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Electric Machines Portfolio: Enhancing Performance and Efficiency

Explore the latest developments in electric machines for various applications. Learn about specific features, maintenance tips, and improvement potentials for optimized functionality. Stay updated on new releases and industry requirements.

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Electric Machines Portfolio: Enhancing Performance and Efficiency

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  1. Modifications e-motion R. Brandstetter / 02/2010

  2. Electric machines - Portfolio S … Standard H … High P … Premium

  3. Roadmap electric machines • EM-T 50: mechanical platform of EMX and EM-T will be reviewed • EM-T 100: Prototype release march 2010 • EM-T 180: New development of a EM-T 200 because of new (market-)requirements • EM-T 225: Canceled, will be covered with EM-T 200 & EM-T 280 • EM-T 280 .. 500: medium term adapted to KEBA & BRC (cost potentiales) • EM 55 .. 150: currently no development planned • EMX 180: Optimizing will be checked

  4. e-motion (Tiebar less) e-motion T (Toggle) e-victory (Hybrid) e-max (Toggle) Electric machines – Clamping units

  5. IN-LINE 50-440 TWIN 740-1640 DIRECT DRIVE 2440-7440 Electrical machines – Injection units

  6. 3440 ! Electrical machines – Injection units Injection speed in [mm/sec]

  7. Watercooled Servo motor for Plasticizing Direct driven spindle for Injection (2 motors– watercooled) Ball spindles for injection (Closed lubrication system – no grease) Direct Drive Unit 2440 (3440)

  8. Direct Drive Unit 2440 (3440)

  9. Direct driven spindles for injection (4 motors – watercooled) Direct Drive Unit 5540 (7440)

  10. Concept e-DUO • Direct-Drive Injection unit • Injection: 2/4 Servo motors/spindles (depending on injection unit size) • Plastizicing: Servo drive • Carriage unit: 2 spindles – 1 Servo motor) • Mould movement • 2 Spindles with each one servo motor • Tiebar locking via 2 asynchronous motors • Ejector • 1 Servo motor/spindle • Clamping force • Hydraulic aggregat built into the frame

  11. Electric machines – „Specific features“ • Ejector • Stroke not calibrated • Mass inertia lead to damage • eg: Standard ejector EM-T 380 (vmax = 222mm/sec, Fmax = 70kN) • 6,2mm up to stand still at max. brake torque • if non-braked to mech. stop • v = 100%: 480kN !!! • v = 50%: 120kN !!! • Thermal Overload • Set-up mode!!! • Option: Spring loaded Ejector coupling

  12. Electric machines – „Specific features“ • Ball threaded spindle failures • General • Overload (Force, temperatures) • Alignment failure • Less lubrication • Injection spindle • at Twin unit (Inline unit without problems) • => Observe work instruction (QW-AA-P01-003) • Clamping- & Ejector spindle • Alignment of the spindle • Observe work instruction (QW-AA-P01-032) • Activities • Qualifying of suppliers (NSK, Umbra, HiWin) • Early recognition of spindle damages (noise, surface, grease color, temperature (< 70°C), lubrication function) • Exchange oil 1x/Year at oil lubricated spindles

  13. Electric machines – „Specific features“ • Ball threaded spindle failure – Adjustment Calibration position offset motor 2 Calibration position offset motor 2 = Motor angle – Motor angle 2

  14. Electric machines – „Specific features“ • Ball threaded spindle failures • General • Overload (Force, temperatures) • Alignment failure • Less lubrication • Injection spindle • at Twin unit (Inline unit without problems) • => Observe work instruction (QW-AA-P01-003) • Clamping- & Ejector spindle • Alignment of the spindle • Observe work instruction (QW-AA-P01-032e) • Activities • Qualifying of suppliers (NSK, Umbra, HiWin) • Early recognition of spindle damages (noise, surface, grease color, temperature (< 70°C), lubrication function) • Exchange oil 1x/Year at oil lubricated spindles

  15. Electric machines – „Specific features“ • Belt topics (esp. carriage unit) • Recently increased belt crackes • Mainly on carriage unit • Reason open (Plastic material, overload, etc. ?) • Belt tension • Belt must be not retensioned • In repair the tension must be measured before and set after the exchange to the same value • Activities • Yearly visual check according maintenance manual ! • additional increased check during service missions ! • => Observe work instruction(DP-AA-P01-034e)

  16. inlet outlet Electric machines – „Specific features“ • Lubrication optimized toggle lever • Concept • Flow-through lubrication with oil in- / outlet in the bolt • Problem • Particle emission at fixed bearing positions • No functional interference • Activities • clamped intermediate crank as improvement

  17. Max. power (short-term) Construction range (60% - 80%) Thermal permanent curve Electric machines – „Specific features“ • Thermal limitationed cycles • Incraesed with long holding pressure time with high pressure • Problem regards to all el. axis

  18. Holding pressure characteristic – Standard cycle Basis : short cycle 6 sec Screw DM 40 mm

  19. Max. holding pressure with unlimited holding time

  20. Improvement potential error analyses • Exact error description • Actual status report (machine in error situation) • Exact description of the error situation • History of the error • Error frequency, problem repeatable • Recording with graphic program (Oscilloscope) • PDP Recordings • Screenshots • …

  21. Oscilloscope • Predefined profiles are since software version 1.20 available (HD0:\DATA), but in the program oscilloscope is no access prepared to this directory. The profiles can be read only from HD1. Starting from V 2.0 it is possible to access the directory HD0:\DATA direct in the oscilloscope. • Solution V 1.20: copy the files (*.swo) to HD1 with KVS-Explorer • 3 possibilities to store the measurement: • Export in BIN-format (can be only read back and displayed in a machine) • Export in txt-format (can be opened and handled with MS-EXCEL) • Hardcopy

  22. Exercise 1 - Oscilloscope • Measure the following signals during the nozzle movement forward: • Nozzle position actual value • Motor servo speed set value • Motor servo speed actual value • Motor servo moment set value • Motor servo moment actual value • Nozzle contact pressure actual value • Export the measured curves in BIN- and TXT-format to forward them to the Engel service department

  23. Solution exercise 1 - Oscilloscope

  24. Exercise 2 - Oscilloscope • Problem: • Mould is closed, clamping force is built up, after a few minutes it is no more possible to open the mould (in set-up mode too) • Measure the relevant signales and export the measured curves in BIN- and TXT-format

  25. Solution exercise 2 - Oscilloscope

  26. Danke / Thank you

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