October 2020

n TECHNOLOGY October 2020 www.drivesncontrols.com 22 THE ITALIANDRIVES manufacturer Bonfiglioli has announced a modular geared motor platform that, it predicts, will set new benchmarks for reliability and efficiency. The first product based on the Evox platform is a range of helical in-line gearmotors incorporating new high-efficiency (IE3 / Nema Premium) asynchronous motors. They have been designed to operate with a new family of inverters from Bonfiglioli that will act as edge computers to provide sensorless condition monitoring and predictive maintenance functions for the motors. The aluminium-framed CP gear-motors will be available initially in six sizes from 55–650Nm – thus covering up to 70% of the market, according to Bonfiglioli – powered by IE3- efficiency motors from 0.12–15kW. The company claims that they will deliver an average of 8% more torque than similar machines from rival suppliers. By moving from using sub-assemblies to a modular design based on individual components, the motor-maker says that the new platform offers “an order of magnitude” more configurations. Components that can be specified include dynamic brakes, incremental and absolute encoders, thermal sensors and switches. Other options include C3/C4 surface protection, reduced backlash configurations, and Atex explosion-proof versions. The low-noise gear-motors, which are interchangeable with other machines on the market, will be available in either compact (MXN) or IEC flanged (BXN) versions. The new geared motor platform is characterised by a simple, clean design. It is “easier to make complete products smooth and washable” says Alessandro Piscopo, Bonfiglioli’s head of strategic business development. An innovative lubrication system overcomes the need to change oil levels and oil plug configurations, allowing the motors to be used in any mounting position or orientation. A new terminal box with nine-pin connectors uses a single winding for up to eight different voltages on 50/60Hz supplies, making it suitable for the EU, US, Indian and Australian markets. A further six winding configurations cover the rest of the world. The gear-motors will be available either with on-board sensors, or in sensorless versions designed to work with a new range of inverters to provide predictive maintenance functions. Bonfiglioli has developed a mathematical model that relates electrical variables to the thermal behaviour of its gear-motors. This will allow its new AxiaVert inverters to act as edge computers to perform sensorless condition monitoring and predictive maintenance. They will, for example, be able to predict the remaining lives of mechanical components in the gearboxes (as well as components in the inverters themselves). They will also be able to perform real-time diagnostics, duty-cycle monitoring, trend analyses, and energy monitoring and optimisation. www.bonfiglioli.com p NSK has developed an ultra- high-speed ball bearing for use in traction motors designed for electric and hybrid vehicles. As well as allowing the motors to run at higher speeds – a 35mm-bore diameter version can run at 30,000 rpm – NSK says the bearings will improve fuel economy, increase vehicle ranges and enhance comfort. The bearings are filled with a proprietary grease that reduces heat generation at high speeds, prolonging grease and bearing lives, and reducing the risk of seizures. A newly developed cage has retainer tabs that are not only thinner and lighter, but reduce the risk of cage deformation or breakage. www.nskeurope.com p Siemens has developed an app that controls wire tensions when winding electric motors, and minimises fluctuations in force. The Wire Brake software for automated winding of rectangular coils controls the tension of the copper wire. It allows higher winding speeds and a better winding quality to be achieved than with passive systems. The functions can be integrated into a machine project using a library that cuts engineering and commissioning costs. It uses algorithms that include the rectangular geometry of the coil former as well as components to control the wire tension brake axis and to calculate cams using reference values. www.siemens.com/wire p RS Components has now signed up more than one million members to its DesignSpark engineering platform, which celebrates its tenth anniversary this year. Registered members can download free mechanical, electrical and PCB design software. Members can also share projects, connect with other engineers and students, and explore new products. DesignSpark has more than doubled its membership in the past three years and a new engineer joins the platform every two minutes. The design software is opened once every 20 seconds. www.rs-online.com/designspark p The world’s first commercial- scale electric aircraft powered by a hydrogen fuel cell has taken off for a test flight from Cranfield in Bedfordshire. The Piper M-class six- seater plane was converted by the UK-US company ZeroAvia , which has an r&d facility at the airfield. The flight was part of the HyFlyer project, an r&d programme supported by the UK Government, and follows the UK’s first commercial-scale battery-electric flight, in the same aircraft in June. ZeroAvia now hopes to achieve to a 400km zero-emission flight from an airfield in Orkney before the end of the year. Fan-maker takes delivery of IoT-connected, PCB-based motors Gear-motors work with drives to deliver predictive maintenance INFINITUM ELECTRIC, the US developer of a patented technology for producing lightweight, high-efficiency electric motors using a PCB (printed circuit board) technology, has shipped its first motors to an American HVAC fan manufacturer, Comefri USA. Comefri will use Infinitum’s IEs205 10hp (7.46kW) motors to power efficient, space- saving plenum fans designed to deliver more sustainable heating and cooling airflows in commercial and industrial buildings. Instead of the traditional iron and copper wire winding components in a motor, Infinitum uses an IoT-enabled circuit board. It claims that the IE5-efficiency motors are smaller, quieter and up to 50% lighter than conventional designs. The cloud-connected IoT capabilities allow remote monitoring of motor data such as power, speed and temperature. Over-the-air software updates will allow users to add new functions to their motors, enhancing the efficiency and operation of their machines. Infinitum claims that its PCB technology will cut the cost, time and complexity of motor manufacturing. Once it ramps up production, it expects to achieve standard lead times of less than six weeks, compared to the 20 weeks quoted by some rivals. Bonfiglioli is producing its new gear-motors either with built-in sensors or in sensorless versions designed to work with inverters to provide predictive maintenance functions