Machinery and plant manufacturers operate in an increasingly challenging market environment. The central role played by software and electronics demands new skills over and above those of mechanical construction practice. At the same time, development periods are becoming shorter. One response to these complex challenges is to create powerful components that are themselves able to perform as many intelligent functions as possible.
It is against this background that Yaskawa has designed the new generation of its Sigma servo system. The current Sigma-7 series satisfies all demands for simple and quick commissioning, maximum speed, and a correspondingly high machine output, coupled with operational reliability and dependability. The motors offer particularly great potential for packaging plants, semiconductor manufacturing, wood processing and digital printing machines.
Rapid commissioning
Extensive pre-sets in the amplifier software simplify and accelerate the servo drives’ commissioning. For example, the ‘tuningless’ function allows immediate use of the Sigma-7 without the need for complex parameterisation or special knowledge of control equipment, while an auto tuning function ensures quick adjustment. By saving time, you also benefit from savings in costs. The servo motor system supports both installation and commissioning on the hardware side too. The new 400 V version has a removable quick-coupling plug, made according to European standards, for easy and simple wiring. Moreover, the book-style housing supports gap-free, side-by-side installation of several amplifiers in a small space. This makes it possible to realise a high performance density inside the switching cabinet. The space inside the cabinet is reduced to a minimum, allowing it and the drive electronics to be integrated in the machine. Devices can also be connected directly from one to the next, so-called daisy-chain wiring, which reduces installation time. An integrated real time EtherCAT interface is also available, for easy integration in the machine environment. Taken together, all of these timesaving features considerably reduce the time to leading up to a machine’s market launch.
Algorithms maximise machine output and precision
In everyday production, servo motor performance is measured above all in terms of two factors: machine output and precision. Torque and acceleration are naturally subject to physical limits. The mechanics of high-quality motors have already approached these limits in many aspects. However, the motors in the Sigma-7 series are up to 20% smaller while offering equivalent performance, and they produce considerably less heat. This means that they not only need less space in the machine but they are also more energy-efficient. Much more potential for efficiency is provided by the software and electronics. Sigma-7 is characterised by its particularly powerful control algorithms. The 'tuningless' function, for example, ensures automatic adjustment to the load. In conjunction with an automatic vibration suppression function, it is possible to keep plants vibration-free, even when running at an inertia ratio of 30:1. The system also runs reliably under dynamic load variations. In addition, force ripple compensation ensures a high level of synchronous operation.
The deft combination of 24-bit encoder resolution and powerful control performance satisfies the highest standards of synchronous operation and precision. The absolute encoders guarantee both, even at low rotational speeds.
Yaskawa combines the benefits of Sigma-7 drives with consistent controller solutions – from high-performance PLC to motion-control units. These combinations allow synchronous applications with up to 62 axes of control, and this number can be increased to 256 using a special version. In this way, the new servo drives fit well in the Yaskawa “Total System Solutions” concept. Modularly coordinated products and software from the Drives & Motion, Robotics and Vipa divisions, complement each other to form technically consistent automation solutions from a single source. Consistent system architectures – from visualisation and control to drive technology and robotics – enable optimised operating concepts and simple device selection.
Operational reliability and retrofitting
The newly developed servo motors have been available for 200 V since 2014 and will shortly also be available for 400 V. They cover a power range of 0,5 to 15 kW. At the same time, this new generation reflects the experience of 25 years of development expertise and more than nine million servo systems in the field. Operational reliability and availability are correspondingly high. This reduces the cost of maintenance and repair and minimises down times.
The new Sigma-7 generation builds on the advantages of the previous Sigma-5 series – with enhanced safety standards (SIL3, Pl-e), double-axle modules, higher motor protection classes (IP67) and other features. It is also no problem to retrofit existing systems, as the new motors are mechanically compatible with the flange dimensions of the Sigma-5 generation.
For more information contact Jaco Taljaard, Yaskawa Southern Africa, +27 (0)11 608 3182, dmc-sales@yaskawa.za.com, www.yaskawa.za.com
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