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Time for efficiency in electric motors with Voltpro series



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.

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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Shaft height record for high-torque motors



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



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



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
5. The steel rods are machined in eight different work steps.

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