Drives (VFD) for positioning and synchronization in food and beverage

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.

Advantages of Integrated Motion Controller

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:

• Reduces costs and system complexity: Fewer components required in the system
• Works with all conventional motor technologies with closed loop or open loop control with no need for additional hardware
• Eliminates the complex programming required for many servo drives: The required functionality is pre-programmed into the drive
• In many cases, eliminates the need for encoder feedback: In open loop, the FC 302 drive equipped with IMC can perform many of the synchronization and positioning tasks which would normally require an encoder

IMC offers three types of positioning

VLT® AutomationDrive FC 302 with IMC offers 3 positioning types using different references for defining the target position:

• Absolute positioning where the target position is relative to the defined zero point of the machine
• Relative positioning where the target position is relative to the actual position of the machine
• Touch probe positioning where the target position is relative to a signal on a digital input

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.

Synchronization made easy

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.

VLT® FlexMotion for servo precision

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:

• VLT® Multiaxis Servo Drive MSD 510
• VLT® Integrated Servo Drive ISD® 510
• VLT® Decentral Servo Drive DSD 510

Advantages of VLT® FlexMotion

• Ultimate freedom: One system caters for central and decentral servo motion solutions
• Scalable concept: Each module allows machine builders to sustain maximum flexibility in case the need arises to add a new line, or extend an existing line with additional drives
• Open platform: Compatibility with all standard technologies gives you free choice to use your preferred communication protocol and your preferred motor type
• Low complexity: Ease of mounting and commissioning
• The highest safety and quality standards: Fast and fail-safe with click and lock mounting, streamlined cabling, and intelligent user interface
• Reliable performance: Built-in vibration resistance, ingress protection up to IP67, easy to clean surface all help to keep
• Time-saving: the modules are virtually maintenance-free and no tools are required for mounting hybrid cables. Built for reliability with high-quality bearings, the only spare part needed is the shaft seal.

Choose your preferred protocol

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.

Resistance in demanding environments

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® 510 and VLT® Decentral Servo Drive DSD 510 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.

The central role of intelligent drives

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.

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.