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Smart Protection: Short time window for commissioning? – 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

Extracting mineral resources is anything but easy. Bauxite and aluminum ore, for example, are produced by open-cast mining. Samples of the mined raw material are taken regularly to examine the ore. This is done with the help of a sampling hammer, which removes the raw material from a conveyor belt at short intervals. The commissioning must take place relatively fast and is tricky.

The challenge

Use Case 2: Sampling hammer

The commissioning and optimization of such hammers is very challenging, since this takes place while the production process is running. In the event of incorrect parameterisation, the hammer could get stuck on the conveyor belt, block the conveyed material and thus stop the entire production. This would cause high loss of production costs. A second difficulty is the time factor. The time window for testing the hammer is extremely short.

The solution

By using ProSimulation, the movement profile and control of the hammer can be optimized in the simulation. To create the model, the simulation parameters are taken directly from the real machine data and standard library components are used. This is necessary to test and evaluate the drive behavior extensively in the simulation. This minimizes or eliminates the risk of belt standstill in the real machine. The simple and user-friendly operation of ProSimulation also enables workers to make settings without prior simulation knowledge.

Simulation model of the sampling hammer in ProSimulation.

A comparison between the real (blue) and simulated (green) torque list value shows good correspondence between the two.
Do you have any questions?

Stefan Hecht
Simulation I Baumüller Nürnberg GmbH

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