drive & motor solutions for rubber & plastics applications · drive & motor solutions...

High performance solutions for increasing product quality and throughput while reducing energy consumption

Drive & Motor Solutions for Rubber & Plastics Applications

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Driving technological advances in rubber and plastics manufacturing

The demand for more sophisticated rubber and plastic end products is ever increasing, making the manufacturing processes more important than ever. Applications include the production of raw materials, converting processes (e.g. compounding, extrusion, molding or calendaring), product finishing and recycling. In the case of tires, there are a number of additional materials (steel and fabric) and several component level production processes before the complex final building and curing techniques form the end product.

Despite the diversity of materials, these industry sectors do share many challenges, such as:

• Stiff market competition

• High energy consumption of manufacturing processes forms a significant portion of operating expenses

• Aging machinery resulting in inefficient production processes with low throughput, waste, downtime and high maintenance costs

• Pressure to continuously improve product quality and performance as demanded by end-users

• Flexibility of machines to cater for evolving and more complex end product designs

• Meeting increasingly stringent environmental regulations

• Maintaining power factor

Control Techniques and Leroy-Somer are leaders in automating rubber and plastics manufacturing processes and the preferred supplier for a global leading tire manufacturer. Many product manufacturers, OEMs and system integrators rely on our products, solutions expertise or services to improve production processes. We help our customers build reliable and high performance machines or modernize existing outdated equipment to the latest technology.

We help support our customers by providing:

• Expertise in energy savings, complimented by our best-in-class efficiency products and energy savings simulation tools

• Customized flexible solutions that handle multiple material recipes or produce final products

• Comprehensive drive and motor solutions, integrating 3rd party components for automation and safety, such as PLCs

• Full local engineering and aftersales support through our worldwide Automation Center network

• DC to AC retrofit solutions to improve throughput, reliability, energy efficiency and machine availability

• Highly accurate performance to meet shorter production cycle times and produce high quality finishes

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Globally organized expertise, development and supportControl Techniques and Leroy-Somer have operated globally for many years, providing unparalleled specialist drives and motors technology, expertise and customer care in a wide range of industries. We offer high quality long life products that improve operating efficiency, resulting in good value and return of investment. Our large staff of qualified engineers with significant automation experience are available to assist you with applying these products optimally, with around the clock technical support to help you meet and exceed your application requirements. With the following assets, our business comprehensively delivers:

Drives & MotorsTechnology

AutomationSolutions

Drives & MotorsServices


AutomationSolutions



AutomationSolutions

OEM AccountManagement


AutomationSolutions


Matched drives and motors technology – enhancing performance and optimizing energy efficiency, offering industry-specific solutions for all customer requirements with best-in-class reliability.

Scalable automation solutions – new or retrofit single axis control up to complete electrical turnkey installations for multi-axes, large scale production projects.

Local customized services – from audit & consultation, commissioning & start-up to maintenance and training, ensuring total support throughout the lifetime of your application to guarantee peak performance.

OEM account management – jointly developed customized solutions and strategic operations to meet the specific market requirements of our OEM customers.


Reliable product packages that save energy, while maximizing performance and connectivity We provide a comprehensive range of drives, motors, brakes and gears in packages that deliver maximum compatibility with minimum effort, saving time and cost in system build, integration and maintenance. As a single supplier, we maximize the ease and speed of procurement.

Maximize machine availability and reliabilityWith long term global experience, we provide proven robust and reliable solutions that maximize uptime and are easy to maintain for rubber and plastic process applications. Features include: • Sensorless open loop operation for less arduous applications• Diagnostics through variable monitoring• Water-cooled solutions for reliability in harsh environments• Fan-less motors that do not blow containment around

Energy savingEnergy efficiency is key to alleviating rising electricity prices and sustainability concerns. We offer AC induction motors to IE3/IE4 efficiency standards and best in-class efficiency (>IE4) PM variable speed solutions to optimize energy consumption in fan, pump, extrusion, calendering and mixing applications.

Wherever variable speed can be applied to optimize processes, permanent magnet (PM) solutions offer exceptional efficiency levels over the whole operating range, resulting in a highly competitive total cost of ownership and rapid ROI.

Our low loss drives(ŋ>98 %) have energy saving features such as:• Common DC bus configuration, enabling energy recycling

• Active Front End for low harmonic regen AC drive systems

High performance features to improve productivity and throughputWe can provide low inertia induction or dynamic servo solutions with high precision low backlash gearboxes. Our technology delivers high overload capability and adjustable limits to support higher peak torques during acceleration/deceleration for challenging applications and extremely fast current control algorithms eliminate nuisance tripping. Other benefits include:• Full torque across the whole speed range• Accurate positioning enhancing productivity/repeatability

with flexible encoder interface options• Precise speed control (compensation) by monitoring the

motor temperature and speed (<0.01 %)

Safety functions to support the protection of people and equipmentOur products provide certified safety functions, such as Safe Torque Off, SIL2/SIL3 or PLd/PLe customized solutions with:• Over and under-torque detection to protect load from

inconsistent mixtures• Torque limits and stall prevention to protect load and detect

foreign materials• Auto-restart a spinning motor

• Failsafe brake design and functions


Reliable product packages that save energy, while maximizing performance and connectivity

Reducing machine complexity with onboard motion Our drives provide onboard integrated machine control ranging from sequencing logic to machine/axis control, with network management using optional MCi 2nd processor modules. This streamlines machine design and minimizes costs, by reducing the size or removing the need of external PLCs and motion controllers. Software tools provide easy IEC 61131-3 motion and automation programming, delivering synchronized multi-axis machine performance.

Flexible and cost effective modular systemsWe provide flexible and compact solutions up to 2.8 MW (4,200 hp) using modular drives. This allows system builders to create high power applications with the smallest number of components, minimizing cabinet size and costs. Extremely fast current control algorithms and high switching frequencies with Active Front End (AFE) and multi-pulse rectifier configurations deliver unparalleled torque precision and power quality.

Outstanding modular design means only a small number of individual replacement parts are required, reducing the diversity and cost of spares inventory.

Flexible architecture to support new and retrofit machine designsOur solutions integrate seamlessly with any PLC industrial network options including ProfiNet, Ethernet /IP, Modbus,

EtherCAT. We also support complete machine control with controllers, I/Os and HMIs providing:• Maximum machine productivity via high performance

deterministic Ethernet, suitable for synchronized motion• A choice of network monitoring / diagnostics tools

• Flexible network topologies including star and tree

Reducing the cost and complexity of commissioning a systemOur optimized package solutions include:• Simple back-up and cloning using SD cards• Easy set-up with autotuning to get peak efficiency • Reduced hardware connections for position, using virtual

master and data sharing between drives

Industry 4.0 / Industrial Internet of ThingsAt the heart of Industry 4.0 and the Industrial Internet of Things is the ability to acquire and process data from sensors and intelligent devices that are embedded within machines or processes and then convert this into useful information. Applications for the data are diverse, such as predictive diagnostics, process optimization and machine-to-machine (M2M) integration.

Our intelligent equipment plays a key role in aggregating the information and providing the first line of processing.


Drives and motors technologyDrives & Motors

TechnologyAutomation

SolutionsDrives & Motors

Services

Drives and Controllers

AC drives for Process ControlAC and servo drives for Industry

DC drives

Powerdrive MD2, FX and F300 Unidrive M - AC & Servo Digitax ST Mentor MP

Flexible and energy efficient drive family for process applications such as pumping, ventilation and compression. Includes high-power modular and compact regenerative and water-cooled variants.

1.1 kW - 2.8 MW (1.5 - 4,200 hp)

200 V, 400 V, 575 V, 690 V

6, 12, 18, 24 pulse operation

2 or 4 quadrant operation

Defined feature-sets to optimize productivity across multitude of automation applications. Includes industry standard Ethernet IEEE 1588 V2 comms, IEC 61131-3 motion & automation programming and high speed I/O

0.25 kW - 2.8 MW (0.33 - 4,200 hp)

100 V, 200 V, 400 V, 575 V, 690 V

Intelligent, compact and dynamic servo drive range

0.72 - 18.8 Nm (6.4 - 166.5 lb.in)

200 V, 400 V

High performance DC drive with field control and integration flexibility

25 - 7,400 A

400 V, 575 V, 690 V


Motors

Permanent Magnet motors

Induction motorsInduction motor with integrated drive

Variable speed optimized induction motors

Servo motors DC motors

Dyneo® range IMfinity® and LS motor range Varmeca LSMV CPLS Unimotor fm and hd LSK and small DC

PM synchronous motors with drives exceed requirements equivalent to IE4 & NEMA Super Premium.

IP55 & IP23

3 - 500 kW (4 - 680 hp)

375 - 5,500 rpm

High, premium and super premium efficiency motors for fixed and variable speed

Air cooled: IP23 & IP55 0.09 - 900 kW (1.2 - 1,200 hp)

Liquid cooled: IP55 150 - 1,500 kW (200 - 2,000 hp)

Non IE, IE2, IE3, IE4 ranges (Atex, Nuclear, High temp & customized versions)

For variable speed applications

Fit to standard gears

0.25 - 11 kW (0.33 - 15 hp)

IP65

Flexible 3 phase motor with encoder and forced ventilation options

0.18 - 132 kW (0.25 - 180 hp)

IP55

High performance motor for variable frequency

7.5 - 560 kW (10 - 750 hp)

95 - 2,900 Nm (70.1 - 2,138.6 lb.ft)

0 - 9,000 rpm

IP23

Dynamic performance AC brushless

0.72 - 136 Nm (6.4 lb.in - 100.3 lb.ft)

(408 Nm / 300 lb.ft peak)

Drip proof and enclosed DC motors delivering constant torque at variable speed

0.06 - 750 kW (0.08 - 1,000 hp)

Gears and Brakes

Geared motors Brake motors Geared servo motors

Range of helical, helical bevel and worm geared motor technologies to meet the various demands of industrial processes for standard or special environments

Output torque:

30 - 23,000 Nm (22.1 - 16961.7 lb.ft)

Brake motors for intermittent or continuous duty, dynamic braking or emergency stops

Braking torque up to 5,000 Nm (3,687.3 lb.ft)

Motor power: 0.06 - 400 kW (0.8 - 550 hp)

Dynabloc

Helical and worm servo geared motor technologies including low backlash and planetary

Up to 3,000 Nm (2,212.4 lb.ft)


AutomationSolutions



Drives and motors technology Meeting all your needs with a comprehensive range

Drives and Controllers

AC drives for Process ControlAC and servo drives for Industry

DC drives

Powerdrive MD2, FX and F300 Unidrive M - AC & Servo Digitax ST Mentor MP

Flexible and energy efficient drive family for process applications such as pumping, ventilation and compression. Includes high-power modular and compact regenerative and water-cooled variants.

1.1 kW - 2.8 MW (1.5 - 4,200 hp)

200 V, 400 V, 575 V, 690 V

6, 12, 18, 24 pulse operation


Defined feature-sets to optimize productivity across multitude of automation applications. Includes industry standard Ethernet IEEE 1588 V2 comms, IEC 61131-3 motion & automation programming and high speed I/O

0.25 kW - 2.8 MW (0.33 - 4,200 hp)

100 V, 200 V, 400 V, 575 V, 690 V

Intelligent, compact and dynamic servo drive range

0.72 - 18.8 Nm (6.4 - 166.5 lb.in)

200 V, 400 V

High performance DC drive with field control and integration flexibility

25 - 7,400 A

400 V, 575 V, 690 V


Motors

Permanent Magnet motors

Induction motorsInduction motor with integrated drive

Variable speed optimized induction motors

Servo motors DC motors

Dyneo® range IMfinity® and LS motor range Varmeca LSMV CPLS Unimotor fm and hd LSK and small DC

PM synchronous motors with drives exceed requirements equivalent to IE4 & NEMA Super Premium.

IP55 & IP23

3 - 500 kW (4 - 680 hp)

375 - 5,500 rpm

High, premium and super premium efficiency motors for fixed and variable speed

Air cooled: IP23 & IP55 0.09 - 900 kW (1.2 - 1,200 hp)

Liquid cooled: IP55 150 - 1,500 kW (200 - 2,000 hp)

Non IE, IE2, IE3, IE4 ranges (Atex, Nuclear, High temp & customized versions)

For variable speed applications

Fit to standard gears

0.25 - 11 kW (0.33 - 15 hp)

IP65

Flexible 3 phase motor with encoder and forced ventilation options

0.18 - 132 kW (0.25 - 180 hp)

IP55

High performance motor for variable frequency

7.5 - 560 kW (10 - 750 hp)

95 - 2,900 Nm (70.1 - 2,138.6 lb.ft)

0 - 9,000 rpm

IP23

Dynamic performance AC brushless

0.72 - 136 Nm (6.4 lb.in - 100.3 lb.ft)

(408 Nm / 300 lb.ft peak)

Drip proof and enclosed DC motors delivering constant torque at variable speed

0.06 - 750 kW (0.08 - 1,000 hp)

Gears and Brakes

Geared motors Brake motors Geared servo motors

Range of helical, helical bevel and worm geared motor technologies to meet the various demands of industrial processes for standard or special environments

Output torque:

30 - 23,000 Nm (22.1 - 16961.7 lb.ft)

Brake motors for intermittent or continuous duty, dynamic braking or emergency stops

Braking torque up to 5,000 Nm (3,687.3 lb.ft)

Motor power: 0.06 - 400 kW (0.8 - 550 hp)

Dynabloc

Helical and worm servo geared motor technologies including low backlash and planetary

Up to 3,000 Nm (2,212.4 lb.ft)

General Purpose

Process

Manufacturing


Australia

Singapore

Republic of South Africa

Brazil

Chile

Mexico

France

Spain

Morocco

United Kingdom

Germany

Ireland

The Netherlands

Belgium

Austria

Czech RepublicDenmark

Sweden

USA Canada

Thailand

Taiwan

China

South Korea

MalaysiaIndia

UAE

Italy

Hungary

Switzerland

Turkey

Romania

Poland

Indonesia

Japan

Venezuela

Global facilities and resources

Note that many countries have more than one of the facilities represented by the icons


Australia

Singapore

Republic of South Africa

Brazil

Chile

Mexico

France

Spain

Morocco

United Kingdom

Germany

Ireland

The Netherlands

Belgium

Austria

Czech RepublicDenmark

Sweden

USA Canada

Thailand

Taiwan

China

South Korea

MalaysiaIndia

UAE

Italy

Hungary

Switzerland

Turkey

Romania

Poland

Indonesia

Japan

Venezuela

An enhanced global presence that benefits all our customers

Through our integrated Drives and Motors organization, we have an extensive global presence that provides comprehensive local support and services. This includes:

40+ Automation Centers

Providing excellent customer support for any product, automation solutions or service requirements

23 Manufacturing sites

Producing a comprehensive range of high quality products, optimized for industry-specific customer requirements

8 Engineering and Design facilities

Develops market leading products and feature-sets using the latest design technology

3 Regional despatch hubs

For quick delivery of product

5,500 employees

Our extensive sales and service networks in Europe, Asia Pacific and the Americas are backed-up by hundreds of carefully selected distributors and service partners, often in remote locations, all over the world.


Automation Solutions Global industry expertise perfectly executed at local level

Our Automation Solutions Team is dedicated to designing, managing and implementing global Automation Solutions projects. This allows us to leverage and mobilize our worldwide expertise and automation knowledge across every project. Dedicated local teams based at our Automation Centers provide a single point of contact while ensuring each stage is perfectly executed, providing:

• Rubber and plastics solutions optimized for reliable and maximum production

• Highly skilled system design to create innovative and energy saving solutions

• Maintenance and trouble-free operation

• Flexibility for future machine or plant expansion

Comprehensive Automation Solutions

Projects can vary from small machine automation projects to comprehensive automation and electrical turnkey solutions for new or retrofit installations.

We provide a global organization for global projects that deliver leading:

• Engineering & Project Management skills (>200 Engineers)

• Regional and global Engineering Centers for engineering and panel building

• Industry expertise at strategic Industry Centers

• Universal tools across organization for engineering efficiency & standardization

• Consistent license management

• Shared project documentation & libraries

• Quality (ISO 9001:2008)


Scalable solutions, total satisfaction

Our Automation Solutions services are scalable to your needs. We offer the ability to act as a one-stop shop for all your system and support requirements including specification, design, build and commissioning.

The project services we offer include:

• Project management from experienced industry leaders

• Functional design specifications

• Detailed engineering design that incorporates:

• Drives, motors and automation equipment that meets and improves customer’s internal quality requirements

• Integrated state-of-the-art safety controls (SIL3/PLe)

• Software application development , including:

• Integration with PLC software

• Customized HMI software

• Procurement of all system components

• Assembly of electrical control system, including:

• Manufacturing of cubicles and control panels

• Installation of engineered system and cabling on site

• Factory Acceptance Test

• Site commissioning, start-up and optimization

• Detailed project documentation

• Training

Customer benefits

• Customized solution: standard core, globally deployed

• Minimized completion time

• Known & minimized costs

• Optimization of:

• Resources

• Efficient knowledge sharing

• Reduced development time

• Quality

• Tested & qualified applications

• Maximized functionality/performance

• Facilitated by global & local service teams

• Shared expertise in

• Sales

• Engineering

• Commissioning


Partnering with OEMs to develop joint solutions

We have many OEM partners across a wide range of industries, from small scale machine developers to global key accounts. No matter what size of operation, our aim is to:

• Deliver unique customer-specific value that can be sustained and leveraged, resulting in profitable growth

Our strategy is to:

• Accelerate our customers’ growth & profitability utilizing our motor & drive solutions

• Align with our customers’ globalization

• Work and grow with new OEMs across many industries

• Take into account current megatrends

The scope is to work closely with OEMs, who are:

• Willing to work as partners

• Prepared to jointly develop products & solutions

• Looking for variable speed technologies to differentiate their market offer

Scalable OEM solutionsWe have the capability and resources locally to provide small scale custom-designed solutions such as mechanically adapted products, customized software modifications or standard products fitted with tailored options to suit machine requirements, up to developing new product designs (e.g. unique drives, motors or exclusive cabinet layouts).

By connecting with you at a deep level we aim to:

• Understand your unique pains and priorities, market pressures, objectives and strategies

• Incorporate our industrial expertise and resources, including key account managers

• Jointly develop and quantify a unique solution

• Deliver this solution and provide operational support

• Meet joint goals while delivering value to our shared customers

• Bring new technology and designs to market quickly with reduced time and effort, by providing:

• Customer equipment for testing and training

• Technically detailed proven success stories

• Technical support with dedicated engineers

• Software training

• Support OEMs through migration from old vendors with:

• Compact and mechanically/electronically compatible standard motor and drive solutions

• Provide easy upgrade path and backward compatibility of hardware and software when upgrading from older products to latest generation


Typical rubber and plastics applications where we can help you excel

Extrusion

Extrusion is a continuous primary conversion process requiring constant torque over the speed range in the rubber and plastics industries where lines vary hugely in terms of the materials used, the manufacturing processes involved and the end product they produce.

In the plastics industry, extruders can produce pellets (compounding), cast and blown films, heavy duty pipe/tubes, highly accurate profiles or used to coat other materials such as electric cables. For tires, due to several rubber compounds being used when creating the tread or sidewall sections, multiple extruders are synchronized, sharing a single head for merger.

Our highly reliable, easy-to-use and simple-to-apply drive and motor technology is perfectly aligned to extruder requirements with flexible and highly accurate control to cater for:

• Different recipes

• Highly variable screw speeds and load (with multiple end products produced on the same machine)

• Parison control (accurate wall thickness of complex profiles)

• Melt pump output to die (speed and temperature control)

• Exact end product tolerances and quality levels

• Continuously changing end customer requirements

Drive onboard PLCs and MCi 2nd processor modules with real-time tasking can be used for logic control, speed following and motor speed synchronization to enhance application capability. This coupled with the exceptional energy efficiency provided by matched permanent magnet or IE3/IE4 air and liquid cooled AC induction motors on an application which has heavy operational usage (often 24/7), means our technology helps:

• Provide a compact powerful solution

• Minimize the cost of ownership

• Enhance end user competitiveness

• Improve production yield

• Increase sustainability

• Provide a quick return on investment

Meeting energy saving targets can result in utility rebates in some parts of the world.


Energy audits to maximize savings

Our sales teams have cutting edge tools to simulate extrusion applications and estimate potential energy savings resulting from our induction and permanent magnet solutions compared to existing equipment or alternative solutions. This covers the optimization of complete AC and DC drive systems including motors, drives and transmissions, detailing various duty cycles in order to match:

• Actual machine requirements

• Production needs linked to machine technology

• Type of material processed

• Production constraints

This provides estimates on payback period and Total Cost of Ownership, along with recommendations for best investment decisions to match specific requirements at all key aspects of the simulation.


Mixing

This is a particularly challenging continuous cycle high power application for rubber, as both high torque and power are required during start-up. Often 150 % to 180 % overload is required for 60 s or more as the hydraulic ram pushes raw rubber through mixing chamber.

We provide reliable, easy-to-size standard drive and motor solutions up to 2 MW which increases to 2.5 MW with water-cooled motors. Dependent on the mixer type and design, our products are particularly adept in taking into account specific torque ripple profiles in motor rotor/rms torque and drive rms torque/current design.

Our modular drive systems can be configured to ensure total harmonic distortion is < 10 %, while allowing for easy expansion with additional units if requirements change in the future. We can supply complete customized designs that:

• Are fully flexible for different recipes/profiles in mixers and dosing units

• Synchronize all key elements such as feeding belt, valves, scale interface, recipe control, safety functions

• Provide maximum performance and accurate control of motion and temperature to ensure quality output and avoid damage such as scorching

• Include an easy-to-use inverter interface with torque control


CuttingThese sophisticated multi-axes servo machines incorporate positioning, synchronization, camming, motion control and indexing in order to achieve high accuracy, no matter what method is used for cutting, such as water, laser or mechanical (e.g. flying shear, rotary knife etc.).

Our servo drive and motor solutions for highly dynamic applications, where high peak torque is required, combine low inertia with high current overload, delivering:

• High performance with superior motor control

• Reduced cabinet size through compact yet powerful design

• Flexibility via a range of options including decentralized control

System programming is made easy with our software tool that provides the industry standard IEC 61131-3 environment and real-time Ethernet using a single cable provides fast communication and accurate axis control.

Winding / RewindingOur proven and fully documented winder solutions, with dedicated and easy-to-set-up software using PC tools, provide accurate and effective, usually closed loop, tension control for numerous materials ranging from cling film to steel belts, providing:

• The ability to either motor or regenerate, enabling use in both coiling and uncoiling applications

• Reduced running cost compared with mechanical equivalents

• Improved reliability

• A wide range of control & flexibility

Gear pumps

Often used in injection molding machines, hydraulic presses, rubber curing presses and mobile applications as a method of creating source of hydraulic power. Our drive and motor solutions help:

• Reduce energy consumption by up to 60 % as oil is only moved when required

• Minimize hydraulic reservoirs

• Reduce valve count, maintenance and wear

• Operate in force, velocity and position control

• Reduce noise & parasitic losses


Tire building

Tire building machines are highly complex and can include anything from 5 to over 100 axes, equating to the control of 200 or 300 motors depending on the number of steps included in the final manufacture. They process multiple tire components made up of various materials such as fabric plies, steel belt and bead assemblies, tread and sidewall and inner liners. Positioning, synchronization, cam & complex profiles can be easily managed by our motion control functionality onboard our drives or in powerful machine control option modules.

Our AC and servo drives and matched motors and gears are flexible and ideal for these kinds of machines. Decentralized motion control, enables the:

• Creation of function blocks for the onboard PLC to easily configure motion (Jog, Home, Index, Synchro, Cam)

• Capability to manage CAM up to 4,000 points

• Ability to change synchro master without additional code or specific procedures for the drive

Onboard drive Ethernet & Advanced Motion Control streamlines tire-building machines by:

• Removing the need for additional hardware

• Eliminating costly external PLC architecture

• Allowing easy daisy chain connections with other drives and 3rd party PLCs (with one cable)

• Providing customizable motion without changing the PLC

• Allowing multi axes control

Common DC bus operation optimizes the power connection enabling braking energy to be recycled within the drive system, reducing energy usage and eliminating external supply components.

Factory space is a primary concern for many tire manufacturers. Our drives and motors have small dimensions, especially high power Dyneo permanent magnet solutions, which are ideal for ultra-compact machines for short series product runs.

Our drives and motors are renowned for their world-class reliability due high quality components and protective features. In modular systems, the master can be changed on the fly to extend lifetimes. Redundancy can be built in, ensuring the system continues to run if one module is damaged and allows safe shutdown. Also, only minimal spares are required if any break-downs do occur.


Tire curing Vulcanization is a chemical process done at high temperature and pressure to make the green tire a single structure and form the tread and sidewall patterns.

Our solutions enable:

• Automation of moving parts

• Controlled loading/unloading and basic positioning of tires

• Enhanced PID control for highly effective temperature/pressure control to produce correct sulfur levels to meet quality requirements

CalenderingOne of the more challenging calendering processes occurs in tire component manufacturing, which is a heavy duty process. Fabric cord and steel belts are bonded with rubber compound using several sets of rollers, some controlled via steam and water, to create the key tire elements to specified thickness and quality. Inner liner calendering is a continuous process, requiring exact gauging and material composition to ensure it retains compressed air pressure when inflated.

Our high power AC drive solutions can provide the required speed, torque and synchronization using closed-loop control to produce high quality yield. These applications are particularly good for maximizing energy savings using our Dyneo PM solutions which exceed requirements equivalent to IE4 and NEMA Super Premium.

Wire drawing/Bead & belt steel cord manufactureWe enable highly precise speed/torque control of winders and rollers for wire drawing and steel cord production to exact tire manufacturer specifications. This includes accurate coating to maximize the adhesion of steel to rubber in later processes. Generally machines have only one motor, but several machines in a line or multiple drawing stages require synchronization which can be provided onboard the drive.

Fabric cord manufacture As with steel cord, fabric is also customized for tire usage. This includes the application of adhesive for rubber bonding and accurate twisting and combining of multiple yarns to exact manufacturer specifications. Along with the speed/torque, positioning and synchronization qualities of our technology, we can provide critical control of temperature, humidity & tension to ensure maximum integrity of fabric cords, to meet safety and quality requirements.

Steel and fabric tire component manufactureCustomized steel and fabric cords are important components in the make-up of tires to ensure they are equipped for the extreme stresses of wear and road safety. Our drive and motor solutions are commonly used in the production of both:


Energy savings and reliability maximized with our DC retrofit capabilities

Many existing rubber and plastics applications still operate using traditional DC variable speed technology. Aging equipment is often inefficient, unreliable and requires lots of maintenance, involving significant costs & downtime. We can provide many references of working with end users where replacing their control system with our AC induction (IM) or permanent magnet (PM) technology has provided benefits:

Increased reliability

• Brand new products

• Solutions designed, qualified and manufactured to the highest standards

• Long term experience from a global company

• Availability of spare products & parts

Significant energy savings

• Full support in solution selection, guaranteeing optimized choice based on application requirements

• Best-in-class efficiency technology (tests conducted by the Swedish Energy Agency ranked Dyneo® motor and drive assemblies first in the high-efficiency category)

• Maximized efficiency over the operating range (self-ventilated design as a standard and no field power)

• Increased site power factor reducing reactive power requirements (possibility of reviewing installation or electricity supply contract with supplier)

Energy Savings Advisor App

This mobile and web app is intuitive and interactive, enabling you to estimate and quickly assess the value of energy savings that can be achieved with our high-efficiency drive and motor solutions. This includes retrofit of DC by AC and PM motors on specific applications such as extruders.

Reduced maintenance & downtime

• Low maintenance requirements; up to 80% cost reduction with no need to replace brushes (where availability can also be a problem) or dust filters

• Production stops typically occur 4 times less often

• Increased mechanical protection

• Preventive & predictive maintenance capabilities from our service organization

Enhanced performances

• Qualified drive and motor packages for optimized performance and guaranteed torque over the full speed range

• Increased production capacity and quality (minimizing scrappage) thanks to torque/speed precision of modern AC drives and real-time Ethernet

• Open-loop control possibilities


• Reduced system losses, with lowest switching frequency requiring no derating and line reactors to reduce harmonics

• Liquid-cooled motor design for specific needs such as noise reduction, compactness, constant torque over full speed range, no air flow around the machine etc

Mechanical advantages

• Simple & robust motor design

• Compact solutions for ease of installation

• DC interchangeable solutions

• Liquid-cooled drives to minimize cabinet size and avoid cooling blowers (smaller dimensions and weight)

Single supplier benefits

• Full support and services to maintain peak performance

Overall, operating costs are significantly reduced, typically by 30%. Payback time is generally less than 2 years while savings over the machine’s lifetime are maximized.

To demonstrate the effectivity of our solutions, the following data has been provided by an end user (plastics converter) based on tests performed with different motors & drives on a laboratory extruder (15 kW) and on a series production extruder (100 kW).

Measures have been provided at extruder level for different operating speeds and compared the energy consumption of an AC PM Dyneo® solution with DC and AC IM Premium efficiency solutions.

82.3%

87.7% 89.4% 90.7%

68.2%

81.8% 82.9% 84.4%

46.8%

63.3%

71.2% 72.8%

40%

50%

60%

70%

80%

90%

100%

0 25 50 75 100

86.2%91.9% 93.1% 93.7% 94.3%

63.9%

81.8%84.3%

87.0% 87.4%

40%

50%

60%

70%

80%

90%

100%

0 25 50 75 100

15 kW Extruder 100 kW Extruder

Effi

cien

cy

Effi

cien

cy

% Speed % Speed

Dyneo® (AC PM) Dyneo® (AC PM)Induction Motor (AC IM) Induction Motor (AC IM)DC

A flexible offer for taking into account processors’ constraints and priorities

50 kWh

65 kWh

80 kWh

85 kWh

100 kWhTraditional solution

Mechanical optimization

IE3/NEMA Premium motors

Variable speed & IE2 motors

ENERGY SAVINGS

Interchangeability CPLS : compact AC induction motor IP23

Energy savings Dyneo® : AC motor + drive permanent magnet solution


Customized services and support to ensure optimized operation for the lifetime of your system

To back our innovative solutions, our Automation Centers can provide the following local services, to ensure the continued optimized operation of your application, including:

• Full field servicing capability

• Energy audits assess energy saving potential using real data

• Extensive after sales support

• Inventory audit solutions to ensure only minimal spares are kept in stock

• Localized and application specific content for support documentation including wiring diagrams, certification files (CE & UL) and integration manuals

• Customized local services and round the clock support

We also provide a range of expert local services tailored to meet our customers’ expanding requirements, while guaranteeing an exceptional response to emergency situations. Customized policies are defined locally and can include:

• 24/7 remote support

• Rapid response, with agreed timescales, to requests for onsite issues by skilled local support teams

• Full application analysis to identify further areas for improvement

Customized training

Scheduled training courses are available for your specific application and held onsite in many regions, or your designers, programmers and maintenance staff can attend regular courses offered at our local training centers. Typical training from industry experts can cover:

• Application operation

• Start-up and shutdown best practices

• Troubleshooting

• Periodic tuning of operating parameters and revision of system settings to improve production


Quick reactivity to customer requirements with Express Availability service

Our industrial organization and regional distribution centers mean that drives,

motors and options are available locally and are dispatched quickly as standard. This helps ensure continuity of production and minimized spares required onsite.

Our Express Availability service, available in many regions, helps customers ensure continuity of production and implement expansion, while minimizing spares and stock requirements onsite. A large range of motors, drives, options and accessories are available to be shipped directly from our regional facilities to customer premises with short lead times in many countries, starting from same day availability. Our production and regional distribution centers have been organized to meet critical customer requirements.

Energy Savings Advisor - Work out your energy savings at the press of a button!

The Energy Savings Advisor mobile and web app is intuitive and interactive, enabling you to estimate and quickly assess the value of energy savings that can be achieved with our high-efficiency drive and motor solutions. Comparisons can be made with different customized scenarios with a graphical representation of the potential savings for your applications.

For further analysis, send your simulation and questions directly to our experts. Go to www.emersonindustrial.com/esa or scan the QR code to access the free application.

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Drives & Motors Technology

www.emersonindustrial.com/esa

Energy Savings AdvisorMobile App

http://www.emersonindustrial.com/esa

http://www.emersonindustrial.com/esa

P.N. 0701-0081-01 06/16 | 5438 en - 2016.06 / a

© Emerson 2016. The information contained in this brochure is for guidance only and does not form part of any contract. The accuracy cannot be guaranteed as Emerson have an ongoing process of development and reserve the right to change the specification of their products without notice.

Control Techniques Limited. Registered Office: The Gro, Newtown, Powys SY16 3BE. Registered in England and Wales. Company Reg. No. 01236886.

Moteurs Leroy-Somer SAS. Headquarters: Bd Marcellin Leroy, CS 10015, 16915 Angoulême Cedex 9, France. Share Capital: 65 800 512 €, RCS Angoulême 338 567 258.

www.emersonindustrial.com/automation

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