THIS month FEN talks to Bonfiglioli Transmission Australia managing director Malcolm Lewis.
Q: How does vector drive technology continue to improve?
The evolution of technological solutions based on Vector drives is influenced by changes in market demand and opportunities created through advancing technology.
Increasing demand for small, powerful and agile automation systems is directing development of drive concepts towards such areas as dimensional improvements, better usability, and powerful communication.
New drives on the market are distinguished by increased power density in terms of rated power vs. space occupied in a cabinet, and in terms of room needed for product mounting and operation.
Usability of more sophisticated devices is ensured through modular software and tools for guided configurations.
An essential component of automation systems is the ability to set up effective and easy communication, both among drives and with other control devices.
This is achieved through field bus communication, with industrial Ethernet being the latest and most powerful standard.
Q: Where do you think drive technology is heading, in terms of its capabilities and applications?
At least two main worldwide needs of industrial applications will affect future drives projects; these are energy rationalisation and integration.
Renewable energy production is a fast growing business that deeply involves drives technology.
Bonfiglioli has recently released a regenerative system for photovoltaic plants from 10 kW to 500 kW, capable of converting photovoltaic energy into 3-phase AC current and managing its delivery to mains.
Q: How is the saying “You get what you pay for” true with vector drives?
Seldom is the cheapest the best, but the best does not need to be the most expensive.
Technology adopters need to look at the whole-of-process benefits and the savings achieved by using the best technology to achieve the best overall result, rather than just comparing the cost of components.
Basic features like product reliability are no longer the sole criteria of vector drives quality.
Vector drive manufacturers have to offer this and more.
The value of a drive is now mainly determined by its ability to provide the appropriate set of functionalities for a particular application, and to effectively integrate itself into the architecture of an automation system.
This is the reason why software is now so important.
Q: What characterises the best control software for vector drives?
Two different philosophies stand out in the history of basic motor control software.
FOC and DTC have alternated in leadership through the years, with DTC gaining much interest in early 1990s, because it has the advantage of ensuring robust and self-adaptive control, with limited microcontroller ability.
FOC can achieve the best accuracy and it is more suitable for synchronous machine control.
FOC has now returned to the leading position because of advances in the power of industrial microprocessors, coupled with cost reductions for the technology, together with the growing interest of industrial applications in permanent magnet synchronous motors.
Q: How is vector drive control software changing?
Vector drive control software is becoming more sophisticated, powerful, and easier to use.
Bonfiglioli distinguishes three levels of software in their drives comprising motor control, machine control, and application control software.
Motor control software governs the main motor variables of speed, torque, and space.
Machine control software includes all functions needed to tailor the drive to the general requirements of the machine.
Application control software includes dedicated functions to fulfill the requirements of a specific application.
The widest opportunities of software improvement are within the machine control and application control software levels.
The enhancement of machine control functions gives the drive higher flexibility to fit to every application.
Q: What impact do you think vector drive technology is having on manufacturing now and into the future?
Manufacturing plants frequently ask for productivity, flexibility, efficiency and non-stop working capability.
Electric drives together with motors and gearboxes give effective answers to first two of these needs, allowing faster machine cycle times and easy rapid machine set up.
Drive challenges in future will be more focused on efficiency and work continuity of production lines.
Efficiency can be gained by intense use of drives even in parts of the of the machine that do not require speed regulation. These parts benefit from energy saving when a drive is applied.
Q: What advice would you offer FEN’s readers about vector drives?
Do not look only to the drive itself, but try to optimise the drive train to get the most effective results in performance and overall cost.
Key Contact:
Malcolm Lewis
Bonfiglioli Transmission Australia
malcolmlewis@bonfiglioli.com.au
www.bonfiglioli.com.au
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