DT Media Newsletter. New impetus for drive systems: Newly developed generation of geared motors provides a pivotal link for consistent drive solutions

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1 New impetus for drive systems: Newly developed generation of geared motors provides a pivotal link for consistent drive solutions Geared motors are encountered in practically every sector of industry. Both standard and individually configurable catalog products are supplied by hundreds of manufacturers, but there are only a very few capable of offering consistently matched drive solutions from the planning stage, through project engineering and implementation to control of the entire drive train. In order to perfect this type of drive technology chain, a renowned system supplier has worked over several years to develop a whole new generation of geared motors. Over recent years, the energy efficiency of plant and machinery has been subjected to ever closer scrutiny. Alongside the degree of efficiency itself, improving energy performance also involves other key aspects such as the precise design and implementation of drive technology solutions. Against this backdrop, the obvious way forward is to optimize coordination of every aspect of the drive drain, from the planning stage through implementation to operation. Where components from different manufacturers are combined to create an overall system, this process can pose certain problems. But there is another way, as Siemens has clearly demonstrated with its Totally Integrated Automation (TIA) concept, which takes an integral view of drive and control solutions. In pursuit of complete continuity, Siemens is working towards the precise coordination of every separate area of drive technology, from planning through implementation to servicing, creating a consistent basis for optimization of the drive train as a whole. A key aspect here is the global availability of the most comprehensive possible portfolio. By developing its totally new Simogear geared motor series Siemens is strengthening another key connecting link in the drive technology chain. Simogear well be replacing the familiar Motox geared motor series, offering users key benefits in terms of type variety, standardization, compactness and power density. The new Simogear generation of geared motors from Siemens which replaces the previous Motox series will be launched initially in a helical, parallel shaft, helical bevel and worm geared version. 1

2 Customary dimensions make for engineering simplicity In the various industries such as automotive, logistics and food & beverage, it is primarily in the field of conveying technology that benefits are gained where planning, design, control and drive technology combine to create a single perfectly functioning drive train. This increases not only the economic efficiency of a solution but also has a positive knock-on impact on operating costs, availability and servicing. For the user, the new Simogear geared motor series from Siemens provides a previously inconceivable degree of design freedom. This is because the standard mounting dimensions selected by Siemens for the axial heights, output shafts, foot and flange mounting and so on all support known design routines which have become entrenched over the years in a market shaped by powerful competitors. As a result, changing suppliers or selecting a second supplier to spread supply risk is just as easily possible as the complete modernization or re-engineering of whole drive solutions, and at reasonable cost. Above and beyond these external signs, detailed technical scrutiny of the new Simogear geared motor series reveals several areas of marked improvement over comparable products in the marketplace. One of the distinguishing features of the new geared motors is their particularly large gear ratio (i) even at the first stage, for instance, which in a two-stage helical bevel gear pair results in a total gear ratio (itotal) of between 3.5 and 60. Special design saves one gear stage By using the plug-in pinion principle instead of the customary push-on pinions used by well-known competitors, the design of the new geared motor series from Siemens allows a complete gear stage to be eliminated. This is done by integrating the pinion into the motor shaft using a positive locking connection instead of attaching it to the motor shaft. This allows the pinion to be dimensioned far smaller, resulting in a much higher gear ratio on the first stage. The characteristic compactness and efficiency of the new Simogear geared motors are down to their underlying design, which frequently allows a three-stage helical bevel gear to be replaced by a two-stage version. The benefits for users are evident: In certain cases, this design feature allows a complete gear stage to be saved, thus enhancing efficiency. As a rough rule of thumb, it can be assumed that efficiency drops by two per cent with each gear stage. At the same time, noise development is reduced, as are splash losses in the geared motor due to a lower peripheral speed on the first stage. The possible elimination of a gear stage also reduces the number of components required within the gear. Together, these effects have a positive impact on the weight of a geared motor solution. As it continues to develop the Simogear series, Siemens will ensure that the gear solutions can be fitted with high-energy efficiency motors complying with both the energy efficiency category IE2 and the even higher IE3 category without this necessitating any change to the mounting dimensions. Consequently no motor size jump from IE2 to IE3 will be introduced at a later date. What this means for users is that the entire gear ratio range is available even after changing over to an IE3 energy efficiency category motor. It will also be possible in future to mount highly dynamic 1FK7 synchronous motors from Siemens directly onto play-reduced versions of the new geared motor series. 2

3 Integrated end shield makes for compact units Another highlight of the new series is the integrated A-end shield on the motor in place of the customary adapter plate plus end shield produced by most manufacturers. This reduces the length of the geared motors and eliminates one intersection or seal point, adding to the compactness and servicing convenience of the new Simogear geared motor generation. The same applies in particular to the helical bevel gear in which a new bearing for the pinion shaft meant achieving a shorter overall length and lower weight. The design improvements achieved together with the standardization of components have resulted in a considerably greater range of Simogear products on offer compared with previous Motox geared motor series. Alongside providing a more cost-effective solution, they also offer fine gradations and reduction ratios, with all the resulting benefits for users designing drive solutions. High level of flexibility through modular design On its motor side, the Simogear series is designed on a modular basis using the patented Siemens Modulog principle. The focus of the modular system is a 2, 4 or 6-pole basic motor designed for international network conditions with an output of between 0.09 and 200 kw (see insert). On the B-side of the motor, an individually configurable add-on shaft system ensures extreme flexibility in terms of required performance: a brake, backstop, rotary encoder and external ventilation can be added using individual additional shaft systems. The benefit is that this type of add-on shaft is easier to handle and store than different rotor shafts. This allows the configuration of the geared motor as specified by the user to be conveniently put together within a short delivery period. The application-oriented approach of the Simogear series is also demonstrated by the selection of materials used for the gears. For applications in which weight plays a predominant role, Siemens offers a range of gears and the respective motors in the lower torque range (see insert) in an all-aluminum housing. The small geared motors up to size 29 also come with a life-time lubrication. Synthetic oil can naturally also be used to extend maintenance intervals. Software and hardware for the perfect drive train Users wishing to change over from motor efficiency class IE2 to an even higher IE3 efficiency rating when this is offered at a later date by Siemens can do so without the need to change to a higher size of motor. The team in charge of developing the new geared motor solutions attached particular importance to achieving the right balance between nominal gear torque, admissible radial force, output shaft diameter, bearing life and fatigue-resistant gearing. With the completely new Simogear geared motor generation, which replaces the previous Motox series, Siemens is taking another major step towards consolidating its image as a system partner and solution provider. In step with its Totally Integrated Automation approach, with its new generation of geared motors Siemens is providing coordinated solutions along the whole of the drive train from planning through execution to servicing. 3

4 The offered hardware encompassing geared motors, starter variants, distributed I/O and control technology is complemented by a range of software tools. A program entitled Sizer supports the configuration of drive solutions, while SinaSave allows a precise advance feasibility study to be performed. Step7 is used to program the automation solution, while the Starter program permits parameterization and commissioning of the various components. Correct configuration of the new geared motors will be aided by the launch of the Simogear configurator, which will allow precise determination of the appropriate geared motor solutions on the basis of specified application data such as gear ratio, torque, output and so on. The program will then supply important information such as the list price, time of delivery, order number and also dimensional drawings in 2D and 3D for compatibility with all standard CAD programs. Siemens views the drive train as an integral whole, and is probably the world s only manufacturer to supply consistent integral solutions in this field made possible by the new Simogear generation of geared motors. Simogear geared motors in grey cast iron and aluminum With grey cast iron housing Market launch Hanover Fair 2012 (22 27 April 2012) Helical geared motors up to size 89 (1,900 Nm) Parallel shaft geared motors up to size 89 (1,850 Nm) Helical bevel geared motors up to size 89 (2-stage 450 Nm; 3-stage 1,600 Nm) Worm geared motors up to size 28 (70 Nm) Market launch sps ipc drives 2012 (27 29 November 2012) Helical worm geared motors up to size 89 (1,600 Nm) Market launch 2013 Helical geared motors up to size 189 (19,000 Nm) Parallel shaft geared motors up to size 229 (50,000 Nm) Helical bevel geared motors up to size 229 (50,000 Nm) With aluminum housing Helical geared motors up to size 39 (200 Nm) Parallel shaft geared motors up to size 29 (150 Nm) Helical bevel geared motors up to size 49 (450 Nm) Helical worm geared motors up to size 29 (100 Nm) Worm geared motors up to size 28 (70 Nm) 4

5 The Industry Sector and Drive Technologies Division in brief The Siemens Industry Sector (Erlangen, Germany) is the world s leading supplier of innovative and environmentally friendly products and solutions for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the Sector enhances its customers productivity, efficiency, and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies. For more information, visit The Siemens Drive Technologies Division (Nuremberg, Germany) is the world s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the Division fulfills the key requirements of its customers for productivity, energy efficiency, and reliability. For more information, visit Download the latest version here: Download the pictures of this newsletter: Media Contact: Siemens Industry Sector Drive Technologies Franz-Ferdinand Friese Phone +49 (0) franz.friese@siemens.com