Category: Industry Trends

Fieldbus systems

Controller functionalities

Encoder angle via field bus:

For motors with multiple windings, the encoder cable is operated without splitting.

Error response “Return motion in case of power supply failure”:

In the event of a power supply failure, the drive performs positioning to a parameterizable position, provided there is sufficient energy in the DC link.

» The advantage: Protection of the machine against uncontrolled coasting down and resulting damage

Master-slave coupling for load balancing:

This feature allows the load of two drives moving a load together to be shared in a defined ratio.

» The advantage: Smaller converter technology possible › Cost savings

Cogging torque compensation:

The cogging torque of synchronous motors influences the concentricity of the motors. Cogging torques are identified by means of automated measurement and an angle-dependent current is pre-controlled. This compensates for the cogging torque.

» The advantage: Improved concentricity of the motors, in particular at low speeds › Cost savings

b maXX-drivePLC: One of the fastest in-drive PLCs worldwide

With a cycle time of 100 μs for 1000 lines of STL, the b maxx-drivePLC is suitable for both extensive control and demanding motion control tasks. This means that by using our PLC, the control PLC can be relieved, downsized or even completely replaced. The clean decoupling of motion control applications from the machine program also creates a new level of transparency and clarity in the application.

Programming via ProDrive

By using softdrivePLC, you no longer need complicated tools for control programming. Control tasks can easily be implemented in a decentralized way in the controller via the ProDrive parameterization tool – from simple calculation to highly complex control algorithms.

Industry 4.0: Intelligent drives function as a data/sensor hub

With the Baumüller SmartValue function, data is collected directly in the process via the intelligent sensor/actuator level, preprocessed with the help of AI and other tools, and then used to optimize the machine. Data available in the servo drive, such as power, current, torque, speed or position, are thus used intelligently – to record the current utilization of the motor-drive combination, for example. In this case, the servo drive acts as a data hub. If the available data is not sufficient, the drive and also the motor with external sensors can easily be used as a sensor hub.

b maXX softdrivePLC – Intelligence in the drive

With the new b maXX softdrivePLC, Baumüller has made separate control hardware unnecessary for certain applications. By combining motion control and PLC functions in the controller, Baumüller has created a decentralized control architecture for programming in accordance with IEC 61131. making it extremely easy to set up distributed intelligence in the machine.

Without complicated tools for control programming, control tasks ranging from the simple calculation of digital inputs to highly complex control algorithms can be implemented in a decentralized way in the controller – tasks made easy by the ProDrive parameterization tool. The b maXX softdrivePLC runs as part of the firmware in the Baumüller drive concepts b maXX 6000. b maXX 5000 and b maXX 3300 and is suitable for single and double-axis applications.

New series – new functions

The new b maXX 6000 series impresses with its numerous new functions, which have been specially developed for sophisticated applications. The new controllers are faster and more reliable than ever before. Despite the expanded functional scope, the firmware is fully compatible with the preceding b maXX 5000 family – a changeover is therefore possible without new programming or parameterization.

Here are some of the innovations at a glance:

Safety for high-performance applications

• Even faster response (1ms) to safety-related events

• Transfer of the safe position via FSoE to the safety control as the basis for 3D space monitoring

• Digital encoders can be used as safety encoders

• Safety possible via load-side encoders

Prepared for Drive-PLC

• Real time data processing in the drive

• Drive can be used as a data hub for connection of direct and indirect sensors

• IoT-ready thanks to OPC-UA and MQTT

Fully compatible firmware

• Simple change from b maXX 5000 to 6000: Parameter data sets can be transferred.

• Drive-based functions and softdrivePLC projects can be further used with no changes required

• Only a minimal amount of work necessary for adjusting the parameterization for FSoE

Safety for high-performance applications

The new safety functions have been specially developed for applications with high requirements for dynamics and precision. The safety module is integrated directly in the device on the new servo-controllers. The advantage: Safety-relevant encoder signals can thus be evaluated with an even higher resolution. This again significantly improves position and speed accuracy. For example, if a simple resolver is used in the application, the speed resolution with the new generation of converters for safety monitoring is less than 1 rpm. This means that the application can also achieve high performance in combination with robust encoder technology, which reduces the overall costs of the machine.

The safety functions of the new servo-controllers also set new standards in terms of responsiveness to safety-relevant events. For example, when STO is triggered, the servo drive is switched torque-free with a time delay of less than 1 ms. This fast response time can increase the speed of the machine and thus boost overall productivity.

The user also benefits from the new SP (safe position) safety function for transmitting the safe position via the FSoE protocol. This not only enables safe room monitoring, but also collaboration in applications with multidimensional movements, such as laser cutting or robotics. The ETG standard (EtherCAT Technology Group) standard for FsoE communication was also implemented in the new generation. This increases flexibility in the selection of a higher-level safety controller.

Application-optimized through scalability

The b maXX 6000 devices have maximum scalability due to numerous hardware and software options and can therefore be even better adapted to the application requirements.

Different encoders, hardware and safety options are available to choose from. For example, in the case of encoders, you can choose between resolvers, optical and pure digital encoders for all standard interfaces. For the hardware, the signal bus, service option, digital and analog I/Os, as well as brake connection can be selected, among other things. With regard to safety, different variations are available, from the simple hardware controlled STO (Safe Torque-Off) through to higher safety functions actuated via FSoE (FailSafe over EtherCAT), all of which comply with the highest safety level.

Thanks to this scalability, a large number of configuration levels are available, from the basic device through to full specs. The machine manufacturer can thus put together the controller and power module equipment to precisely fit their application.

Greater flexibility, higher safety functions

The b maXX 6300 is even more flexible than the current b maXX 5300. It has additional safety functionalities, and extended software, PLC and IoT functions. These improve OEE (overall equipment effectiveness) and thus machine availability and productivity.

The converter series b maXX 6300 includes feed-in and regenerative feedback units as well as axis units, which can be quickly and easily combined by an integrated drive connect system. This allows the machine builder to benefit from low installation costs and short commissioning and service times. The controllers impress with their high power density and very small installation space.

Module systems for high power outputs

The b maXX 6300 axis units enable peak currents of up to 420 A and significantly higher nominal currents of up to 180 A.

b maXX 3300 — Compact small servo-controller

For the control of synchronous machines, our product range includes the following:

• Current control (sampling time 62.5 μs)

• Speed control (sampling time 125 μs)

• Position control (sampling time 125 μs)

• Jogging mode

• Reference point run

Functions b maXX 3300

• 230 V or 400 V grid connection

• Clock frequency 4/8/16 kHz, parameterizable

• Integrated ballast transistor

• Integrated ballast resistor

• External 24 V power supply

• A choice of 1 or 2 encoder inputs

• Digital I/Os 24 V; 4 in; 2 out

• Analog I/Os ± 10 V; 2 in; 2 out;

• 7 Parameter data records

• Open loop control and closed loop control

• V/f and I/f control

• EtherCAT/CANopen onboard

Encoder types

• Resolvers

• Square-wave incremental encoders

• SINCOS absolute value encoders (single-/multi-turn)

• SINCOS incremental encoders

• ENDAT 2.1

• ENDAT 2.2

• SSI encoders

• Hiperface DSL

High-quality servo-controller for small drives

The b maXX 3300 servo-controller is a high-quality servo-controller with integrated position control for the small power range. The maXX 3300 features a compact, space-saving design. The field-oriented regulation ensures an excellent smooth running quality. The higher-level speed and position control ensures dynamic and precise positioning. The b maXX 3300 is compatible with b maXX 5000 servo-controllers in terms of handling, communication, parameter structure, main functionality and operation. The b maXX 3300 is parameterized via ProDrive.

The highly dynamic control of the b maXX 3300 in conjunction with the highly dynamic small servo motors of the DSD series increases the clock rate of the application and thereby the production rate of machines and systems. Thanks to the high clock frequency (16 kHz) of the actuating signals, the noise emission of the machine and thus the burden on the environment is significantly reduced.

Thanks to the consistent design of the controller with a view to economy and compact construction, the b maXX 3300 is just as suitable for applications in the handling or robotics sector as it is for applications in the printing, textile and packaging industries. The servo-controller is specially designed for operation with the DSD 28-100 servo motors and disc and linear motor series.

The highly dynamic control of the b maXX 3300 in conjunction with the highly dynamic small servo motors of the DSD series increases the clock rate of the application and thereby the production rate of machines and systems. Thanks to the high clock frequency (16 kHz) of the IGBT gate control, the noise emission of the machine and thus the burden on the environment is significantly reduced.

The b maXX 3300 servo converter was designed for small outputs of up to approx. 5 kW and is specially configured for operation with Baumüller servo motors of size 28-100 as well as disc and linear motors. Thanks to the consistent design of the controller with a view to economy and compact construction, the b maXX 3300 is just as suitable for applications in the handling or robotics sector as it is for applications in the printing, textile and packaging industries.

Encoder types

• Resolvers

• Square-wave incremental encoders

• SINCOS absolute value encoders (single-/multi-turn)

• SINCOS incremental encoders

• ENDAT 2.1

• ENDAT 2.2

• SSI encoders

• Hiperface DSL

b maXX softdrivePLC

• Basic and extended version

Safety technology

• Certified STO safety function acc. to EN ISO 13849 up to PLe