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Perfect interaction reduces life cycle costs

Integrated Drive System boosts productivity, efficiency and reliability
Perfect interaction reduces life cycle costs

The Integrated Drive System (IDS), a new approach in solutions for drive tasks, was presented by the Siemens Drive Technologies Division at the 2013 Hannover Fair: IDS provides full and reliable integration of the powertrain with different focuses for almost all industries and benefits customers with a high level of productivity, efficiency and reliability.

Technologically, the IDS concept is based on three-fold integration: horizontal integration fine-tunes the components required for the powertrain both to each other and to their intended use in the factory. This is done by drawing on the vast Siemens portfolio of gear units, couplings, motors and converters, which can be combined to optimise the sizing process for the task at hand. The fully integrated Simogear range of geared motors, for example, has a compact design and is suitable for nearly all applications. However, IDS also pays dividends in the highest performance classes. At the recent Hannover Fair, Siemens showed a complex powertrain for vertical mills in the cement industry.

Vertical integration, that is integration of the powertrain into the system architectures of the industrial production processes, is an essential precondition of production with maximum added value. IDS therefore utilises the integration of the powertrain and its components into the Siemens Industry TIA architecture: all TIA components, from the sensor level to the manufacturing execution system, are attuned to each other and enable maximum communication and control.
Lifecycle integration is the third dimension of IDS. Siemens offers comprehensive solutions throughout the factory and process automation lifecycles. At every stage, from design through planning, engineering, commissioning and operation to modern industry services, considerable optimisation potential can be leveraged. This includes not only integration of the powertrain components into TIA Portal but also software products such as Sinasave for evaluating the most energy-efficient drive solution or the DT Configurator for fast selection of suitable products for a customised powertrain.
The three-fold integration system has a number of advantages: the unique portfolio from a single source ensures compatibility and therefore simplified engineering, leaner commissioning and increased reliability of the entire system. Vertical integration additionally provides a high level of monitoring, precise control and hence efficient use of energy, resources and raw materials. Integration of the drive technology into TIA Portal makes engineering, commissioning and diagnostics work much more straightforward. From configuration during the planning phase and the associated simulation through powertrain sizing, including seamless data management as part of the PLM engineering, right up to operation, a whole new dimension in efficiency and reliability is opened up.
Explosion-proof motors
Several new drive solutions for the process industries were presented by Siemens at the 2013 Hannover Fair. The next expansion stage of the Simogear geared motor series comprises unit torques up to 5000 Nm for helical, parallel shaft and bevel geared motors. The performance range has been extended up to 30 kW and the geared motors are now available in efficiency classes IE2 and IE3.
For applications that demand a particularly high degree of precision when positioning, Siemens also offers the gear units in a low-backlash version. Ductile iron housings can be supplied for harsh ambient conditions with high vibration and shock loads. All Simogear gear units will in future be certified in accordance with the 94/9/EC (Atex) Directive for use in potentially explosive atmospheres (Zones 1, 2, 21 and 22).
Siemens has simultaneously supplemented its Simotics XP portfolio with explosion-proof 1MB10 motors which are available in efficiency classes IE1, IE2 and IE3. These motors were designed to drive pumps, fans and compressors and meet all requirements for maximum safety in Ex-environments.
The explosion-proof 1MB10 motors belong to the Siemens Simotics low-voltage range. Dust explosion protected (Ex t) and non-sparking (Ex nA) versions are available. Zone 21/22 (dust) and 2 (gas, vapour, mist) applications are especially common.
The motors cover a performance range from 0.75 kW to 18.5 kW and can be delivered with shaft heights from 100 to 160 mm. The 1MB10 series has an identical design to the 1LE10 standard motors.
Noisy motor for pumps & co
The Simotics HV series is characterised by high output and low noise levels, with a wide selection of cooling configurations ranging from air-water cooling (IC8Xw) and air-air cooling (IC 61x) to open cooling (IC01) for 2- and 4-pole machines. When enhanced with a subcritical design, H-compact Plus motors allow the full speed control range to be used.
The motors are available with 450, 500 and 560 mm high shafts. They constitute a grey cast iron enclosure with optional anti-friction and sleeve bearings. Their efficiency has been increased by 0.4% to 96.5%, leading to remarkable vibration behaviour and a longer lifetime.
The power ratings of the second generation H-compact Plus motors vary from 900 to 4000 kW. The motors can also be ordered with an explosion-proof design for supply voltages from 690 V to 11 kV and Ex nA, Ex p, Ex tc or Ex e explosion protection.
Like all the H-compact Plus modular motor family, the second generation is available in virtually any configuration and can be mounted horizontally as well as vertically. These motors are used to drive pumps, compressors, fans, blowers, refiners, crushers, presses and mills as well as to propel ships.
Drive solution for Ex-certified motors
Siemens now offers a specific drive solution for the process industry in the shape of the Sinamics G180 converter. This drive solution, which is based on the Dynavert T frequency inverter, has now been seamlessly incorporated into the Sinamics drive family under the name Sinamics G180. It is integrated in the Sizer and DT Configurator engineering tools for maximum convenience and easy start-up. With its industry-specific features such as a dV/dT filter, line filter and Atex certified PTC monitoring for Ex-certified motors, this efficient drive is also ideally suited for operating pumps, fans and compressors in combination with explosion-proof motors.
The frequency converter, which is designed according to Namur Recommendation NE 37, has a terminal strip for variable speed drives in the standard version. Thanks to the Atex certified temperature monitoring facility in combination with the “STO” function, it is possible to operate the explosion-proof motor without the otherwise indispensable line contactor. The PTC thermistor installed in the motor winding as sole protection is used for evaluation purposes. Optimised pulse patterns ensure high utilisation of the motor voltage with only minimal additional noise.
The industry-specific version of the variable speed drive covers an output range from 2.2 to 6600 kW at the 400/500/690 V voltage levels (voltage range: 230 V to 690 V). It is suitable not just for pumps, fans and compressors but also for conveyor applications as well as mixers and extruders.
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