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Drive systems

Environmentally friendly and field-proven drives for agricultural machines

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Baumüller will be participating in Agritechnica in Hanover from November 10 to 16, 2019. The Nuremberg-based drive and automation specialist will be presenting its motors and systems in Hall 17 at stand H05a. At the trade fair, experts will present their achievements in the conception, engineering and development of individual drive concepts for agricultural technology.

Baumüller is making use of its many decades of experience in developing motors and producing electric engines, supplying energy-efficient components and comprehensive solutions for hybrid and fully electric drive systems. The low-noise, low-emission drive solutions are used in tractors, semitrailers, plowing machines as well as yard and wheel loaders.

Environmentally friendly and powerful alternative to diesel

Electric agricultural machines are a real alternative to diesel-powered vehicles. With their dynamic and powerful driving behavior, electric vehicles master the usual tasks with flying colors and they do this with long operating durations, flexible charging options and minimum noise pollution.

Baumüller’s engineering company, Baumüller Anlagen-Systemtechnik, designs and implements innovative drive concepts for mobile machines and implements them comprehensively, i.e. from battery management and the control system to the user-friendly user interface.

Baumüller equips both main drives and auxiliary drives, e.g. the hydraulic system in the bucket of a wheel loader, with its components and offers the option of integrating the BAUDIS IoT diagnostic and remote maintenance tool in addition to the electric drive system. In this way, necessary service measures can be planned in advance in a targeted way and operating times and loads can be optimally monitored and evaluated. This saves costs and enhances efficiency.

Intelligent drive solutions for agricultural machines

The powerMELA® drive concept, which Baumüller developed especially for mobile use in collaboration with Sensor-Technik Wiedemann GmbH, meets all the requirements for e-mobility thanks to its high power density, its compact and robust construction and its recovery capabilities. It consists of a combination of a permanent magnet synchronous reluctance motor, assisted by embedded magnets and an integrated four-quadrant converter. The compact design is firstly due to the integration of the converter, and secondly the compact construction of the electric motor. The drive’s innovative cooling concept enables an extremely high power density. The drive system thus requires minimum installation space and only weighs around 300 kg for the highest power category, including the motor, converter and transmission. The power density is thereby double that for motors using standard water cooling. With a degree of protection up to IP6k9k and a permissible temperature range from – 40 °C to 85 °C, the drive is especially robust. The motor design is also characterized by a broad speed control range, due to its excellent field weakening capacity.

The motor is available in the 50 kW to 140 kW nominal power classes. Alongside direct use in vehicles, the powerMELA® is also ideal for other applications, such as for trailers. In the higher power categories, a choice can be made between internal and external electronics. The drive can be used as a motor or a generator. Thanks to the extensive decoupling of the operating modes, it is possible to store excess energy, which improves the system’s energy efficiency as well as offering greater flexibility when designing innovative drive concepts.

The powerMELA® duo 280 is the latest drive package. The summation gearbox is designed for commercial vehicles with a power of 160 to 280 kW. It consists of two identical powerMELA C140 synchronous machines, a summation gearbox with speed and temperature sensors and a control unit.

Easy to integrate into existing vehicles and easy to swap with a combustion engine, the drive package is the perfect retrofit solution.

Smart innovations for efficient drives

The powerMELA® drive concept with internally toothed shaft is an absolute innovation. This interface version does not require any other costly transmission elements, such as couplings or pump supports.

This cuts down on costs and optimizes the installation space. For the powerMELA® drive system, this is offered for power ratings of 50 – 140 kW.

One of the major challenges for drive technology is the peak power required, for example, when starting up heavy commercial vehicles or moving heavy work loads and occurring at peak times. In such cases, enormous maximum torques are required to generate the required power and, if necessary, to maintain it. This is why Baumüller’s latest solution combines the powerMELA® drive concept with an internally toothed shaft and a hydraulic pump. Peak power can also be achieved by adding a smaller motor to the hydraulic pump, making it more cost-effective.

The hydraulic pump provides a further advantage. In addition to providing support for the drive, it can also be used for steering and working hydraulics. This ensures that the high power for starting, high speeds and movement of high work loads are implemented efficiently.

The complete powerMELA® system with internally toothed shaft and hydraulic pump can be seen live at Baumüller’s Agritechnica stand and is ideally suited for wheel and telescopic loaders.

Product Highlights

Another highlight at Agritechnica 2019 will be the drive solutions for small mobile applications. The bmaXX mobil is designed with an IP66 or IP20 degree of protection for four-quadrant operation and can not only supply power but also brake in both directions and feed back energy. For mobile use, the water-cooled controller is shock- and vibration-resistant. It can also be used at temperatures between – 25° and +65° Celsius. In combination with compact water-cooled servomotors of type DSP1 and DSD2 with degree of protection IP65, which impress with their high power density and a broad speed control range, they can be used even under extreme temperatures – ideal for mobile machines such as wheel loaders or agricultural machines.

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Drive systems

Motors and Gears for every drive

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KEB Drive Technology – Individually, but in a system

Configure according to the needs of your own application. A modular system for all requirements – and that for motors with an output of up to 45 kilowatts or 13,000 Newton metres. KEB manufactures motors and gearboxes in Schneeberg, Saxony.
“Our roots lie in the geared motor. But in the meantime the servo motor has become one of our most important products”, explains Daniel Lehmann, Product Manager Motors at KEB. By different options, the motors are optimally prepared for the operation with the frequency inverter. An example for this are safe encoders. “Via their space-saving mounting we can guarantee the necessary safety functions”. This also applies to communication with the drive controller.

Fast lane

The modular system allows customers to assemble “their” motor individually. “This enables us to offer a wide range of products and we can help customers flexibly,” says Lehmann. In addition, there is the option of fast production, which offers a kind of “fast lane” for urgent orders in case of time bottlenecks.
This is also possible through the high vertical range of manufacture. From individual housings to turned parts, toothed parts and assembly, everything takes place under one roof. Main industries for KEB motors and gears are for example the textile, woodworking and plastics industry.

Ideally matched

In combination with KEB’s control systems and drive controllers, the motors form an optimized system. “With our KEB system, we deliver very powerful drive solutions”, explains the application engineer.
Managing Director Nils Natkowski and his employees have been manufacturing KEB motors and gearboxes for more than 25 years. In the small town in the Erzgebirge Mountains about 180 employees, work on currently 15,000 square meters. From research and development to design and sales, everything takes place within KEB.
Another advantage: “Due to the flat hierarchy we are always in close contact within the entire KEB Automation Group”, says Daniel Lehmann.

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Drive systems

Intelligent frequency inverters for digital production

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NORD DRIVESYSTEMS provides pioneering drive solutions for networking and connection of an Industry 4.0 environment. With pioneering hardware and software, NORD drive technology enables networked or autonomous production processes of the “Smart Factory” and keeps them running.

NORD drive systems fulfil all conditions for intelligent digitalised production with advanced maintenance concepts and new services. In combination with NORD frequency inverters , all NORD drives can be directly integrated as active components in Industry 4.0 environments throughout the world. The prerequisites for this are the internal PLC as decentralised intelligence and the extensive range of communication options of the NORD frequency inverters. Internal or global networking in the Industrial Internet of Things (IIoT) or connection to cloud solutions is possible at any time and opens up all the opportunities of Industry 4.0. Via their digital output interfaces, the drive units’ frequency inverters can control actuators in conveyor systems or production plants and therefore deliberately affect processes. Analogue and digital external sensor signals and data (e.g. from light barriers, temperature sensors or vibration sensors) can be received, processed and transmitted. Thanks to the integrated PLC that every NORD frequency inverter has on board, the decentralised drives can form master-slave groups that intelligently communicate with each other and take on control tasks autonomously. This supports the central control system and opens up numerous opportunities for a modular system design with production groups and production islands as well as for the intelligent networking of the entire factory up to the “Smart Factory”. Fast, efficient and comprehensive evaluation of analogue and digital data by the intelligent PLC in the drive electronics forms the basis for modern maintenance and servicing concepts such as condition monitoring and predictive maintenance.

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Drive systems

Drives for pallet conveyor technology

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Pallet conveyor technology primarily requires economical drive solutions with high overload capacity. NORD DRIVESYSTEMS supplies optimally matched, individually configurable and flexible drive technology which reduces the number of versions and minimises costs, especially for transporting pallets and cage pallets with roller or chain conveyors.

For simple pallet conveyor technology applications, NORD has developed an efficient drive combination consisting of an asynchronous motor and a NORDAC BASE frequency inverter. This drive solution is specially tailored to the requirements of pallet conveyor technology and provides dependable technology with a robust design. It can be combined with all NORD geared motors and can be flexibly extended according to requirements, or the customer’s specifications. Standardisation results in a reduction of the number of versions. This considerably reduces stocks of spare parts, optimises maintenance and saves costs in the sense of TCO (Total Cost of Ownership).

The three-phase asynchronous motors provide powers up to 1.5 kW and feature high overload capacity, solid workmanship and a long service life. The frequency inverters are installed close to the motor and are equipped with an integrated PLC. The freely programmable PLC processes the data from sensors and actuators, provides diagnostic options and communicates with the higher level controller. A pre-installed software for control, parameterisation and diagnosis is configured for the special drive requirements of pallet conveyor technology.

The drive units can be integrated into all common bus systems. The AS interface or I/O interface are especially suitable as a simple and cost oriented solution for communication in pallet conveyor technology. A different bus system can be used without any problems if there are more sophisticated requirements.

Dependable, flexible, robust and service and maintenance friendly – with the combination of an asynchronous motor and the NORDAC BASE, NORD has created an application oriented drive solution for pallet conveyor technology.

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