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The machine concept
DAM and Lenze have together designed the drive tech-
nology used in the universal test bench to achieve the
maximum expected performance data. For this reason,
servo controllers in Lenze’s 9400 servo drives series with
a power output of 370 kW were used, even though the
asynchronous motors used have a power output of only
105 kW. To achieve the high torque without a gearbox, a
motor current of 690 A is needed. At this operating point,
the asynchronous motors are working, at 3.4 Hz, virtually
in short-circuit operation. “In terms of mechanics and
control technology, we went to the limit. No one knew
exactly where that was beforehand”, recalls Gerald Matzer.
“This is where our close collaboration with the Lenze
development department proved to be extremely valuable.”
The specialist for drive and automation technology
had already developed the first setting in the laboratory.
“As a rule, the system deviations that occur under high
performance conditions have to be kept under control, but
so do the costs. Working as a team with Lenze, we were
very successful in accomplishing this”, Matzer sums up.
The test preparations
Together for one solution: Robert Fandler, Robert
Gradischnig und Gerald Matzer (left to right).
The test system is loaded by means of an articulated
robot. The test oil is then automatically filled, and the
actuators, sensors, and drive and output flanges are connected.
Three drives are required for the actual test
process, one as the driving force before the transfer
gearbox, another two in generator mode as a breaking
force on the two outputs of the gearbox. Because the
currents are high even at minimal speed, the three asynchronous
machines are forced ventilated. The drive
solution developed is supplied as a complete package by
Lenze Anlagentechnik of Enns, Austria. This also includes
the implementation of the control cabinet and commissioning.
In the test bench, the drive control is connected
to the programmable logic controller through a PROFIBUS
connection. The visualisation runs on a separate IPC. DAM
uses the servo controller as a speed and torque actuating
drive and as a gateway. “Through the integrated inputs
we collect bearing temperatures, among other things,
and transmit them by fieldbus to the master computer.
In addition, we save all quality-relevant values in a database
to provide unbroken product traceability”, explains
Robert Fandler.
Energy efficiency by DC bus connection
Apart from its flexibility and precision, what also sets the
universal test bench apart is its cost effectiveness. While
in gearbox test benches the main drive assumes the role
of the internal combustion engine, another two motors
simulate the resistance of the wheels at the output end.
The obvious thing to do, then, is to operate the controllers
via a DC bus connection. “Consequently, what we draw
from the mains is purely to replace the power loss
replacement”, emphasises Robert Fandler in describing
the energy efficiency of the DAM test bench technology.
At a glance
The task
• To develop a universal test bench of maximum and precise
performance
Solution
• Design and implementation of the desired universal test bench
with the utmost energy efficiency
Products
• 9400 servo drives with 370 kW power output and regenerative
module
• Asynchronous motors with 105 kW power output
www.d-a-m.cc
on the job
DAM test bench: The efficient and reliable drive
solution is provided by Lenze as a complete package.
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