Feature Machine building/ frameworks & safety
Driving technology forward A
direct drive technology has been developed by Magnomatics that is now beginning to realise its full potential in many industrial solu- tions, challenging applications of stan- dard electromagnetic topologies such as motors, generators and actuators. The Pseudo Direct Drive PDD
technology is a type of motor/generator capable of achieving ground-breaking continuous torque densities. The change in torque capability delivers a compact direct drive solution through the use of integral magnetic gearing. Not only does this offer high levels of efficiency, but other benefits include prevention of failure mechanisms such as jamming, and reduced levels of drive train noise and vibration.
In many challenging applications, significant performance benefits can
result from replacing the motor and gearbox with a direct drive motor. Primarily, efficiency is improved due to the removal of gearbox losses and gear wear is eliminated, but in addi- tion there is also a lack of lubrication, reducing servicing requirements and the potential for oil leaks.
The PDD motor overcomes the torque density limitations of conventional direct drive permanent magnet motors by exploiting a mechanically and mag- netically integrated passive magnetic gear which acts as a speed-reducing, torque-increasing transmission with- out requiring lubrication. The resulting motor offers superior torque density,
The PDD solution is highly scalable
A new Pseudo Direct Drive (PDD) has been developed which offers a step change in continuous torque density, allowing the motor to directly drive many industrial process and control loads where a motor and gearbox combination would typically be employed. Dr Richard Clark, research director at Magnomatics, looks into the technology
enabling reductions in motor frame size for a given load. An inner high-speed permanent magnet rotor and outer stator carrying windings act as a conven- tional permanent magnet brushless DC or AC motor. The rotation of the high-speed inner rotor is magnetically geared to give a high-torque, low-speed output on a second, low-speed rotor. The key benefits of the PDD are: high torque density (hence com- pact machine for given torque); high efficiency across a wide operating range; removal of a mechanical gear- box; reduced servicing requirements; very low vibration and acoustic noise; no, or minimal, cooling required; high power factor operation; and it uses standard ‘off-the-shelf’ power electronics/drive technology.
Development
In collaboration with a major European commercial vehicle OEM and several key suppliers, Magnomatics has successfully developed a PDD machine with a continuous rated torque
capability of 4000Nm, suitable for packaging within a standard 22” truck wheel for hybrid commercial vehicle applications. It has a rated output speed of 750rpm and an efficiency of over 97% at rated load. This development was part funded by the Technology Strategy Board (TSB).
The resulting machine has a torque density of 80kNm/m3, which is over four times greater than an equivalent direct drive permanent magnet motor. In testing, the machine has surpassed expectations for perfor- mance and efficiency.
The PDD solution is highly scalable and provides a solution for where con- sideration is being given to a variable speed drive to better match the drive to varying load requirements to reduce energy consumption.
Suitable applications are currently being found in renewable energy, auto- motive, commercial vehicles, marine propulsion, aerospace, industrial pumping and many other industries where compact, high torque direct drive motors and flexible transmission technology are demanded.
Magnomatics
www.magnomatics.com Enter 229
A sweet solution to box security labelling
Label Solutions of York stepped up to the challenge. A machine had to be designed where the labelling heads and parallel conveyors could be moved in unison to pre-determined positions to accord with box dimensions. The basis of the resulting system is two pairs of parallel conveyors mounted on linear slides that are coupled together to form an ‘L’ shape. The conveyors, on each leg of the handling system, enable the width to be adjusted to suit the different box sizes. For the maximum box width of 400mm the conveyors are at their widest apart, and for the smallest, 100mm, they are brought together. Precision was needed here as L-clip labels had to be applied, so the box has to overhang the 30mm wide conveyors on two opposing sides, enabling the label to be affixed to the side and bottom faces of the box. The linear speed of the conveyors is 30m/per minute with a maximum product throughput of
W 28
hen a special machine was required to apply security labels to all four sides of a box of sweets, as well as accommodating a range of pack sizes, Sessions
60 boxes per minute; and to move these in and out the company selected the HepcoMotion double-acting PSD80 linear actuator, which can run dry. With the new machine, the labelling heads are fixed to the carriage plates of HepcoMotion's GV3 linear motion system that easily provides the required positioning accuracy of ±1mm. The entire machine is mounted on the HepcoMotion MCS aluminium machine construction system.
In operation, the conveyors and label heads on both sections of the machine are manually adjusted to suit the dimensions of the next batch. On leaving the packaging line, the boxes then travel down the first pair of conveyors to the label heads where the L-clip labels are applied to the first two opposing sides of the box and secured underneath. They are then turned through 90° by the cross over unit and steered along the second pair of conveyors for the application of L-clip to the two remaining faces. HepcoMotion T: 01884 257000
www.hepcomotion.com OCTOBER 2011 Design Solutions 1971-2011
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