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Deviation Monitor

Analyze speed deviations directly in the drive

progamming drive intelligence

The Deviation Monitor technology solution detects clutch slippage early on, thereby helping to prevent damage.

b maXX 6500 Deviation Monitor softdrive PLC

By continuously monitoring the speed difference between the servomotor and the load-side speed — for example, at the transmission output — clutch slip is detected immediately. Increased clutch wear and resulting mechanical damage can thus be minimized by appropriate actions taken by the customer.

Fast response due to evaluation in the servo converter

The speed is measured at the converter's high switching frequency. Exceeding the configurable limit values thus leads to rapid detection of the fault condition. The software also provides detailed status and diagnostic information that can be used by the higher-level machine control to respond accordingly.

The measurement is taken autonomously and in real time within Baumüller’s b maXX servo converters, thereby reducing the load on the machine control.

Applications in the Recycling Industry

Protection of the slip clutch

In a shredder, the motor and the slip clutch rotate at the same speed. If the machine shaft becomes blocked, this is immediately detected by means of the speed deviation. Based on the data, the motor can be stopped immediately, thereby protecting the clutch. Fast detection of clutch slip increases the reliability of the powertrain.

From Experience: Measurements during Stress Tests

Baumüller has developed the Deviation Monitor software for shredders in collaboration with Nidec DESCH, an expert in custom gearbox and clutch technology. WEIMA, a manufacturer of shredders, enabled field tests of the drive function on the drive system of the W5 shredder. The single-shaft shredder is equipped with the PowRex drive system from Baumüller and the Tevox®, a gearbox/slip clutch combination from Nidec Desch.

In the following videos, the hopper camera recordings and the corresponding measurement data were combined. Thanks to the Deviation Monitor, a speed deviation was detected with both materials, which allowed for earlier stopping and reversing. This protects both the shredder shaft and the powertrain, and increases the machine's throughput.

W5.22 Single-shaft shredder: Shredding of ship's ropes with Deviation Monitor

W5.22 Single-shaft shredder: Shredding of car tires with Deviation Monitor

Your benefits at a glance:

  • Increasing Machine Throughput: Fast deviation detection enables earlier stopping and reversing
  • Improved mechanical protection through fast response: Protection of the slip clutch, the shredder shaft and the powertrain
  • Ready to use: A validated and tested software package saves development time and costs
  • Engineering as a Service: We can solve your challenge too!