January 2012

Feature Article

Paper Cup Machine Manufacturer Uses Servo Drive Technology to Shape Greater Flexibility and Productivity

The paper cup is one of the most common containers we encounter every day. Yet, as with many of the seemingly simple packages we routinely use, the best forming machines to make paper cups and paperboard canisters utilize advanced engineering and system design, combined with high performance components that can sustain production of thousands of containers per hour, 24 hours a day. <Click here to read the full article>

Sponsored Announcement

Discover the Latest Technology Advancements, Maximize ROI, Network with Industry Leaders

Motor, Drive & Automation Systems 2012, March 13-14 in Orlando, Fla., will feature in-depth presentations that highlight new technology developments critical to OEMs and end users, manufacturers and industry suppliers. The event will have two tracks running simultaneously so the event can be customized to fit your particular interests. This annual event will feature presentations on advanced power electronics, improving energy efficiency, motor and motion control, as well as new market trends and technology developments.

This is your opportunity to learn what's ahead in motor, drive and automation technologies and markets, to network with leading worldwide players and to explore new opportunities, alliances and suppliers. If you are involved in the motor, drive or automation industries or if your products and systems integrate motors and drives, this is your must-attend event of the year!

Register by January 26th for exceptional early-bird discounts.

Before January 26th: $695; After January 26th: $995; Onsite Registration: $1,295. Sending more than one person to the conference? Team discounts are also available.

BEI Kimco Magnetics Introduces Limited Angle Torque Motor Featuring Zero Cogging for Smooth Operation
Precision positioning and actuation applications require smooth motor operation without disruption from cogging. To meet these specialized demands, BEI Kimco Magnetics, has introduced the new BLDC Limited Angle Torque motor model LAT40-48. The LAT40-48 motor meets market demand for a zero cogging motor with high peak force in a small form factor package.

The LAT40-48 motor is a limited angle torque motor. The rotor of this motor has no preferred position. These design elements combine to provide a motor that completely eliminates cogging. The result is consistent, smooth performance critical to applications that depend on uninterrupted operation, such as stabilization platforms, scanning and beam steering.
  
The new motor also features a single phase winding that provides easy control, a 30° excursion is accomplished with no commutation. Use of rare earth, high energy magnets creates a power density of 10.08 oz-in Watt.  Other performance characteristics include +/- 15° stroke, a peak torque of 21.5 Nm, and single phase winding. These high level functions are all packed in a 100.0 mm diameter by 100.0 mm stack length size. 

As a Brushless DC Motors (BLDC) with fixed magnets, the LAT40-48 offers all the inherent advantages over brushed DC motors, including more torque per weight, more torque per watt (increased efficiency), increased reliability, reduced noise, longer lifetime (no brush and commutator erosion) and overall reduction of electromagnetic interference.
                
BEI Kimco products have been used successfully in countless applications from high-end industrial to military and aerospace to medical applications. The ability to provide high performance solutions tailored to the specific needs of the customer has allowed BEI Kimco to fulfill many challenging requirements.

Hitachi Introduces Advanced AC Micro Drives
Hitachi America, Ltd. has announced two new 100 V Class models in the WJ200 series of inverters. The new models are rated at ½ hp and 1 hp, 100 VAC to120 VAC, single-phase input, and 200 VAC to 240 VAC, three-phase output.

The WJ200 series sets a new benchmark for performance, flexibility and functionality in micro-size AC drives. The WJ200 is a sensorless vector (SLV) drive capable of 200 percent or greater torque across the speed range. Speed regulation at low speed is dramatically improved, fluctuation is half that of previous models. Improved trip avoidance measures have been incorporated for unsurpassed system reliability and availability.

The WJ200 is distinguished by its integrated PLC-like functionality. With its Easy Sequence (EzSQ) logic controller function, programs up to 1,024 lines can be created on a PC using a structured language editing tool. These programs can then be transferred to the WJ200 to control its operation and allow very sophisticated control schemes to be created without the use of external controllers.

Simple position control applications are also possible with the WJ200 utilizing the integrated pulse input. Together with EzSQ, intricate motion profiles can be developed. Further adding to its flexibility, the WJ200 has the capability to drive both induction motors and permanent magnet (PM) motors, a single drive for two motor realms.

A new EzCOM peer-to-peer communications function is standard and allows multiple WJ200s to share data. One drive is designated as the “administrator,” and controls the network. Other drives on the network can be master or slave, with masters able to write data to any designated slave(s). Master/slave roles are rotated under the control of the administrator automatically. Up to eight masters can reside on the network, and up to 32 drives (up to 247 drives, if external signal repeaters are used). The administrator can be master or slave also. EzCOM allows for creation of sophisticated coordinated systems without any additional external hardware or programming.

Siemens Introduces Sinamics G110D Distributed Drive for Material Handling and Industrial Applications
Siemens has recently released the new Sinamics G110D drive platform. The latest solution in the company’s Totally Integrated Automation (TIA) portfolio, the Sinamics G110D is well suited for installation in close proximity to motors located throughout facilities where dust and water ingression are a concern.
 
The Sinamics G110D combines improved functionality, increased energy efficiency, a smaller footprint, lower total cost-of-ownership and enhanced usability in a single drive. Applications for this new drive range from material handling or packaging conveyors and airport baggage carousels, to pumps, fans, compressors and other industrial equipment.

Offered as an economically-priced drive with improved features, the Sinamics G110D includes integrated plug-and-play power and control for easier installation and an optional Intelligent Operator Panel (IOP) for simple text application setup in a reduced footprint. The IOP further assists the machine operator with a greater level of control, as well as alarm status alerts and resolution advice, so troubleshooting time is greatly reduced. 

The Sinamics G110D is suitable for either direct communication with a Programmable Logic Controller (PLC) or control via I/O inputs.  AS-Interface bus configuration and optional maintenance and manual-auto switch are incorporated into the drive, making it easy to integrate with other hardware in an overall control schematic.  Integrated brake control and quick stop functions provide a higher degree of reliability in heavy-load operations. 

Yaskawa Releases the Z1000 Family of Drives for HVAC and Building Automation Applications
The Drives & Motion Division of Yaskawa America, Inc. has released the Z1000 family of HVAC drives. This family of drives is comprised of the Z1000 variable speed drive as well as the Z1000 Bypass Package designed specifically for commercial HVAC applications.

The Z1000 Variable Speed Drive is designed for building automation applications such as fans, pumps and cooling towers through 500 HP. Its features begin with an easy-to-read LCD operator with Hand-Off-Auto functions.  An internal real-time clock with time /date stamping and timer controls allows for speed variations without the need for external controls. A built-in 5 percent line impedance reduces input harmonic distortion, while a 5 kHz carrier frequency with dynamic noise control provides quiet motor operation. An on-board EMI/RFI filter compliant with IEC 61800-3 minimizes interference of surrounding equipment. All Z1000 drives also feature embedded BACnet communications (BTL certified), along with Modbus/Memobus. Applications macros are available to facilitate quick and easy setup.

Closed loop control of fans and pumps for pressure, flow, or temperature regulation is accomplished via the Z1000’s PI feature, which eliminates the need for a closed loop output signal from a BAS. Independent PI is also available to control an external device in a system.

Available NEMA 1 models include ratings of 3 to 150 HP (208 V) and 3 to 500 HP (480 V).  A sealed heatsink allows the drives to be mounted in a NEMA 12 enclosure with heatsink external. All Z1000 drives are Plenum Rated (UL 1995), Seismic Rated (March 2012), and made with RoHS compliant materials.

The Intelligent Bypass, when enabled, can transfer the motor across the line when the application requires 60 Hz.Most HVAC systems require 60 Hz at peak demand (summer months – daytime), which will utilize the intelligent bypass function. Removing the drive at 60 Hz saves energy and removes harmonics at worse case conditions.

Lenze Compact I/O-System 1000 Modules Blend Intelligent Plug-and-Play Electronics
Lenze Americas recently launched the modular L-force I/O-System 1000, which incorporates intelligent electronics and an innovative mechanical concept to deliver a higher degree of value and machine automation functionality.

The slim-line Lenze I/O-System 1000 features a highly deterministic method of controlling input and output modules and the ability to read touch probe inputs required for synchronized movements in cyclic production processes. A minimal internal cycle time and a time stamp ensure the I/O-System 1000 is suitable for real-time-based architectures and can meet the most stringent automation speed requirements.

Lenze I/O-System 1000 modules allow eight connection points in 12.5 mm of space on a conventional DIN rail.  A clearly structured labeling and diagnostics concept includes identifiable status LEDs with a single labeling field uniquely assigned to each LED. An I/O 1000 station can be assembled completely without tools, with up to 64 modules configured to form a station using the integrated backplane bus. Digital output modules include a module with two integrated relays (DC 30 V / AC 230 V, 5 A). The product range includes function modules for connecting thermal resistors and thermocouples, a range of counter modules and a module for evaluating encoders with an SSI interface.

Plug-and-play electronic modules eliminate the need for field wiring and simplify module replacement. Tension spring terminals and the block diagram on the housing help prevent mismating and facilitate a secure connection during installation and maintenance.

Smart Grid Technologies Drive Growth for Low Voltage Contactors Market
In a recently published study from IMS Research, entitled The World Market for Low Voltage AC & DC Contactors and Overload Protection Devices – 2011, the global trend towards installing smart grid technologies is forecast to be the strongest market driver for low voltage contactors over the next five years, spurring contactor market revenues to over $5 billion by 2016.

Contactors are traditionally used to start and control AC induction motors, where large power switching may occur and safety is a concern. The market here for contactors generally follows machinery production forecasts and is tied in heavily to underlying GDP forecasts. However, adoption of smart grid technologies drove 2010 volumes up higher than expected, and is forecast to continue to do so as smart grid initiatives gain momentum worldwide.

Michael Markides, the reports author, said, “With more decentralized power generation, and more parties likely to act as electricity providers, the need for safe and reliable power switching is expected to increase. Growth in renewable energy, and related grid integration and management of renewable energy, is the single strongest driver for further adoption of contactors in power switching.”

2010 market revenues grew to an estimated $3 billion for contactors, with over a third of the revenues being for contactors sold into power switching. By 2016, revenues for contactors sold into power switching alone are forecast to reach $2 billion globally, or just over half the total projected market revenues. Said Markides, “All parts of electricity infrastructure, including generation, distribution and consumption, are rapidly adopting some level of smart grid technology. As a result, suppliers of contactors will increasingly shift attention to OEMs that manufacture devices such as electric vehicle charging stations, solar and wind inverters, generators, UPS, capacitor banks and electrical paneling, all key end equipment types forecast to grow the power switching segment for contactors over the next five years.”

Airline Hydraulics Corp. Completes Acquisition of Innovative Automation & Controls, Inc.
Airline Hydraulics has announced the acquisition of Innovative Automation & Controls, Inc. (IACI), an electrical controls and automation components distributor located in Maryland. IACI, services the industrial market in Maryland, Pennsylvania, Virginia and West Virginia, representing and partnering with manufacturers that focus on quality, reliability and innovation.

Commenting on the acquisition of IACI, Joseph A. Miceli, CEO of Airline Hydraulics, said, "We are pleased to have IACI and their dedicated team become a part of the Airline Hydraulics organization. Their electrical control application expertise and value-added systems solutions approach to solve customer needs, complement the successful business strategy of Airline Hydraulics. This acquisition will strengthen our combined ability to serve customers in Maryland and surrounding regions with enhanced application support, sub-assembly capability and added service and support resources."

Headquartered in Pennsylvania, Airline Hydraulics Corp. is a regional distributor of fluid power and automation products with capabilities including stocking inventory, engineering design, manufacturing, assembly, service, repair, and installation. Airline represents Bosch Rexroth, SMC, HYDAC, ABB, Omron, and other major fluid power and automation product lines and has been in business for over 60 years, with six branch offices and a number of sales offices located throughout the Mid-Atlantic and New England states.

Festo Servo-Motion Control Accelerates Throughput of Plastic Joining Machines
Phasa has enhanced the performance of its specialist plastic component joining machines with high performance new versions employing a key servo-based motion control system in place of a pneumatic actuator. The servo enables several seconds to be shaved off the assembly time of complex car door panels, increasing productivity significantly. The slight additional cost of a machine fitted with servo technology will typically repay its investment after just a couple of months.

Phasa takes its name from the process it has pioneered: Plastic Hot Air Stake Assembly. Essentially, the process involves selectively heating parts of thermoplastic moldings using super-hot air, and then using cold tools to form, clamp and chill the parts into their required shapes. The fixings often take the form of rivets or 'roll overs', and the non-contact heating method ensures that the process is clean, without marking the 'A' face surface, and the resultant assemblies are strong, tight and stable. Applications for these fixings are diverse and include the automotive, electrical/electronics and white goods industries.

Until relatively recently, all of Phasa's standard machines used only pneumatically-powered motion control. However, when the company started to experience supplier product changes for the machines' rodless cylinders, it approached Festo for help. After investigating the application, Festo recommended using its DGC pneumatic cylinders to provide the machines' main platen movement. These rodless linear actuators feature a sealing mechanism that ensures efficient operation by virtually eliminating air leakage, and have proved a very reliable replacement. Since then, Phasa has progressively re-designed its range of standard machines to incorporate Festo pneumatic automation components for many of their motion axes.

Phasa recently expanded its standard machine range to include models that use a servo system in place of a pneumatic cylinder to provide the main movement of assembly nests. The principal advantage of the servo approach is that by using closed-loop control it is capable of fully programmable multi-stop positioning, compared to the end-to-end positioning of standard pneumatic cylinders. This results in faster and more accurate placement of the assembly nest, reducing the overall processing time.

In this particular case, Phasa chose a complete Festo assembly comprising of a toothed belt axis, servomotor, gearbox and servo motor controller to provide the horizontal movement of the assembly nest platen on its large 40/80 machine. This combination, together with the power supply and mechanical connecting kit, is supplied by Festo as a turnkey solution. The servo controller is networked to the 40/80 machine's host PLC. Compared to the all-pneumatic version of the machine, the electric servo based model accomplishes the same assembly operation in 33 seconds, improving throughput by nearly 6 percent.

Event Listings

Motor, Drive & Automation Systems 2012 will be Co-Located with the MAGNETICS 2012
March 13-14, Orlando

Motor, Drive & Automation Systems 2012 is an international, industry-leading conference focused on the latest economic trends and technical advancements impacting motor, drive and automation systems. Join hundreds of peers and potential business partners and discover how new technologies are improving performance, energy efficiency and providing cost savings in a variety of applications.

Magnetics 2012 will focus on the latest advancements in magnetic applications, technology and materials. Serving OEM developers of products that utilize magnets and magnet systems, design engineers, OEM developers involved in EMC technology and magnetic effects, magnetics manufacturers and integrators, and material suppliers in the magnetics industry.

Early Registration Deadline for Both Events Ends January 26th.

APEC 2012
February 5-9
Orlando, Fla.

APEC 2012 IS AROUND THE CORNER
Make your plans to attend APEC 2012, Feb. 5-to-9, in Orlando, Florida.  APEC 2012 continues the longstanding tradition of addressing issues of immediate and long-term interest to the practicing power electronics engineer.  Outstanding technical content is provided at one of the lowest registration costs of any IEEE conference. APEC 2012 will provide:

• The best power electronics exposition.

• Professional development courses taught by world-class experts.

• Presentations of peer-reviewed technical papers covering a wide range of topics.

• Time to network and enjoy the company of fellow power electronics professionals in a beautiful setting.

Pacific Design & Manufacturing

Anaheim, California

February 14-16

At Pacific Design & Manufacturing, at the Anaheim Convention Center, Anaheim, California, February 14-16, 2012, you will meet face to face with hundreds suppliers of the products and services you need to move your project forward to a successful and profitable completion. While at the event, don’t miss the complimentary presentations at the Innovation Briefs Theater, featuring concise sessions by leaders in industry on new advances in technology relevant to your business. With your admission to Pacific Design & Manufacturing, you will have free access to these eight co-located events: Medical Design & Manufacturing West, WestPack, ATX West, Electronics West, PLASTEC West, AeroCon, SensorTec, and the Sustainability in Manufacturing. Don’t miss this resource that can accelerate your project!

ATX West
Anaheim, California

February 14-16

Attend ATX West where leading automation suppliers showcase the latest lean manufacturing, cost reduction, and enhanced productivity
products and technologies, including: Custom Automation; Robotics; Control Software/Hardware; Assembly Systems and much more! Registration is now open at www.ATXwest.com.

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