Customized motors
The efficiency and performance of every electrical machine and system are largely determined by the drive system. The motor is the heart of the drive system. That's why choosing the right motor is essential to ensure that your machine can deliver full performance with minimum resource consumption and set standards in terms of productivity and efficiency.
Customized standard:
The Baumüller modular motor system
We specialize in efficient electric drives. Our aim is to provide the optimum motor for every application. In our Baumüller modular motor system for torque motors, servomotors and three-phase synchronous motors we offer an incomparable range of variants, enabling us to meet 80% of all customer requests. A large selection of sizes, power ratings, connector variants, different cooling types and various mechanical connection options are all part of our customized standard. In addition, our industry expertise, e.g. in plastics machinery or mobile applications, enables us to optimize our motors specifically for customer-specific requirements and thus offer individual industry solutions.
The Baumüller modular servo motor range is so flexible
The structure of a servo motor is individual. Application-specific products are created due to all kinds of different cooling options, connections, gear boxes, brakes, and encoder solutions. Baumüller also implements customers’ specific wishes.
Customized adaptations
If your application presents special challenges that we cannot meet with the solutions in our modular system, then take advantage of our motor development expertise.
The search for the perfect drive
Your challenging project benefits from the very start from our drive expertise and our comprehensive range of engineering and service offerings. Our design experts have the necessary tools and valuable project experience. We map complex kinematics using simulation tools. With the optimum drive variant and the right motor, the foundation for the success of your project and the efficiency of your machine is laid right from the start.
Use Case 1: Customized torque motors - simplified vertical mounting
Baumüller high-torque motors are high-pole direct drives with very high torque and are particularly suitable for use in presses, shredders, or extruders.
The challenge
A machine manufacturer is planning to install a water-cooled torque motor with the shaft facing upwards. Despite its high power density and compact dimensions, the motor with a shaft height of 315 mm reaches a total weight of up to 1.2 tons. Handling during installation was therefore a major challenge. The motor had to be placed upright on the N-side with the shaft pointing upwards under the machine. As the machine mechanics could only be raised minimally, space was very tight during assembly. With the standard motor, there was a risk of the encoder being damaged by contact with the ground.
The adaptation
A mounting plate with spacers was constructed on the rear N-side of the motor, on which the motor can be placed if required (see diagram). Two additional attachment options have also been added, allowing the motor to be attached to the hoist at several points and moved much more easily in an upright position. This has significantly reduced assembly times at the machine manufacturer's plant.
The spacers protect the encoder when mounted in a vertical position (1). Two additional fastening options further simplify handling (2). The standard motor can be seen on the right.
When installed, there is only a few centimeters of space between the encoder and the floor. The encoder is also protected by the newly designed spacers in the event of ground contact
Use Case 2: Customized torque motors - flexible connection options
Direct drive systems with high-torque motors impress with their high energy efficiency, compactness and low maintenance requirements. The precondition is that the electric motor can be optimally integrated into the machine. This requires flexible adaptation to the specific requirements of the application. This is why various mounting options are available for the DST2 torque motors from Baumüller.
The challenge
In the case of a press, a jaw coupling with a feather key was intended for power transmission, mounted on the solid shaft of the torque motor. This robust design enables efficient torque transmission at low speed. However, this proven solution was not able to achieve the required precision in this case. Due to the damping elements used in the coupling, the positioning of the motor was not precise enough in some cases.
The adaptation
The Baumüller torque motor modular system offers various mounting options as standard. In this case, the solid shaft version was modified to include a blind hole. In addition, the shaft was designed to accommodate a shrink disc, which is already pre-assembled on delivery. Only the screws of the shrink disc need to be tightened to connect the machine shaft to the motor shaft. This allows the torque to be transmitted directly from the blind hole with frictional engagement.
Standard version with solid shaft, next to it with extension of the solid shaft by a blind hole and shrink disc (1) for faster installation
The advantage of this solution is that tension is applied on the outside and the compressive forces only act inwards. There are no impermissible clamping forces on the rotor fitted with magnets inside the motor. At the same time, the solution with the backlash-free shrink disc offers very good concentricity properties. This also reduces the commissioning time, as the alignment of the motor in the machine bed is simplified.
Use Case 3: Customized three-phase synchronous motors - space-saving motor for maximum integration into the machine
With the DS2 series, Baumüller offers synchronous motors in various cooling types with outputs of up to 300 kW. These are used as the main drives in plastics or forming machines, for example. To enable completely new applications, Baumüller also offers extensive customizing of its motors for series applications.
The standard motor with terminal box is too large. In the customized motor, the cable tail is routed out of the pressure vessel, ensuring that the motor fits precisely into the vessel.
The challenge
In this case, the motor was to be deeply integrated into the machine and used as a generator to produce electricity from heat. This required 90 kW of power. The generator was located inside a pressure vessel, which is why the terminal box of the standard motor did not fit into the available installation space.
The adaptation
To optimize the DS2 motor for the application, the connection concept of the motor was revised. The terminal box was removed to accommodate the motor in the existing installation space. The cable tail was routed out of the pressure vessel to enable connection outside. Due to the heat development, standard cables could not be used. These were replaced by heat-resistant cables.
At the same time, a second shaft end was to be implemented. This can also be used to drive a pump without having to accommodate an additional motor in the tight installation space.
Write us a message, our sales experts will be happy to advise you.
