Efficient, easy to use and compact - the new IE5/IE7 Motor Drive System
Nuremberg/Hameln, 12 November 2024. Automation specialist Lenze is presenting its new, compact IE5/IE7 motor drive system just in time for the SPS fair in Nuremberg. The drive system performs without sensors, even in dynamic applications. The combination consists of the m550/m650 motor, the g500 gearboxes and the newest generation of variable frequency drives, the i550 and i650. The first synchronous motor is as easy to use as an asynchronous motor. Thanks to its innovative design, it achieves energy efficiency classes IE5 and IE7. Motor losses can be reduced by up to 60 per cent, significantly lowering energy requirements and CO2 emissions. The performance is also impressive: 300 per cent overload torque accelerates the motor from standstill to full load.
Klaus Dierkes, Product Manager Electromechanics at Lenze, is delighted with the excellent feedback from test customers in the intralogistics sector: "Our customers are primarily interested in lower energy costs and reducing their carbon footprint. This is a very big issue, especially in logistics, and we can deliver this with the m550". Reality shows that the new Motor Drive System can reduce motor losses by up to 60 per cent. This is achieved by a newly designed permanent magnet synchronous motor. What's more, the motors are the same size or smaller than comparable IE2/IE3 motors.
Impressive performance: 300 per cent overload torque
High performance is also important to our customers: "We promise a 300 per cent overload torque from a standstill and we deliver it. The start at full load from standstill is achieved without any problems. The beverage industry, the textile industry and, above all, intralogistics benefit from this. This means that the system can be sized more precisely for continuous operation, as it is not oversized, and then immediately delivers the required power.
Lenze offers the new synchronous motor m550 in power range 0.25 - 11 kW and the m650 for more dynamic applications in 0.75 - 22 kW. Both can be seamlessly combined with gearboxes from the Lenze modular system. Helical, angular or bevel gearboxes are available for a wide range of requirements.
In the design phase, the first test customers worked with Lenze's new System Designer. The result: a precisely dimensioned drive solution and an energy-efficient machine concept. The web-based engineering assistant shows the energy consumption of the respective application and drive components.
Efficiency in harmony with great usabilty
Dierkes looks at the feedback from customers: "Efficiency and usabilty are crucial for our customers. One must only enter one parameter to set the motor data on the variable frequency drive. There is no encoder, therefore less wiring, no adjustments and fewer components."
The new Motor Drive System is also extremely resource efficient. The sensorless feedback means a budget-friendly chain reaction on the hardware side: no encoder, no expensive feedback system, no expensive cables. Another effect: mounting and installation are quick and safe. This contributes to the reliability of the system.
If the motor is controlled with the decentralised variable frequency drives i550 or i650 motec, there is even less need for hardware, as brake resistors are not required. The regenerative unit integrated in the motec feeds any braking energy back into the mains. The i500 cabinet frequency drives can also exchange excess energy via the DC network and make it available to other axes.
Lenze has a new solution for the positioning of goods, which is often necessary in material handling technology. "We use the SLSM algorithm (Sensorless Synchronous Motor Control) in the variable frequency drives to achieve the performance of a closed control loop without a motor feedback system and cabling. This allows us to realize sensorless and precise positioning."
So, less is more
Lenze’s new Motor Drive System opens up a solution space in intralogistics and numerous other industries, such as textiles, packaging technology and material processing, which provides a clear competitive advantage in economic terms. The system makes life easier for the user, scores highly in terms of energy efficiency and offers the potential for servo solutions. The frequency drive-controlled synchronized control is therefore a cost-effective alternative to the more expensive servo solutions and is very reliable overall due to its reduced complexity.