Ensure your positioning and synchronization are precise and cost-effective
To optimize performance, applications in food and beverage industries such as conveyors, palletizers and packaging machines, have a need for precise positioning and synchronization. To date, these operations have been performed using servo drives.
The Integrated Motion Controller (IMC) from Danfoss is functionality configurable in the software of VLT® AutomationDrive FC 302, which enables a VFD to perform high-precision positioning and synchronization operations with no need for additional modules or hardware. In effect the VFD becomes a synchronous drive. Usually an encoder is not required.
Motion control is traditionally synonymous with exact position control, velocity control, and acceleration control. Typically, such applications require complex servo solutions or an AC drive plus an additional motion control assembly and an encoder. With the Integrated Motion Controller (IMC) function, Danfoss offers an attractive alternative to servo motion control, which:
VLT® AutomationDrive FC 302 with IMC offers 3 positioning types using different references for defining the target position:
For absolute positioning with sensor less control and closed loop control with an incremental encoder, homing is required. Homing defines the zero point of the machine after power up. VLT® AutomationDrive FC 302 with IMC offers several home functions with and without sensor. In addition, the home synchronizing function can be used to continuously realign the home position during operation, when there is some sort of slip in the system. For example, in case of sensor less control with an induction motor or in the event of slip in the mechanical transmission.
In synchronizing mode, the drive follows the position of a master. Multiple drives can follow the same master thus obtaining synchronization of several axes. The master signal can be an external encoder signal, a virtual master signal generated by a drive or master positions from a PLC/controller distributed by fieldbus. Gear ratio and position offset can be set and continuously adjusted while running.
Thanks to IMC functionality, the VLT® AutomationDrive FC 302 is a competitive performer in positioning or synchronizing applications — with no additional hardware modules required.
The VLT® FlexMotion™ central and decentral servo drive system empowers you to build ultra-flexible machines for smart manufacturing in food, beverage, packaging, and pharmaceutical industries. Would you like to build machines in a smarter way for greater flexibility and performance? And do you experience the need for special motors with maximum precision? Then our modular and multi-purpose servo drive solution may be the answer.
VLT® FlexMotion™ is a modular platform designed to meet the requirements of tomorrow’s machine architecture, today. This single system can create a diversity of machine concepts, based on three servo product lines:
The open system architecture of VLT® FlexMotion™ supports the real-time Ethernet protocols PROFINET®, POWERLINK® and EtherCAT®. Program masters via IEC61131-3 and PLCopen-conformant motion libraries or use the fieldbus specific motion profiles like EtherCAT NC, PROFIdrive or CiA 402. Gateway-free fieldbus communication contributes to seamless communication with less equipment.
After years of working with the food and beverage industry, we understand the need for robust performance based on well-protected construction. Our decentral servo drives VLT® Integrated Servo Drive ISD® 520 and VLT® Decentral Servo Drive DSD 520 are ideal for this purpose. These drives are available with ingress protection ratings up to IP67. A completely smooth and easy-to-clean surface, free of cooling fins or fans, ensures these are hygienically fully reliable and chemical-resistant. Vibration class 3M7 ensures trouble-free operation and renders these drives ideal for rotating machine parts.
To maintain the reliability of synchronization and positioning, drives from Danfoss also provide integrated condition-based monitoring. This functionality uses vibrational analysis of rotating to equip operators with monitoring and advanced diagnostic functions to predict maintenance requirements and optimize.
The data acquisition ability and processing capacity of the VLT® drives means they can correlate their operating parameters in real time — for example speed, current and torque — with the data of other external variables coming from the field, for example by accelerometers.
To thrive in today’s world, you need a food plant that can be scaled up time and time again — quickly and efficiently. Using drives that focus on sensor technology and predictive-based monitoring.
The synchronous speed of an AC motor is determined by the frequency of the source and the number of motor poles. The synchronous speed of a 4-pole/50Hz motor is 1500RPM. Due to slip the real speed of an induction motor will be lower than the synchronous speed depending on the load. VLT® AutomationDrive FC 302 offers very accurate slip compensation ensuring constant speed at varying loads.
To find the right size of VLT® AutomationDrive or servo drive your applications, first confirm the motor full load amps rating. Then select a drive rated greater than or equal to that motor full load rating:
For servo drive applications, select the drive based on the servo motor and movement profile used in the application. The motor datasheet shows the peak and continuous current requirements. Both values are important as these applications typically require a high overload up to 400% for short time intervals.
A variable frequency drive (VFD) can control several motors in applications where appropriate designs and proper protection is provided for each motor. The solution has many advantages including reduced costs and reduced complexity.For servo applications, the VLT® Servo Drive Module SDM 512 (a component of the VLT® Multiaxis Servo Drive MSD 510) is able to run two motors independently. This solution reduces space in the cabinet and reduces costs and complexity.
Yes, VLT® AutomationDrive FC 302 and the VLT® FlexMotion portfolio support multiple synchronous motor types such as permanent magnet and reluctance motors.
All drives in the VLT® FlexMotion portfolio operate on the same DC Link. So, energy can be shared in the system with a smart machine design.
Whatever the environment, the iC7-Automation delivers the reliability and performance you need. With connectivity, security and intelligence, this drive lets you take advantage of the latest in Industrial IoT.
The VLT® AutomationDrive FC 301 / FC 302 is designed for variable speed control of all asynchronous motors and permanent magnet motors. It comes in a standard version (FC 301) and an advanced high dynamic version (FC 302) with additional functionalities.
Motion control and servo drives
Select servo drives and motion solutions, designed to meet the requirements of tomorrow’s machine architecture, today. Uniquely open, modular, and scalable. You get one system capable of creating a diversity of machine concepts, based on decentral and central servo drives.
Easily integrate this modular multi-axis servo system with open system architecture into all kinds of high-performance motion solutions.
Challenged by aging machinery and no time for downtime, AB InBev Hoegaarden® chose Danfoss iC7-Automation and VLT® OneGearDrive®—for high energy efficiency.
DENMARK: Kohberg Bakery upgraded its conveyor line for bread rolls to implement full control with built-in sensors and easy scalability for future adaptability.
AUSTRIA: Motion control is traditionally synonymous with exact position, velocity, and acceleration control. Typically, such applications require complex servo solutions or an AC drive plus an additional motion control assembly and an encoder. With the Integrated Motion Controller (IMC) function, Danfoss offered Bühler Group an attractive alternative to servo motion control.
The 1,000 VLT® drives installed throughout the plant control everything from simple conveyor belts to more advanced applications.
Triple the throughput and decimate the downtime? That’s what the Dutch powder mix provider, Huijbregts Groep, achieved by automation of mixers using VLT® AutomationDrive with wireless PROFINET.
Since upgrading its filling plant to energy-efficient drives from Danfoss, Stiegl Brewery of Salzburg saves about EUR 15,000 annually in maintenance and energy consumption.