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Servo Motors with maximum torque density

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Dynamic powerhouse added to B&R’s servo motor lineup.

B&R has taken the next step in development of its 8LS servo motors. Three newly designed size 5 motors in lengths A, B and C fill out the mid-range of the 8LS product line. Compared to their predecessors, they offer more compact dimensions and improved thermal design.

High dynamics and strong performance

The new 8LS servo motors motors are highly dynamic and offer a high torque-overload ratio. They are perfectly suited for applications such as plastics processing, printing presses and servo pumps. With a flange size of 142 mm, the new motors deliver excellent torque density. Customers profit from more power with smaller space requirements. They can be combined with any of B&R’s many gearbox options and shipped as pre-assembled motor-gearbox combinations.

Safety included

All motors from the 8LS series are offered with an optional digital encoder and optional safety functions. For the majority of speed variants, motors up to size 7 are also available with a single-cable solution that combines the cables for the motor and encoder. This reduces cabling to a minimum and substantially reduces installation costs.

 

Türkiye endüstrisine, alana özel, spesifik yayınlar üreten MONETA Tanıtım’ın sektörel dergilerinin editörlüğünü yapmaktayım. Yeni nesil, dinamik yayıncılık anlayışıyla, dijital ve basılı mecralarda içerik geliştirmek için çalışmaktayız.

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Motors

Bauer gear motors make a splash at US theme park

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Robust IP68-rated motors solve reliability problems on popular water ride.

Boat rides are a perennial attraction at theme parks around the world. The formula is simple, but effective: passengers start their experience dry, and a relatively sedate pace. By the end of the ride, they have been soaked by spray, thrilled by rapids and – usually – terrified by a seemingly impossible plunge.

At one large theme park located in Williamsburg, Virginia, USA, the climax of its popular boat ride is a 15 metre vertical drop down a 24 metre long chute into a plunge pool. Thrills along the way include scenery that appears to burn and crumble before passengers’ eyes.

The progress of the flat-bottomed boats through the ride’s canal system appears to be magical. In practice, or course, motion depends on sophisticated mechanical and electronic control systems, mainly hidden beneath the water’s surface. Around 100 photo sensors distributed around the ride monitor the progress of boats, and 30 or so submersed, powered, rubber wheels propel them from point to point along the route.

During the early years of the ride’s operation, however, its hidden propulsion system proved to be an Achilles heel. Due to water ingress, the original geared motors driving those wheels were failing within 6 months of operation, requiring the ride to be shut down while replacements were installed. In fact, technical problems meant the ride was closed for almost half of its first peak season – frustrating for customers who were prepared to queue for up to two hours to experience its thrills.

Eventually, the theme park’s owners decided enough was enough. Their search for a more reliable solution led them to Bauer Gear Motor, part of the Altra Industrial Motion Corporation. Bauer’s engineering expertise and highly efficient, modular designs made it a perfect partner for the ride’s propulsion system. Furthermore, with many years of experience supplying gear motors to the water treatment industry, Bauer’s products are proven to be reliable in fully submerged applications.

Chris Macock, Project Manager for Bauer in the US, comments: “After suffering multiple failures it wasn’t surprising that the park owners wanted to find a reliable alternative. Each period of downtime resulted in unhappy customers, lost revenue and maintenance costs – which you don’t expect in a ride’s first season.

Having conducted a site visit to understand the environment in which the gear motors would be located, we were confident that we could supply a solution that would keep the ride operational throughout the year.”

The motor selected to replace the failing units was from the Bauer BG series. These compact, economical gear motors use high-tensile cast housings and can be configured to produce torques of up to 18,500 Nm. They comply with major North American and international technical standards, including NEMA, IEC, CSA and CE.

The modified BG50 units supplied for the water ride feature IP68 gearbox sealing, shaft seals with stainless steel springs and V4A stainless steel output shafts. A WIMES (Water Industry Mechanical and Electrical Specifications) compliant coating was also added to provide an extra level of corrosion protection.

The theme park operator is very pleased with the Bauer solution: there have been no BG Series failures due to water ingress after more than four years of service. Furthermore, while they may not be aware of it, the ride’s customers are pleased too: the enhanced reliability of the Bauer gear motors means they get the thrilling ride they were hoping for on their big day out.

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Time for efficiency in electric motors with Voltpro series

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In this issue we interviewed Mr. Ferudun Özdemir, Director of Sales and Marketing, Volt Electric Motors. As we leave you alone with this interview, we would like to thank the Volt Motor family and Mr. Ferudun who hosted us and answered our questions at Volt Motor stand in ISK SODEX 2018.

Can you shortly describe your company?

Founded in 1966 to produce coils, Volt Motor also started to produce mono-phase electric motors and later tri-phase electric motors as of 1987, taking its place in the electric motor sector.

Volt Motor became an associate of Saya Group in 2011. With 45,000 sqm of production area and more than 500 employees Volt Motor has achieved a product portfolio reaching from type 63 bodies to type 315 bodies and up to 200 kW in power in result of investments in new technology and R&D.

Today, Volt Motor has become one of the largest electric motor producers in Turkey.

As Volt Motor we introduced electrical motors in IE3 efficiency class, the premium energy level, in result of pioneering R&D studies we conducted in order to decrease national energy consumption and to increase energy efficiency. We also produced motors in IE4 class, super premium energy level, with our own R&D efforts and under our own patent.

On the other hand we started producing the most efficient motor of the world with our newest technology and compact series product Voltpro, and we started to offer this product in domestic and international markets.

Celebrating its “30th anniversary” in 2017, the aim of Volt Motor is to continue growing and developing in Turkey, its main market, and to increase its exports to Germany in main as well as other European countries and Middle Eastern countries, on its way to taking its place among top 500 industrial companies of Turkey.

Growing rapidly, Volt Motor continues its journey towards excellence, towards becoming a global company, under guidance of TURQUALITY and EFQM, with world level product and service quality and sustainable success goals.

In scope of its year 2023 vision, Volt Motor advances towards “Powered by Volt” mission with firm steps on the way to its goal to create a “content brand”.

What are the products and services you offer to your clients?

As Volt Electric Motors we produce Asynchronous Motors. We produce two types, comprising mono-phase and tri-phase motors. Our mono-phase models range from type 71 to type 100 bodies and from 0.18 kW to 3 kW in power. Our tri-phase models range from type 60 to type 315 bodies and from 0.18 kW to 200 kW in power. Again, in line with the recent popularity of innovative products, we also started to produce magnetic synchronous motors. This later product is especially targeted towards foreign clients. In addition, now we also offer our new driver application, introduced in Sodex 2018, to our clients through both sales and technical services channels.

Which are the main sectors you provide solutions in?

As electric motors are the initial drive for all revolving mechanisms, as well as providing an element converting electric power into kinetic energy, they are widely used in all fields of industry. Volt Motor provides solutions in many sectors, mainly comprised of pump sector, compressor sector and power transmission and reducer sectors, as well as the agricultural sector where Volt Motor holds more than 50 percent market share in mono-phase motors, and the air conditioning sector which is the subject of the Sodex Expo. Of course, as I mentioned above, our products are used in all fields of the industry.

Can you tell us about your sales and after-sales services?

We conduct our sales through our dealers. We provide our products to our clients through our dealers at every point of Turkey, especially in metropolises where industry is concentrated. In addition to our commercial dealers we also have OEM vendors that buy our products and sell them on the market alongside their own products. They are also large producers in sectors like pump and compressor sectors. We use the OEM sales channel more in foreign areas. We receive more demand for our technologic know-how from foreign clients, therefore the foreign markets, especially Germany is our largest export destination where we concentrate our sales and after-sales service efforts.

What would you like to say about energy efficiency in electric motors?

As you know energy efficiency became mandatory by regulation as of 2012 in the electric motors sector. The Turkish Ministry of Industry made it compulsory to produce and sell electric motors up to IE2 standards in 2012, simultaneously with Europe. The schedule ran like this: production and sale of motors up to IE2 standard would become compulsory as of April 2012. Approximately 3 years after that, in 2015, compliance with IE3 standards became compulsory for electric motor production. This became a requirement for motors above 7.5 kW of power. Similarly, the requirement to comply with IE3 standard in production of motors of 0.75 kW and above in power entered into force on 01 January 2017, in tandem with Europe. Of course we had already made our preparations towards this eventuality in 2012. Currently we are developing our IE4 motor production line with our magnetic series which exceed IE3 requirements. Especially, most of our export volume is comprised of IE4 and higher motors. Even though efficiency development is not as quick as Europe in Turkey, we also offer our IE3 motors in Turkey.

Can you review ISK Sodex Expo for your company?

As Volt Motor we are participating in Sodex Expo for the first time this year. This is the most important exposition event in this sector. It is the most important exposition event in pump and air conditioning sector in Europe and in Turkey. We are very satisfied with this event. We made substantial business partnerships. We have a new demo presenting our new series and the interest it garnered made us very happy. It looks like we will be a constant participant of this event. Both the quality of visitors and the value and care the participants clearly give to the event point out the importance of this exposition. There are many foreign visitors at the event. I never saw an event with so many foreign participants in Turkey before. People attend from all over the world.

Can you evaluate sector development in scope of Industry 4.0?

The sector is interested in embracing innovative products, especially in case of technologic products. The Turkish market is not culturally very used to technology, but we wish to be a pioneer on this front. Electric motor was invented by Nicola Tesla in 1800s, but it has been produced and sold on the same technology for about 150 years. While their contribution to the sector is very large, the energy conversion efficiency of electric motors is substantially low. We wish to overcome this shortcoming with our newly developed magnetic motor series.

Voltpro magnetic synchronous motor series with permanent magnets is a new industrial motor range developed to meet the need in IE4 and higher energy efficiency classes. The greatest advantage of Voltpro product range is the fact that it provides a cost efficient solution by using ferrite magnets in the rotor. Combining fundamental characteristics of two different motor technologies in the motor design, we developed products above IE4 efficiency class with vector drive method. The magnetic circuit of the rotor is designed to create both magnetic and reluctance moment in the motor at the same time.

The magnets are placed in lamination, in a configuration providing suitable projection between d and q axes of the motor.

Major diameter coiling technology is used on stators in order to decrease coil end heights and thus minimise copper loss. As you know major diameter coiling causes high moment fluctuations. These fluctuations are decreased to a level under 15% with magnetic circuit design.

In order to provide high efficiency and suitable moment speed characteristic in all motor applications (pump, fan, compressor, transport, etc.) the motor EMF waveform is in sinusoidal form in line with FOC control. In case of variable speed applications using speed control devices the IE1-IE2-IE3 efficiency class motors can be replaced with Voltpro PMSM series products without any additional cost to provide high gains in system efficiency.

Can you share the projects you intend to implement in the short- and long-term?

Our vision is to produce what is not yet produced but imported in Turkey. This is our starting point. Currently we sell imported drivers, but we plan to combine all elements in the future. First we will learn to sell, then we will try to make. There is a product called servo motor, which is not produced in Turkey, but has a significant consumption. We are taking middle-term steps to produce this type of product. We also have a vision to potentially produce electric car motors. Electric motors might be useless on their own in regard of industry, but they are also the lifeblood for many applications. Our future vision is one we symbolise with the slogan “Powered by Volt”. We hope one day users of pump, compressor or any electric motor application will see and seek the mark “Powered by Volt”. We have our short- and middle-term strategies ready towards this goal.

Would you like to give some last remarks?

The Ministry of Economy has a stimulus program named TURQUALITY, especially targeting export companies for creation of international brands. We can refer to this as a champions’ league of industry, supporting companies seeking the dream of becoming international brands. TURQUALITY is a stimulus program providing significant contributions for corporate and brand development of companies. We are the first and only company to apply for this program from the electric motor sector. After a 4 year preparation period we had our first round of inspections and we are currently waiting to hear the results from the Ministry.

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Motors

Get a first-class ticket to productivity

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High-feed side milling cutters boost ISO S material machining ideal for aerospace industry.

To enhance milling performance on ISO S materials, cutting tool and tooling system specialist Sandvik Coromant is introducing a series of end mills featuring unique geometries and grades. The CoroMill® Plura HFS (High-Feed Side milling) ISO S cutters deliver reliable and productive results on workpieces made from titanium and nickel-based alloys, bringing benefits to both aerospace engine and frame applications.

To help address the predicted growth in aerospace business in the coming years, the CoroMill Plura HFS range comprises two end-mill families optimised for titanium alloys, and one for nickel alloys. As chip evacuation and heat are specific challenges when machining titanium, Sandvik Coromant has developed a solid version for normal chip evacuation conditions, and another featuring internal coolant and a new cooling booster (patent pending) for optimum swarf and temperature control.

The end mills for titanium are available in GC1745 grade, which is based on a tough, fine-grained (sub-micron), cemented-carbide substrate with sharp, controlled edges for very tough milling operations. Furthermore, a new multi-layer coating that contains silicon provides excellent wear resistance and low thermal conductivity. The geometry of the cutters is based on a six-flute concept with no centre cut and uneven tooth pitch. Additionally, the core dimension has been optimised for higher stiffness in titanium alloys, while the corner radius, rake angle and relief are all designed specifically for machining these challenging materials.

For nickel alloys, grade GC1710 is deployed, which also features sharp, controlled cutting edges. A hard, wear-resistant, fine-grained substrate is optimised to resist high working loads when machining hard, highly adhesive, work-hardened materials such as aged Inconel 718. Here, a new coating produced with innovative HIPIMS (high power impulse magnetron sputtering) technology also offers adhesion reducing properties to avoid the formation of BUE (built up edge) and increase tool life.

“The new cutters are designed to offer high-feed side milling with large axial depths of cut (ap) and low radial depths of cut (ae), along with a controlled maximum chip thickness, so that the cutting forces are managed and provide a smooth cutting action” explains Tiziana Pro, Global Product Manager Solid End Mills at Sandvik Coromant. “The result is two-fold: increased productivity provides higher output, while greater tool life and reliability reduces scrap rates in what are typically high-value components. Further customer benefits include reduced tool cost per component and greater safety levels.”

Target aerospace components include titanium wings and pylon parts, as well as engine cases made from Inconel 718. Applications in sectors such as oil and gas, medical and motorsport, where titanium and nickel alloys are becoming increasingly prevalent, will also benefit.

To highlight the potential gains on offer, a customer trial was performed involving an LPT (low-pressure turbine) case made from aged Waspaloy 420 nickel-based alloy. Using a horizontal machining centre, axial depth of cut was increased and radial depth of cut reduced (high radial forces are known to create deflection issues). Comparing a 12mm diameter CoroMill® Plura HFS end mill against a competitor cutter of the same size, metal removal rate increased substantially, leading to an impressive 198% increase in productivity. As a result of this success, the customer has committed to ordering the new cutters from 1 October 2017.

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