Electrifying ships – Electric marine propulsions are no longer a futuristic fantasy

Go emission free – Baumüller has developed a compact drive system for multi-

functional municipal vehicles

Baumüller is moving northwards – Baumüller is strengthening its local market

presence with its own branch for Scandinavia

ProMotionThe Baumüller Group MagazineIssue 2

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Editorial

EDITORIAL

Dear readers,

The Baumüller Group is developing rapidly at the moment: We started the current commercial year with new projects and a new subsidiary and we will be updating you about these developments in this edition of our company magazine ProMotion.

On page 14 we provide you with in-formation about an exciting spon-sored project in which Baumüller was one of five companies develo-ping a compact drive system for a multifunctional municipal vehicle. This fully electric vehicle is designed for speeds of up to 80 km/h and a range of up to 100 kilometers.

We are working in close collabo-ration with our clients to develop globally innovative drive and au-tomation solutions. For instance in Taiwan: where we have designed an innovative, comprehensive solution for the first fully electric passenger ferries in Asia, using solar power amongst other energy sources. You can find out more and follow a link to the YouTube video from page 19.

We would also like to thank every-one who made donations in me-

mory of my father who passed away. Instead of flowers, my family and I had requested donations for the clinic for newborns, children and adolescents at the Nuremberg South Hospital. A total of 25,000 Euros was collected. With this support, the clinic will be able to set up a new intermediate care unit which will be named after Günter Bau-müller. You will find more details on page 3.

Enjoy reading all about it and plenty more besides

Andreas BaumüllerManaging Partner of the Baumüller Group

04 Continued growth in China Baumüller anticipates a successful future at its Chinese locations

05Baumüller heads northBaumüller is strengthening its local market presence with its own branch for Scandinavia

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Contents

CONTENTSEDITORIAL 1

SOLUTIONS Practical training 8

Linear motors break 10 through silence

Precision combined with 12 mobile drive systems

Electrifying ships 16

First electric ferry in Asia 19

TRENDS Go emissions free 14

INNOVATIONS Flexibility through 6 decentralized drive concepts

COMPANY A donation to benefit 3 the little ones

Continued growth in China 4 Baumüller is moving 5 northwards

Three questions for 21

MASTHEAD 22

14 Go Emissions FreeBaumüller has developed a compact drive system for multifunctional municipal vehicles

Precision combined with mobile drive systems In conjunction with the fire truck manufacturer Rosenbauer,

Baumüller is realizing mixing systems for foaming agents

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Company

Günter Baumüller, owner of the Baumüller Group, died in October last year. Instead of flowers, the Baumüller family requested donations to support the clinic for newborns, children and adolescents at the Nuremberg South Hospital. Throughout his life Günter Baumül-ler was passionate about the well-being of children and young people. Alongside other social projects, e.g. in the area of education, he was a supporter of the clinic for newborns, children and adolescents over a period of many years. By combining the proceeds from the annual Christmas fund-raising appeal and direct contributions from the Baumüller company, the total

A DONATION TO BENEFIT THE LITTLE ONESBaumüller sponsors the expansion of the intensive care unit for newborns, children and adolescents at the Nuremberg South Hospital

donations on this occasion came to 25,000 Euros.

Karin Baumüller-Söder handed over the donation to the Nuremberg South Hospital. The money will go to-wards the construction of a pediatric intermediate care (IMC) unit. The unit will offer treatment for children who require monitoring until their condition can be stabilized after a stay in intensive care. Previously the-se children had to remain in the intensive care unit, or be specially monitored on normal wards or even be transferred to other hospitals. “I'm so pleased the new unit is becoming a reality and that we will be able to offer the children the care they need”, says Judith Peltner, nursing services at the hospital.

The unit will include four beds and will be named after Günter Baumüller in honor of his many years of invol-vement in supporting the clinic for newborns, children and adolescents. “My father was always hugely com-mitted to supporting and promoting the well-being of children and young people, and he would have been happy to help young patients with this donation”, says Karin Baumüller-Söder, “we would like to extend our heartfelt thanks to all those who contributed to the fund-raising with their donations.”

▲Karin Baumüller-Söder (2nd fr. l.) hands over the donation to extend the pediatric intensive care unit to representatives from the Nuremberg South Hospital, Judith Peltner (nursing services, left), Prof. Dr. Christoph Fusch (head physician, 2nd fr. r.) and Prof. Achim Jockwig (CEO of the Nuremberg Hospital)

With its two subsidiaries, the Baumüller Group offers the complete range of drive and automation technology with sales, application, service and production in China.

With the current management team consisting of Leon Wei Wei and Fabian Krane, an international manage-ment team is leading Baumüller on a long-term growth course in China.

Since 2003 the drive and automation specialist has supported domestic and foreign customers in China with sales, application and service. In 2012 the steady growth of Baumüller on the Chinese market led to the opening of its own production facility where today motors, converters and control cabinets are manufac-tured in accordance with German quality standards.

With the planned expansion of the application team, Baumüller China will continue to grow in future; pro-viding products, systems, service and expertise for the entire life cycle of industrial machines and systems, mobile equipment and commercial vehicles.

The core issues for the future are solutions for intelli-gent automation and drive technology, the expansion of Industry 4.0 solutions as well as increasing the pro-duct range on site.

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Unternehmen

CONTINUED GROWTH IN CHINABaumüller anticipates a successful future at its Chinese locations

▲With Leon Wei Wei and Fabian Krane, an international management team is leading Baumüller on a growth course in China

▲Baumueller Automation (Suzhou) Co., Ltd. produces in Wujiang, China

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Unternehmen

BAUMÜLLER IS MOVING NORTHWARDSIn February of this year, Baumüller created its own contact point for all Scandinavian customers with a branch in Copenhagen. The newly founded Baumüller Scandinavia ApS, based in Kongens Nytorv, Copenhagen, will now take care of customers and prospective clients in Denmark, Sweden, Norway, Iceland and Finland. With the new establishment, Baumüller offers compe-tent contact partners directly on site when it comes to drive technology and automation solutions for indus- trial systems and mobile application areas.

The Baumüller Group headquartered in Nuremberg, Germany offers solutions for drive and automation systems as well as a huge service portfolio. Baumüller also offers services throughout the entire life cycle of machines and systems: from maintenance and repair, to installation and assembly, to retrofitting.

Carsten Loie is the contact partner for customers and prospective customers. The electrical engineer offers expertise as an area sales manager domestically and abroad as well as many years of experience in the field of drive and automation technology.

Baumüller wants to serve the Scandinavian region di-

rectly with the new branch. Many high-tech providers and globally leading companies are involved in me-chanical engineering and e-mobility there and in the future they will benefit from Baumüller’s products, systems and services even more. Baumüller offers “made in Germany” drive and automation technology with its own local contact partners.

▲The newly founded subsidiary Baumüller Scandinavia ApS supports customers and interested parties in Denmark, Sweden, Norway, Iceland and Finland | Photo: Antony McAnlay / fotolia

▲Carsten Loie is the sales manager of the new Baumüller branch in Scandinavia

Baumüller is strengthening its local market presence with its own branch for Scandinavia

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Innovations

FLEXIBILITY THROUGH DECENTRALIZED DRIVE CONCEPTSThe transition from centralized to decentralized offers numerous simplifications and enables compact and economical designs. Instead of being located centrally in the control cabinet, converters are mounted close to or directly on the motor. This results in a significant reduction in the size of the control cabinets and in many cases they can be dispensed completely, which saves space and reduces costs. The cost of wiring is also much lower in decentralized solutions because it is no longer necessary to lay motor and transducer ca-bles through the entire machine for every drive. Often a single cable will suffice for all drives, which minimi-zes the work involved in laying cables and reduces the space required and the cost of materials, particularly for branched units with multiple drive axes. The trend towards increased modularization also makes decen- tralized drive technology an attractive option.

Baumüller has been using decentralized and central drives in modular machine designs for many years: the use of decentralized drives allows a more economic design, depending on the application, and also op-timizes the installation area through a more compact construction. The technology is deployed in a wide range of applications. Baumüller offers decentralized designs both in industrial applications and also in technology for mobile drives.

SOLUTIONS FOR THE INDUSTRIAL SECTOR

The decentralized drive b maXX 2500 with a power supply of up to 780 VDC is particularly suitable for deman-ding, dynamic positioning tasks, such as filling systems with lots of individual drives. In the b maXX 2500, Baumüller combines technology from the b maXX 3300 converter series with Baumüller servo drives. Thanks to a large number of supported, Ethernet-based field- bus systems and a flexible installation position, the b maXX 2500 offers mechanical engineers great flexibi-lity during construction and enables the creation of op-timally customized machine solutions. The b maXX 2500 will also soon be available with a 60 V power supply for motor size 28. In combination with the b maXX 5030 feeder unit, Baumüller offers the option of a cost- efficient STO (safe torque off) safety function. The b maXX 2500 also provides integrated safety technology. In addition to this, the integrated b maXX-softdrivePLC enables very straightforward decentralized program-ming in the controller in accordance with IEC 61131, which rounds off the characteristics of the high perfor-mance controller in the b maXX 2500.

In standard applications in the low power range, such as for adjuster drives, the DSDI-small servomotors are used. The intelligent drive with a nominal power of up to 400 W is available in sizes 28 and 36 and is cha-racterized by its robust construction. The DSDI can be mounted directly on the system which enables a mo-dular machine design. The DSDI can be deployed with a supply voltage of between 9 and 60 VDC, CANopen is installed by default. An optional EtherCAT fieldbus module or ProfiNet are available. With its very short structural shape, the drive has an excellent mass in-ertia ratio.

Another highlight of decentralized drive technology is the DSMI disc motor drive with integrated servo- controller.

The high-torque servo drives were developed for users whose machines have particularly stringent require-ments in terms of smooth running and overload ca-pabilities. With its extremely short structural shape,

▲With the decentralized b maXX 2500 drive concept, Baumüller combines its tried-and-tested converters from the b maXX 3300 series with Baumüller servo drives

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Innovations

the drive can be optimally integrated into the machine design. Thanks to the DSMI’s high overload capabili-ty, significant load changes are possible. In addition, good acceleration characteristics ensure higher ma-chine outputs, making the system more economically efficient.

DECENTRALIZED DRIVES FOR MOBILE APPLICATIONS

The powerMELA® drive concept, which Baumüller de-veloped especially for mobile use in collaboration with Sensor-Technik Wiedemann GmbH, meets all the re-quirements for e-mobility thanks to its high power density, its compact and robust construction and its recovery capabilities. It consists of a combination of a permanent magnet synchronous reluctance motor with buried magnets and an integrated four-quadrant converter. The compact design is thanks firstly to the integration of the converter, and secondly the compact construction of the electric motor. The drive’s innova-tive cooling concept enables an extremely high power density. The drive system thus requires minimum ins-tallation space and only weighs around 300 kg for the highest power category, including the motor, converter and transmission. The power density is thereby double that for motors using standard water cooling.

With a degree of protection up to IP6k9k and a relia-ble temperature range from – 40 °C to 85 °C, the drive is particularly robust. The motor design is also cha-racterized by a broad speed control range, due to its excellent field weakening capacity.

The motor is available in the 40 kW to 140 kW nominal power classes. All models are available with a separate converter to reduce the motor’s installation dimensi-ons. Thanks to the external electronics, it is also possi- ble to control the motor from a central location, e.g. from a towing vehicle. Alongside direct use in vehicles, the powerMELA® is also ideal for other applications, such as for trailers. In the higher power categories, a choice can be made between internal and exter-nal electronics. The drive can be used as a motor or a generator. Thanks to the extensive decoupling of the operating modes, it is possible to store excess energy, which improves the system’s energy efficiency as well as offering greater flexibility when designing innova-tive drive concepts.

With the DSA 200 motor generation, Baumüller offers a weight-optimized solution for mobile drives. The ex-ternal rotor motors have good recovery capabilities and can handle a wide range of applications with a maxi-mum nominal power of up to 3 kW. This sustainable drive solution is suitable for two-wheelers, mopeds, motorbikes and delivery bicycles as well as in the he-alth care sector, where it can be used as an intelligent drive e.g. for wheelchairs or patient transport systems.

Other potential areas of use include conveyor techno-logy and ventilation systems. The DSA 200 is characte-rized by its high continuous output and quiet opera-tion with minimum noise emissions. In addition, the motor is constructed with an IP65 protection rating and so can withstand harsh environmental conditions. Our customers also benefit from outstanding flexibility

▲The powerMELA® drive concept consists of a permanent magnet synchronous reluctance motor with buried magnets and an integrated four-quadrant converter, and is suitable as a hybrid or purely electric drive in vehicles and mobile machinery. It stands out thanks to its compact and robust construction and is also available with a separate converter (on the right in the picture)

▲The powerMELA® drive concept is used in mobile utility vehicles and machinery, such as battery-powered electric 18 metric tonne trucks

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Innovations / Solutions

in terms of drive integration because the housing can be custom-designed to suit each client. In conjunction with the b maXX controller, Baumüller is able to offer a highly dynamic, comprehensive solution.

Baumüller will extend the DSA motor series with a size 150 option to achieve maximum rotation speeds of up to 10,000 min-1 and a greater power range up to 19 kW nominal power. This makes the DSA 150 the ideal drive for mobile vehicles and machinery.

Decentralized drive concepts for industrial and mobile applications

We know them as calm and friendly service personnel - the air stewards and stewardesses who work for national and international airlines. But just being friendly isn’t enough in this job, where these ladies and gentleman

are responsible for all the passengers on board. The aircrew have to be completely capable, particularly when it comes to matters involving safety.

Flight attendants undergo regular safety training to practice how to behave in every possible situation; in flight, during landings and on the ground. Modern simulators make this training possible, so action plans aren’t just learned as a theoretical process but can also be taught as a practical exercise. The company TFC Simulatoren & Technik GmbH (based in North Rhine- Westphalia) provides cabin, service and door trainers which the cabin crews can use to practice under highly realistic conditions.

PRACTICAL TRAININGCabin staff practice on door trainers from TFC using servo technology from the automation equipment provider Baumüller

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Solutions

QUICK, PRECISION CONTROL WITH SERVO TECHNOLOGY

Baumüller equips these realistic door trainers with ser-vo drives which simulate different situations. With up to three servo drives per door, the handle functionality and door lift and swivel movements can be adjusted precisely. “Previously we used hydraulic solutions”, says Thomas Reichelt, production manager at TFC, “but the servo-electric solutions can be controlled far more precisely and quickly than the hydraulic systems.”

This means it only takes split seconds for training staff to simulate a door which is stiff to open. TFC selec-ted servo drives manufactured by Baumüller (based in Nuremberg) which consist of compact DSC servo drives and flexible b maXX 5000 converters; amongst other things this choice was prompted by the extensive range of safety technology for Baumüller products. By utili-zing optional safety modules, engineers can equip the drives with different safety functions.

The door is the simulator’s core component and its operation is one of the most important elements du-ring safety training. But the simulators can also model other conditions which cabin crew may face. For in-stance, visual tools or movements may be deployed to imitate hazardous situations and to simulate smoke or fire. For effective training the door trainers are also equipped with video cameras to enable training per-sonnel to offer feedback and evaluation sessions after training run-throughs.

TFC offers door trainers as customized solutions for all types of aircraft and consequently has customers which include well-known airlines such as Condor, Air France and Alitalia.

COMPACT AND FLEXIBLE

The DSC motors from Baumüller are up to 30 percent more compact than conventional servo drives and are also easy to install in awkward locations thanks to rotating plugs for the main connection and encoder connection. The permanently excited synchronous drives have an outstanding power density and excel-lent rotational and control properties. For higher tor-que densities, the DSC series motors reach maximum speeds of up to 6000 rpm.

The b maXX 5000 converters allow both standardized and complex automated solutions in a performance range from 1 to 315 kW and the four different safety modules enable flexible adjustments to the require-ments posed by different applications. The double axis contained in the compact b maXX 5000 is what drives the Baumüller DSC motors and enables the client’s technical requirements to be met.

▲Up to three DSC servo drives are incorporated in each TFC door trainer

▲The door trainer simulates circumstances such as the doors becoming blocked, fire and other hazardous situations which may arise in the event of a crash landing or other incident

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Solutions

LINEAR MOTORS BREAK THROUGH SILENCEBaumüller drives make the bells of the Protestant St. Nicholas and Ulrich Church in Nuremberg- Mögeldorf ring

For two years it was quiet in the Protestant church community of St. Nicholas and Ulrich in Nuremberg- Mögeldorf. No bells could be heard far and wide. This was due to the unstable roof structure of the church, which was reconstructed last year. Thanks to the linear drives of the company Baumüller, which is headquar-tered just two kilometers from the church, the bells are now ringing again.

A UNIQUE SOUND

The top of the hour has been reached in Mögeldorf. A soft hum in the belfry precedes the loud chimes, which announce the time. With the humming, the two church bells begin to swing and ring: Ding-dong, ding-dong. The reverend Ulrich Bauer-Marks smiles saying, “It's nice to hear that sound again after two years of silence.”

Linear direct drives were used instead of the conven- tional solution, i.e. using three-phase motors com-bined with mechanical transmission elements. They are impressive due to their narrow design and a jerk-free ringing. In addition, they allow for a particular-ly beautiful sound, since the bells are rung without contact via induction forces.

The asynchronous linear drives are maintenance and wear-free and are only six centimeters wide each. The assembly on the belfry directly next to the bell is simple, since this solution does not have any moving components, such as chains or gear belts. The drives power develops near the bell's axis of rotation, thereby only generating small vibrations, which is accommo-dated by the tower structure's weight bearing.

▲Using linear motors from the company Baumüller, the church bells in Nuremberg-Mögeldorf are back in operation. The motor’s narrow design makes it easy to attach it to the belfry right next to the bell

▲Two bells with asynchronous linear motors from Baumüller provide the unique sound in the Mögeldorf church in Nuremberg

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Solutions

25 YEARS OF EXPERTISE IN BELL CHIME TECHNOLOGY

In 1993, the company Schmidt Glocken- technik introduced this type of bell chime technology with linear drives from Baumüller. Each linear motor consists of a motor and a reaction rail. The motor corresponds to the stator and the reaction rail corres-ponds to the rotor of a three-phase drive. The reaction rail is secured to the bell's hoke, which is a rotatable beam.

A magnetic field is required to put the bell into motion. The motor ge-nerates this magnetic field and also induces another magnetic field in the reaction rail. These opposing magnetic fields attract and repel each other, thus putting the bell into motion. It begins to swing and rings.

The Mögeldorf bells were cast in the 16th century and are well- preserved. The large bell weighs 930 kilograms and the small bell weighs 262 kilograms.

Baumüller linear direct drives only gene-rate small vibrations, which are absorbed by the tower structure of the 600 year old Mögeldorf church

►

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Solutions

The Austrian company Rosenbauer is one of the world’s biggest manufacturers of firefighting equipment and includes fire trucks in its product portfolio. The foam pressure proportioning system DIGIMATIC42 is an equip-ment option offered by Rosenbauer. It is driven electri-cally using a controller and motor from the Nuremberg drive and automation manufacturer Baumüller.

FIREFIGHTING WITH FOAM

Many fires cannot be fought with water alone, or there may be a limited amount of water available due to the absence of a central firefighting water supply. For example, on motorways the only source of water is the tank installed on the fire truck. In both these scenarios it is necessary to use a foam pressure pro-portioning system to mix additives, such as foaming agents, in a particular ratio with the water in order to successfully extinguish the fire. Precision is a pre-requisite in this mixing process to ensure that the resulting fire extinguisher foam can be used effec- tively and efficiently.

The comprehensive Baumüller drive solution for the DIGIMATIC42 electric proportioning system includes a mobile controller from the b maXX mobil series and the DSM disc motor. Due to the highly stringent de-mands in terms of precision and reliability for pro-portioning systems used in firefighting operations, Rosenbauer opted for the mobile drive technology and electric motors supplied by Baumüller.

The b maXX mobil is designed for four-quadrant ope-ration, it can also be braked in both directions and can feed back energy as well as supplying power. For mo-bile use, the controller is vibration resistant and can be used at temperatures ranging from -25° to +65° Celsius. The three-phase DSM disc motor has almost no residual torque and its impressive features include a high capacity given a small construction volume and extremely short structural shape.

PRECISION COMBINED WITH MOBILE DRIVE SYSTEMSIn conjunction with the fire truck manufacturer Rosenbauer, Baumüller is realizing mixing systems for foaming agents

▲Rosenbauer’s foam pressure proportioning system DIGIMATIC42 is electrically powered with a controller and motor from Baumüller

The comprehensive Baumüller drive solution for the DIGIMATIC42 electric proportioning system includes a mobile controller from the b maXX mobil series and the DSM disc motor▼

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Solutions

NUREMBERG’S PROFESSIONAL FIRE DEPARTMENT USES LOCAL KNOW-HOW Nuremberg’s professional fire department has recently switched to using Rosenbauer fire trucks and the first

batch of vehicles is already in action. So Baumüller’s extensive expertise is being used not just internatio-nally, but also right here in their local area.

▲The Nuremberg fire department has switched to Rosenbauer fire trucks. The foam pressure proportioning system DIGIMATIC42 is an equip-ment option offered by Rosenbauer and it is electrically driven using a controller and motor from the Nuremberg drive and automation manufacturer Baumüller | Photo: Rosenbauer International AG

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Trends

GO EMMISSIONS FREEBaumüller has developed a compact drive system for multifunctional municipal vehicles

Baumüller has developed a compact drive system with very high energy efficiency for fully electric munici-pal vehicles. The vehicle is designed for speeds of up to 80 km/h and has a range of up to 100 kilometers. The end-result of this collaboration with other com-panies is an emission-free, environmentally friendly, low-noise, multifunctional municipal vehicle. It can be used with interchangeable accessories for a wide array of municipal cleaning and maintenance activi-ties, e.g. as a road sweeper, snowplow or loader.

This joint development project with the companies Cosyst Control Systems GmbH, bLz - Bayerisches Laser- zentrum GmbH, Polyplast Sander GmbH and SMS Engineering GmbH was supported by sponsorship from the Bavarian State Ministry for Business and Media, Energy and Technology. The project owner is Bayern Innovativ.

ELECTRIC AXLE FOR REAR-WHEEL AND FOUR-WHEEL DRIVE

Baumüller’s compact drive system consists of two fully electric drives, each mounted on the vehicle’s rear axle. Alternatively, instead of a rear-wheel drive, a four-wheel drive can be deployed with four drive systems. Each drive system consists of a Baumüller DSA synchronous axial flow motor with inte- grated converter, power elec-tronics plus planetary gears and has been designed speci-fically for this grant-assisted project.

The planetary gears are loca-ted in the wheel rim and are directly connected to the drive

system. This has the advantage that there are lower transmission losses because there is no need for an additional drive train, such as a cardan shaft, drive shaft or differential. Other benefits of the compact drive system include greater versatility and improved driving comfort. The drive also has excellent overload capabilities, for instance gradients of up to 18 percent can be handled quite easily.

The key feature in the robust, re-designed DSA motor, with a nominal power of 18kW, is the winding switch- over. This enables the municipal vehicle to automati-cally change gears from working speed to high-speed without losing any efficiency. This switchover allows different torque values and speeds to be achieved, with automatic adjustments depending on the appli-cation being made via the motor controller developed by Baumüller. This means that in the first gear, at wor-king speed, e.g. for sweeping or mowing operations, double the nominal torque can be achieved at just half the speed.

This gear is used for speeds up to 40 km/h. The power source is not burdened with large currents, which en-ables a significantly larger range and longer operating

Baumüller has developed a com-pact drive system with very high energy efficiency for a fully electric municipal vehicle. The vehicle is designed for speeds of up to 80 km/h and has a range of up to 100 kilometers

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Trends

duration than previously. In second gear, the high-speed gear, speeds of up to 80 km/h can be achieved. Despite the higher speed, the power requirements correlate to those for the first gear. Efficiency also re-mains very high, thus enabling both a significantly larger range and a longer operating duration.

The installation space for this electric axle (motor and converter) has been optimally adjusted to suit the in-stallation conditions in the vehicle, with small dimen-sions of just 414 mm length and 300 mm diameter.

COMPREHENSIVE SAFETY CONCEPT

For fieldbus communication and thus the connection to the control unit, Baumüller uses CANopen for this purely electric vehicle. In addition, there is reciprocal monitoring of both drive controllers in the b maXX series as well as all important safety measures affec-ting the drive.

ENERGY RECOVERY INCLUDED

The fully electric municipal vehicle is 3.4 meters long, 1.4 meters wide and is able to generate energy when braking or driving downhill. This energy is then fed back into the three battery modules each with 8.5 kWh. This further enhances the range and energy balance. The vehicle has a range of approximately 100 kilometers.

PLENTY OF EXPERTISE IN THE E-MOBILITY SECTOR

Baumüller is exploiting its many decades of experience in developing motors and producing electric engines;

for over ten years it has been supplying energy- efficient components and comprehensive solutions for hybrid and fully electric drive systems. These low- noise, low-emission drive solutions are being used in hybrid agricultural machinery, tracked vehicles and fully electric city buses and municipal vehicles, to name just a few examples.

▲The electric axle developed as a drive system by Baumüller is inserted in twin mode on the rear axle, or in a four-way operation for four-wheel drive systems. It consists of a Baumüller DSA synchronous external rotor motor with planetary gearing and integrated power electronics with motor controller and converter

eTruck - drive solutions for e-utility vehicles

Maximum speed: 80 km/h

Range: 100 km

Vehicle length: 3,40 m

Vehicle width: 1,40 m

DATA & FACTS:

Hazardous particulate and nitrogen oxide emissions which far exceed the thresholds applicable for road transport are routinely found in the shipping industry. Legislators now want that to change and are introdu-cing limits which make electric propulsion for ships particularly attractive. The technology is ready. As a specialist in electric drive technology, Baumüller can offer concepts for equipping barges, yachts, ferries and working vessels which will enable a significant reduc-tion in emissions.

Shipping must become cleaner. That is the aim. And that is why the European Commission has stipulated

that ship emissions in ports should be reduced by 60 percent by 2050. The same trend applies to over-seas transportation and, according to the International Maritime Organization (IMO), vessels must be equip-ped with environmentally friendly technology and, to some extent, vessels will have to be retrofitted to meet the requirements. Inland shipping is also affected: the European Parliament has adopted new emissions limits for mobile machinery and equipment not in-tended for road transport; this includes tractors, con-struction machinery and vessels on inland waterways. As a consequence, no later than from 2020, all motors that are brought to market must comply with the Euro 5 emissions standards.

These requirements demand clear technological ad-vancements and a rethink when it comes to choosing drives for all types of ships.

THE TECHNOLOGY IS READY

Along with fully electric solutions, diesel-electric hybrid drives are the technology of choice when it comes to

16

Cover Story : Rubrik

ELECTRIFYING SHIPSElectric marine propulsions are no longer a futuristic fantasy – the technology is ready for a generational change

▲Photo: isavira / fotolia

equipping ships to meet the new standards. Baumüller has all the necessary technology and experience to equip barges, yachts, working vessels, offshore vessels and ferries with electric drive systems. Baumüller has the appropriate components, systems and experience to serve as a system supply partner for shipyards, sys-tem integrators and shipowners.

DIESEL-ELECTRIC HYBRID DRIVE FOR GREATER EFFICIENCY

With a diesel-electric hybrid drive, the ship’s propellers are powered via converter-fed synchronous motors that obtain their energy from diesel generators. In principle there are two options when designing this kind of drive system. The parallel hybrid, in which the diesel and electric motors are synchronized to achieve full power; this is seldom used. The state of the art approach is the series hybrid, in which the electric motor has sole responsibility for driving the propel-lers. In this solution, the combustion motor drives the generator which supplies the electric power and which can be operated with excellent efficiency thanks to the fact that it is completely decoupled from the drive sys-tem. In addition, the series model offers the option of operating the ship completely electrically and thus with zero emissions, which is particularly beneficial for harbor navigation. With a parallel hybrid, this would

only be possible with an additional diesel generator and all the associated extra costs, e.g. for particulate filters.

For fully-electric navigation the drive systems are usually equipped with lithium-ion batteries which can be charged from the drive system on board or via an on-shore connection. These offset any power peaks for the diesel motor and do away with the need for extra harbor diesel.

ADVANTAGES

Numerous advantages make the combination of diesel and electric motors particularly attractive for shipping. Along with a significant reduction in fuel consumpti-on, this system also reduces noise and vibrations.

Another benefit is the improvement in the diesel mo-tor’s overall efficiency. For instance, only a low pow-er level is required for ships that need to maneuver precisely out in the open sea or that need to keep to a fixed deployment location. With a pure diesel drive the speed in these cases is massively reduced when compared to the previous, faster moving journey. This means the motor isn’t operating in its ideal efficiency range. By contrast, when an electric drive is used in these situations, the frequency converter controls the propeller speed directly via the synchronous motor, thus enabling it to run far more slowly.

Since synchronous motors achieve high efficiency even at low speeds, the electric mode saves fuel. Another

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Solutions

With a hybrid drive designed in series, the electric motor has sole responsibility for propulsion. The combustion motor here is opera-ted at a very high level of efficiency, over 95 percent, and this can be done using only electric power with zero emissions▼

benefit is the enhanced maneuverability which is a consequence of the electric motor’s constant torque. Full torque is available even at low speeds, which is a major advantage when maneuvering in harbors or when mooring or setting sail.

The advantages of the battery-powered ship solution from Baumüller lie, on the one hand, in the intelli-gent overall design based on many years of experien-ce in the marine propulsion sector and, on the other hand, in the highly-efficient synchronous motors. The drive system thus achieves efficiency levels of over 95 percent.

BAUMÜLLER PROVIDES

The Nuremberg-based company Baumüller offers ex-pertise in drive and automation solutions and has experience with drive systems for shipbuilding and mobile drive technology in general. Baumüller meets specific shipbuilding requirements with motors that are optimized for use in ships in accordance with the Lloyd’s Register and with special wing mounts for ins-tallation in ships.

SYSTEM EXPERTISE

In addition to its component expertise, Baumüller is also a system partner. In collaboration with companies such as battery manufacturers, the system engineering experts from Baumüller create complete solutions for drive and automation systems and fit out ships using in-house torque motors, converters and control units, among other devices.

The Baumüller complete solution includes electric mo-tors, converters, scalable lithium-ion batteries with

energy management systems, control cabinets, thrus-ter and propeller control units. The electric battery drive system is complemented by the prescribed statuto-ry safety drives in the form of redundantly designed diesel units. So maneuvering capabilities are guaran-teed, even if battery levels are low.

Baumüller uses energy-efficient motors in its drive systems for ships. These have the advantage of a small size and comparatively low weight and, above all, they are highly efficient. This makes them particularly well-suited for mobile use.

FULLY ELECTRIC SHIPS

It is already possible to transport goods and passengers on the water using fully-electric rather than hybrid systems. One example of this is the electric battery- powered ferry for the port of Kaohsiung in Taiwan. Baumüller planned and implemented the innovative drive concept, which also uses solar power. You can read a more detailed article on the first electric ferry in Asia from page 19.

CONCLUSION

When it comes to hybrid or fully electric ship drives, Baumüller has tried-and-tested, efficient designs which will meet the requirements posed by ships’ captains, shipping companies and legislators in equal measure. The technology is ready and the transition to quiet and environmentally friendly drives has already begun.

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▲Baumüller has experience with drive systems for shipbuilding and general mobile drive technology and is an interesting partner for shipyards, system integrators, ship owners, operators and captains as well as being an independent supplier of complete systems

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Solutions

In Kaohsiung, the second largest city in Taiwan, the first completely electrically-operated ferry in Asia was launched a few months ago. The Qi-Fu No. 1 has been operating on the route between Kaohsiung in the southwest of the island of Taiwan and the peninsula Cijin Island since December of last year. Up to 8 million passengers travel this route per year.

The high exhaust emissions and the noise levels of diesel ferries were the reason why the port city of Kaohsiung commissioned an electrically-operated ferry from the local Reederei Ting Hai Shipbuilding Co., Ltd. The 25 meters long, 6.50 meters wide and 108 ton ferry offers space for 150 passengers and 46 bicycles. The electric drive with 80 batteries allows for an average travel speed of six knots and four hours of operating time. The charge time is about three hours.

INNOVATIVE DECENTRALIZED DRIVE WITH A HIGH DEGREE OF EFFICIENCY

Baumüller uses the powerMELA drive concept in the ferry, which is a joint development with Sensor- Technik Wiedemann. This decentralized concept of an electric motor and integrated frequency inverter im-presses with a compact design. The drive system thus requires minimum installation space and only weighs around 300 kg with the motor, inverter and transmis-sion. Thanks to its innovative direct cooling concept, the motor offers a very high power density and, due to its recuperation capability, i.e. the ability to recovery energy while braking, it meets all the requirements of an efficient system.

In the innovative Baumüller complete solution, the ferry's two ship propellers are each powered by two powerMELA systems in a dual drive each with 150 kW. The ferry's operating and on-board network is powered by three parallel-connection lithium ion batteries, which are charged overnight using shore power via the local power grid. During the day, solar cells on the ferry’s roof feed additional energy into the batteries.

FIRST ELECTRIC FERRY IN ASIA The first fully electric passenger ferry in Asia is operating with Baumüller technology and uses solar power

The first fully electric passenger ferry in Asia Qi-Fu No. 1 operates with an efficient Baumüller drive

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Solutions

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Although the ship is designed for purely electric ope-ration, it has two diesel emergency units as an additi-onal source of power. This makes it possible to realize hybrid driving profiles as well.

The advantages of the battery-powered ship solution from Baumüller on the one hand lie in the intelligent overall concept based on the many years of experience in the marine propulsion sector and on the other

hand in the highly-efficient synchronous motors. The drive system thus achieves a degree of efficiency of over 95%.

▲In the innovative complete solution from Baumüller, the power for the operating and on-board network of the battery-powered ferry is acquired from solar power in addition to the power grid from shore power

Fully electric passenger ferry – innovative drive solution from Baumüller

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Company

Antonio Jung, Managing Director of BMK Co., Ltd.

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ning. In addition, we support our customers with pro-duct and application training plus system and compo-nent sales.

? Is there an interesting customer project you’d like to outline briefly for us?

Jung: Yes, our client Simpac, which is based in Incheon, uses Baumüller motors and converters to operate its servo presses. Thanks to our high-torque motors, the motion profile required for new manufacturing pro-cesses can be achieved. This year systems will be put into operation in the Czech Republic and Vietnam.

Baumüller has two agencies in South Korea. BMK Co., Ltd. was founded in 2013 and has its headquar-ters in BuCheon City, which is about 25 kilometers from the capital city Seoul. With a further two branches in Suwon and Gumi, the sales and service for Baumüller is coordinated for the whole of South Korea. The second branch, Bomac Systems, ser-ves customers exclusively from the plastics sector and has been active for Baumüller in Korea since the 1990s.

? Mr Jung, to what extent are the needs of South Korean customers different from those in other countries? And which sectors are particularly import-ant for you?

Jung: South Korea is active in lots of sectors and it exports products across the world to supply the machine and entertainment industry. Our focus is on the coating, con-verting and entertainment sectors. In addi- tion, machines for producing batteries and servo presses plus injection molding machi-nes are very important.

? What services do you offer your customers? Is trai-ning possible on site?

Jung: Our local spare parts warehouse and trained ser-vice team guarantee swift repairs and maintenance for Baumüller products. We also offer expert commissio-

THREE QUESTIONS FORAntonio Jung, Managing Director of BMK Co., Ltd.

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Masthead

MASTHEAD

Publisher: Baumüller Nürnberg GmbH

Ostendstr. 80-90 90482 Nürnberg

Germany www.baumueller.de

Editorial Staff: Anja Andraschko

Stefanie Lauterbach Susanne Reinhard

In collaboration with: Nina Soentgerath: layout, graphics

Image credits: © Antony McAnlay / Fotolia GmbH: Page 5 © Rosenbauer International AG: Page 13

© isavira / Fotolia GmbH: Seite 16

Baumüller ProMotion is published in German and English.

2018