|
Click on the cover to read the latest issue of PSB
Affiliate Links
|
Danfoss VLT FlexConcept - flexible, user-friendly and energy-efficient28 April 2011High availability and high energy efficiency, uniform system design, reduced spare parts inventory and low life-cycle costs are what industry demands from modern drive systems. These requirements are the result of new EU eco-design regulations for motor efficiency, which call for significant changes in drive technology to be implemented in three stages by 2017, and society’s need to reduce CO2 emissions and protect the environment.For manufacturing plants in the food and beverage industry in particular, rising costs are leading to increasingly stringent requirements for energy efficiency and flexibility. Different application areas, such as production, filling, packing and storage, also place different demands on the technology.
In the past, for example, a large variety of drive system versions with different sizes and power ratings were used to drive the conveyors that form the lifelines of a production plant and connect its individual stations. This meant that manufacturers had to maintain large inventories to have spare drives available for the different types. With new, high efficiency motor technology remaining unused, energy costs were not optimised and different gear unit, motor and control concepts tended to significantly increase maintenance costs.
The new Danfoss VLT FlexConcept reduces project engineering and maintenance costs
To address this situation using a modern, contemporary drive system, Danfoss has seamlessly integrated modern motor technology with the latest motor control components to create a fully coordinated, standardised system, called VLT FlexConcept, for use in production lines.
For conveyor drives in particular, this system promises to dramatically simplify project engineering, installation, commissioning and maintenance - regardless of whether the plant operator opts for a centralised or decentralised drive configuration. The system components allow maximum flexibility with a minimum number of unit variations such as motors, gear unit sizes or frequency converters, all of which offer a uniform user interface concept and the same functionality.
The system is also available with European Hygienic Engineering Design Group (EHEDG) and IPA (Fraunhofer Institute) certification for use areas where hygiene is extremely important.
Danfoss VLT OneGearDrive – high efficiency motors across the board
The current basis of the OneGearDrive concept is the Standard version. The geared motor of the VLT OneGearDrive combines the advantages of bevel gearing with the outstanding efficiency of a permanent magnet (PM) synchronous motor in a single compact unit. The PM motor used here exceeds the requirements specified for the IE3 (Premium Efficiency) motor efficiency class defined in the new EU regulation.
This provides plant operators with a high level of investment security for the future and the most efficient motor technology available today. These highly efficient motors ensure maximum energy efficiency, and the highest possible overall system efficiency is achieved by the optimal matching of the motors and gear units – since combining modules usually results in a considerable reduction in overall efficiency.
Thanks to the optimal matching of the VLT OneGearDrive geared motors, Danfoss engineers have managed to achieve an overall efficiency that is up to 25% higher than that of previous drive concepts.
Enclosure design compliant with DIN 1672-2 hygienic design standard
For optimum protection and reliable use even in areas where hygiene is critical, Danfoss has designed the enclosure of the geared motor to comply with DIN 1672-2 hygienic design requirements and with IP67 or IP69k protection ratings. The unit has a completely smooth, easy to clean surface without cooling fins, which prevents pockets of dirt from forming and allows cleaning agents to drain off freely.
The engineers also managed to eliminate the fans needed in previous designs. This avoids the risk of air-borne germs and dirt particles being drawn in and then expelled back into the surrounding air. This significantly reduces the possibility of aerosol formation and the subsequent contamination of products or components in the production plant. These factors combined make these drives ideally suited to installation in all areas, especially wet areas.
The VLT OneGearDrive also dispenses with the ventilation valve in the gear unit, which prevents moisture penetration and thereby increases service life and maintenance intervals. By using food grade oil, maintenance intervals of up to 35,000 operating hours in partial load can be achieved in conveying systems, which amounts to being virtually maintenance free.
The VLT OneGearDrive Standard is optionally available with an integrated resolver, which allows plant operators to implement synchronisation and positioning applications as well as open loop operation without a generator or encoder.
The VLT OneGearDrive Hygienic is specially designed for areas where hygiene is critical. Its principal features are an ultra-smooth aseptic coating, which is resistant to all detergents and disinfectants (pH range 2 ..12) typically encountered in this industry, and a hollow stainless-steel shaft (AISI 316 Ti) as standard. The electrical connection of the motor is provided by a specially developed stainless steel circular connector.
A single gear unit size
The VLT OneGearDrive has only one gear unit size, which provides three standard gear ratios. These gear units are designed to meet the widest possible variety of torque and speed requirements with the minimum number of versions. The 3 kW or 1.5 kW output power of the PM motor also contributes to optimum standardisation for all necessary applications.
Perfectly coordinated speed control with VLT AutomationDrive FC 302 and VLT Decentral Drive FCD 302
To optimise processes in production plants, especially in conveying systems, and to further enhance the energy efficiency of the high efficiency motor, the best option is to combine the VLT OneGearDrive with a VLT AutomationDrive FC 302 frequency converter or the new VLT Decentral Drive FCD 302.
The VLT AutomationDrive FC 302 is the perfect choice for a centralised plant configuration. Compact dimensions that enable side-by-side installation in the electrical cabinet or electrical room also allow electrical equipment areas to be kept compact, even in large production plants with many drives. The drive design also supports long motor cables to ensure reliable operation without restrictions even in such situations. Different cooling concepts tailored to each application make installation quick and easy.
The VLT Decentral Drive FCD 302 and the VLT AutomationDrive FC 302, available with IP55 or IP66 protection rating, can both be used with a decentralised plant configuration. Both series offer optimum protection for production plants in the food and beverage industry and are also able to withstanding frequent cleaning with commonly used cleaning agents and disinfectants.
The EHEDG certified FCD 302 additionally has angled cooling fins for better drainage of detergents, making it even more suitable for installation directly in the drive system. The VLT Decentral Drive FCD 302 can be mounted directly on the motor, on the wall or in the drive system, while the VLT AutomationDrive is suitable only for wall or system mounting.
Contact Details and Archive...Related Articles...Most Viewed Articles... |
|