The adaptation of different tasks and concepts in industrial automation requires high computing power on the one hand, and on the other hand intelligent functions with which the requirements of Industry 4.0 can be efficiently implemented. The Lenze i950 inverter is designed precisely for these requirements.

One example is its unusually dynamic control performance. The inverter's optimized kinematics take into account both the drive axis itself and the control path behind it. This means that faults and deviations are corrected much faster than with standard inverters on the market. As a result, the target value is restored in less time, and the deviation from normal operation of the servo axis is only minimal.

During operation, this pays off twice over. On the one hand, there is the high precision in positioning, as required for example in print shops. High-quality print products can only be produced with exact ink application. On the other hand, in the higher speed that can be driven. Viewed over the entire press, this advantage adds up to a 20 percent higher cycle rate. For the user, this means a considerable gain in performance and efficiency, which is not bought at the expense of lower quality but is accompanied by better results.

Information centre for IIoT

Future-proof factory automation must take into account the development towards the Industrial Internet of Things (IIoT) - the intelligent use of data to make machines smarter and more flexible, to make servicing and maintenance more efficient and to enable new OEM sales and service models.

But where does the required data come from? The seemingly simplest answer is additional sensors. But they involve a lot of effort: wiring and control systems become more complex, planning and installation costs rise, as do the costs for materials and maintenance. But Lenze shows that there is another way. Intelligent use of the data already available from the servo axis makes additional components superfluous. Instead, the drive itself becomes a sensor that lays the foundation for services such as condition monitoring. The Lenze development experts advise their partners on how to detect belt tension, friction and inertia anomalies in existing data and how to generate profitable new service models from this data.

Easy access to the cloud

Data processing for condition monitoring and predictive maintenance can be handled by the powerful i950 at the edge. However, IIoT also means networking beyond the individual machine, for example to monitor different systems together, to maintain different locations centrally or to benchmark. Such more complex tasks are usually handled via cloud services that enable the use of machine learning (ML) and artificial intelligence (AI). A simple way to transfer data from the powertrain to IIoT is therefore essential.

With the x500 gateway, combined with the X4 Remote platform, machine builders receive a ready to use  cloud solution from Lenze that includes continuous condition monitoring, remote machine maintenance and user-friendly asset management. OEMs and users are free to choose the cloud provider to build their IIoT platform.

Easily networked

Lenze also meets the requirements of mechanical engineering when it comes to wiring. The standardized One-Cable-Technology (OCT) further simplifies the design of the machine. Instead of separate supply and data lines, only one single connection is required. The open motor feedback protocol transmits the motor data digitally. In the case of Lenze's MCS and m850 series drives, for example, it also transmits the encoder signal and motor temperature. This is also part of the "drive as sensor" concept, as resolvers and motor temperature sensors can be omitted here. Less wiring reduces material costs and saves space in the control cabinet. In addition, potential sources of error are reduced: connection and wiring related failures become less frequent, and finding the cause is easier because fewer options have to be tested.

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Lenze believes it is the first of its kind to offer this level of communication integration for decentralised applications, making it suitable for use with conveyors, fans, pumps and lifting units.

Thanks to the inclusion of the IO-Link V1.1 standard interface, sensors and actuators distributed throughout an application can be linked to a centralised control system using the new i550 protec. The exchange of process, asset and parameterisation data in harsher environments becomes easier and more economical as the requirement for the manual addressing of nodes or the use of expensive screened motor cables is removed.

If an IO-Link master is already in use in the network, additional costs can be saved by using the i550 protec, as devices will be automatically parametrised during standard set-up, or as part of an in-service device replacement. The new decentralised communication standard ASi-5 can also be connected to the Lenze i550 IO-Link interface, along with other common fieldbus interfaces.

The i550 protec is a compact yet robust device. The 0.75kW version of the inverter, for example, has a volume of 3.1dm³ - at least half the size of typical solutions on the market. With IP66 / NEMA4X ingress protection, the device can be installed in areas that experience adverse environmental conditions such as high temperatures, dust, dirt or water jet during cleaning operations.

Neil Beaumont, Marketing Manager at Lenze, says: “The i550 protec is particularly suited to large-scale machines, distribution applications in material flow or wherever control cabinet space is expensive. With the introduction of this decentralised frequency inverter, we have opened new opportunities for mechanical engineers to control drives outside the control cabinet.”

In addition, Lenze’s latest X4 Remote with x500, an out-of-the-box solution for cloud-based remote services and condition monitoring, will be available to view. The X4 platform integrates with Lenze's x500 IoT gateways, so that customers can bring both machines and systems into the cloud without specific IoT knowledge.

Neil Beaumont, marketing manager at Lenze says: “We are constantly looking at offering more freedom for engineers and looking forward to demonstrating the X4 platform at IMHX where visitors can drop by for a coffee to discuss the considerable benefits this solution provides. From remote access over VPN to the storage of machine data in the cloud, there’s much more for a system integrator to discover.” 

He adds: “We are consistently among the top choice for system integrators and OEMs offering specialist knowledge in intralogistics, packaging, textiles and converting and printing. IMHX is one of the best exhibitions in the country and this is the perfect opportunity to demonstrate our many design and engineering solutions.”

Visit Stand 20C125 on the 24-27th September, NEC Birmingham for coffee and a chat with Lenze regarding automated solutions. 

With a barista and coffee shop style seating area on the stand, Lenze will provide opportunities for machine manufacturers to network and consult with experts in machine automation solutions. 

Lenze is actively involved with PPMA BEST (Business Education, Skills and Training) and on Thursday 27th September 60 students will attend the Young Peoples' skills seminar and workshop. As well as a visit to the Lenze stand and other key exhibitors, new business automation manager, Michael Sachpekidis, will present and discuss the latest automation technology innovations within the industry. Stand J70.

Towards the end of last year, Business Secretary Greg Clark launched the government’s ambitious Industrial Strategy, part of which pledged to establish a technical education system to 'rival the best in the world' and which also promised to invest an additional £406 million in maths, digital and technical education, helping to address the UK's shortage of science, technology, engineering and maths (STEM) skills.

While the government has the greater responsibility to deliver the nation’s education needs, industry, too, has a role to play. Companies can use their, not inconsiderable mentoring powers and technical resources to further the government’s aims of engaging young people with career opportunities that are not only rewarding, but which ultimately add wealth to the economy.

Proactive support

Take for example, UK based Lenze, a global supplier of machine automation and motion control systems and support services; the company is strongly focused on product design, development and innovation, activities that demand the highest levels of workforce skills. Recognising the importance of accessing and retaining these skills, Lenze has a policy of proactively supporting students who express an interest in industrial automation at both technical academy and higher education levels.

In the UK, the company achieves these aims through various support initiatives for technical colleges and university departments. These include a System Engineering Trainee Program, preparing the future generation of mechanical engineers with hands-on experience. The trainees receive individualised coaching and mentoring throughout the program and into subsequent job entry.

The provision of Teachware consoles for students’ exclusive use at their places of education, as well as places at Lenze’s professional training days enabling students to gain insights into automation engineering at a more practical level.

Lenze's donation of teaching consoles covering electric motor drive technology to the new Bridlington Mechatronic Centre is an illustration of this activity. The Centre, set up by UK tech companies, offers specialist engineering courses in response to address the growing skills gap issue.

More recently, Lenze partnered with the Engineering Development Trust and the Processing & Packaging Machinery Trade Association to support a STEM educational day at Bedford Free School. A variety of engineering themed tasks challenged the children's abilities in areas such as product design and environmentally focused problem solving.

These included a 'STEM Den' session where students were tasked with developing a new design for an everyday household item. Various teams were charged with drawing up their designs, building a prototype or model of their design and presenting it to a team of judges in ‘Dragon’s Den’ style, who voted on the best potential for investment.

The aim of this STEM day was not just to have a break from the day-to-day curriculum, but to give these children a better understanding of what engineering can offer as a career choice, while breaking down some typical stereotypes.

On show will be Lenze’s i500 range of frequency inverters, which make commissioning and diagnostics faster through flexible communication options. Engineers can set parameters and access data through a channel that is easy for their installation. The simplest option is through a plug-in keypad which has a easy to understand phone-style file structure.

For a more remote data transfer using free of charge software and standard or real-time buses, a USB connection is provided. Where commissioning the inverters is best done at a distance from the control cabinet, a WLAN module is available for wireless access using an Android smartphone and a free app. Thus the i500 inverters can be easily checked and adjusted to conveyor performance requirements, saving time on site.

To make life easier for system design engineers, Lenze has also used its deep experience of pallet conveyor systems to create a new approach for drive system selection. Lenze Smart Products include 14 geared motor drives that have been preconfigured to suit most chain and roller conveyors that carry pallets. With a simple on-line specification tool, designers need only choose between a chain or roller conveyor, an inline or right-angle gearbox, and the payload (from 500 to 5200kg). The system generates instantly downloadable technical data, macros and CAD drawings, allowing the chosen option to be rapidly integrated into a conveyor system design.

Smart Products are just one of a suite of Lenze solutions and services developed to support designers and operators of conveyors, storage systems and packaging machinery. The company’s DSD Drive Solution Designer, for example, is a powerful dimensioning tool that can be used to optimise the size and configuration of geared motors, like those used in automated storage and retrieval units. The system can predict the energy consumption of a complete system in operation, allowing motion profiles to be adjusted to achieve maximum efficiency. And once systems are in the field, Lenze’s support continues with a 24/7 technical helpline and comprehensive optional training and support packages.

For machine designers and systems integrators, in-service monitoring and support is becoming an increasingly important part of the offering to customers. At IntraLogisteX, Lenze will also be explaining the benefits of its partnership with Internet of Things (IoT) specialist ei3 Corporation. The secure, powerful and easy-to-use on-line platform established through this partnership makes it easy for users to access the data collected by Lenze drives and motion components, then use that data to optimise the performance, efficiency and reliability of their machines.

To celebrate its70th anniversary, Lenze organised a special event at the company’s HQ in Groß Berkel, Germany. Alongside a factory tour and talks from international consumers and other speakers, CEO’s and CTO’s learned about the latest innovations. As well as discussing current industry trends, the event included discussion of the future and the part Lenze will play as the world of drives and automation continues to expand.

Lenze’s MD, Stewart Hylden, says: “Lenze now employs 3300 people worldwide and has a depth of drive and automation expertise that means that many European production lines now operate with our drives, thanks to their high performance and reliability. We are standing on the edge of a whole new era of industrial revolution with Industry 4.0 and are looking forward to what the next 70 years will bring in terms of automation and drives innovation.”

Visitors who participate in a demonstration can take away their personal VR viewer. Lenze engineers will also explain new options for data acquisition, analysis and storage of a machine's operating data in the Cloud along with remote support communication technologies for predictive maintenance.

Lenze is increasingly using Virtual Reality technology as an extremely effective engineering and training tool. PPMA visitors can experience it themselves on the Lenze stand and those that do so will be given a smartphone VR viewer to take away. The main potential of VR lies in making it easier to deal with the growing complexity of machine automation, by giving programmers and design engineers live experience of their applications through a digital twin. This term describes a digital virtual copy of the design that is put together in parallel with the real machine. Evaluating the digital twin before the machine design is fixed gives a sense of depth and scale that cannot be achieved with a 2D monitor. Design projects are speeded, safety can be enhanced through virtual simulation, and software such as the Lenze FAST modules can be fine-tuned for optimum performance.

Also on the Lenze stand, machine manufacturers can discover what Industry 4.0 and the Internet of Things (IoT) can do for their business model. Lenze offers here an easy way for OEMs to create a digital business of their own by adding value to machine data. Machine and systems engineers using automation technology from Lenze can now create online data services very easily with secure access to machine operating data in the cloud. Lenze has joined forces with the IoT specialist ei3 Corporation to offer a combination of remote analysis of machine performance and also remote predictive maintenance. "We want to enable our OEM customers to set up their own digital business quickly and easily, because it will strengthen their relationship with their own customers. It will add value and improve margins,” explains David Krampe, Senior Marketing Manager at Lenze.

Lenze recognises that processing and packaging machinery needs to operate reliably, often 24 hours a day. Engineers on the stand can explain how intelligent service concepts can help to achieve that aim. Service modules allow Lenze experts to remotely analyse performance data and rectify errors online. New innovative techniques include the use of “smart glasses” to increase the quality level of the data transmitted, and barcode scanning of the product nameplate which reveals full hardware and firmware data, improving response times.

Visit the Lenze stand - J56 in Hall 5 - to see the future for food and beverage machinery. Under the theme “Dinner is served”, experienced engineers will present the best recipes for the processing and packaging industry based on 70 years’ experience in drives and automation.

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Stand - J56

Demonstrations show how Virtual Reality can give engineers an insight to the operation of complex mechanics and software, leading to faster machine development.

Visitors who participate in a demonstration can take away their personal VR viewer. Lenze engineers will also explain new options for data acquisition, analysis and storage of a machine's operating data in the Cloud along with remote support communication technologies for predictive maintenance.

Lenze is increasingly using Virtual Reality technology as an extremely effective engineering and training tool. PPMA visitors can experience it themselves on the Lenze stand and those that do so will be given a smartphone VR viewer to take away. The main potential of VR is said to lie in making it easier to deal with the growing complexity of machine automation, by giving programmers and design engineers live experience of their applications through a digital twin. This term describes a digital virtual copy of the design that is put together in parallel with the real machine. Evaluating the digital twin before the machine design is fixed gives a sense of depth and scale that cannot be achieved with a 2D monitor. Design projects are speeded, safety can be enhanced through virtual simulation, and software such as the Lenze FAST modules can be fine-tuned for optimum performance.

Also on the Lenze stand, machine manufacturers can discover what Industry 4.0 and the Internet of Things (IoT) can do for their business model. Lenze offers here an easy way for OEMs to create a digital business of their own by adding value to machine data. Machine and systems engineers using automation technology from Lenze can now create online data services very easily with secure access to machine operating data in the cloud. Lenze has joined forces with the IoT specialist ei3 Corporation to offer a combination of remote analysis of machine performance and also remote predictive maintenance. "We want to enable our OEM customers to set up their own digital business quickly and easily, because it will strengthen their relationship with their own customers. It will add value and improve margins,” explains David Krampe, senior marketing manager at Lenze.

Lenze recognises that processing and packaging machinery needs to operate reliably, often 24 hours a day. Engineers on the stand can explain how intelligent service concepts can help to achieve that aim. Service modules allow Lenze experts to remotely analyse performance data and rectify errors online. New innovative techniques include the use of “smart glasses” to increase the quality level of the data transmitted, and barcode scanning of the product nameplate which reveals full hardware and firmware data, improving response times.

Stand J56

It is available as an unbranded product without visible evidence of the ei3 brand; only the name and logo of the machine manufacturer is visible.

As part of their service contract with Lenze, machine builders can collect all the data that is available inside the Lenze automation controllers and drives. They can then evaluate this data and make it available to their own customers, either as an up-to-the-minute dashboard or in the form of reports providing performance figures.

The data can be used as the basis for advice on how to optimise systems and processes. In addition, the solution is suitable for services such as remote diagnosis and maintenance, and it can also be used to provide predictive maintenance.

"We want to enable our OEM customers to set up their own digital business quickly and easily, because it will strengthen their relationship with their own customers. It will add value and improve margins,” explains David Krampe, senior marketing manager at Lenze. He believes that Lenze has a competent and reliable partner in ei3. The Industrial IoTspecialist is based in New York and has been working with manufacturing companies since 1999. Its solution is currently running in over 20,000 machine systems in more than 90 countries.

The data from a machine is first transferred via OPC-UA (Unified Architecture) to secure devices in the production network. From then on, all the communication takes place in encrypted form at a high level of security. The data is stored in ei3’s own regional data centres, of which there are three: one in the USA, one in Europe and one in Asia. An additional one will soon be available in Germany. These data centres meet all European data-protection requirements and adherence to the data handling regulations will be certified by DEKRA, Germany’s biggest technical inspection agency.

The ei3 data centres collect the data to a private cloud where it is processed and analysed. Output reporting to authorised users is in easy-to-handle web pages, dashboards and reports. “Our partner ei3 has solutions that have been put to successful use for many years. The company is making these solutions available for OEMs and they are preconfigured,” says Lenze applications engineer Jurgen Rijkers. This means the machine builder does not need any prior knowledge of IT or big data. He only needs to specify the desired data points in the required application and the collection of data can begin.

“Of course, we need a sizeable set of data, known as big data, before we can learn much from the analysis,” says Rijkers. But what is important, he says, is that we are able to begin collecting data quickly and that the usual performance figures and evaluations, such as OEE (Overall Equipment Effectiveness), utilisation and availability are accessible immediately. Once the product is up and running it is easy for the OEM to carry out remote diagnosis and predictive maintenance. Rijkers says that in his experience this means that time on-site can be reduced by up to 80%.

David Krampe adds: “Of course, Lenze has to ensure that we can make use of the most common industrial protocols and data buses, also that our controls can work with Microsoft  Azure, the Amazon Web Services (AWS) and other cloud platforms. Here we have a solution that makes it especially easy for our OEM customers to get started in the future-oriented business of offering their own online services and data-based added value”.