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Simulation and optimization

We want your machines to be equipped with the best possible drive systems. In doing so, our goal is to keep the extent of work required as low as possible. That is why our experts are glad to support you in designing, simulating, commissioning and optimizing your machine.

Do you want a machine with complex, non-linear movement, for example bent levers or cams? Are you looking for the right drive design, and want to test out different options and settings risk-free? Then take advantage of customer support from our simulation experts. Our team offers process and drive expertise, and a valuable wealth of experience with complex motion applications.

In addition to simulating the drive for the design and virtual commissioning process, we also conduct simulations on the component level. This allows us to test out different structural adjustments to our components, and offer custom motor solutions for unusual challenges.

We’re happy to help!

  • Virtual commissioning
  • Dimensioning/design
  • Optimization of existing machines and systems
  • Training/instruction for machine operators and service technicians
  • Support and enhancement of functions and components

Your challenge

Are you looking for the best drive solution for your machine with complex, non-linear movement?

Our service

Send us an inquiry – by email or by phone. You are welcome to include initial technical details.

Are you interested in buying our products?

Write us a message, our sales experts will be happy to advise you.

Our teamwork

With the help of checklists, we collect all the technical information we need on your machine and system. Then your personal, reliable contact person gets in touch with you.

Our performance

We start with the design software sizemaXX or SERVOsoft, then move on to modeling in ProSimulation. We generate a model of your application based on the information we collect on motion control, load profile, etc., then determine the right components and the ideal dimensions.

Your result

  1. You receive a list of the most efficient components for your drive system, verified with state-of-the-art simulation technology.
  2. Would you like to continue working with the models? No problem – you are welcome to use our ProSimulation software yourself. We will provide you with the models of your machine.
  3. If you want, our experts will support you through the end of virtual commissioning.

Your advantages

We ensure the best possible drive design through simulations. In some cases, simulations can replace prototypes, and different variants and settings can be tested risk-free. Commissioning is much quicker and smoother.

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Digital twin as an engineering service

Simulation On The Test Bench

When developing their new machine generation, the Felss Group worked together closely with the drive specialist Baumüller. As part of the project, Baumüller tested the current possibilities of driv...

Applications: When are simulations used?

Solution 1: Sampling hammer

A sampling hammer is used to remove up to 300 kilograms of bauxite from a conveyor belt at a speed of 5 m/s in less than two seconds.

Commissioning and optimizing the hammer was a very challenging task, as it was carried out in Africa while the production process was ongoing. If parameterization was incorrect, the hammer could remain stuck on the conveyor belt, blocking the conveyed material and stopping production entirely. This would result in high costs for the production shutdown. In addition, there were only very short time periods available to test the hammer.

“We were able to use ProSimulation to virtually map and optimize the movement profile and regulation of the hammer in the simulation. This allowed us to thoroughly test and evaluate the drive behavior in the simulation. This measure eliminated the risk of causing a belt shutdown on the real machine” explains Franscoir Potgieter from Motion Tronic.

The Nuremberg simulation team generated a virtual model of the machine containing the drive components used in the commissioning software. The simulation parameters were taken directly from the real machine data and structured from standard library components.

Simulation model in ProSimulation
Simulation model of the sampling hammer in ProSimulation.

comparison between real and simulated speed values
A comparison between the real (blue) and simulated (green) actual speed values shows how well they match.

Motion Tronic is impressed by the simple, user-friendly operation: “Thanks to the complete integration into ProDrive, I was able to use the simulation without any prior knowledge and virtually test the drive behavior of the hammer” Potgieter says.

The solution in brief:

Commissioning of the sampling hammer was completed during ongoing operation. To extend the extremely limited time available on the machine, commissioning was carried out virtually. The biggest advantage of this approach was that it allowed production to simply continue.

Application: Energy management for hydrogen compressor

A hydrogen compressor caused high costs due to its high grid connection power level, although this was needed for only a short time. The idea to reduce grid connection power via an energy management system came from Baumüller's experts, and immediately inspired the mechanical engineers involved. An electrical power storage device would buffer the high power level. The toughest hurdle was dimensioning the capacitors, a complex and time-consuming task.

virtual model in ProSimulation
The extensive library also contains an energy management model. This allows the modeling of the hydrogen compressor to be implemented quickly.

Comparison power
Comparison of the electrical power of the motor (red) and the limited grid power (green). With intelligent energy management, the peak grid power can be halved.

The functional principle of the hydrogen compressor is similar to that of a simplified piston compressor. The higher the pressure becomes, the more power is required.

Baumüller received the required movement and load profile from the customer, then used it to calculate the required power profile. The aim was to reduce the connection power of the machine to keep costs as low as possible for the machine operator. With the simulation, we were able to quickly and easily find the most affordable solution for the customer. The simulation showed that installing just 50 mF intermediate circuit capacity made it possible to reduce the connection power by more than half, from 106 to 50 kW.

The solution in brief:

High connection power levels lead to high costs for the machine operator. The Baumüller team simulated loads to find out which combination of intermediate circuit capacitors and installed connection power would be most efficient. By choosing the best possible drive with integrated energy management, we were able to reduce the connection power by more than 50%.

Modeling on the component level

Often, standard components cannot be used for electric motors used under particularly high loads. By modeling motors, Baumüller is able to simulate unusual loads on them and test out the effectiveness of different structural changes. With this new method, Baumüller helps save time and costs and makes it possible to work from anywhere – a feature that is becoming more important i an age of globalization, digitization, and networking. Baumüller has added motor modeling and drive simulations as new services expanding its portfolio.

Application: Cold forming machines

One of our customers was looking to convert their machines for rotary swaging of components from hydraulic to electric drive technology. The vibrations generated by tool oscillations were transmitted to the motor via the spindle. This, then, caused bearing damage and early failure of the motor. Baumüller's motor offered the best service life – although at just a few weeks long, it was still by far too short.

motor insidesWhen modeling the motor, contacts and their properties are realistically simulatedMechanical engineers contacted Baumüller early in the product development process with this drive technology challenge. The goal, in close collaboration between the mechanical engineer and drive specialist, was to achieve key requirements for process reliability and optimizing resource efficiency.

In order to determine the vibration amplitude, measurements were completed on the machine using the Baumüller standard motor. The parameters obtained in this way were then used as the basis for the simulation, virtually loading the motor with the real vibrations.

As a specialist with decades of expertise in electric drive technology, Baumüller was able to model the motor with all relevant characteristics. Information on materials, contacts and connection methods were included. Components excluded from he analysis were taken into consideration through remote masses with the corresponding mass inertia values.

The solution

Based on the calculations, we determined that it was theoretically possible to increase the service life from a few hundred hours to over 50,000 hours if two angular contact ball bearings were used in place of the standard deep groove ball bearings with the assumed loads. Even before physical testing, we were already able to select an appropriate approach and make an assertion regarding the effectiveness of the measure.

At first glance, modeling motors to complete calculations seems complicated. Simulations with modeled motors, however, should be seen as a true alternative to prototyping with clear possibilities for optimization.