Sometimes, a simple tweak can lead to significant improvements. We reached out to several experts for their insights—here are their top tips for smart solutions that can add extra value for designers.
How energy-efficient are low-voltage DOL motors that operate without a frequency converter for speed control? Answers are provided by an online calculator from ABB.
(Image: ABB)
Energy Efficiency Audit "light" quickly quantifies energy savings
Energy saving—of course! After all, improved energy efficiency is one of the quickest and most cost-effective ways to reduce environmental impact and operational costs. But how energy efficient are existing low-voltage DOL motors that operate without a frequency converter for speed control? What benefits does an energy-efficient retrofit bring? Answers to these questions are provided by a new online calculator from ABB. The calculator is a light version of ABB's comprehensive energy efficiency audit and is based on the same algorithm. It focuses particularly on motor-driven systems in fan and pump applications. By entering information about the installed motors, operating hours, and average operating performance, companies can estimate energy and emissions savings as well as the payback period. The calculator accounts for low-voltage motors of efficiency class IE3 and lower and quantifies the energy savings that can be achieved by upgrading to the latest motor and drive technology—a package of IE5 synchronous reluctance motor with a frequency converter. The first step towards saving energy is thus taken.
Motion Controller: Support for EMC Certification
When working with controlled drives, it is always important to consider electromagnetic compatibility (EMC).
(Image:Faulhaber)
Those who use regulated electric drives must keep electromagnetic compatibility (EMV) in mind. When certifying a device with an integrated small drive, the interference field strength often poses a challenge. The immunity requirements cover various electromagnetic effects in the standard tests, such as immunity to static electricity discharge (ESD) or to high-frequency electromagnetic fields from a nearby transmitter. However, the typical voltage fluctuations from several dynamic drives on a DC network are not really captured in the tests. Thus, EMC in small drives is by no means trivial for users. Therefore, all motion controllers in the Faulhaber product portfolio comply with current EMC regulations. Additionally, users are optimally supported through documentation during the certification of their own device.
Linear Motor Module (LMM) enables precise and short cycle times
The new linear motor axes from Bosch Rexroth offer high precision and dynamics with low space requirements.
(Image:Bosch Rexroth)
For the manufacturing of electronic and optical components, semiconductors, or in electromobility, precision and short cycle times are of great importance—for example, for precise pick-and-place tasks. For these applications, Bosch Rexroth has developed compact linear motor modules with an excellent cost-performance ratio. The integrated spindle-free direct drive replaces mechanical power transmission. This increases the dynamics and efficiency and enables highly precise repeatability. At the same time, the modular design reduces assembly effort.
Servo Drive: Three smart design advantages increase efficiency
A compact solution with improved efficiency and optimized housing design: the Sinamics S200 servo drive system.
(Image:Siemens)
The Sinamics S200 servo drive system enables maximum utilization of cabinet space while meeting safety requirements with three design advantages:
Advantage 1: Compact system solution—The drive system is a compact, performance-optimized solution. With a reduced width of only 40 mm, the space required in the control cabinet is significantly minimized.
Advantage 2: Improved efficiency in horizontal installation—In addition to the width, depending on the variant, only 1 mm of space is needed between devices during installation. This significantly improves space utilization in the cabinet and allows for the accommodation of more devices in the limited available area. Moreover, the installation process for the entire Sinamics S200 system has been optimized for efficiency. This not only makes installation more efficient but also ensures effortless and reliable connectivity.
Advantage 3: Optimized housing design—Furthermore, the Sinamics S200 system models, especially those in the main power range, are designed with a uniform height of between 170 and 180 mm. This uniformity greatly simplifies the overall design and leads to a compact and optimized layout that seamlessly integrates with other devices.
The frequency converter generates compensating currents to neutralize the harmonics
The Sinamics G220 frequency converter features an active feed-in unit that monitors the power grid for harmonic distortions and generates compensating currents.
(Image:Siemens)
Frequency converters improve operational efficiency through energy savings, enhanced process control, and reduced wear on equipment. However, they face one challenge: Harmonics create unwanted electrical frequencies that increase losses and can lead to potential damage from overheating and torque pulsation. What many designers may not yet know: The Sinamics G220 frequency converter features an active line module that monitors the power grid for harmonic distortions and generates compensating currents in real-time to neutralize the harmonics. This keeps the total harmonic distortion (THD) below 3%. This feature eliminates the need for bulky additional filters and ensures a compact design. Additionally, it improves voltage quality, which reduces the load on the electrical infrastructure and leads to a longer lifespan of the drive and connected devices.
Date: 08.12.2025
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Simulation: Optimally design drive technology for toggle levers
Simulation of an electric clamping unit with toggle lever, which enables efficient design of drive and motor and provides transparency regarding speed, torque, energy consumption, and other parameters.
(Image:Baumüller)
Toggle levers are used wherever large forces need to be transmitted with relatively little effort, such as in presses, punches, bending machines, or in locking systems in injection molding machines. A major challenge in implementing toggle lever systems is the design of the electrical drives. In these comparatively complex systems, torque, speed, and velocities do not behave linearly. This complicates the design process, meaning the drive system may not be optimally sized for the machine cycle required by the end user. As a result, systems are often designed with a performance buffer or are undersized. Since standard tools for designing toggle levers do not suffice for precise sizing, Baumüller uses high-performance simulation tools for this task. First, a toggle lever model is created based on customer requirements and then linked in the Prosimulation software module with the drive and motor model. This allows the drive experts to accurately map the dynamic behavior of the machine and test various force and motion profiles. This way, they can optimally design the drive technology and test the limits of performance.
This article was first published on our sister website www.elektrotechnik.de (German Language), Vogel Communications Group
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