November/December 2019

Drive condition-monitoring technology uses on-board PLCs to perform predictive maintenance n TECHNOLOGY TECHNOLOGY n November/December 2019 www.drivesncontrols.com 26 THE GERMAN sensor-maker Sick has unveiled a second generation of smart motor sensors for servodrives that support its Hiperface DSL single-cable feedback system, with the claim that they represent a “step-change” in resolution and dynamic performance. The EDS 35 single-turn and EDM 35 multi- turn encoders incorporate a newly-developed optical system with dual-channel scanning that achieves 24-bit resolution per single-turn revolution, as well as a 12-bit mechanical gear design that enables up to 4,096 revolutions for the multi-turn system. The new encoders have been developed “from ground up” to fit into servomotors with frame sizes from 40mm, offering new opportunities for integration into restricted- space applications where precise speed regulation and control are critical – in printing, packaging or machine tools, for example. “This brand-new encoder design achieves a factor of two increase in performance capability, compared to our first-generation Hiperface DSL products,” explains Darren Pratt, Sick’s product manager for motion control sensors. “Capable of collecting, evaluating and transmitting digital data via the single-cable system, these encoders become true smart motor sensors delivering invaluable diagnostic feedback, right from the heart of the machine.” The encoders are wear- and maintenance- free, and resistant to shocks and vibrations. They offer the option of SIL 2 / PL d certified safety for safe speed monitoring and safe single-turn absolute positioning. As with other Hiperface DSL encoders, the new devices can record speed, temperature and revolution data, supporting the development of preventative maintenance programmes both for the servodrive and for the machine itself. Since the Hiperface DSL technology was launched in 2011, it has been adopted by many manufacturers of motors, servo controllers and drive systems, including ABB, Beckhoff, SEW Eurodrive, Lenze and B&R. “One of the greatest advantages of Hiperface DSL is in the savings made using a single-cable technology,” says Pratt. In the packaging industry alone, he points out, around 300,000 servodrives are built into new machines every year. With an average motor cable length of around five metres, the technology has the potential to save the industry 1,500km of cable every year. “The saving is not just financial,” he adds, “but also environmental, in the form of reduced use of copper and plastics and also reduced energy consumption as the weight of drag chains is also reduced.” The EDS/EDM 35 encoders are Sick’s fourth motor feedback sensor family to support Hiperface DSL. www.sick.co.uk New-generation smart motor sensors ‘double performance’ +44 (0)161 432 7824 mail@baumuller.co.uk www.baumueller-services.co.uk be in motion 24 HOUR SUPPORTLINE Baumüller UK Your Partner for Industrial Service Solutions OEM DC/Servo Motors & Drives Full Field & Workshop Support All makes of Large AC/DC Rotating Equipment Repairs 40 Tonnes/10MW/11KV Repair & Supply of LV Motors, Inverter Drives, Pumps and Gearboxes In-situ Motor /Alternator Health Checks & Service Full Laser Alignment Condition Monitoring & Troubleshooting SERVICES & CAPABILITIES The UK’s Leading Authorised Service & Parts Centre Sick’s new generation of smart motor encoders offer twice the performance of the previous generation NORD HAS developed a condition-monitoring technology that uses PLCs built into its frequency inverters and motor starters to pre- process data which can then be used for predictive maintenance, avoiding the need to perform maintenance at fixed intervals. One of the system’s functions is to determine the optimal time to change oil in gearboxes based on a“virtual measurement”of the oil temperature. Real temperature sensors are not needed because algorithms running on the PLC calculate the oil temperature continuously based on drive parameters. The system also uses data from hardware sensors such as vibration sensors, and temperature sensors in the motor. Customers’ analogue or digital sensors can also be connected to the system. As well as pre-processing the drive parameters and evaluating drive conditions, the on-board PLCs can also provide access to industrial Ethernet or fieldbus data, and be used to implement application-specific tasks. Nord’s Nordcon software offers intuitive parameterisation and programming of several drives, as well as multi-axis access via Ethernet. It includes an IEC 61131-3-compliant PLC editor that supports structured-text programming. There is also an app available, which provides dashboard-based visualisation of drive activities and faults. www.nord.com