500 gearbox and the latest generation frequency converters i550 and i650. The first synchronous engine is just as easy to use as the asynchronous ones. Thanks to its innovative design, it reaches energy efficiency classes IE5 and IE7. Engine losses can be reduced by up to 60%, which significantly reduces energy requirements and CO2 emissions. Performance is also convincing: a 300% overload torque accelerates the engine from standstill to full load.
Klaus Dierkes, Electromechanical Product Manager at Lenze, is pleased with the excellent feedback from intralogistics test customers: “Our customers are particularly interested in reducing energy costs and reducing CO2 emissions. This is a very big topic, especially in the logistics sector, and we can achieve this with the M550. We have actually seen that the new motor drive system can reduce engine losses by up to 60%. This is made possible by a new design of permanent magnet synchronous engine. What’s more, the engine is the same size as or even smaller than a comparable IE2/IE3 engine.
Excellent performance: 300% overload torque
High performance is also important to our customers. “We promise 300% overload torque and we keep it. Full load starts from the stand are also easy to achieve. The beverage industry, the textile industry and especially the internal logistics benefit from this.” This allows the system to be dimensioned more precisely for continuous operation, without being too large and providing the required performance immediately.
Lenze offers the new M550 synchronous engine with a power range of 0.25-11 KW and the M650 with 0.75-22 kW for more dynamic applications. Both can be seamlessly combined with gears from the Lenze kit. Fine wheel, angle or bowling gearboxes can be tailored to the different requirements.
During the build phase, the first test customers worked with Lenze’s new system designers. The result is precisely dimensioned drive solutions and energy-efficient machine concepts. A web-based engineering assistant shows the energy consumption of the respective application and drive components.
Efficiency combined with high ease of use
Dierkes considers customer feedback: “Efficiency and ease of use are very important to our customers. You simply enter the parameters and configure the engine data for the frequency converter. There are no encoders, which means less wiring, settings and components.”
The new motor drive system is also very resource-efficient. The sensorless return means no encoders, expensive return systems or expensive cables – a budget-friendly chain reaction. Another benefit is that assembly and installation are quick and safe. This contributes to the reliability of the system.
If the engine is controlled by a decentralized frequency converter i550 or i650 Motec, the hardware burden is even less, since no brake resistors are required. The back feed unit integrated in the Motec feeds the brake energy back into the network. The frequency converter i500 cabinet can also exchange surplus energy via the DC network to serve other axes.
Lenze has a new solution for the positioning of goods that is often required in conveyor technology. “We use SLSM algorithms (sensorless synchronous motor control) in our frequency converters, which allows closed control loop performance without motor feedback systems or cabling. This allows us to achieve precise positioning without sensors.”
Less is more
Lenze’s new motor drive system opens up solution space in intralogistics and many other industries such as textiles, packaging technology and material processing, while also providing a clear economic competitive advantage. The system makes the user’s work easier, improves energy efficiency and offers the possibility of servo solutions. Frequency-controlled synchronous control therefore represents a cheaper alternative to more expensive service delivery solutions and is overall much more reliable due to reduced complexity.