Berger Lahr IclAIntelligent compact drives

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Contents

Motion Control with Berger Lahr

What is IclA? – Integrated Intelligence

Market trends (demands)

Keyfactors: Compactness and Flexibility

BL Answer: IclA - Product range

Applications - References

Questions and Conclusion

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Motion Control with Berger Lahr

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What’s IclA? – The concept of Integrated Intelligence

Intelligence close to the application Electronic and Motor form a unit Reduction of components,

reduced space in control cabinet, wiring and installation effort

Flexible Integration to customer systems by: 3 different motor characteristics Manifold options as standard

(variance) Fast Track Solution for

individual demands

Intelligent compact-line Actuator

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IclA - Intelligent compact-line actuator

Communication interface:

Profibus DP CANopen RS485 Pulse/Direction

Motor: AC Servomotor, Stepper Motor, DC brushless

Electronic: Positioning control Power stage Motor Feedback Internal Power Supply

> I/Os Power Removal

Additional options: gearboxes Holding brakes Industrial connectors PCB-connectors

24-V signal interface Programmable I/Os Power Removal interface DIP-switches

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Berger Lahr Experience

1999 20032000 20102001 2002 2004 20062005

D0xx – EC Motor

IFS6x Stepper

IFA6x AC-Servo

IFE EC-Motor

IFS9x Stepper

IclA Ixx:

IclA D/N0xx:

N065 – EC-Motor

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Market Trends

Application demands: Decentralization

Continuously Miniaturisation Optimisation of production (flexible product changes)

Increasing Individuality Easy Integration

IclA-Characteristic: Flexibility – easy and fast integration

Compactness – size and integration of motor, electronics and functionalities Modularity – Project Planning, Installation, Set Up and operation

Safety – integration and controlled

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Increasing Individuality

Flexible production of small series requests for new solutions in positioning and drive

technology

Trend in Cost per unit

Batch size

Co

st p

er u

nit

Trend

= kconventionel produktion

= automated produktion

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Optimisation of production (flexible product changes)

Increasing Process reliability by elimination of manual adjustments, >> ristk of wrong adjustments in machine change over

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Fieldbus - Communication

DC-Power 18-36 V

De-Centralized solution:

IclA – Decentralized Intelligence

- Machine - Application

Motion

Controller

Centralized solution:

Electronic

Control Cabinet: Motor Power

Feedback

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IclA Ixx - Product Portfolio

The fantastic four: Motor Characteristics

IFA

AC Servo-Motor

IFE

EC-Motor (BL-DC)

IFS

Stepper-Motor(Fieldbus)

IDS

Stepper-Motor(Pulse/Direction)

Common features:Various power ranges by different motor sizes and supply ranges

Operating modes

Communication interfaces

Programmable signal interface

Connection technologies

Integrated Power Removal

Holding brakes

Gearbox options

Commissioning Tool IclAeasy

Accessory

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IclA Ixx = Integrate it!

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Flexibility – Communication Interfaces

Field Bus interfaces:-

CANopen Profibus DP RS 485

IDS (Stepper): Pulse/Direction interface

Motion Controller or PLC

Ethernet

Pulse/Direction interfaces

RS 485

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Flexibility – Functionalities

Application >> e.g. Pick and Place

500 mm

1.200 mm

Absolut positioning

0

500 mm

Relative positioning

0 700 mm

Positioning mode (Point-to-Point)

v

t

v1v2

v3

Speed profile

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Flexibility – Functionalities

Application >> e.g. cutting material on a conveyor

Electronic gear mode:

NC:200 Incr.

200 Incr.

300 Incr.

600 Incr.

1 : 1

3 : 2

3 : 1

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IclA Ixx - Internal Power Supply

Supply of max. four 24 V-Outputs by the power supply of the IclA (Standard from week 44!) Supply V DC: 24 +- 10% Switching current mA < 200 Energy recovery safe

Alternative (Option) as known – Supplied by an external (separate) Power supply unit

24V - I/0s (4x)

Signal interface:

24V DC

power amplifiercontrol electronics

24V... 36V DC

Power Supply Unit

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IclA Ixx – Integrated Power Removal

Standard in all IclA Ixx Power Removal (=Safe Standstill) integrated safety function Emergency Stop

(EN 60204-1) for Category 0 stop and Category 1 stop

Safety levels in accordance with the standards of functional safety:

SIL 2; IEC 61508 (Functional safety of electrical/electronic/programmable electronic safety-related systems.)

SIL 2; pr IEC 62061 Category 3; EN 954-1 Category 3; pr EN 13849-1

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IclA Ixx – Category 0 Stop

Category 0 stop (EN60204-1) Standstill by immediate power shutdown to the machine drive elements (i.e. an

uncontrolled stop).

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IclA Ixx – Category 1 Stop

Category 1 stop (EN60204-1) A controlled stop in which the machine drive elements are retained to effect the

standstill. Power feed is only interrupted when everything has come to a standstill.

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Integrated Power Removal Benefits

Emergency safety Control function acc. EN 60204-1 Continuous connection to positioning electronic Control over position Reduced Costs for safety components (external power contractors) less space required in the machine

24V..35V DC

24V

24V..35V DC

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Flexibility – Software Tool IclA Easy

Field bus interface for software update & diagnostics Commissioning-Software: Look & Feel

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Flexibility – Connection Technologies

Two different connection technologies are available:

Industrial Connectors:

Generally used in specialised machines and small production runs

Wire to Board Connector:

Generally used in serial machines in with cable harnesses

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IclA® IFA – The Dynamic AC-servo

AC Servo Motor based Closed-Loop controlled drive system High dynamic characteristics High resolution encoder Options:

Holding brake Planetary gearbox

For processes which require dynamicaccelerations, high speed and exact resolution

Max. Torque: 0.40 ... 0.72 Nm Max. Speed: 6000 – 11.000 rpm

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IFA News 2005: new winding variants: /... 3D

IFA61:

IFA62:

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IclA® IFE – The Reliable Format Adjuster

Electronically commutated – EC Motor Closed-Loop controlled drive system Absolute position feedback High detent torque Options:

Spurwheel gearboxes or Planetary gearboxes

For automatic format adjustment –with minimum setup times

Max. Torque: 0,24 Nm Max. Speed: 4.800 rpm Detent Torque: 0,08 Nm

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IclA® IFS – The Strong, Precise Stepper

Stepper Motor based High torque - no need for gearbox Excellent constant velocity characteristics High-resolution positioning Options:

Planetary gearboxes Encoder with index pulse Holding Brake

For short range positioningIFS6x: Max. Torque: 0.45 ... 1.5

Nm Max. Speed: 2000 rpm

IFS9x: Max. Torque: 2 ... 6 NmMax. Speed: 1000 rpm

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IxS9x news: Optional Holding brake

Technical Data:

Protection Class (unit) IP54 EMC Cl. B acc. EN55022

Holding Torque MH: 6Nm Electrical pick-up power: 22W Make Time (release brake): 40ms Break Time (close brake): 20 ms Moment of inertia: 0.2

(kgcm²) Weight: 1,8kg

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IclA N065

New Format setting IclA (Update of IclA D065)

Fieldbus: CANopen DS 402 Planed Market Launch:

1. Quarter 2006 Replacement of D065 ASAP 4 gearbox option:

Spurwheel Wormgearbox Planetary gearbox Angular planetary gearbox

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Application – CD/DVD production cell

Application Requirements: dynamic acceleration, speed, easy integration

Solution: IclA IFA with AC-Servo Benefits with IclA:

Reduced production space (approx. 10%) Increased productivity (approx. 20%)

Field bus: CANopen

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Application – CNC furniture machine

Application requirements: Replacement of manual settings (hand wheels) Fast product changes Save position after switching

Solution: IclA IFE with EC-Motor Benefits with IclA:

Reduction of change over time High detent torque – no brake or gearbox required No referencing required

Field bus: CANopen

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Application – PCB Machines

Application Requirement: Automated Precision Positioning (camera) Repeatable printing quality Field bus communication (8 different drives) Easy integration

Solution: IclA IFS - Stepper Benefits with IclA:

Reduction in size (footprint) “Plug and Play” – no tuning required Precise positioning

Field bus: CANopen

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Applications – References

Printing Wood and Furniture Paper Handling Labelling Textile Electronics Medical technology Material Working:

Rubber, PlasticMetal, Wood,Paper ...

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Perspective IclA® - Product Range (1)

IclA Ixx: Safety Functionality „Power Removal“

>> released in 2005 Internal Power Supply

>> released in 2005 Fieldbus –

CANopen DS402 >> Next Generation IclA Ixx – Beginn of 2008DeviceNet on demand!

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Perspective IclA® - Product Range (2)

IFA – AC-Servo Medium Power:

>> Beginn of 2007 Absolute multiturn encoder

>> Mid 2006IFE/N06x – DC-Brushless Power Extension for IFE

>> in 2006 Wormgear for IFE

>> in 2006 Power Extension for N06x

>> on FTS-Basis from todayIFS - Stepper ATEX certification for IFS 6x

>> 2. Quarter 2006

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Conclusion: Main benefits of Berger Lahr IclA®

Integrated Intelligence at the application: Positioning Electronics, Power Electronics, Safety Function, Internal Power

Supply High Flexibility and Availability by modular variant configuration

for easy integration and individual demands Interference Resistance by internal motor wiring and

high failure detection field bus Little wiring(field bus + power supply). Significant

reduction in costs and installation Significant reduction in control cabinet space No climatisation of control cabinet Significant reduction in floor space

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for your attentionThanks