Smart Protection: Problems with your motor design? – Simulation helps!

Stefan Hecht, Baumüller Nürnberg GmbH

Read min.

Baumüller Smart Value
Get more out of your drive technology with IoT: Baumüller Smart Value is all about the added value that smart drive technology gives mechanical engineers and machine operators. Baumüller Smart Value enhances the scope of our servo drives: It takes existing data, such as power, current, torque, speed and position, and provides users with important additional information (e.g. machine operating status) or decisions are made directly in the drive to prevent machine failures. The same can be said of the associated design software, which ensures that the motor / controller combination is optimally dimensioned for the respective application and the controller is parameterized. In addition, the design can be immediately verified and optimized on the digital twin using simulation technology.

The problem

The recommended load inertia ratio is 1:10, i.e. the moment of inertia of the load should typically be maximum ten times that of the motor. In this specific example, the moment of inertia of the turntable is 500 times larger than that of the motor.

The challenge

Use Case 5: Design of a turntable

If the load inertia ratio is exceeded, a larger motor with a higher moment of inertia must frequently be used, although the higher power is not required. Such a safety buffer was necessary to prevent unpleasant surprises during commissioning.

The solution

ProSimulation provides the possibility of testing the drive behavior realistically during the design phase. To this end, the customer provided the required movement profile and the mechanical data of the mechanics. Based on this data, it was possible to create a simulation model.

The drive behavior could therefore be evaluated,  although the machine didn’t even exist yet.

Simulation model of the turntable

FFT analysis of the turntable model.

The integrated FFT analysis function was used to evaluate the mechanism, identify the characteristic natural frequency and make the relevant filter settings in the data set.

Position setpoint (yellow), actual position value (green) and lag error (magenta) during a positioning process

The simulation results show that due to the mechanically very stiff link between the turntable and the motor and the associated high natural frequency, the required dynamics and accuracy are achieved despite the high load inertia ratio.

The simulation enabled precise motor dimensioning. The customer therefore benefits from a cost and installation space-optimized drive system. And incidentally, the drive had already been optimized virtually, which saves valuable commissioning time for the real plant.

Do you have any questions?

Stefan Hecht
Simulation I Baumüller Nürnberg GmbH

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