VFD technology for waste disposal.

The amount of waste produced in the meat processing industry can be considerable and costly in terms of production and disposal of the material.

A meat processing company has worked with Engefi Engenharia Eficiente Ltd to create greater speed control over its compactor, allowing for changes in the incoming quantity and type of waste. Engefi developed a solution that could be integrated into compactors using Optidrive E3 variable frequency drives (VFD).

Waste compactors are one way of continuing production without the need to stop to remove waste at intervals from containers or skips within the production process. By compacting the waste it can also be removed and handled more easily and safely for disposal.

“The existing compactors worked well but having greater control of the operating speed meant it could mirror production levels and the type of meats and waste being used,” said Marcus Silva, Head of Sales, Latin America.

“By matching the compactor’s speed to production levels and the type of product, created a faster process with less downtime. The compacted meat also takes up less room, making it easier to handle and dispose of. This provided added safety for staff involved in the production and disposal processes.”

An Optidrive E3, Frame Size 3 with an IP20 enclosure is being used in the application. Its compact size meant it could be easily installed into the panel, as well as being able to handle the environmental conditions.

The 380V, 3PH, 24A, drive was more than capable for the application. It will now be used on other compactors operated by the company.

Denner Ferreira of Engefi, said: “There were several factors in choosing the Optidrive E3 for the application. The first was reliability and ease of use. We needed a VFD that could operate in the production environment and could be easily set up. The Optidrive ticked all these boxes.

“Additionally, its compact size and robustness made it ideal for such an operating environment. It could also be easily installed into a smaller panel, taking up less space.”

The Optidrive E3 provides simplicity of installation, connection, and commissioning, allowing the user to benefit from precise motor control and energy savings within minutes.

@Invertek_Drives #PAuto #Waste #Brazil

Green go-kart in education!

At the University of Southern Denmark (SDU), engineering students are taught electronics and challenged with real-life industrial equipment driven by electric motors and drives manufactured by Nidec.

SDU gives young engineering students an opportunity to be part of developing the green technology of the future in a creative study environment with modern teaching facilities and dedicated teachers.

The students have access to a genuine go-kart 

The use of high-tech technologies in the form of real-life industrial equipment and advanced electronic techniques is an important part of the teaching and education of Denmark’s future electronics specialists. As part of the teaching projects, the institute and the students have access to several advanced electronic test benches, which gives them a good insight into the handling, testing and research of different combinations of industrial electronic equipment and teaches them to test torque, speed, load, etc. under realistic conditions.

The test benches combine different set-ups of advanced variable speed drives and high-tech electric motors, which have the flexibility to test a wide variety of electronic equipment. The test benches use Nidec Leroy-Somer motor units (servo motors, LSMV and IMfinity induction ranges) and Control Techniques Unidrive M600/M700 drives.

Each semester, the electronic engineering degree programme includes project work on a current topic, for example how to design the electronic controller of an electric go-kart motor. In the course of the project, the students work with the design of variable speed drives, programming, modulation and simulation of the drives as well as the design of electronic hardware. The students have access to a genuine go-kart with an electric motor as well as a corresponding test bench with programmable drives and electric motors.

All in all, the realistic project provides useful knowledge and intuitive understanding of the control of electric motors, which can also be used in connection with variable speed drives for electric cars,
robots, etc.

 @NidecMotorCorp #Education #Green #Denmark @SyddanskUniv

Variable speed drives.

WEG has expanded its CFW500 series of variable speed drives (VSDs) to enable users in a wide range high-power applications achieve further energy efficiency. The new E frame size for the rated power range 18.5 kW - 22 kW is a great fit for applications such as mechanical engineering systems for conveying, turning, hoisting, pumping and ventilation.

“In light of EN 50598, the new standard looking at Ecodesign for power driven systems and their applications, an integrated approach to electrical drive technology is becoming more widespread and VSDs are particularly sought after across broader sections of the industrial market,” says Johannes Schwenger, Head of Product Management Low- and Medium-voltage Drive Systems Europe at WEG. “As a leading manufacturer of both electric motors, drives and automation components, we can supply optimally matched motor and VSD packages that help boost energy efficiency and offer outstanding value for money.”

With a plug-and-play user-friendly design, the CFW500 VSDs feature an integrated micro PLC with pre-programmed macros for positioning, timing and acceleration functions. They can be programmed locally with the convenient LCD display or externally with a computer over a variety of interfaces, including CRS232, USB and CRS485. Users also can download the corresponding SuperDrive G2 programming software from the WEG website free of charge.

The VSDs are designed for fast installation and easy operation. The numerous plug-and-play modules are ideal for distributed automation architectures and can easily be connected to all common fieldbuses, including Profibus DP, Profinet IO, Ethernet IP, DeviceNet, CANopen and Modbus RTU. Individual adaptations to specific customer requirements can also be easily implemented thanks to additional plug-in extension modules.

@weg_wr #PAuto 

Boosting sugarcane delivery at Thai plant.

A Control Techniques Unidrive M600 variable speed drive is helping a major sugar plant in Thailand to guarantee the efficient delivery of sugarcane between processes.

First established in 1946, Mitr Phol Sugar Corp is the largest sugar producer in Thailand today, the biggest in Asia and the world’s fourth largest, producing 2 million tons of sugar a year from its various plants. To help produce this much sugar, Mitr Phol has to process around 20 million tons of sugarcane. At its Phulaung plant (in northeast Thailand), the company recently opted to replace the drive on its principal variable speed sugarcane conveyors to help meet demand.

“We have used various drives for this application in the past, but were attracted to the closed loop control of the Unidrive M600 with SI-Encoder module, as well as the low harmonics,” explained Mr Wanchai, the plant’s electrical & automation manager.

The SI-Encoder module features incremental encoder input to provide closed loop rotor flux control for induction motors (RFC-A) in Unidrive M600 applications.

“This is vital as the equipment is conveying sugarcane to each process station, including the crushing station,” said Mr Wanchai. “We need to run at full capacity, particularly during September to March, which is when the sugarcane comes into season. Any downtimes during these months can very damaging to the supply of sugar in the off-season.”

Another principal reason for selecting Unidrive M was its task-based commissioning, diagnostics and maintenance, which in turn helps minimise downtime at high-volume plants such as Mitr Phol.

“Unidrive M600 allows us to greatly enhance performance. For instance, we now have better overload torque (180% for 3 seconds) in RFC-A mode. Moreover, we reduced downtime from 1-1½ hours to just 30 minutes by using Control Techniques’ commissioning software tool Unidrive M Connect.”

Unidrive M Connect is the latest drive configuration tool from Control Techniques for commissioning, optimising and monitoring drive/system performance. It uses graphical tools that enhance and simplify user experience, although, for experienced users, dynamic drive logic diagrams and enhanced searchable listings are also present.

“We received highly responsive technical support during of pre-sales and after-sales from Control Techniques and local partner Contrologic throughout the process,” concluded Mr Wanchai. “We certainly plan to incorporate additional products from Control Techniques into our business moving forwards.”

@EmersonIndAuto  #Pauto @Emerson_News #Food

High power modular drives.

Control Techniques has extended its range of high power modular drives. Both its Unidrive M and Powerdrive F300 variable speed drive ranges are now available in the larger frame size 11, providing a flexible method of building compact, reliable high-power solutions.

Paralleled together, Unidrive M can control asynchronous and permanent magnet motors in systems up to 2.8 MW (4,200 hp). The new frame 11 is a 250 kW (400 hp) module that allows system builders to create high power solutions with the smallest number of components, keeping both footprint and costs to a minimum.

Unidrive M differentiates itself on performance with extremely fast current control algorithms and high switching frequencies. Active Front End (AFE) solutions deliver unparalleled torque precision and power quality.

The Unidrive M modules can be paralleled into a wide range of flexible solutions to solve all system needs including Active Front End and multi-pulse rectifier configurations. They can be controlled by Control Techniques’ Unidrive M600, M700, M701 and M702 controllers.

Control Techniques also offers a full range of high powered drive products tailor-made for fan, pump and compressor applications from 90 kW to 2.8 MW. The Powerdrive F300 series also features a modular design and can control permanent magnet or standard AC induction motors. This modular approach to building high power systems also provides the flow industry with flexibility while keeping complexity low.

@EmersonIndAuto  #PAuto #ControlTechniques

Drives commissioning from anywhere.

When Newton Tesla sets up new variable speed drives for their customers, they can do configuration, re-programming and monitoring from any location. By connecting the HMS Netbiter gateway to their drives systems, they can offer their customers immediate assistance and do remote commissioning during the critical start-up period.

Newton Tesla drives control and Netbiter

George Newton in action commissioning cranes 

at a customer site

Newton Tesla is one of Britain’s leading experts in variable speed drives and a supplier of advanced automation systems to factories and plants across the world. Specializing in Mitsubishi products, they have been working with drives and inverters since 1987.

When commissioning an automation system, it is often hard to solve everything in one go. Usually, there are certain processes you have to wait for or other systems that need to be installed before everything is 100% finished. That means that you often have to go back to the site several times resulting in expensive and time-consuming service trips.

Another issue is physical access. George Newton, Managing Director at Newton Tesla and drive system expert explains: “At some sites, we need special permits or have limited access to our drives. For example, we recently built a system for a silver and platinum processing plant in America. Security was so tight that our mechanical commissioning engineer could not take any tools, mobile phone or even his laptop into the area. This makes on-site commissioning a challenge.”

To get access to their drives systems remotely, Newton Tesla had been looking for a remote management system for some time, but no system had quite lived up to their demands.

George Newton continues: “I always had the fear that a remote management system would be complex — that it would be hard to establish a connection and, above all, that the connection would be unstable which could really be a problem if you are programming a PLC. But when we found Netbiter, it was surprisingly easy.”

How it works
When Newton Tesla delivers a new drives system, they connect a Netbiter EC350 gateway to their Mitsubishi PLC which controls the drives. The Netbiter communicates via the cellular network and sends data from the PLC to the cloud-based Netbiter Argos service. By logging into the Netbiter web site, Newton Tesla can see data such as operating frequency, running hours, energy consumption and much more.

By using the function called “Remote Access” they can also use the gateway to establish a secure data tunnel to the PLC, through which they can debug, program and commission the drives system. They simply open the tunnel, and can then access their Mitsubishi PLC, just as if they were connected on site.

Connection stability important
When programming a PLC, you do not want the connection to go down as it can corrupt your programming and cause the system to malfunction. So naturally, connection stability was a main concern for Newton Tesla. “The Netbiter connection is really robust which is very important for us,” says George Newton. “In fact, I have so much confidence in the connection that I even operate our drives remotely. On a recent project, I moved a crane to a specific position from the office, being confident that the connection wouldn’t be interrupted.”

Quick return-on-investment
The first time Newton Tesla used Netbiter in a customer project, was when they shipped a system to a customer in Phoenix, Arizona. After the initial set-up on site, they could handle the rest of the commissioning remotely from the office in Warrington (GB). “Naturally, the Netbiter quickly paid for itself on the Arizona project, but the return-on-investment is quick even if the customer only is a few kilometers away,” says George Newton. “If you calculate the costs for a service engineer to get all the gear ready, take the car to a customer and connect everything on site, you quickly realize that even a short service trip is costly.”

Nowadays, Newton Tesla always equip their systems with a Netbiter EC350 gateway. Since the Netbiter itself is quite easy to connect, this process can be done by someone who isn’t a PLC programmer, giving the PLC programmer more time to focus on the system itself. “Netbiter has given us the convenience of not having to travel to the site every time we need to adjust a system. It has given our offering an edge since we can spare our customers expensive service trips and offer faster support and commissioning,” finishes George Newton.

@hmsnetworks #IoT #PAuto  @newton_tesla @HMSAnybus

Variable speed drives for low-power motors.

WEG has launched a new cost-effective, reliable and easy-to-use series of compact variable speed drives (VSDs) to enhance energy efficiency across a wide range of applications requiring low motor power. Designed to drive motors with power from 180 W to 4 kW, the CFW300 series is ideal for relatively small machinery such as centrifugal and metering pumps, fans and ventilators, stirrers and mixers, extruders, roller conveyors, cutting machines and rotary filters.

“WEG is committed to boosting energy efficiency across a broad range of industrial applications and has launched the CFW300 to meet the needs of those sections of the market where the demand for inverters is growing, even when it comes to relatively small industrial applications,” says Johannes Schwenger, Head of Product Management Low- and Medium-Voltage Drive Systems Europe at WEG. “With the addition of the CFW300 series to our existing range of drives, which include the CFW100 Mini Drives and the CFW500 VSD series, WEG now boasts a comprehensive VSD offering for industrial requirements.”

Easy to use and maintain, the CFW300 features an integrated micro PLC and a user-friendly control panel with LCD display. Installation is also easy and quick thanks to plug-and-play extension modules and the drive unit’s fan can be easily removed for maintenance.

The CFW300 has two slots for extension modules - one for communication and the other for a wide variety of I/O modules. This enables users to integrate RS485 or RS232 interfaces and use Modbus RTU, Bluetooth or USB communication protocols. The VSD can also be connected to fieldbus systems such as Profibus DP, CANopen or DeviceNet, or configured for operation under remote control. An Ethernet IP interface is also available. As such, it provides increased flexibility and high levels of connectivity to best fit users’ needs. Other accessories include a plug-in EMC filter, which can be connected to the VSD quickly without tools or wiring and mounted on the top-hat rail.

Designed to operate at ambient temperatures up to 50°C without derating, the CFW300 is equipped with independently acting, integrated thermal protection functions for the motor (electronic motor circuit breaker) and the drive. In addition, the drive has varnished circuit boards (IEC 60721-3-3, category 3C2), for enhanced corrosion resistance, which contributes to longer service life, while an optional flash memory card enables optimal storage and convenient loading of parameter data sets.

The CFW300 will initially be available in frame size A for rated power from 180 W to 1.5 kW and frame size B for rated power from 2.2 to 4 kW. It will provide supply voltage flexibility with versions for single-phase and three-phase power. The single-phase version can also be powered directly from a DC supply connected to the DC link, in order to drive three-phase induction motors from a DC power source.

@WEG_Europe  #PAuto

Drives designed for high speeds

The Control Techniques variable speed drive range has been expanded by Emerson with the addition of two new models designed specifically for applications which demand high speeds.The Unidrive HS30 and HS70 variable speed drives, capable of output frequencies of 3,000Hz, are perfectly suited to high speed applications frequently required for automotive & aeronautical engine and transmission line test equipment, machine tool manufacture and centrifuges for the food & beverage and oil industries.

Unidrive HS70 and HS30 are essentially designed with the same specifications as the standard Control Techniques Unidrive M700 and Unidrive M300 variable speed drives, however, unlike the Unidrive M models, HS30 and HS70 have been engineered specifically for high speed applications.

The new drives are controlled products under new laws in the EU and USA covering the export of ´dual use´ goods, software and technology. This refers to items normally used for civilian purposes but which may have military applications, or may contribute to the proliferation of weapons of mass destruction.

OEMS and machine builders which incorporate high speed drives in their designs are responsible for checking and evaluating whether or not their machines comply with, or contravene, the relevant legislation. In order to assist its customers, Control Techniques has introduced the Unidrive HS range of high frequency variable speed drives.

Unidrive HS70 offers class-leading induction, permanent magnet and servo motor performance, with on-board real time Ethernet. It provides maximum control of high speed motors and incorporates an on-board Advanced Motion Controller and PLC. Different variations of Unidrive HS70 are available, including models with on-board Ethernet, RS485 and Dual Safe Torque Off (Dual STO).

Unidrive HS30 is designed for applications that require cost effective integration into safety systems and incorporates Dual STO and advanced Rotor Flux Control of open loop induction motors.

The existing Unidrive M models, which are restricted to a frequency of 550Hz, are uncontrolled products in the eyes of the new laws in the EU and USA restricting the sale of variable speed drives with an output frequency of higher than 600Hz. This means no export restrictions reply.

In order to comply with the new legislation, businesses which export goods or machines that incorporate goods classed as dual use under the terms of the EU regulation to locations outside the EU must apply for the relevant export licences from their respective governments. The changes also have an effect on the documentation required in any transaction, as well as the measures which are taken to securely store the controlled goods.

Variable speed drives improves the quality of glass ovens.

A leading manufacturer of glass tempering ovens has turned to the Unidrive M family of variable speed drives from Emerson Industrial Automation to greatly improve the quality of its products. Glaston America, (NJ USA), has established a strong reputation for excellence serving both the commercial and residential glass markets. The company´s biggest customer is Cardinal IG, a market leader in the manufacture of residential glass. To ensure its glass tempering ovens meet the demanding requirements of high profile customers, every effort is made by Glaston to maximize quality.

A recent case in point saw the company address the issue of tiny scratches that can occur as a result of the glass being tempered without precise speed control on the oven´s drives. To overcome the challenge, Glaston researched the market for an alternative to its existing drives supplier.

"The solution arrived initially in the shape of Control Techniques' Unidrive SP drive because of the flexibility of programming and option cards for feedback and communications," explains Cliff Matukonis of Glaston America. "However, we soon migrated to the Unidrive M701 as its new features and functionality better suited our needs. The integration of PROFIBUS communications and application modules for increasing the drives' flexibility was also crucial in our decision."

Led by the results of extensive customer-driven market research, and designed specifically for manufacturing automation applications (Emerson Industrial Automation's traditional area of expertise), each Unidrive M model suits specific application needs. For instance, the Unidrive M701 series drives now preferred by Glaston offer benefits specific to sectors such as ovens and heat treatment equipment.

A total of 14 Unidrive M701 drives with SI-PROFIBUS are now deployed in the company´s glass tempering ovens, one for each roll section. Rollers pass glass through various oven sections to be treated and then through a cooling section prior to packaging. Glaston also uses 14 Unimotor HD - highly dynamic brushless servo motors from Control Techniques, one for each drive.

"The main benefit of the Unidrive M701 is the precise speed control we can now exert on the oven rolls which greatly reduces scratches and imperfections on the glass," states Mr. Matukonis. "Furthermore, we now have more capability and flexibility, and found integration to the control system extremely straightforward. The system´s design and interfaces, along with its extensive diagnostics capability, also ensure ease-of-use for the machine´s operator."

The Unidrive M family of drives offer class-leading induction and permanent magnet servo motor performance with real-time Ethernet. Each drive delivers maximum machine throughput through greater control with single and multi-axis network synchronization. On-board real-time Ethernet (IEEE 1588 V2), advanced motion control and high speed I/O for position capture has made it easier than ever for machine builders to create more sophisticated and flexible machines.

"The new line-up of Unidrive M701 with SI-PROFIBUS is now integral to all our new and upgraded installations," said Mr. Matukonis. "The option cards give these drives incredible flexibility. For example, we are able to bring two encoder signals from other motors into a single drive. With minimal programming, we have been able to have the drives follow either of these encoders with smooth ramps between the two different encoder speeds. I could only find this option in significantly more expensive servo solutions.

"As well as this, we are impressed at how the system deals with any issues. If a drive fails, all the parameters are kept on a magnetic card that can easily be used to program the new drive. It was much easier for the maintenance department to simply put in the card and program the new drive.

"Between the Unidrive SP and Unidrive M series, we have to date installed over 100 servo drives at our production facility and we couldn´t be happier with the results we´re seeing."

Better delivery from medium voltage variable speed drives.

WEG has more than doubled the maximum power of its air-cooled MVW01 medium voltage variable speed drives - from 6.5 MW to 16 MW for voltages from 2.3 kV to 4.16 kV - to meet the needs of medium voltage three-phase induction and synchronous motors across a broader power range. The overall product line now covers the voltage range from 2.3 kV to 6.9 kV and the rated power range from 400 kW to 16 MW; a water-cooled version is also available, offering up to 40% higher rated power than the air-cooled one. With efficiency levels of more than 99%, the MVW01 achieves the best efficiency of any medium voltage drive currently available on the market, meaning customers can increase energy efficiencies in their application, reducing their environmental footprint and making associated cost savings.

WEG boosts the rated power of the MVW01 medium voltage variable speed drives from 6.5 MW to 16 MW in some voltage ranges.

WEG’s MVW01 variable speed drive combines robustness with ease of use and handling, reliability and safety, so end users can improve their operational processes. The drive is suitable for a variety of applications including pumps, fans, mills and agitators in the oil and gas, mining, minerals and metals, chemical, paper, plastics and rubber, and water and wastewater sectors.

The MVW01 features voltage source inverter (VSI) topology with a three-phase rectifier, DC link and multi-level output converter using Neutral Point Clamped (NPC) technology with 3/5 voltage level for output voltages from 2.3 kV to 4.16 kV or 5/9 voltage level for output voltages from 6.0 kV to 6.9 kV. Specifically designed for the harsh conditions of traction applications, the frequency inverter is equipped with the latest generation of insulated-gate bipolar transistors (IGBTs) for voltages up to 6.5 kV – and a DC link with a 12-pulse bridge rectifier, with 18-, 24- or 36-pulse rectifiers available as an option.

The drive has exceptionally good dynamic characteristics with the multi-pulse diode configuration of the input rectifier offering a power factor over 97%, which translates into lower demand for incoming current and thus less costs. Driven by the Optimised Pulse Pattern (OPP) clocking method developed by WEG, the output stage topology of the inverter (multi-level NPC) enables optimal switching behaviour that reduces motor current harmonics to an absolute minimum.

Additionally, WEG’s medium voltage variable speed drives are based on the same user interface philosophy as WEG's low-voltage variable speed drives, offering ease of use and simple device programming. Maintenance is simplified by plug-in inverter power modules (one per phase), while the NPC inverter topology with multi-level technology offers a relatively low number of power components, which contributes to increasing efficiency and reliability.

All critical components, including the high-voltage IGBTs and dry-type plastic power film capacitors, are designed for long life. A fibre optic interface is used for the inverter drive signals and signal feedback to the CPU to reliably isolate the medium-voltage components from the control circuit and the control interfaces. In addition, the variable speed drives are housed in IP41-rated cabinets and support all commonly used network protocols, including DeviceNet, Modbus, Profibus DP and Ethernet. Flow-through ventilation with top-mounted fans provides extremely effective heat dissipation and a low noise level (less than 75 dB A).

“Thanks to its advanced technology, the MVW01 is easy to use and provides excellent reliability and safety combined with exceptional energy efficiency,” says Fábio Gonçalez, European Automation Manager at WEG. “WEG has a long history as a provider of motor speed control solutions and manufactures all essential components such as switchgear, oil- and air-cooled transformers, frequency inverters and electric motors, and at our European Automation Centre in Unna, we can also make custom solutions and application-specific software modifications.”

Energy efficiency for a big cheese!

La Compagnie des Fromages counts on innovation with Emerson technologies

La Compagnie des Fromages is part of the Bongrain Group, the world's fifth-largest milk-processing company and an employer of 18,870 people. The company is pursuing a policy to reduce its energy usage and CO2 emissions by investing in a facility designed by Cofely Axima, a leader in industrial refrigeration and a subsidiary of GDF Suez. This solution stands out for its use of a process that heats and cools within a single cycle and its use of key components supplied by the Emerson Group – a Vilter single-screw compressor from Emerson Climate Technologies and a Leroy-Somer variable-speed drive from Emerson Industrial Automation.

Vilter single-screw compressor driven by a Dyneo® PLSRPM permanent-magnet synchronous motor

"Because we serve as a consultant to our customers, we conducted an energy audit with la Compagnie des Fromages' plant in the town of Vire," says Jean-Yves Druillennec, Sustainable Development Manager for Cofely Axima–GDF Suez. The audit, which was based on a series of measurements, provided a snapshot of the Vire plant's consumption levels and suggested replacing its four piston compressors, which provided only cooling, by a thermorefrigerating pump.

A thermorefrigerating pump is a thermodynamic heat-transfer system that can cool and heat at the same time. The refrigeration system makes it possible to provide cooling capacity to the evaporator and heating capacity to the condenser. When 1000 kW of chilled water is produced at Vire, 1300 kW of energy is recovered at the same time and combined with just 100 kW of electricity to heat water to +62°C. All the energy produced and used is fully recovered. A 150 m³ buffer storage unit allows energy to be used to produce hot water as needed by the process (particularly cleaning operations). With the old system, this water was heated by gas, which has a much higher carbon footprint. In addition, the heat produced was rejected to the atmosphere by a cooling tower instead of being recovered and reused. The new system saves 9000 m3 of water a year and has reduced use of the cooling tower, which, with its plumes of steam, always reflects negatively with local residents.

The Vilter single-screw compressor’s technology

At the heart of the system are a 390 kW motor and a variable-speed drive. Both are made by Leroy-Somer and power a Vilter single-screw compressor with 1000 kW of cooling capacity. The refrigerant circulated in the system is ammonia (NH3), a natural heat-transfer medium commonly used cases such as the present one. Cooling and heating are simultaneously produced for one-third of the time. To raise the water temperature from 15 to 58°C (with a combined COP of 7.67), the ammonia, after having removed heat from the cold side to produce chilled water, is compressed to achieve the right pressure and temperature. As this temperature is much higher than the usual temperature for a conventional cooling system, the ammonia condenses at 59°C. The water is heated by transferring the heat from the ammonia via the condenser and other heat exchangers located at various points in the system for heat-optimisation purposes.

During the remaining one-third of the time, chilled water is produced conventionally with a COP of 5.75. Ultimately, the system will recover all the heat extracted during the production of chilled water.

An 18-month return on investment
Chilled water at 1 to 7°C and 200 m3 of hot water at 60°C are produced daily at the Vire plant. To do this, the old system consumed an average of 820 kW of energy per tonne of production per year. With the new system, this level is now only 560 kW. "As a result, the payback period is particularly short, even when you factor in the aid, which amounts to less than 20% of the funding," says Patrick Marie, Maintenance Manager of la Compagnie des Fromages. "The process for producing heat with less grid electricity is not the only source of energy savings," says Jean-Yves Druillennec. "The use of much more energy-efficient components is the other source."

Dyneo® drive systems: high efficiency and high reliability
The Dyneo® LSRPM is a range of permanent-magnet synchronous motors incorporating technology patented by Leroy-Somer. The innovative design of the magnet rotor significantly increases efficiency to levels approaching 98%.

"It is 7% more energy efficient than high-efficiency induction motors, which is significantly beneficial in terms of profitability, especially considering that electricity costs are expected to rise by 25% in the next five years. What sets this motor apart is that it is ideal for speed control. We noticed that some induction motors were under excessive load under non-steady-state conditions. We don't have this problem with Leroy-Somer's motors. They stay reliable whatever the load applied to them. Had we used induction motors, they would have had to be oversized."

The low losses of the magnet-rotor technology considerably reduce heating of the bearings. As a result, they need to be lubricated much less often and the life of the motor is increased. "We've implemented more than 30 applications in four years without experiencing the slightest problem," adds Jean-Yves Druillennec.

Vilter technology for greater reliability and energy efficiency
Vilter is a brand of Emerson Climate Technologies, which employs more than 16,000 people worldwide. Instead of standard twin-screw compressors, the company uses a highly distinctive process – single-screw compressors. Compression is accomplished by a single screw and two star-shaped gaterotors. The compressor is designed to balance the single screw both radially and axially. This balance ensures that very low loads are placed on the bearings, thus achieving a high level of reliability with considerably reduced vibration and noise levels. This design allows Vilter to offer its exclusive 5/15 warranty (5 years for the compressor and 15 years for the bearings).

The key to the single-screw compressor’s high energy efficiency is Vilter’s exclusive Parallex™ slide system, which allows the compressor to run at optimum efficiency throughout its capacity range. The capacity and volume slides (with an expanded volume ratio of 1.2 to 7.0) move independently of each other under all operating conditions, eliminating over- or undercompression and saving motor horsepower. "What makes these compressors stand out is their ability to independently adjust their capacity and volume ratio. That makes a real difference under partial load conditions. We have always found Vilter compressors to be clearly more energy efficient than the standard twin-screw technology. Depending on the application, they can be as much as 10% more efficient," says Jean-Yves Druillennec.

It's the total cost that counts

"The proof of the pudding is in the eating"
Coeur de Lion camembert, one of la Compagnie
des Fromages' best-known brands

Cofely Axima was in charge of managing every aspect of the project, from engineering and installation, to control and supervision (PLC control, instant performance monitoring and traceability of all parameters). Only the electrical wiring was contracted out. La Compagnie des Fromages' process was down for only 3 hours, during the commissioning phase. Cofely Axima is installing many systems in countries such as Thailand, Kuwait and Italy. "We are seeing a downward pressure on prices. Our clients are interested only in solutions that pay for themselves in less than two years. It is important to be able to make promises that you are sure you can keep. Overall, Emerson's solutions are more efficient and reliable and much more flexible for non-steady-state conditions. The entire system makes it possible to make a real difference on the total cost," says Jean-Yves Druillennec.

Save operational costs with energy reduction initiative

WEG has launched a new energy reduction initiative, which is designed to help manufacturers optimise efficiencies of existing equipment throughout their plants and processes. The free assessment reviews equipment and outlines a number of steps manufacturers can take to reduce energy use and increase equipment efficiency and reliability, enabling them to minimise costs, reduce carbon footprint and total cost of ownership.

In partnership with Sulzer, WEG is educating British customers in selecting suitable plant equipment with energy saving potential, and giving objective, professional advice on improving productivity while reducing energy consumption and costs.

Experts will assess existing plant equipment and can install drives on-site to monitor and demonstrate existing energy usage. Then a variable speed drive (VSD) can be fitted, energy savings proven and potential savings related to project payback, on-going operational savings and total cost of ownership can be calculated.

The free energy assessment is a simple process and enables the customer to trial equipment before purchase. It is suitable for all plant equipment, including pumps, compressors, fans and conveyor belts.

“Today there is greater pressure than ever on organisations to minimise their carbon footprint and reduce their costs and at WEG we’re committed to increasing energy efficiency, offering customers valuable choices on how they can best enhance their bottom line,” says Daniel Griffiths, product specialist – automation, at WEG. “Our energy efficient technologies like the W22 electric motors and our CFW inverter drives can play a real role in helping them to do both. Our products are always designed to increase energy efficiency, reduce noise and temperature levels, reduce size and increase reliability.”

Motors are responsible for generating over 40% of total global energy consumption. Selecting motors that have been designed with energy efficiency as a priority, such as WEG’s W22 Super Premium motor that exceeds the yet to be implemented IE4 regulations, will enable manufacturers to make significant energy savings, reduce operational costs and increase productivity.

WEG’s new frequency inverter CFW501, which has been designed to meet the needs of the heating, ventilation and air conditioning (HVAC) industry, is another example of energy efficient technology. The robust, compact and easy-to-use drives are currently available with a power range from 0.18 to 7.5 kW and are suitable for all pump and fan applications. Thanks to their advanced features and design, they help users to optimise the operation of their motors, while being quick and easy to install and cost-effective to maintain.

Cost effective variable speed drives

A new cost-effective range of inverter drives that gives exceptional performance for three-phase induction motor control has been launched by WEG. The CFW500 range features state-of-the-art technology to deliver a high level of control, but at an affordable price, enabling industrial manufacturers to improve processes and make significant cost savings.

This new range of CFW500 inverter drives is robust, flexible and smart, and available in power ratings from 0.18 kW up to 22 kW. It has been designed to be versatile for many industrial automation applications including centrifugal and process pumps, fans, compressors and conveyors.

The CFW500 drives are based on modular plug and play design, extremely easy to use and program. The drive includes a built-in micro-PLC, which can be programmed according to standard protocol IEC 61131-3. It also comes with pre-programmed macros for a range of applications, for example positioning, timer and acceleration. Users can simply program the drive using the LCD HMI display, or via a computer through a variety of interfaces (RS232, USB, RS485). In contrast to other providers, WEG offers its WLP software for programming and monitoring to customers free of charge.

Designed with simplicity of installation and operation in mind, it can identify up to 64 different plug-in modules. CFW500 is ideal for supporting decentralised automation concepts and is easy to connect to all the major fieldbus systems including Profibus-DP, DeviceNet and CANopen. The drive features expansion plug-in modules, which makes it easy to customise even for bespoke applications.

The simple-to-use and intuitive LCD HMI gives indication of up to three simultaneous variables, such as speed, as well as indication of the main units and performance statistics of the inverter. The inverter drives are reliable and can operate in ambient temperatures up to 50°C.

“Our CFW500 range has been developed to be extremely easy to use and operate,” says Paulo Krüger, European Automation Centre Manager at WEG. “I’m delighted that our customers can now benefit from advanced programming and control features to increase productivity and improve the quality of their processes, but at a cost-effective price. Typically applications do not run at full load all the time and by installing the CFW500 drive customers can save money by controlling the speed of their process and adjusting it to the specific load at any time.”

Cost-effective intelligent servo drive

Based on the Technosoft MotionChip™ DSP technology, ISD860 is a flexible intelligent drive specially developed for motion applications that need cost-optimized design, embedded intelligence, networking possibilities and high servo performance control. It is able to drive 12 A continuous and 31 A peak currents at a supply voltage ranging from 12 to 72 VDC, with a PWM of 20 kHz frequency. Embedding motion controller, drive and PLC functionality in one unit (size: 136 x 84 x 26 mm), ISD860 controls brushless, DC or linear motors up to 860 W continuous / 2.2 kW peak voltage. Thanks to its advanced motion control algorithms, a precise control of position, speed or torque over a wide range of dynamic conditions can be achieved.

ISD860 works in single-axis, multi-axis or stand alone configurations. The drive setup, tuning and motion programming are simple with EasyMotion Studio and Technosoft Motion Language (TML). With ISD860, motion programming can be done from a CAN master, via PC / PLC, using the appropriate motion library, or directly at drive level through its built-in motion controller. The embedded Technosoft Motion Language includes a high-level command protocol, which can be used by the host through the on-board RS232 / CAN serial interfaces. A CANopen version of the ISD860 drive, supporting DS-301 and DSP-402 profiles, is also available. In stand-alone operation, ISD860 can be managed with programmable I/Os or analog inputs.

Using the TML language, multiple operations can be performed with ISD860: setting of various motion modes (profiles, PVT, PT, electronic gearing or camming, etc), change of motion modes and/or parameters, execution of homing sequences or program flow control. At the same time, IDS860 can handle digital I/O and analog input signals, execute arithmetic and logic operations, and transfer data between axes. The drive is able to control other axes via motion commands. Moreover, ISD860 can send commands to a group of axes, or synchronize all the axes from a network.

Flexibility and easy implementation make ISD860 an ideal solution to fulfilling today's higher-power motion axis control needs using modern distributed intelligence architecture. The drive is perfectly suited for cost-sensitive applications from medical to factory automation requiring high servo performance and enhanced compactness.

BA simulators energy consumption

The latest variable speed drive technology from Parker Hannifin, the global leader in motion and control technologies, is being used by British Airways (BA) to improve the efficiency and reliability of its flight cabin simulators. By enabling the simulators’ hydraulic control systems to be powered only when needed, the drives are cutting energy consumption by 95%, in addition to extending maintenance intervals and service life considerably.

The two British Airways flight cabin simulators, one based on a Boeing 737 and the other a 747 passenger cabin, are used by the airline for essential cabin crew training. The ability to simulate various incidents allows trainee crews to practice safety procedures and emergency drills in a realistic setting, preparing them for real life situations. With thousands of crew members training each year, the simulators are in high demand, making it essential they are available for use 24/7.

The cabin area in each of the simulators is a life-size representation of a section of a real aircraft, complete with seats, overhead lockers, and all other fixtures and fittings. The 747 simulator is static, with doors that are hydraulically operated in exactly the same way as on a real aircraft. In addition to hydraulic doors, the 737 version is mounted on a large hydraulic rig, which controls the rise, tilt, and shake of the simulator. This system can move the cabin forwards, backwards and side to side, simulating flight conditions, such as turbulence.

Both simulators are controlled from a single hydraulic control system located in a small external plant room, with the power output typically split 30% to the 747 rig and 70% to the 737 if both are in use simultaneously. Previously, two separate pumps and motors in the hydraulics system had to be constantly run at 100% speed, leading to high energy costs and significant wear and tear on the system. To remedy this problem, BA approached Parker SSD for a more efficient solution.

Parker worked closely with BA and Trend Control Systems to modify the hydraulic system using the latest drive and control technology. The improved system combined a Parker AC variable speed drive with a Trend controller and Parker accumulators and valves. This set up would allow the hydraulic system to be driven only when needed, and therefore reduce energy consumption considerably.

The Parker SSD 650v AC drive was ideal for the application as it offered a flexible, easy to use solution that would provide dependable performance over a long service life, and therefore maximise the return on BA’s investment. The drive makes setting up complex open-loop AC motor control systems simple and fast, with pre-programmed options and a user-friendly interface. Additionally, the compact dimensions of the unit would allow BA to make the most efficient use of space in the simulation area.

Once installed, the new system had a noticeable effect on energy consumption. Dennis Doody, Senior Engineering Technician for BA, commented, “We are very impressed with the new hydraulic control system for our simulators. The combination of the Parker SSD drive and the Trend Controller have allowed us to use the system in a much more efficient way, cutting overall energy costs by as much as 95%, from 360kW/day to just 21kW/day. As the operating conditions are now much more stable, and the system isn’t being driven flat out all the time, we are seeing a reduction in the need for maintenance, which is lowering our costs still further. “Aside from the money saving implications, we’re really happy that we’ve managed to cut the environmental impact of the simulators. They are a vital part of our training processes and essential to our ability to safeguard passenger safety, but we want to make sure we’re using them in the most efficient way. The new hydraulic drive and control system has enabled us to meet our economic objectives in line with our company-wide sustainability goals. We’re very happy with the outcome and feel sure we made the right decision choosing Parker as our partner on the project.”