Lenze DSD User Manual
Drive solution designer, Ä.ns?ä
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Table of contents
Document Outline
- Drive Solution Designer
- Contents
- 1 Notes on usage
- 2 About this documentation
- 3 User interface
- 4 Setting up the DSD workplace
- 5 Managing projects
- 6 Drive dimensioning tools
- 7 Applications
- 7.1 Overview
- 7.2 Basic calculations
- 7.3 Belt drive, rotating
- 7.3.1 Applications with a horizontal direction of movement
- 7.3.2 Applications with a vertical direction of movement
- 7.3.3 Calculations
- 7.3.4 Data for the entry
- 7.3.4.1 Belt pulley diameter
- 7.3.4.2 Mass of the slide
- 7.3.4.3 Angle of tilt
- 7.3.4.4 Transmission efficiency of toothed belt
- 7.3.4.5 Mass of toothed belts
- 7.3.4.6 Moment of inertia, deflection pulleys
- 7.3.4.7 Moment of inertia of belt pulley
- 7.3.4.8 Specific travelling resistance
- 7.3.4.9 Velocity
- 7.3.4.10 Mass of the payload
- 7.3.4.11 Tensile force at the slide (counterforce)
- 7.4 Omega belt drive
- 7.4.1 Applications with a horizontal direction of movement
- 7.4.2 Applications with a vertical direction of movement
- 7.4.3 Calculations
- 7.4.4 Data for the entry
- 7.4.4.1 Belt pulley diameter
- 7.4.4.2 Mass of the slide
- 7.4.4.3 Angle of tilt
- 7.4.4.4 Transmission efficiency of toothed belt
- 7.4.4.5 Drive train mass
- 7.4.4.6 Moment of inertia, deflection pulleys
- 7.4.4.7 Moment of inertia of belt pulley
- 7.4.4.8 Specific travelling resistance
- 7.4.4.9 Velocity
- 7.4.4.10 Mass of the payload
- 7.4.4.11 Counterforce
- 7.5 Rack drive
- 7.6 Spindle drive
- 7.7 Wheel drive
- 7.8 Hoist drive without counterweight
- 7.8.1 Calculations
- 7.8.2 Data for the entry
- 7.8.2.1 Diameter of cable drum
- 7.8.2.2 Reeving, load
- 7.8.2.3 Mass of hoisting cage
- 7.8.2.4 Efficiency of the cable drum
- 7.8.2.5 Additional moment of inertia
- 7.8.2.6 Cable diameter
- 7.8.2.7 Width of cable drum
- 7.8.2.8 Max. lifting height
- 7.8.2.9 Cable mass
- 7.8.2.10 Active cable mass
- 7.8.2.11 Shaft efficiency
- 7.8.2.12 Efficiency of the rolls
- 7.8.2.13 Lifting speed
- 7.8.2.14 Mass of the payload
- 7.9 Hoist drive with counterweight
- 7.9.1 Calculations
- 7.9.2 Data for the entry
- 7.9.2.1 Diameter of traction sheave
- 7.9.2.2 Reeving, load
- 7.9.2.3 Reeving, counterweight
- 7.9.2.4 Mass of counterweight
- 7.9.2.5 Mass of hoisting cage
- 7.9.2.6 Additional moment of inertia
- 7.9.2.7 Cable diameter
- 7.9.2.8 Cable mass
- 7.9.2.9 Active cable mass
- 7.9.2.10 Shaft efficiency
- 7.9.2.11 Efficiency of the rolls
- 7.9.2.12 Efficiency of the driving pulley
- 7.9.2.13 Lifting speed
- 7.9.2.14 Mass of payload
- 7.10 Chain conveyor
- 7.11 Roller conveyor
- 7.11.1 Calculations
- 7.11.2 Data for the entry
- 7.11.2.1 Diameter of the transport rolls
- 7.11.2.2 Leverage of rolling friction
- 7.11.2.3 Chain efficiency
- 7.11.2.4 Bearing diameter
- 7.11.2.5 Moment of inertia of transport rollers
- 7.11.2.6 Number of wrapped chain turns
- 7.11.2.7 Additional force
- 7.11.2.8 Angle of tilt
- 7.11.2.9 Coefficient of friction of the bearing
- 7.11.2.10 Velocity
- 7.11.2.11 Mass of the payload
- 7.12 Belt conveyors for unit loads
- 7.12.1 Calculations
- 7.12.2 Data for the entry
- 7.12.2.1 Diameter of the drive roll
- 7.12.2.2 Mass of the belt
- 7.12.2.3 Mass of supporting rollers
- 7.12.2.4 Moment of inertia of rollers
- 7.12.2.5 Additional force
- 7.12.2.6 Angle of tilt
- 7.12.2.7 Coefficient of friction belt/bearing
- 7.12.2.8 Coefficient of friction belt/supporting rollers
- 7.12.2.9 Velocity
- 7.12.2.10 Mass of the payload
- 7.13 Belt conveyor for bulk material
- 7.13.1 Calculations
- 7.13.2 Data for the entry
- 7.13.2.1 Diameter of the drive roll
- 7.13.2.2 Length of conveyor line
- 7.13.2.3 Mass of the payload
- 7.13.2.4 Mass of the belt
- 7.13.2.5 Angle of tilt
- 7.13.2.6 Fill level coefficient
- 7.13.2.7 Shunt-force coefficient
- 7.13.2.8 Mass of supporting rollers
- 7.13.2.9 Moment of inertia of driving roller
- 7.13.2.10 Moment of inertia of supporting rollers
- 7.13.2.11 Velocity
- 7.14 Synchronous drive - single roll
- 7.14.1 Calculations
- 7.14.2 Data for the entry
- 7.14.2.1 Roll diameter
- 7.14.2.2 Tensile force, infeed
- 7.14.2.3 Tensile force, outfeed
- 7.14.2.4 Efficiency, roll mechanics
- 7.14.2.5 Moment of inertia, rolls/material
- 7.14.2.6 Static friction coefficient of roll surface
- 7.14.2.7 Angle of wrap
- 7.14.2.8 Safety coefficient static friction
- 7.14.2.9 Velocity
- 7.15 Synchronous drive of squeegees
- 7.15.1 Calculations
- 7.15.2 Data for the entry
- 7.15.2.1 Roll diameter
- 7.15.2.2 Tensile force, infeed
- 7.15.2.3 Tensile force, outfeed
- 7.15.2.4 Roll contact force
- 7.15.2.5 Leverage of rolling friction, lower roll
- 7.15.2.6 Leverage of rolling friction, upper roll
- 7.15.2.7 Efficiency, roll mechanics
- 7.15.2.8 Moment of inertia of the rolls
- 7.15.2.9 Static friction coefficient of roll surface
- 7.15.2.10 Safety coefficient static friction
- 7.15.2.11 Velocity
- 7.16 General rotary drive
- 7.17 Rotary table drive
- 7.18 Pump
- 7.19 Fan
- 7.20 Importing M-n-operating points
- 7.21 Dimension the multi-axis system
- 7.21.1 Using braking energy
- 7.21.2 Combining drive axes
- 7.21.2.1 Central mains supply via regenerative power supply module
- 7.21.2.2 Central mains supply via power supply module
- 7.21.2.3 Central mains supply via inverter
- 7.21.2.4 Decentralised mains supply via several inverters
- 7.21.2.5 Decentralised mains supply via regenerative power supply modules and inverters
- 7.21.3 Combining Lenze products
- 7.21.4 Dimensioning
- 7.21.5 Parameterising projects
- 7.21.6 Defining options
- 7.22 Winding drive for rewinder/unwinder
- 7.22.1 Rewinder (single)
- 7.22.2 Unwinder (single)
- 7.22.3 Dimensioning strategies
- 7.22.4 Traction-controlled winding drive
- 7.22.5 Checking emergency-off scenarios
- 7.22.6 Application data
- 7.22.6.1 Winder control mode
- 7.22.6.2 Min. reel diameter (rewinder)
- 7.22.6.3 Min. reel diameter (unwinder)
- 7.22.6.4 Max. reel diameter
- 7.22.6.5 Max. material width
- 7.22.6.6 Medium material density
- 7.22.6.7 Min. material thickness (rewinder)
- 7.22.6.8 Min. material thickness (unwinder)
- 7.22.6.9 Coil and winding shaft moment of inertia
- 7.22.6.10 Winding system and winding shaft efficiency
- 7.22.7 Data for the motion
- 7.22.7.1 Max. velocity
- 7.22.7.2 Acceleration time
- 7.22.7.3 Deceleration time
- 7.22.7.4 Max. tensile force with dmin (rewinder)
- 7.22.7.5 Max. tensile force with dmax (rewinder)
- 7.22.7.6 Min. tensile force with dmin (rewinder)
- 7.22.7.7 Max. tensile force with (unwinder)
- 7.22.7.8 Min. tensile force (unwinder)
- 7.22.7.9 Motion profile shape
- 7.22.7.10 Jerk ratio
- 7.22.7.11 Downtime 1
- 7.22.7.12 Downtime 2
- 7.22.7.13 Downtime 3
- 7.22.7.14 Brake at standstill
- 7.22.7.15 Controller inhibit at standstill
- 7.22.7.16 Emergency-off time (without material, M-calculation only)
- 8 Motion design
- 8.1 Selection of motion profile
- 8.2 MotionDesigner
- 8.2.1 Control and function elements
- 8.2.2 Toolbar
- 8.2.3 Screen divider
- 8.2.4 Object area
- 8.2.5 Managing motion profiles
- 8.2.6 Graphic area
- 8.2.7 Parameter area: Description
- 8.2.8 Positioning
- 8.2.9 Parameter area: Data for the entry
- 8.2.9.1 <Parametername> - Type
- 8.2.9.2 Specification - Type
- 8.2.9.3 Specification - basic values
- 8.2.9.4 Distance / angle - basic values
- 8.2.9.5 Time - basic values
- 8.2.9.6 Velocity / speed - basic values
- 8.2.9.7 Time (right) - basic values
- 8.2.9.8 Velocity (right) / speed (right) - basic values
- 8.2.9.9 Velocity / final speed - basic values
- 8.2.9.10 Starting velocity / starting speed - basic values
- 8.2.9.11 Acceleration - basic values
- 8.2.9.12 Left - basic values
- 8.2.9.13 Right - basic values
- 8.2.9.14 Controller / brake - basic values
- 8.2.9.15 Specification - acceleration
- 8.2.9.16 Left - acceleration
- 8.2.9.17 Middle - acceleration
- 8.2.9.18 Right - acceleration
- 8.2.9.19 Specification - jerk
- 8.2.9.20 Left - jerk
- 8.2.9.21 Middle - jerk
- 8.2.9.22 Right - jerk
- 8.2.9.23 Jerk ratio - jerk
- 8.2.9.24 S-ramp time - jerk
- 8.2.9.25 Jerk - jerk
- 8.2.9.26 Max. acceleration - jerk
- 8.2.10 Application notes for motion profiles
- 8.3 Predefined motion profile according to operating mode
- 8.3.1 S1, continuous operation
- 8.3.2 S2, short-term operation
- 8.3.3 Intermittent operation S3, S4, S5
- 8.3.4 Intermittent load S6, S7
- 8.3.5 Description of the data for the entry
- 8.3.5.1 Max. velocity
- 8.3.5.2 Speed
- 8.3.5.3 Variable payload mass
- 8.3.5.4 Torque load
- 8.3.5.5 Variable force associated with the application
- 8.3.5.6 Basic setting of motion profile
- 8.3.5.7 Relative operating time
- 8.3.5.8 Operating time
- 8.3.5.9 Brake at standstill
- 8.3.5.10 Controller inhibit at standstill
- 8.3.5.11 Acceleration time
- 8.3.5.12 Deceleration time
- 8.3.5.13 Cycle time
- 8.3.5.14 Direction of movement
- 9 Mains and environment
- 10 Structure of the drive axis
- 10.1 Mechanical drive axis
- 10.2 Electrical drive axis
- 10.3 Drive concept
- 10.3.1 Gearbox features
- 10.3.2 Motor properties
- 10.3.3 Motor/gearbox: Direct mounting or standard mounting
- 10.3.4 Inverter properties
- 10.3.5 Overview of motor/inverter control types
- 10.3.6 Selection help: Products for applications (without winders)
- 10.3.7 Selection help: Products for winding drive systems
- 10.3.8 Selection help: Control types for winding drive systems
- 11 Drive Dimensioning
- 11.1 Preselection of the geared motor
- 11.2 Motor selection
- 11.2.1 Motors for 87-Hz operation
- 11.2.2 Motors for 120-Hz operation
- 11.2.3 Dimensioning guidelines and dimensioning information
- 11.2.4 Field weakening for winding drives
- 11.2.5 M-n characteristic
- 11.2.6 Thermal utilisation
- 11.2.7 Selection table
- 11.2.8 Load-matching factor
- 11.2.9 Radial forces/axial forces
- 11.3 Mechanical brake selection
- 11.4 Lenze gearbox selection
- 11.5 Selection of an additional drive element
- 11.6 Inverters
- 11.7 Motor components
- 12 Components in the DC bus
- 12.1 Supply concept
- 12.2 9400 power supply module
- 12.3 9400 regenerative power supply module
- 12.4 i700 power supply module
- 12.5 Selection of components
- 12.6 Brake resistor selection
- 13 Details on Lenze products
- 14 Energy efficiency
- 15 Results: comparing, optimising, logging
- 15.1 Drawing
- 15.2 Results
- 15.3 Protocols
- 15.4 Comparison and additional results
- 15.5 Construction data
- 15.6 Reserves with regard to the drive dimensioning
- 15.6.1 Dynamic reserves
- 15.6.2 Stationary reserves
- 15.6.3 Speed reserves
- 15.6.4 Torque reserves of the motor
- 15.6.5 Reserves for inverters, power supply modules, regenerative power supply modules
- 15.6.6 Reserves for brake resistors and brake choppers
- 15.6.7 Reserves for gearboxes
- 15.6.8 Reserves for drive systems with an active load
- 15.6.9 Reserves for drive systems with a passive load
- 16 Auxiliary means
- 16.1 Auxiliary means integrated in the DSD
- 16.1.1 Auxiliary calculator
- 16.1.1.1 Calculator (Microsoft® calculator)
- 16.1.1.2 Mass calculator
- 16.1.1.3 Inertial calculator
- 16.1.1.4 Gearbox calculator
- 16.1.1.5 "Pinion diameter" calculator
- 16.1.1.6 "Mass of counterweight (hoist drive)" calculator
- 16.1.1.7 "Mass of rope/cable (hoist drive)" calculator
- 16.1.1.8 "Uniform load mass (material handling technology)" calculator
- 16.1.1.9 "Mass of delivery volume (material handling technology)" calculator
- 16.1.1.10 "Mass of belt" calculator
- 16.1.1.11 "Backing force (material handling technology)" calculator
- 16.1.1.12 "Travelling resistance" calculator
- 16.1.1.13 "Leadscrew efficiency" calculator
- 16.1.2 Tables of values
- 16.1.3 MotionDesigner
- 16.1.4 Lenze intranet
- 16.1.5 Lenze Internet
- 16.1.6 Lenze «Drive Solution Catalogue» (DSC)
- 16.1.1 Auxiliary calculator
- 16.1 Auxiliary means integrated in the DSD
- 17 Restrictions of the drive dimensioning
- 17.1 Field weakening
- 17.2 Worldwide mains voltages and supply forms
- 17.3 Undervoltages: Impact on operational performance
- 17.4 Highly dynamic applications with acceleration times < 50 ms
- 17.5 Feedback systems
- 17.6 Mechanical brakes for winding drives
- 17.7 Saturation effects in the motor at > 200 % Mrated
- 17.8 Radial and axial loads of the motor or gearbox shaft
- 17.9 Service brake, holding brake with safety function
- 17.10 Displacement of the M-n characteristic
- 17.11 Maximum permissible motor cable length
- 17.12 Effects of low switching frequencies on the motor
- 17.13 Motor temperature monitoring acc. to UL 508C
- 17.14 Operation of inverters on the earth-leakage circuit breaker
- 17.15 Qualitative requirements with regard to the application
- 17.16 System disturbances
- 17.17 Parallel operation of several motors on one inverter (group drives)
- 17.18 Parallel operation of several motors on several inverters
- 17.19 ATEX for gearbox
- 17.20 Applications with low field frequencies
- 17.21 Emergency-off scenarios
- 17.22 Switching in the motor cable
- 17.23 Filter in the motor cable
- 17.24 Application of bearing current chokes
- 17.25 Improved motor control with temperature detection (KTY)
- 17.26 Cooling servo motors without gearbox via mounting flange
- 17.27 Permanent load at low motor speeds for applications acc. to UL
- 18 Drive dimensioning messages
- 18.1 Applications
- 18.1.1 Ratio of the tensile forces Fin / Fout > limit value
- 18.1.2 Ratio of the tensile forces Fout / Fin > limit value
- 18.1.3 Difference of the tensile forces Fin - Fout > limit value
- 18.1.4 Speed of the application = 0 (standstill)
- 18.1.5 Safety check of controller inhibit failed
- 18.1.6 No values available for the torque of the application
- 18.1.7 Parameter of the motion profile is not evaluated
- 18.1.8 Utilisation of the DC busbar system is xxx %
- 18.1.9 Torque setting range > 50 for winding control mode xxx
- 18.1.10 Low-friction dancer required for tensile force setting range xxx
- 18.1.11 Value range for the reel diameter not plausible
- 18.1.12 Value range for the tensile force of the winder not plausible
- 18.2 Drive system
- 18.2.1 Utilisation >100 %, regarding the max. torque
- 18.2.2 In the DC-bus connection, the braking circuit of the inverter is not checked
- 18.2.3 In the DC-bus connection, the EMC protection of the device is ineffective
- 18.2.4 Product has been discontinued
- 18.2.5 No effective starting current limitation available
- 18.2.6 Dissipation of the regenerative power is not guaranteed
- 18.2.7 Checking the drive system and the tensile force sensor
- 18.2.8 Torque setting range yyy requires measures
- 18.2.9 Torque setting range yyy and tensile force setting range zzz require measures
- 18.2.10 Max. torque for emergency stop exceeded
- 18.3 Additional drive element
- 18.4 Lenze gearbox
- 18.4.1 Utilisation >100 % regarding the equivalent torque
- 18.4.2 Utilisation >200 %, regarding the max. torque
- 18.4.3 Utilisation >100 % regarding the max. speed
- 18.4.4 Utilisation >100 % regarding the thermal speed
- 18.4.5 Utilisation of the clutch >100 % regarding the torque
- 18.4.6 Utilisation of the clutch >100 % regarding the speed
- 18.4.7 Thermal overload when mineral gearbox oil is used
- 18.4.8 Utilisation is xxx %, regarding the max. torque
- 18.4.9 Load of the shaft sealing ring is xxx %, regarding the speed
- 18.4.10 Wear of the gearbox >100 %
- 18.4.11 Using synthetic oil for gearboxes of the winding application
- 18.4.12 No product options available
- 18.5 Lenze motor
- 18.5.1 Utilisation >100 %, regarding the effective torque
- 18.5.2 Max. motor speed is higher than the permissible motor speed
- 18.5.3 Max. motor torque is higher than the permissible motor torque
- 18.5.4 Motor is operated in the field weakening range
- 18.5.5 Max. mismatch is higher than permissible mismatch
- 18.5.6 Motor speed too low
- 18.5.7 Max. permissible motor current of yyy is exceeded
- 18.5.8 Overload of the motor >xxx %
- 18.5.9 Max. permissible ambient temperature of the blower is exceeded
- 18.5.10 A continuous operation characteristic for inverter operation is not available
- 18.5.11 Motor temperature too high at switching frequency < 8 kHz
- 18.5.12 The limit value of xxx % of the rated torque is exceeded
- 18.5.13 Compliance of the ErP Directive 2009/125/EC
- 18.5.14 Overdimensioned motor in the case of traction-controlled winding drive
- 18.5.15 Speed-controlled winding drive may show unstable behaviour
- 18.5.16 Field weakening factor kf > as winding ratio q
- 18.6 Brake
- 18.7 Feedback
- 18.8 Inverters
- 18.8.1 Ambient temperature too high
- 18.8.2 Max. permissible site altitude exceeded
- 18.8.3 Max. output current exceeded
- 18.8.4 Max. thermal utilisation >100 %
- 18.8.5 Control mode not suitable for hoist drive
- 18.8.6 Inverter designed as double axis
- 18.8.7 Current resolution is not adapted to the motor
- 18.8.8 Utilisation of the inverter >100 %
- 18.8.9 Utilisation of the inverter too high after mains connection
- 18.8.10 Control mode VFCplus without feedback is not permissible
- 18.8.11 The SLVC control mode is not permissible for inverters >55 kW
- 18.8.12 Too low braking torques at low speed
- 18.8.13 Motor limit rating is exceeded
- 18.8.14 The inverter cannot provide the rated output current
- 18.8.15 VFCplus eco control mode for quasi-stationary drives
- 18.8.16 Activate VVC control
- 18.8.17 SLVC and VFCplus control modes not possible for synchronous motors
- 18.8.18 No product options available
- 18.8.19 Mains choke required
- 18.8.20 Special measures for operation with increased rated power
- 18.8.21 Motor control xxx not suitable for winding control mode yyy
- 18.8.22 Motor control xxx suitable to a limited extent for winding control mode yyy
- 18.8.23 No electrical brake components available
- 18.8.24 I°t utilisation of the brake transistor is >100 %
- 18.8.25 Thermal utilisation of the inverter is > 80 %
- 18.9 Regenerative power supply module
- 18.9.1 Ambient temperature too low
- 18.9.2 Ambient temperature too high
- 18.9.3 Max. site altitude exceeded
- 18.9.4 Utilisation (supply) relative to the max. DC-bus current > 100 %
- 18.9.5 Utilisation (supply) relative to the continuous DC-bus current > 100 %
- 18.9.6 Utilisation relative to the permissible continuous power exceeded
- 18.9.7 Max. DC-bus current (power recovery) too high
- 18.9.8 Continuous DC-bus current (power recovery) too high
- 18.9.9 I°t utilisation of the brake transistor is >100 %
- 18.9.10 Permissible pulse power is exceeded
- 18.9.11 Permissible power of the regenerative power supply module is exceeded
- 18.10 Supply module
- 18.10.1 Ambient temperature too low
- 18.10.2 Ambient temperature too high
- 18.10.3 Max. site altitude exceeded
- 18.10.4 Utilisation exceeded, regarding the max power (supply)
- 18.10.5 Utilisation exceeded, regarding the max. power (power recovery)
- 18.10.6 Utilisation exceeded, relative to the max. power of the brake transistor
- 18.10.7 Utilisation >100 %, regarding the DC-bus power (supply)
- 18.10.8 Utilisation of the power supply module in supply mode is > 100 %
- 18.10.9 Utilisation of the power supply module is >100 %
- 18.11 Brake chopper
- 18.12 Brake resistor
- 18.12.1 Resulting brake resistance too low
- 18.12.2 Permanent utilisation of the equivalent resistance > 100 %
- 18.12.3 Max. utilisation of the equivalent resistance is >100 %
- 18.12.4 Max. permissible resistance value is exceeded
- 18.12.5 Thermal time constant of the brake resistor is too small
- 18.12.6 Temperature monitoring of the cartridge responds
- 18.13 User motor
- 18.1 Applications
- 19 Feedback, help & support
- 20 Glossary
- Index
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- Contents