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Baumüller Develops New DSH Servo Motors for High-Precision Applications

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With the new DSH1 series, where “H” stands for high precision, the drive specialist Baumüller has created another derivative in its servo motor range. The latest product by the Nuremberg-based provider of drive and automation solutions impresses with a particularly low detent torque and thus achieves an extremely high control accuracy, especially in combination with the Baumüller drive technology.

 

 

Quiet and Extremely Adjustable

Fotoğraf Açıklama: With their excellent control properties, the servo motors of the new DSH1 series (on the right) achieve the high quality and precision that are required e.g. for specific welding seams

 

The DSH1 high precision servo motors were developed specifically for applications with the highest standards for quality and smooth operation. Typical areas of application, e.g. in the handling and robot field, include welding robots that produce components with a precise and high-quality welding seam. Due to the excellent control properties of the new servo motors, they are also ideal for label printing machines that have to achieve a consistently high and reproducible print quality.

 

The new motors can be optimally integrated into the current DS servo motor product range. With the existing modular system, the mechanical interfaces and connection technology are designed analogous to the existing Baumüller servo motors in the DSH1 series as well. This means that depending on the application requirements, the optimal servo motor can be used without requiring the machine manufacturer to make adjustments in the mechanics or connection technology. The maximum rotational speed range of the DSH1 servo motors, which are available in the sizes 45-100, is up to 6000 1/min with rated outputs of up to 10 kW in the self-cooling version.

Fotoğraf Açıklama: Welding Application of DSH Servo Motors / Carl Cloos Schweißtechnik GmbH
Baumüller offers the right solution for every industry and application with its broad range of servo motors. Offering a selection of the motor series DSC1, DSD2, DSH1, DSP1 as well as the DSE-integrated motors, tasks in the handling and robotics area as well as special tasks in plastics, printing, textile, tool and packaging machines and many other areas can always be achieved with the precisely required performance.

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Motors

Shaft height record for high-torque motors

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Baumüller is expanding its portfolio of high-torque motors with a shaft height of 560 mm.

Baumüller is breaking its own shaft height record with the current expansion of its motor portfolio. With a shaft height of 560 mm, the new DST2-560 high-torque motors are now the largest motors that the manufacturer and pioneer of direct drive technology offers in series production.

High torque for industrial use

With a maximum torque of up to 80,000 Nm, the motors are suitable for use in various industries and systems, such as servo presses, extruders and shredders. The water-cooled high-torque motors offer very high torques even at low speeds and also impress with outstanding true running characteristics, a robust design and a smooth housing surface that is not prone to accumulating dirt.

Powerful and clean alternative for ships

Specifically designed for use in ships, the DST2-560 is optionally also available with so-called wing mounts. These feet diametrically arranged on the outer diameter of the motor make it easier to integrate it into the ship design. In addition, the high-torque motors have already been prepared for approval according to Lloyd’s Register and the DNV GL. With degrees of efficiency of 96% over a broad speed range, the DST2-560 motors are very energy-efficient.

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Module systems with higher performance

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The drive and automation specialist Baumüller is introducing new axis units for its module system b maXX 5000. The new units are suitable for a performance range with a peak performance of up to 240 kW. The entire range of b maXX 5000 devices covers a nominal power range of 1 to 100 kW and thus displays a suitable solution for various applications in machine and plant construction

Safe stackable servo controller

The converter series b maXX 5000 includes feed-in and regenerative units as well as drive units, which can be quickly and easily combined by an integrated drive connect system. For the machine builder and operator this means less installation effort and short start-up and service times. The controllers are available in the air, water and cold plate cooling types and score with minimal assembly space thanks to high performance density. With plug-in modules the devices can be equipped with safety functions according to IEC 61800-5-2. The machine builder can choose from four different modules to adapt the safety functions to his specific application. The plug-in modules enable a fast and flexible reaction to new requirements.

 

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The all-around solution in metal machining

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Everything is turning: AKM servomotors from KOLLMORGEN in CNC multi-spindle machines from INDEX. The MS40C-8 from Index is designed as a CNC multi-spindle machine for large and small production batches.

MS40C-8 is the name given to an eight-spindle metal processing machine from INDEX for fully-automated production of complex components. Yet with double 4-spindle machining, the same machine is also available for cost-effective production of simple parts with double the output quantity. There are a number of good reasons why the CNC multi-spindle machine, made in Deizisau near Esslingen, southern Germany and driven by KOLLMORGEN servo technology, is seen as a true all-around solution in machining technology.
The solution from INDEX is used both in the production of high quantities of precision parts and – due to their shorter set-up times – for smaller batches. “We are pioneers in CNC multi-spindle machines,” says Karl-Heinz Schumacher, head of development and design of multi-spindle machines at INDEX. There are currently several thousand of these machines in use around the world.

Demand for dimensional accuracy
INDEX specializes in both selling standard machines and also supplying fully equipped machinery with all tools assembled. Multi-spindle machines are mostly used for parts that will be on the road at some point in the future. These include injection pump components, valve needles, small gears or injector nozzles – all featuring accuracy levels within tolerance grade IT5.
The centerpiece of the INDEX MS40C-8 multi-spindle automatic lathe is the compact spindle drum with eight fluid-cooled motor spindles using synchronized technology. These can reach speeds of up to 7,000 rpm with 24 kW of power and torques of up to 57 Nm. They feature infinitely variable speed control, high torques, and a compact design; and they require no maintenance. As a result of the increased number of main spindles and tool carriers, the
MS40C-8 is also completely capable of machining highly complex components in a single operation. There are also two pivoting synchronous spindles available, each able to work on up to seven rear-end machining tools, with four of these capable of being powered. The capacity for two rear-end machining tools to work on the workpiece at the same time is a new feature.

Perfect workflows for perfect parts
In all cases, the optimum speed and feed rate can be programmed for each spindle location and each cutting edge, and these can even be modified during the cutting process. The eight fluid-cooled motor spindles integrated in the spindle drum are infinitely variable, require no maintenance, and are driven with synchronous motors. The KOLLMORGEN AKM permanent magnet servomotors are installed in the cross slides. The synchronous machines in the INDEX systems also include the added benefit of high-quality control mechanisms and high torque density. The optimum power-to-volume ratio allows INDEX to work with smaller drives during the design process. Careful use of space is a particular benefit in confined work areas.

High torque density
Plenty of power with minimum space: INDEX uses the KOLLMORGEN motors in part as positioning axes for the tools. The high-power density enables compact designs that take up less space when installed in the work area. The very good torque density of the AKM synchronous servomotors allows INDEX to convert the rotation movement of the motors into a linear motion without gears. The ball bearing spindles are connected directly to the motor shaft for this. “The lack of gears means there are fewer moving parts, and improves the zero backlash and the overall stiffness of the drive,” says Metin Han from KOLLMORGEN. As Key Account Manager he took INDEX´s requirements on board and translated these into a suitable design solution. “We need zero backlash and stiffness, especially with multi-stage thread cutting, so that the tool always completes the next machining step precisely on the threaded attachment,” explains Karl-Heinz Schumacher.

Drives directly in the work area
INDEX uses these features without having to clad the AKM synchronous servomotors in the work area beforehand–a time-consuming process. The AKM servomotors are specially designed to meet the requirements provided by INDEX and undergo extensive IP67 testing in the aim of keeping the work area as orderly as possible. The motors can be installed directly with the cross slides thanks to their special washdown exterior paint. This allows the units to be introduced directly into the machining process without impairing their service life. “That´s a good argument for the AKM servomotors from KOLLMORGEN”, says Karl-Heinz Schumacher. This just leaves the connecting cables. These are also exposed to constant bombardment from metal chips. As a result KOLLMORGEN placed these in a metal cable duct specifically designed to meet INDEX´s needs. Today, this co-engineering initiative securely protects the servo drive, together with its wiring, from the metal chips that fly around and from the cutting oil that gets into the work area at pressures up to 80 bar. Integration standards are maintained even though the AKM synchronous servo motors from KOLLMOREN are perfectly aligned towards the usage conditions in the INDEX CNC multi-spindle machines as a result of the co-engineering project. Background: the motors need to fit seamlessly into the machine´s overall automation mechanism without time-consuming adjustments. The connection via DRIVE-CLiQ is an example of this. This allows the performance benefits of the AKM synchronous servo motors to be used for CNC applications
directly with Sinumerik control units in metal machining, without needing to compromise on the connection technology. Until now, anyone who wanted to use motors from other manufacturers outside these Siemens world proprietary motors had to rely on special and costly DRIVE-CLiQ sensor modules. “DRIVE-CLiQ is available for the AKM motors, allowing us to continue processing the position signals 1:1 without requiring any SMC modules. They cost space and money,” notes Metin Han. “This leaves us free to exploit the performance benefits of the AKM motors in full in this application.”

The Bottom Line
Fitting with DRIVE-CLiQ is an example of how the synchronous servo motors from KOLLMORGEN can adapt to the diversity of CNC and automation technology – particularly for metal machining. This lets machine constructors use drives outside of closed systems, without losing any of the convenience or performance benefits. Very simple adjustments can also be carried out outside of mass production, opening up whole new avenues for INDEX – from gearless use of the AKM servo motors to protection for the connecting cable using a specially developed cable duct.

2. The AKM servo motors have been co-engineered for use at INDEX with a lasered nameplate and special cable duct.
3. “The AKM servo motors are simply compact”: Karl-Heinz Schumacher, head of development and design of these machines at INDEX.

4. The machining centers are very easy to use–a prerequisite for high levels of
productivity.
5. The steel rods are machined in eight different work steps.

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