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DriveWare User Manual

1. Idler roller Diameter m Enter the idler roller diameter for the calculation of the effect of the inertia of these rollers to the system inertia 47 Idler roller Inertia kgm Enter the total inertia for all the idler rollers typically there are several idler rollers to support the belt or use the inertia and mass calculator to define the inertia value Notice that you must enter the exact diameter of the idler rollers for the correct calculation of system inertia Use zero value when there are no rotating idler rollers in the conveyor Coupling Inertia kgm Enter the inertia of the coupling between the gearings and the conveyor or use the inertia and mass calculator to define the inertia value This value should also include all additional coupling inertia that is not included in the driver pulley inertia value for example the additional inertia caused by the shaft Efficiency Enter the efficiency percentage of the conveyor mechanics You can take into account power losses with efficiency The efficiency value defines how much more torque is needed due to the losses Incline Angle deg Enter the incline angle between the belt and the horizontal plane Only a positive value of the incline angle is possible Positive distance means upward motion and negative distance means downward motion Coefficient of friction Enter the coefficient of friction It takes into accou
2. 2009 ABB Oy All rights reserved Table of contents 1 About this MANUAL ais 8 AL OVER ie De a eee ee 8 1 2 Document CONVENTIONS 3 3 gecoccecccesees sade deceeeeweeadedenenecessvacsaatats iaa aia 9 2 Overview of MCSIZG ccoo a aida 10 A A antenne manne nan donnee eae nn re dae awe cee ed ea eee en 10 2 2 e TE rene mnt A en Re de PAR LA rl nt tar cake 10 2 3 MCSize user interface iii 11 2 3 1 Main WindOW oia 11 2 3 2 WOolbats 2526 Mecca ia aie thn ai acd Sota G dede bare Rare tn ne rade 12 3 Installing MC SIZO siirre nonin innan detail 14 3 1 System requirements sisi cia 14 32 Installation Mr mt tte 14 3 3 UnINStalliINg ice einen thse Hated Aia 14 Starting PlOjpe Cl iisiccissssccccstvecsecstesasveccevestees ss iveccdeaiecsetszcdaseessesdseenciocivaaedsdaciiceesededesasceddeczees 15 4 1 OPENING NEW project cian rinitis 15 4 1 1 Changing project information 16 4 1 2 Selecting ambient conditions cooonnocccccnnnnnnnnnnncncccnncnnnnnnnnncnnnccnnnnnnnnncnnncnnnnnnnnnnncnancnnnns 17 4 2 Creating New project file cional on Seated ial ce dad ee E 17 4 3 Saving project file 2c sess secee cet its rc 17 4 4 Opening Saved project miracle a aE a 18 SIZINQ An o po 19 5 1 Sizing procedure Overview idees 19 5 1 1 System configuration tree iii 19 5 1 2 Order of selections iiien deta t aani 20 5 2 Transformer data ci dd A enduit it das 20 5 2 1 Entering transformer data oessa srein iana iari ia a aai a aaa a
3. Total distance or angular distance from the start position to the end position 5 7 3 Entering mechanics data You can select the type of the mechanical application from the Type drop down list in the Mechanics display see Figure 21 The available mechanics types are the following e Conveyor which is also the default e Cylinder e Feed roll e Lead screw e Rack amp pinion Sizing 45 e Rotating table e User defined e Winder e Unwinder Each item has its own view and input fields User defined and Cylinder are more universal mechanics types for linear and rotational movements respectively Mechanics Type Conveyor v Load mass kg fi 0 Belt mass kg 5 Diameters m Inertia kgm 2 Incline angle deg Coefficient of friction Opposing force N Driver roller fo2 0 HE Driven roller 0 2 fo HE Idler roller 0 2 fo HE Coupling inertia kgm 2 fo TEE Efficiency 5 oon a Figure 21 Mechanics input data You can use the inertia and mass calculator to calculate the inertia of mechanical parts on the basis of their dimensions weight and material To open the inertia and mass calculator click the calculator button next to an inertia input field 5 7 3 1 Conveyor Industrial conveyors are material handling machinery that are used for moving bulk materials from one place to another at a controlled rate see Figure 22 A belt conveyor consists of an
4. 33 e Gear gear e Gearbox e Chain and sprocket e Belt and pulley Ast T Type Driver gear Driven gear Coupling inertia kam 2 fo FH Efficiency 4 fi oo Figure 14 Gearing data input field 5 6 1 Belt and pulley In belt and pulley gearings the power is transmitted from one pulley to another via a belt see Figure 15 The ratio of gearing depends on the diameters of the pulleys Coupling Driven pulley Driver pulley Figure 15 Belt and pulley You can enter the driver pulley inertia driven pulley inertia and coupling inertia directly or you can use the inertia and mass calculator see chapter 5 1 3 Inertia and mass calculator You can see the input fields for the belt and pulley gearing in Table 12 Table 12 Belt and pulley gearing settings Sizing 34 Setting Explanation Driver pulley Diameter m Enter the exact actual diameter of the driver pulley for the correct calculation of reflected inertia Driver pulley Inertia kgm Enter the value of the driver pulley inertia or use the inertia and mass calculator Driven pulley Diameter m Enter the driven pulley diameter The speed of driven pulley rotation depends on the belt velocity and the diameter of the pulley Therefore the exact value of the driven pulley diameter is required for the correct calculation of the reflected inertia value Driven pulley Inertia kgm Enter the value
5. ABB Oy AC Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 2000 Fax 358 10 22 22681 Internet http Awww abb com 3AFE 00000000 REV D EN EFFECTIVE 13 11 2009
6. File Edit Insert Data Tools Result Help Pani 2l lal sl ajel aie elal els Altitude 1000 m h 40c 40C en aoc System configuration dh transformer GQ drive E E motor El HE le Conveyor Driver gear 1 Driven gear hi Coupling inertia kgm 2 jo HE Efficiency fico te Gearbox y Inertia kam 2 Gear ratio Coupling inertia kgm 2 fo FA AMS Max Efficiency 100 Speed rpm Pass pers Torque Nm 2 946 2nd Driven gear Type Gear aear y Number of Teeth Inertia Kgm 2 Driver gear RMS Max Speed rpm ja 3 529 286 479 Torque Nm 2346 3rd Type Chain and sprocket y Driver sprocket fi Driven sprocket fi Coupling inertia kgm 2 fo Number of Teeth Inertia Kgm 2 Chain Coupling 7 Driven sprocket Driver sprocket k RMS Max Cag Driver sprocket Efficiency Fr 00 Sante Ln Speed rpm ja 3 529 286 473 Chain mass kg g 0 2 Torque Nm 2 946 Gears totally Ratio fi Inertialkgm 2 0 05 Overall efficiency fico Figure 13 Gearings input data display The visible gearing settings are determined according to the selected gearing type Select the desired gearing type from the Type drop down list see Figure 14 The order of gearings from the motor to the load is Motor The available gearing type options are e None 48 9 3 Load Sizing
7. 70 6 5 1 Results Drive Results E xj Drive data Type designation Selection data Criteria ACSM1 04Ax 0540 CHK 02 Specifications Required Result Margin Name Catalogue data Voltage V Ims 3983 5 26 Inverter amount Nominal power kW 22 Imax A 9161 105 15 Type Air cooled Nominal current 4 5 Pmax kw 2523 4 62 83 AC choke Yes Continous current 4 5 Dyn current limit 9 IP class Not specified Imax 4 Switching frequency Braking chopper Included AC choke uH Nominal AC choke uH Braking resistor Not considered IP class Drive losses at RMS speed kW 0 14 Nominal fsw kHz Figure 41 Drive Graph Drive results display You can see the drive results also in graphical form see Figure 42 Current speed curves define the limits for continuous green and intermittent currents red The latter current limit depends on drive heatsink temperature output frequency and switching frequency Calculated RMS current actual current trajectory and limits are shown in the drive graph Also this graph can have two quadrants Unit name drive Selected inverter ACSM1 044x 0340 CHK 01 Return 84 Report C Load Motor Current A Inverter 64 yr Performance and EA E profile 200
8. Not specified Not specified Stall current 4 Nominal current 4 Temp rise class Not specified Nominal speed rpm IC class Size 10 0041 Max speed rpm Auxiliary brake Results Inertia ratio fi4a2308 Max air gap torque Nm es RMS torque Nm pas Motor copper losses kw fo 5 Not specified Back EMF V Inertia kam 2 Torque constant Nm 4 1 131 Figure 38 Motor selection data Motor Graph You can see the motor results also in graphical form see Figure 39 and Figure 40 Calculated RMS torque at RMS speed dynamic torques and limits are illustrated in a motor graph The green torque speed curve defines the thermal long term limits of the motor The red curve defines limits for short term intermittent loads and maximum allowed speeds for these loads These required results are calculated on the basis of the motor air gap torque The effect of motor inertia is also taken into consideration The selection criteria for a motor are e Calculated RMS torque must be inside the range of the Cont loadability limit e Dynamic peak torque curve must be inside the range of the Max loadability limit Results 68 Results x Retum Report Load Motor Inverter Selected motor 8C1 4 30 Unit name motor c Performance and profile 4000 Speed rpm Max loadability 20 RMS torque Dynamic torque Cont l
9. Setting Explanation Segment Sequence number You can enter 2 50 segments Segment Type Speed amp Accl Decl Speed amp Time Speed amp Distance Accl Decl amp Distance Accl Decl amp Time Distance amp Time Dwell segment Const speed distance only Const speed time only Hold segment Accel DeclType Select the acceleration deceleration type You can increase the smoothness of motion with this option S curves are used when it is necessary to limit the Sizing 44 acceleration change rate jerk The available s curve options are the following Linear 1 4 s curve 5 8 s curve Full s curve You can achieve the smoothest motion with the Full s curve setting but it requires higher peak acceleration and deceleration to produce an equivalent profile This means that when s curves are used more torque is required to accelerate or decelerate the system inertias Time s The duration of the segment Speed m s rad s The end speed for acceleration or deceleration segment Distance m rad Angular distance traveled during the duration of the segment Accel Decl m s rad s The mean value of acceleration for the segment A positive sign means acceleration to the positive direction and vice versa A negative sign means deceleration when the direction of the movement is positive and vice versa Total Dist m rad
10. File gt Open File gt Save File gt Print Data gt Ambient Condition Data gt Motion Profile Tools gt Network Check Tools gt Dimension Unit Result gt Dimensioning Result Result gt Graphs Result gt Units Selected Tools gt User Selection In the upper right corner of the main window you can see the ambient conditions display The displayed ambient conditions data are described in Table 3 Table 3 Picture dh 40 C Ql 40 c Overview of MCSize Ambient conditions on the toolbar Description Indicates the transformer s ambient temperature Indicates the drive s ambient temperature Crim 40 C Indicates the motor s ambient temperature Altitude 1000 m Indicates the installation s altitude Overview of MCSize 14 3 Installing MCSize 3 1 System requirements To run MCSize you must have DriveSize installed on your computer For system requirements refer to the DriveSize manual Additionally MS NET Framework 1 1 or later is required 3 2 Installation To start the installation of MCSize 1 Start Windows 2 Insert the MCSize CD into the appropriate drive or download the setup package to your local hard disk 3 Select Run from the Start menu 4 Type the drive letter of the drive followed by MCSize exe for example C MCSize exe Click OK or press ENTER 5 Follow the instructions the installation program gives you The software installation copies all the necessar
11. Inertia amp Mass Calculator File Edit Units Language Help Cylinder me leans L o Rout jo mm E jo Rin Material Other ba Density jo kg m Y Axis aa C bb Mass fo kg y Inertia jo kgm x ES m Calculation Table Type Mass kg Inertia kg rr LX le OK Cancel Figure 31 Inertia and mass calculator 5 8 Sizing examples The software includes example project files that include pre filled input data With these files you can learn quickly how the software works and how to enter data To open a sizing example file Select File gt Examples and pick the desired file from the list 5 9 Network check Use Network check for harmonics calculation Refer to the DriveSize user manual Chapter 5 Network check Sizing 6 Results 6 1 Motion and mechanics results To open the Motion results display see Figure 32 click the Motion icon in the System configurati on tree 61 Motion results mechanical results and combined results are calculated immediately when new data is entered to the Motion and Mechanics input fields 6 1 1 Motion results The calculation of motion results is based on the Motion profile input data The results are also shown in graphical form The motion profile graph in the Motion results display includes two Graph type display options Speed vs time and Displacement vs time Motion results Acceleration tim
12. endless loop belt and a roller system in which idler rollers are often used to support the belt The belt position can be horizontal inclined or declined The direction of movement is mostly forward but reverse is also possible Sizing 46 Sizing E Driven roller Coupling Driver roller Figure 22 Conveyor mechanics You can see the input fields for conveyor mechanics in Table 19 Table 19 Conveyor mechanics settings Setting Explanation Load Mass kg Enter the total mass of the load to be conveyed Belt Mass kg Enter the belt mass lt affects the value of total inertia and the frictional forces Driver roller Diameter m Enter the exact driver roller diameter for the correct calculation of driven roller inertia load inertia belt inertia and idle roller inertia Driver roller Inertia kgm Enter the value of driver roller inertia or use the inertia and mass calculator to define the inertia value Driven roller Diameter m Enter the driven roller diameter for the calculation of the effect of the inertia of these rollers on the system inertia Driven roller Inertia kgm Enter the driven roller inertia or use the inertia and mass calculator to define the inertia value The rotation speed of the driven roller depends on the belt velocity and the diameter of the driven roller For correct inertia value calculations enter the exact diameter of the driven roller
13. exists Only the quadrants that really exist in the mechanical application are shown in the motor input load view You can see the definitions of quadrants in Table 8 Table 8 The definition of quadrants Quadrant Description Q1 Positive torque positive speed Q2 Negative torque positive speed Q3 Negative torque negative speed Q4 Positive torque negative speed 5 5 2 Modifying motor load specifications Sizing You can see the input fields for motor load specifications in Table 9 Note that some of the input fields are dependent on the selection made in the Motor type field Table 9 Motor load specifications Specification Options Name Any text or string Motor type ServoMotor Permanent magnet servo motors in database InductionMotor ABB s catalog induction motor ExistingServoMotor Enter motor characteristics case by case ExistinglnductionMotor Enter induction motor characteristics UserDefinedServoMotors Motors per inverter Normally 1 but can be in the range 1 100 similar motors per an inverter unit The load is given for one motor One inverter feeds several motors connected in parallel Family According to the Motor type selection the motor family choices are shown If you have no preferences use Not specified Polenumber Not specified 2 4 6 8 10 12 Feedback type Not specified Encoder Resolver With servomotors an e
14. of the driven pulley inertia or use the inertia and mass calculator Belt mass kg Enter the belt mass It has an effect on the value of total inertia Coupling inertia kgm Enter the inertia of coupling at the motor side of the gearing or use the inertia and mass calculator This value should also include all additional coupling inertia that is not included in the driver pulley inertia value for example the additional inertia caused by the shaft Efficiency With the efficiency setting you can take into account the losses of torque In MCSize the losses are assumed to happen between the belt and driven pulley 5 6 2 Chain and sprocket In chain and sprocket gearings the ratio of gearing is inversely proportional to the speeds of the sprockets that is to the number of teeth on the sprockets see Figure 16 Sizing 35 Driven sprocket Driver sprocket Figure 16 Chain and sprocket You can enter the driver sprocket driven sprocket inertia and coupling inertia directly or you can use the inertia and mass calculator see chapter 5 1 3 Inertia and mass calculator You can see the input fields for chain and sprocket gearing in Table 13 Table 13 Chain and sprocket gearing Setting Explanation Driver sprocket Number of teeth Enter the number of teeth on the Driver sprocket This value along with the Driven sprocket Number of teeth value generates the gear ratio Th
15. that is to the number of teeth on the gears see Figure 17 The correct gear ratio is required in the calculation of reflected inertia You can enter the driver and driven inertia directly or use the inertia and mass calculator Driven Gear Coupling Driver Gear Figure 17 Gear gear You can see the input fields for gear gear gearing in Table 14 Table 14 Gear gear gearing settings Setting Explanation Driver gear Number of teeth Enter here the number of teeth on the Driver gear This value along with the Driven gear Number of teeth value generates the transformation ratio MCSize accepts also the value 1 Driver gear Inertia kgm Enter the driver gear inertia value or use the inertia and mass calculator to define the inertia value If you want to use the 37 inertia and mass calculator to define the inertia value you must also know the driver gear diameter Driven gear Number of teeth The number of teeth on the Driven gear This value along with the Driver gear Number of teeth value generates the transformation ratio Driven gear Inertia kgm Enter the driven gear inertia value or use the inertia and mass calculator to define the inertia value If you want to use the inertia and mass calculator to define the inertia value you must also know the gear diameter Coupling inertia kgm Enter the inertia of coupling on the power input side of the gearing or use
16. the inertia and mass calculator to define the inertia value Efficiency With the efficiency setting you can take into account the losses of torque In MCSize the losses are assume to happen in the teeth of gears 5 7 Motion profile and mechanics 5 7 1 Entering motion profile data To open the Motion display click the Motion profile and mechanics icon see Figure 19 Enter motion profile information to the data input fields When you enter a new input value the program calculates a new motion profile The results are displayed in the Motion results display The layout of the Motion results field changes according to the selected mechanics type whether linear or rotational You can also select an optional unit for distance Click Change type to open a drop down list with options for the type of mechanics Sizing 39 Motion Duty type Simple cyclic y Profile type Trapezoidal 1 3 1 3 1 2 y Accel Decel type Linear Movement time s Bo Dwell time s jo Figure 19 Motion input data You can see the input fields of Motion display in Table 16 Table 16 Motion input fields Setting Explanation Duty type Select the duty type The Simple cyclic duty type consists of just one profile that includes the acceleration continuous speed and deceleration segments If the Multiform cyclic duty type is selected you can create more complicated cycles for example enter several acceler
17. the system inertias Movement distance m Top speed m s Rotational angle deg Number of revolutions Enter the total distance traveled during the cycle Acceleration deceleration is calculated on the basis of given distance and movement time When linear load is selected the options are Movement distance m and Top speed m s When a rotational movement type is selected a drop down list with three options Rotational angle deg Number of revolutions and Top speed rev appears Movement time s Enter the total movement time for one cycle Includes the acceleration constant speed and deceleration segments but does not include the dwell time Dwell time s Enter the waiting time between sequential cycles 5 7 2 Entering more complex profile To enter the more complicated duty type select Multiform cyclic from the motion input data view see Figure 19 Select a suitable segment type from the drop down Sizing 41 list for each segment Enter the data for different segment types in the input fields and the software calculates the rest see Table 17 MCSize will display an error message in the motion profile view when entered inputs are incomplete for example if the final speed of the previous segment does not fit with the new segment A new row appears automatically after you have entered acceptable inputs for the segment Click the right mouse button to delete or to insert a new segm
18. you can perform the dimensioning selections in any order For example you can easily change the supply voltage and frequency at any stage 5 2 Transformer data 5 2 1 Sizing Entering transformer data To modify transformer input data open the transformer display see Figure 7 by selecting the Transformer icon from the System configuration tree To modify transformer data 1 2 Select the Secondary voltage V setting from the drop down list The default Frequency Hz setting is 50Hz but you can change it to 60Hz if valid MCSize also displays the Calculated load power kVA which you may override by typing a value for Load power kVA This will affect the transformer selection 21 Transformer load Secondary voltage V Frequency Hz Load power kVA Calculated load power kVA Specification Name transformer Type Dry Figure 7 Transformer load data definition 5 2 2 Modifying transformer specifications Insert data in the Specification field of the Transformer load display You can see the input fields for transformer load specifications in Table 4 Table 4 Transformer load specifications Specification Options Name Any text or number string This will also show up in reports and depending on the Tools Options settings on screen Type Dry Oil Sizing 22 5 3 Supply input data 5 3 1 Sizing To enter supply load data open the Supply
19. 0 Speed rpm Current Limit ae Actual Current RMS Current RMS Limit Figure 42 Drive Graph display Please notice that in this example due to s curves the acceleration starts smoothly runs most of the time at 2 4A and will easy up at 1520 rpm The deceleration will happen with lower current but with the same idea 6 6 Supply unit results In the Supply unit data display you can see the results and specification data for Selection data Figure 43 Specifications Catalogue data and Supply unit losses The selection criteria for a supply unit are e Calculated RMS current must be lower than the nominal current Peak current must be lower than temperature dependant max current limit e Additionally the dynamic thermal current and temperature limits are checked Results 72 Drive Results 2 M Line converter data Type designation ACSM1 204AR 07A0 4 Selection data Specifications Catalogue data Current Required Result Margin lms Supply amount il Nominal power kw Imax 0 699 14 7 2004 Ait cooled Nominal current 4 Dyn current limit 2004 Line filter Included Temperature 191 IP class Not specified Included Filter Switching frequency 3kHz IP class Nominal fsw kHz 3 Line converter losses Kw 0 05 Figure 43 Selection data of supply unit 6 6 1 Supply unit Graph You can see the supply unit results in graphical form Figure 44 There the DC po
20. 0 5 Inertialkom 2 5 Overall efficiency 100 Figure 36 Total values of all gearings You can see the results in the Gears totally field in Table 31 Table 31 Gears totally result items Result Explanation 65 Total gear ratio Combined gear ratio for all gears Inertia due to gears kgm Combined inertia of all gears at motor shaft Overall efficiency Combined efficiency for all gears 6 3 Results menu To show dimensioning results first select the drive component or the supply unit from the tree and then click the icon or select Result gt Dimensioning result 6 3 1 Graphs To show Graphs click the icon or select Result gt Graphs This opens the Graph window that displays graphs for the following graph options e Load Motor graph e Inverter e Performance and profile graph For inverters the following options are available e Current e DC power To show supply unit DC power graph select supply from system configuration tree and click the graph icon 6 3 2 Multi graph view To show several graphs at a time select the components from the system configuration tree To highlight several components use the Ctrl key mouse and left mouse button Press and hold down the Ctrl key when selecting components Select first the object that you want to see uppermost Two of the graphs are shown at once and you can change the lower one by scrolling the graphs You can show the multi graph vi
21. 1885 70 2382 ACSM1 04A4x 0464 CH 22 46 2183 81 2772 772 Figure 45 User selection display 75 7 Printing This software uses Microsoft Excel for printing You can use the print and preview options if you have Microsoft Excel 97 2000 or later version installed on your computer You can use the printing function for two purposes e to export project information to Excel or PDF formats e to print project information on paper To print results 1 Open the Print display by e Clicking the toolbar icon al e Selecting File gt Print from the menu or e Pressing the Ctrl P short cut key 2 Select the items to be moved to Excel You can print a project data sheet a project technical data sheet or all data sheets for a project see Figure 46 DEN x M Information Print Project data sheet Preview C Project technical data sheet Return C All data sheet Setup Figure 46 Print display 3 Click Print to print the desired information If you select Setup you can select the printer and print options Paper size Source and Orientation Printing 76 8 Help The software s context sensitive Help file contains the same information as this document To open the Help file select Help gt Contents For information on how to use the help select Help gt How to use help Select Help gt About to view MCSize version information Help 77 AA ED ED PADDED
22. Drive Ware User Manual MCSize 2 DriveSize MCSize ACSM1 Drive Cover File Edit Insert Data Tools Result Help olele e alaj 0 8 218 a Altitude 1000 m db 40 Q 40 C ex 40c System configuration PC 3PU 5 ACSM1 044x 0245 CHK 01 ex 8C1 1 30 Ratio 10 ACSM1 044x 0124 CHK 03 Ee 805 5 15 E de Ratio 5 lo Conveyor M Motion Duty type Profile type Accel Decel type Movement distance m Movement time s Dwell time s fr tapezoidal 1 3 1 31 w 548 s curve y fi 0 Change type Mechanics Type Load mass kg Belt mass kg Driver roller Driven roller Idler roller Coupling inertia kgm 2 Efficiency Incline angle deg Coefficient of friction Opposing force N Coupling Driven roller Driver roller Motion results Acceleration time s reer jeer ke Fa F Velocity at max dyn power m s Ras Deceleration time s Acceleration m s 2 Deceleration m s 2 Max velocity m s 6 Time s Graph type Speed vs time Mechanical results Opposing torque Nm Equivalent inertia kgm 2 Combined results Max torque Nm Max speed rpm Max power kW RMS torque Nm ET aos paar EN Speed at max dyn power rpm 221 448 RMS speed rpm MCSize User Manual ACSM1 Code 3AFE 68831776 REV D EN EFFECTIVE 13 11 2009 FIDRNEIF2006 PDM code 00561632 DOC
23. Ruv is line to line armature resistance ohm Sizing 31 Mpo 0 Mes 0 Mp1 n1 Mn Speed Torque Nm Continous Torque 0 1000 2000 3000 400 Speed rpm Figure 12 The definition of loadability curve You can see the input fields for existing motor specifications for ExistinglnductionMotor in Table 11 Table 11 Existing motors specifications for Existing Induction Motor Specification Options Type designation Any text or string Voltage V 400 Frequency Hz 50 Power kW 1 Poles 2 4 6 8 10 12 14 16 18 20 Speed rpm 1000 Efficiency 90 Power factor 0 8 Tmax Tn 3 Temp rise class B lt 80K F lt 105K Inertia Kgm 2 0 001 IC class 1C411 10416 5 5 3 Importing own motor list You can perform dimensioning with motors from your own motor list Options are Import user motors and Import user induction motors For User motors refer to the DriveSize manual Sizing 32 5 6 Gearing input data To enter gearings data open the Gearing display see Figure 13 by clicking the Gearing icon in the System configuration tree You can set a maximum of three gears Each has its own view and data input field This software does not include an automatic gear ratio optimization Set the gear ratio so that the maximum speed is as close to the maximum speed of motor as possible L DriveSize MCSize ACSM1 Drive Untitled
24. aph Enter the new values of axis and click Update push button The zoom function is available when the total cycle time exceeds ten seconds or the number of segments is ten or more Select Enable Zoom use mouse and left mouse button to highlight a period you want to zoom in Click the al push button to zoom out You can see the input fields of Multiform cyclic display in Table 18 Table 17 Segment types Point type Explanation Speed amp Accl Decl For the acceleration or deceleration segment Enter the final velocity in the end of this segment and the desired value of acceleration Negative acceleration means deceleration when the speed is positive and vice versa Speed amp Time For the acceleration or deceleration segment Enter the duration or accelerating decelerating segment and the final speed in the end of this segment The initial speed and the end speed must have the same sign both negative or both positive Reversal is possible via zero speed point only Speed amp Distance For the acceleration or deceleration segment Enter the final velocity at the end of this segment and the desired distance to be travelled during this segment The distance and the speed must have the same direction both negative or both positive Accl Decl amp Distance Segment type for acceleration or deceleration segment Enter the desired acceleration and the distance for the segment Negative value means deceleration w
25. ation and deceleration segments Enter the data in the separate Motion profiles display see Figure 20 With several accelerations it is possible to accelerate or decelerate from one nonzero speed to another nonzero speed A motion profile can contain a maximum of 50 segments including acceleration deceleration constant speed dwell and hold segments Only simple cyclic is available for Winder and Unwinder mechanics Profile type Select the profile type The available profile type options are the following Trapezoidal 1 3 1 3 1 3 Trapezoidal 1 4 1 2 1 4 Triangular 1 2 1 2 User defined Fractional numbers here refer to the relative times of acceleration continuous velocity and deceleration Acceleration time and deceleration time become Sizing 40 editable when the profile type is User defined Accel Decel type Select the acceleration deceleration type You can increase the smoothness of motion with this option S curves are used when it is necessary to limit the acceleration change rate jerk These curves are also used in dynamic braking The available s curve options are the following Linear 1 4 s curve 5 8 s curve Full s curve You can achieve the smoothest motion with the Full s curve setting but it requires higher peak acceleration and deceleration to produce an equivalent profile This means that when s curves are used more torque is required to accelerate or decelerate
26. ching frequency braking chopper and resistor Sizing 26 To modify drive specifications click on the desired item Select new values from the drop down lists or type the new value to the field You can see the input fields for drive load specifications in Table 7 Table 7 Drive load specifications Specification Options Name Any text or number string This will also show up in reports and depending on the Tools Options settings on screen Inverter amount Number of similar drives with range 1 100 for one branch in the System configuration tree Type Air cooled Cold plate IP class Not specified IP20 This selection means that the user is specifically limiting the choices to the IP20 protection class Switching frequency 4 8 16 kHz Higher switching frequency will reduce the audible noise and give better motor performance but will adversely cause losses in the drive and the max current providing capability Braking chopper Ignored This selection means that even though the internal chopper is used the losses of it are anyway ignored when a drive selection is performed Internal This selection means that the losses of internal chopper are added to drive losses and the limitations of the internal chopper are considered when selecting a drive Braking resistor Not considered The braking resistor is not selected this time Selected T
27. e s Deceleration time s Acceleration m s 2 Deceleration m s 2 Max velocity m s A Speed m s nN Graph type 667 667 ITA o 3 4 5 Time s Speed ws time y Figure 32 Mo tion results You can see the result fields of the Motion results display in Table 28 These values produce the profile that is entered to the input fields of the motion display Table 28 Motion results Results 62 Result Explanation Acceleration time s Calculated acceleration time This field is editable when the Profile type is User Defined Deceleration time s Calculated deceleration time This field is editable when the Profile type is User Defined Acceleration m s deg s or 1 s Calculated equivalent value of acceleration Units are selected automatically depending on whether linear or rotational movement is used Deceleration m s deg s or 1 s Calculated equivalent value of deceleration Units are selected automatically depending on whether linear or rotational movement is used Max velocity m s deg s or rpm Calculated maximum velocity Velocity at max dyn power m s rpm or When S curves are applied the deg s movement speed where the maximum power is required is not at maximum speed but lower Applying s curves might allow smaller motors than without because the high torque at max speed is avoided 6 1 2 Mechanical re
28. e MCSize refers to motion control and machinery drives and the MCSize software is meant to be a fast technical computing tool for all users who need to select electrical drive system components Typically a sizing process starts from the selection of mechanics and motion profiles Also gears are an essential part of the system Because the automatic gear ratio optimization is not currently included in the software users are expected to use their common knowledge when setting the gear ratios since it is an important part of cost effective solutions The motor selection is based on technical facts only usually on the torque requirements of the motion and mechanics MCSize does not contain cost or price information and thus cost optimizing has to be performed manually After the calculation of choices the frequency converter also called drive is then selected on the basis of motor current function The single drive selections and the sizing of line converter with one or several inverters are supported MCSize is a part of the DriveSize system and inherits the same principles To help new users MCSize inserts reasonable default values to the required input fields This way the users are able to command the software to dimension the motors and drives right away The software for example gives the default value of 0 2 m for the driver roller of the conveyor as a value of 0 m would cause the software to give unnecessary error messages about missin
29. e of the input torque provided to output The losses of the cylinder drive mechanics are taken into account in the efficiency Conversion diameter m Enter the diameter for thrust force The thrust load diameter is the doubled distance between the center of the cylinder shaft and the impact point of the opposing force 49 Opposing force N Enter the total sum of opposing forces in this input field The opposing forces include for example the thrust load acting against the movement at a certain radius on the load 5 7 3 3 Feedroll You can see the example of feedroll mechanism in the Figure 24 Driven Roller Coupling Driver Roller Figure 24 Feedroll mechanics You can see the input fields for feed roll mechanics in Table 21 Table 21 Feed roll mechanics settings Setting Explanation Load mass kg Enter the total load of the material to be moved Number of rolls Driver roller Enter the number of driver rolls in the feedroll Number of rolls Pinch Enter the number of rolls in the pinch Inertia Driver roller Enter the driver roller inertia or use the inertia and mass calculator to define the inertia value Inertia Pinch Enter the pinch inertia or use the inertia and mass calculator to define the inertia value The rotation speed of the pinch feed roll depends on the strip velocity and the diameter of the roller Diameter Driver roller E
30. e ratio is smaller when reducing the value MCSize accepts also the value 1 Driver sprocket Inertia kgm Enter the driver sprocket inertia value or use the inertia and mass calculator to define the inertia value Driven sprocket Number of teeth The number of teeth on the Driven Sprocket This value along with the Driver sprocket Number of teeth value generates the gear ratio Driven sprocket Inertia kgm Enter the driven sprocket inertia value or use the inertia and mass calculator to define the inertia value If you want to use the inertia and mass calculator you must know the gear diameter Coupling inertia kgm Enter here the inertia of coupling at the motor side of that gearing This value should also include all additional coupling inertia that is not included in the driver pulley inertia value for example the additional inertia caused by the shaft Sizing 36 Efficiency With the efficiency setting you can take into account the losses of torque In MCSize the losses are assumed to happen between the chain and driven sprocket Chain mass Kg Enter chain mass information It affects the value of total inertia Driver sprocket diameter m Enter the true diameter of the driver sprocket in order to define the chain s effect on the reflected inertia value 5 6 3 Gear gear Sizing The gear ratio of gear construction is inversely proportional to the gear speeds
31. ed in the table inertia value for example the additional inertia caused by shafts Efficiency Enter the efficiency percentage of input power provided to output The efficiency value takes into account the losses of the rotating table mechanics Opposing force distance m Enter the opposing force distance It is equivalent to the distance from the center of the table to the impact point of 55 opposing frictional force Opposing force N Enter the opposing force The opposing force can be any additional frictional force that acts on a certain area from the center of the table 5 7 3 7 User defined User defined is the universal load type for linear movement in this software The inertia of linear load is converted to rotational movement with the conversion diameter defined by the user See the general structure of user defined mechanics in Figure 28 Load with Linear Motion Coupling d Conversion diameter Figure 28 User defined mechanics You can see the input fields for user defined mechanics in Table 25 Table 25 User defined mechanics settings Setting Explanation Load mass kg Enter the total load mass to be conveyed Conversion diameter m Enter the conversion diameter The diameter defines the distance the load travels for the full revolution of the input shaft The distance is equal to x multiplied by the conversion diameter Coupling ine
32. ee format see Figure 6 MCSize includes different data input displays for the transformer supply drive motor gearings and motion profile and mechanics data When you click on an item in the System configuration tree the input data display will change accordingly System configuration f transformer Gl fl supply E fl drive E E motor E e gearing lo Conveyor E fl drive E e motor gearing Ia motion Figure 6 System configuration tree The System configuration tree includes the following icons cp Transformer al Supply when regenerative drive i Drive Motor Gearing la Motion profile and mechanics Sizing 20 5 1 2 Order of selections Dimensioning selections can be performed for example in the following logical order 1 OONOAR YON Select a Secondary voltage V for the system Select the Frequency Hz setting Select the type of application Enter motion profile input data Specify application data for mechanics Select gearings and enter input data Select motor specifications and motor sizing Select drive specifications and sizing Select supply specifications and sizing when regenerative drive To add a second axis select Insert gt Drive Motor Mechanics or Insert gt Supply Drive Motor Mechanics from the menu bar and repeat the selections from 3 to 9 However MCSize allows you to select and modify units at any level and
33. ent between two segments Select the segment you want to delete or a segment after which you want to insert a new segment The profile is shown also in graphical form Graph type options Speed vs time and Displacement vs time are available for graphics There is also a possibility to graphically reshape the profile by mouse Select Edit from Graph options use mouse and point out the segment you want to divide into two parts Click right mouse button and select Add point click left mouse button and a new point appear Similarly use Delete line command to remove segments Select Drag from Graph Options use mouse and left mouse button to move the red dots Motion profiles Segment Type Accel DeclType Ti s Distance m Accel Decl m s 2 Total Dist m OK Speed amp Accl Decl Linear 25 25 Cancel Const Speed time only Linear Speed amp Accl Decl Linear Dwell segment Linear 5 Speed amp distance Linear 25 as Report Speed amp distance Linear Error info Dwell segment Linear Graph type Speed vs time c Displacement vs time C All Graph Options C Edit Drag Zoom M Graph Settings Min Y Ez Max Y la Max X hn Update Figure 20 Motion profiles display Sizing 42 Sizing Use Graph Settings to change the scale of gr
34. ew for all graph options see Figure 37 Results 66 6 3 3 Reports Graph Unit name Axis 1 Time s 10 33 6 89 3 44 10 33 9 47 4 74 4 74 9 47 Torque Nm Torque Nm le Figure 37 Performance and profile multi graph view 6 4 Motor results The motor Selection data is shown in the Motor data field of the Motor Results display see Figure 38 Calculated margins are between the following values Results e Required RMS torque to the nominal torque of motor e Required peak torque to the maximum short term torque of motor To show Reports select Result gt Reports or click the Report button in the result or graph display To show more project data sheets at once see chapter 7 In the motor data display you can see also Inertia ratio Max air gap torque RMS torque Motor copper losses Specifications and Catalogue data for the selected motor 6 4 1 Motor Results 67 Motor data Type designation 9C1 2 30 Product code 9C1 2 30 0 0 0 0 0 0 1 M Selection data Specifications Torque Nm Required Result Margin Name Motor type motor ServoMotor Return Graph User selecti Report Catalogue data Frequency Hz Motors per inverter Family 1 Not specified Power kW y Nominal torque Nm Const stall torque Nm Polenumber Not specified Peak stall torque Nm Feedback type Max inertia ratio
35. g data However it is easy to override the default values and save new values for future use In any case an inexperienced user should read all inputs through before making any decisions In addition MCSize provides plenty of intermediate results for users This helps the user to 1 double check results 2 easily find good and cost effective solutions 3 use some of the computed data when the drive or motor is started and commissioned with mechanics MCSize requires DriveSize 2 7 or a newer version to be installed on the computer DriveSize also contains the induction motor database MCSize itself contains the servomotor and frequency converter databases MCSize has been tested with the Windows 2000 and Windows XP operating systems 2 2 Functions With MCSize you can e Compute Torque requirements for various mechanical arrangements Overview of MCSize e Compare gearing alternatives 11 e Select the correct size of a drive and the correct motor combination e Select a suitable line converter for the regenerative drive system e Compute the proper braking chopper and resistor e Compute multiple axis systems e Export the produced results from MCSize to the xls format 2 3 MCSize user interface 2 3 1 Main window After you have opened or created a project the main window opens You can see the layout of the main window in Figure 1 L Drivesize MCSize ACSM1 Drive Untitled File Edit Insert Data Tools Re
36. he braking resistor is selected on the basis of the motion duty braking power requirements Sizing 27 5 5 Motor input data 5 5 1 Entering motor load data Open the Motor load display see Figure 11 by clicking the Motor icon in the System configuration tree The calculated values are shown in grey fields To enter optional motor load data fill in at least one value Torque Nm Speed rpm Motor load Load type Conveyor Simple cyclic Input Calculated RMS torque Nm fo 2 21 2 RMS speed rpm fo 21 3 529 RMS power Kw 0 049 Input Calculated Torque Nm Speed rpm 2 858 286 479 2551 286 479 Eb Max power Kw Reflected inertia kgm 2 Specifications Motor type Motors per inverter ServoMotor 1 Not specified Family Polenumber See Not specified Not specified Not specified Not specified 1C411 Not specified Figure 11 Motor load input data Input fields are editable and calculated values are based on profile mechanics and gearings The calculated values include primarily dimensioning criteria but motor load inputs are optional and they override the calculated values The calculated torque is a peak torque at motor shaft and in the final results the motor inertia is also taken into account The calculated speed is the speed at the max dynamical Sizing 28 power or the speed when the calculated peak torque really
37. hen the speed is positive and vice versa Accl Decl amp Time Segment type for the acceleration or deceleration segment Enter the desired acceleration and the duration of acceleration for the segment Negative acceleration means deceleration when 43 the speed is positive and vice versa Distance amp Time For the acceleration or deceleration segment Enter the duration of this segment and the desired distance to travel during the segment Negative distance means that the direction of movement is negative Dwell segment This is zero speed and no load waiting segment between motion segments The final speed of the previous segment must be zero Enter the duration of dwell segment Const speed distance only For the constant speed segment Enter the distance traveled during this segment Speed is the final speed of previous segment The previous segment determines the direction of movement Const speed time only For the continuous speed segment Enter the duration of constant speed segment Speed is the final speed of the previous segment The previous segment determines the direction of movement Hold segment This is zero speed hold segment between motion segments Hold torque is determined by mechanics Enter the duration of hold segment The end speed of the previous segment must be zero Table 18 Motion profile inputs for Multiform cyclic load type
38. ii 20 5 2 2 Modifying transformer SpecificatiONS ooonnnnnccncnnnnnnnnnccocccncnncnnnnnannccnnncnonnnnnnnccnnnnananns 21 5 3 Supply INPUL dali eati ent ae sede steed dates abe aaa nn T e a aaa AAEN 22 53 Profile tye h his chute a aT EAE EE cate eae iia 22 5 3 2 Modifying supply specifications 23 54A Drive Inputidalausiniucacit rss last msn tr gases tds ra dat bape est dun nda te feet 24 5 4 1 Entering drive load data 24 5 4 2 More complicated inverter profile ccccccceceececeeeeeeeeeeneeeeeeeeeesecnaeeeeeeeeeeeeeneeeeeeeeeee 25 5 4 3 Modifying drive Specifications coonmnccccccnnninnnnnooccconcnccnnnnnanccnnncnnnnnnnnnnnnnncnanannnnncnanininanns 25 5 5 Motor input data ave eraan dadea ateina ated neti reine tdci renaud ee bv isi Gada Wastin mess 27 5 54 Entering motor load Ata den aient annees nent etes de 27 5 5 2 Modifying motor load specifications ooonnnnncccnnnnnonnnoconcccnnccnananannccnnncnonnnnrnnccnnnnananns 28 5 5 3 Importing OWN motor list 31 5 6 Gearing INPUt data visite A ae eet 32 Table of contents 5 6 1 Belt and pulley toi 33 5 6 2 Chain and sprocket sise 34 516 3 Gear dear ances Stick stele a RE RSS aude E are RUG ea deers 36 A CE A saintes urnes mine er tetes E EASE TEES 37 5 7 Motion profile and mechanics sis 38 5 7 1 Entering motion profile data 38 5 7 2 Entering more complex pr
39. k and pinion mechanics settings Setting Explanation Load mass kg Enter the total load mass to be transferred Rack mass kg Enter the mass of the rack including the mass of all parts that move linearly Pinion diameter m Enter the exact pitch circle diameter of the pinion for the correct calculation of 53 load inertia rack inertia etc Pinion inertia kgm Enter the inertia of the pinion or use the inertia and mass calculator to define the inertia value Coupling Inertia kgm Enter the inertia of coupling between gearings and pinion or use the inertia and mass calculator to define the inertia value This value should also include all additional coupling inertia that is not included in the pinion inertia value for example the additional inertia caused by shafts Efficiency Enter the losses of rack amp pinion mechanics For example the frictional loss of bearings is taken into account in the efficiency coefficient The efficient defines how much more torque is needed due to the losses Incline angle deg Enter the incline angle It is the angle between the rack and the horizontal plane Only a positive value of the incline angle is possible Positive distance means upward motion and negative distance means downward motion Coefficient of friction Enter the coefficient of friction It takes into account the frictional losses between
40. load display see Figure 8 by clicking the Supply icon in the System configuration tree Profile type Two Profile type options are available One for Manual load entering and another for Derived load Derived load means that load is calculated based on mechanics connected to that regenerative supply unit The loads that have identical cycle time are collected to own groups It is also possible to define phase shift between loads with same cycle time see Figure 8 Supply Load Profile type o erived zi Cycle Phase shift Pdemax Pdemin group s kw kw CSS E EA TES dive 0 676 4568 dive o 7777 592 Total 14537 10481 zi o OOo drive o 3 752 2 374 Total 13 752 2 374 Specifications Ne oy ine filter Included Switching frequency 3 kHz Figure 8 Supply data definition wo clo 23 Supply Unit Profile i Pde kw ll Figure 9 Manual supply data definition Select manual profile option to enter load manually These inputs override the load calculated on mechanical load When manual profile is selected then Supply Unit Profile view opens see Figure 9 Manual can consists on up to 50 load points 5 3 2 Modifying supply specifications You can set the following specifications for the regenerative supply Line converter amount type line filter IP class and switching frequency To modify drive specifications click on the desi
41. ltSet ln daa 71 6 6 1 Supply nit Graphics amener antenne nes ae ann Ses eee nl 72 6 7 User selection coccion AE nantes t digne nan reed nette 72 7 AA E o E T 72 8 OID A O O OU GU PO ORO O e 72 Table of contents Table of contents 1 About this manual 1 1 Overview This manual gives you instructions on how to use the MCSize sizing tool The main principles of operation are also explained The manual is targeted to machine designers and anyone who needs to select electrical drive system components or wants learn how to select them The manual is also available as an online help file Driven Gear Coupling Driver Gear Coupling Driven pulley Driver pulley Coupling Driven sprocket Driver sprocket About this manual Driven roller Coupling Load with Linear Motion Coupling a Conversion diameter Driver roller Load Load Coupling Coupling Leadscrew Coupling Load Cylinder Coupling 1 2 Document conventions The following table lists the terms and conventions used in this manual Table 1 Terms conventions and abbreviations used in this manual Term or abbreviation Explanation Sizing dimensioning Calculation of the correct size of the parts in a frequency converter assembly IC International Cooling IP International Protection RMS Root mean squared About this manual 10 2 Overview of MCSize 2 1 General The nam
42. mechanics Max power kW Calculated maximum torque for given profile and mechanics RMS torque Nm Calculated root mean squared torque for given profile and mechanics RMS speed rpm Calculated root mean squared speed for given profile and mechanics This is the speed that corresponds with the calculated RMS torque Results 64 Speed at max dyn power rpm Rotational speed where maximum torque load exists This appears when s curves are used Applying s curves might allow smaller motors than without because the high torque at max speed is avoided 6 2 Gearing results Results To view gearing results click on the Gearing icon in the System configuration tree You can see the results of gearings in the Gearing display on the right side of the gearing settings see Figure 35 Belt Coupling Driven pulley N Driver pulley RMS Ma x Speed rpm 106 764 j 43 239 Torque Nm fai 159 Figure 35 Gearing results RMS torque and speed are root mean squared results at the input side of gearing The order of gearings is read from the motor output to the mechanics input that is the 1 gearing is connected to the motor shaft the 2 shaft is coupled to the output shaft of the 1 gearing and so on At the bottom of the Gearing display you can see the total values of all gearings in the Gears totally field see Figure 36 Gears totally Ratio
43. meter to minimum without stops Due to this the Multiform cyclic Duty type is not valid Figure 30 Unwinder mechanics Sizing 58 5 7 4 Sizing You can see the input fields for winder mechanics in Table 27 Table 27 Unwinder mechanics settings Setting Explanation Max diameter m Diameter of the full coil This is the initial value of diameter when unwinding Min diameter m This is the final value of diameter when unwinding ends In many cases this is the diameter of core or reeling drum Coupling inertia kgm Enter the inertia of coupling between the gearing and the winder mechanics or use the inertia and mass calculator to define the inertia value You can add any load side rotating inertia to this input field Core inertia kgm Enter the total inertia of core and shaft or use the inertia and mass calculator to define the inertia value Efficiency Enter the efficiency percentage of input torque provided to output The efficiency value takes into account the losses of the unwinder mechanics like bearings Width m Enter the width of material Density kg m Enter material density information It affects the value of coil inertia Tension N Enter the tensional force that is needed to achieve the desired material tension Opposing force N Enter the sum of any opposing forces that affect the movement of reeled material This force is acti
44. n tenfold if it is important to maintain the control performance Motor selection criteria are also based on system voltage which is given as the Supply voltage Frequency and Switching frequency of the drive Catalog induction motors will have the same nominal frequency as the supply and a nominal voltage similar to the system voltage The switching frequency of a drive does not affect the thermal behavior of a motor within MCSize The output voltage of a drive at a field weakening area is less than the system voltage and this is taken into account when the maximum short term torque curve is drawn You will notice this from the fact that the turning point of the curve is not exactly at the level of nominal frequency but below it On the other hand the permanent magnet servomotors have non standard nominal voltages and they are always lower than the system voltage When overloaded at higher speeds the motor voltage will be higher than the nominal voltage but anyhow lower than the system voltage Some reserve voltage has to be available for the good performance of drives The nominal values of servomotors are given with a switching frequency included in the database If the setting of drive switching frequency is lower the nominal values of servomotors must be scaled down If the drive switching frequency is higher than the motor s switching frequency the Sizing 30 motor s nominal values are kept in the original values The best the
45. ncoder motor might give less output than a resolver motor because resolver motors withstands higher temperatures Max inertia ratio Not specified 2 3 4 10 100 Read the text below this table Temp rise class Not specified B lt 80K F lt 105K Not specified means that MCSize will use 29 the class given in motor catalogs IC Class Not specified C 0041 1C411 1C416 1C 0041 enclosed motor without cooling fan 1C411 cooling fan on motor shaft means lower loadability at partial speeds 1C416 separate cooling fan Choose this option for constant torque cases where the min speed is very low For large motors there are other choices available Size If specified limits the selection to the particular shaft height of induction motor or the size code of servomotor Auxiliary brake No brake Holding Affects to the inertia of motor Max speed rule Standard Metal fan Available only for Induction Motors Motor Tmax margin 43 20 Available only for Induction Motors In inertia calculations the inertia ratio corresponds to the reflected inertia divided by the motor inertia You can set the maximum acceptable value for this ratio The ratio will be the motor selection criterion The ideal ratio for reflected inertia to motor inertia is 1 1 a ratio that yields the best positioning and accuracy The reflected inertia should not exceed the motor inertia more tha
46. ng against movement at the surface of the coil Inertia and mass calculator When entering inertia data for example in the Motor load Gearing or Mechanics displays you can use the Inertia and mass calculator v1 1 program developed by ControlEng Corporation for the calculation of inertia see Figure 31 59 i next to the Inertia kgm value fields to open the Click the calculator button inertia and mass calculator To calculate the inertia and mass with the inertia and mass calculator 1 Select the element shape and in most cases enter the dimensions of the mechanical component 2 Enter the material and density The mass and the inertia are calculated automatically and displayed in the Mass and Inertia fields 3 Add the calculated mass and inertia to the Calculation Table field for the calculation of total mass and inertia by clicking the positive or y negative button at the bottom of the Inputs field To replace an active row from the Calculation table with the information in the Inputs field click the El button 4 Feed another mass and inertia information and add it to the totals if necessary To remove a row from the Calculation Table activate it and click the x button To display and modify information in a row in the Calculation Table in the Inputs field activate the row and click the 2 button Note that the unit of inertia must be kg m Sizing 60 m Project1 txt
47. ngs is taken into account with efficiency The value indicates how much more torque is needed due to the losses Incline angle deg Enter the incline angle between the screw and the horizontal plane Only a positive value of the incline angle is possible Positive distance means upward motion and negative distance means downward motion Coefficient of friction Enter the coefficient of friction It takes into account the frictional losses between the table and the support or the guide Sizing 52 bar These losses are caused by the total weight of the load and the table This opposing component is dependent on the cosine of incline angle Opposing force N Enter the sum of all opposing forces that affect the movement of the table for example the thrust load or the preload force Preload is the opposing force that must be overcome before the load starts to move Lead screw pitch mm Enter the linear distance the nut advances for one complete turn of the screw 5 7 3 5 Rack amp pinion The rack amp pinion mechanics consist of pinion and rack gears that transfer the rotational motion of the pinion to the linear movement of the rack see Figure 26 The rack position can be horizontal vertical inclined or declined Sizing Coupling Load Figure 26 Rack and pinion mechanics You can see the input fields for rack and pinion mechanics in Table 23 Table 23 Rac
48. nt all the frictional losses of the conveyor system due to the load and belt It includes the friction between the guides and the belt the belt and the rollers as well as the bearing friction of the rollers It is assumed that frictional losses are independent when the angle is inclined Opposing force N Enter the sum of forces acting against the belt movement for example thrust load trying to push the load off from the belt Sizing 48 5 7 3 2 Cylinder In MCSize the cylinder drive is the universal load type for rotational movement see Figure 23 For example a load can consist of several cylinders with different diameters that are attached to a common shaft Sizing Coupling Cylinder Figure 23 Cylinder drive mechanics You can see the input fields for cylinder drive mechanics in Table 20 Table 20 Cylinder mechanics settings Setting Explanation Load inertia kgm Enter the total inertia of the cylinder or use the inertia and mass calculator to define the inertia value Coupling inertia kgm Enter the inertia of the coupling between the gearing and the cylinder drive mechanics or use the inertia and mass calculator to define the inertia value This value should also include all additional inertia that is not included in the load inertia value for example the additional inertia caused by the shaft Efficiency Enter the efficiency percentage the percentag
49. nter the exact diameter of the driver roller for correct load inertia and tensional torque calculations Sizing 50 Diameter Pinch Enter the exact diameter of the pinch for correct system inertia calculations Coupling inertia kgm Enter the inertia of the coupling between the gearing and the feed roll mechanics or use the inertia and mass calculator to define the inertia value This value should also include all additional coupling inertia that is not included in the driver roller inertia value for example the additional inertia caused by the shaft Efficiency Enter losses that should be taken into account in the torque efficiency This data defines how much more torque is needed because of the losses Strip tension N Enter the tensional force or pull through force that is needed to achieve the desired material tension on the input side of the roller system Frictional force N Enter the tensional force that is needed to pinch the strip material in the roller system 5 7 3 4 Lead screw A lead screw consists of a screw with a nut moving along it see Figure 25 The rotational motion of the screw turns to the linear motion of the nut The high torque and low speed of the linear motion can be achieved depending on the value of the screw pitch The screw position can be horizontal vertical inclined or declined Use counterbalance to eliminate the gravitation componen
50. oadability Figure 39 Motor Graph display for ServoMotor Please notice in this case the dynamic torque curves They are shown as black arcs and in this close to optimal case they are very close to max torque of motor The Motor Graph may have up to four quadrants if the application is braking and running in reverse direction at the same time The required torque curves are not shown in full length to keep the graph uncluttered If s curves are applied the parts of torque curve representing maximum mechanical power are displayed Notice that drive s switching frequency has an effect to torque curves x Unit name motor Selected motor 3G44 091 313 E Return 1 Report A o 3 Torque Nm Load Motor 20 CO Inverter c Performance and 4 profile 1000 2000 3000 4000 4 Speed rpm Sou A Max loadability 2 RMS torque Dynamic torque Cont loadability Figure 40 Motor Graph display for Induction Motor 6 5 Drive results In the Drive Results display you can see the results and specification data for Selection data Specifications Catalogue data and Drive losses at RMS speed The selection criteria for a drive are e Peak current trajectory must be lower than the max current limit e Calculated RMS current must be lower than the nominal current e Inverter maximum output power must not be exceeded e Additionally the dynamic thermal limit is checked Results
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52. red item Select new values from the drop down lists or type the new value to the field You can see the input fields for drive load specifications in Table 5 Sizing 24 Table 5 Supply unit load specifications Specification Options Name Any text or number string This will also show up in reports and depending on the Tools Options settings on screen Supply amount Number of similar drives with range 1 100 for one branch in the System configuration tree Type Air cooled Cold plate Line filter Included IP class Not specified IP20 This selection means that the user is specifically limiting the choices to the IP20 protection class Switching frequency 3 4 5 8 or 16 kHz 5 4 Drive input data 5 4 1 Entering drive load data To enter drive load data open the Drive load display see Figure 10 by clicking the Drive icon in the System configuration tree White fields are editable and grey fields are calculated on the basis of profile mechanics gearings and motor input data The calculated values include primarily dimensioning criteria However drive load inputs are optional and they override the calculated values The inverter is loaded with the calculated motor currents frequency and power factor You can change the motor currents Enter new values to editable fields for each segment These values override the calculated values Note that all the other motor data and the gi
53. rmal characteristics for a motor are achieved with the highest drive switching frequency The system voltage also affects the servomotor maximum speed and available short term torque at high speeds You will notice this by changing the system voltage for example from 380V to 400V or 415V and by monitoring the short term torque of the same motor Notice Stall torque allowing 30 seconds at zero speed in maximum If you select ExistingServoMotor or ExistinginductionMotor in the Motor type field the Existing motor window opens You can see the input fields for existing motor specifications for ExistingServoMotor in Table 10 You can see the definition of loadability curve in Figure 12 Ensure that the motor data are valid for the same switching frequency that you are going to select from the drive specifications Table 10 Existing motors specifications for Existing Servo Motor Specification Options Type designation Any text or string Voltage V 400 Frequency Hz 50 Power kW 0 62 Poles 2 4 6 8 10 12 14 16 18 20 Speed rpm 1500 Efficiency 90 IC class 1C410 Temp rise class B lt 80K F lt 105K Mcs Mn 3 9 Mp0 14 Mp1 14 Mp2 14 ni 1500 n2 1500 n3 6000 Kt 3 04 Inertia Kgm 2 0 001 Luv H 0 004 Ruv ohm 2 Back EMF V 190 Where Kt is torque constant Nm A Luv is line to line armature inductance H and
54. rtia kgm Enter the inertia of coupling between the gearing and the user defined mechanics or use the inertia and mass calculator to define the inertia value You can add any load side rotating inertia to this input field Efficiency Enter the losses of user defined mechanics For example frictional losses are taken into account in the efficiency Sizing 56 The system s efficiency is defined as the percentage of the input torque provided to output Coefficient of friction Enter the coefficient of friction It takes into account the frictional losses caused by the weight of load Opposing force N Enter the sum of any opposing forces that affect the movement of linear load for example thrust load 5 7 3 8 Winder Sizing A centerwind type of mechanics winds material around a core or a reeling drum see Figure 29 In this type of winder the center of coil is driven by motor In the figure the positive direction of angular speed and tension are shown The MCSize assumes that winding starts from minimum diameter to maximum without stops Due to this the Multiform cyclic Duty type is not valid a a Figure 29 Winder mechanics You can see the input fields for winder mechanics in Table 26 Table 26 Winder mechanics settings Setting Explanation Max diameter m Diameter of the complete coil Min diameter m This is the initial value of diameter when rewinding s
55. single drives and regenerative drives to the same project It is possible to convert single drive to line converter supplied unit too First Drive Type xi Select the type of drive you want to start wath Single drive C Regenerative drive Figure 3 First Drive Type dialog box Changing project information To open the Project information window see Figure 4 select File gt Project Info Enter new project data MCSize saves this information when you save your project and includes it in your reports Click OK to save the project information or Cancel to discard the changes Project Information E Xx Customer information Customer flundefined 2 Project untitled Cancel Location none ABB Ref fe Cust ref iunte toc fi Date Date Handled by undefined qe CE Figure 4 Project information window Starting a project 4 1 2 Selecting ambient conditions To open the Ambient conditions dialog see Figure 5 click the toolbar icon 4 or select Data gt Ambient Condition Type new data to the appropriate text boxes to change the ambient conditions The practical range for altitude is between 1000m and 4000m Note The altitude s dependency to the load capacity is different with different components The practical range of ambient temperature is usually from 30 C to 50 C This also changes according to the component For example a temperature up to 55 C is acceptable for ACSM1 dri
56. sult Help 10 x oleja e alal ala eleal ala S drive E E motor E gearing la motion System configuration Supply load Secondary voltage V Frequency Hz Load power kVA Calculated load power kVA 0 af Input data and specifications Specification Name transformer Type Dry Figure 1 MCSize main window Altitude 1000 m h soe 40 C ex 40c Selected data and results Overview of MCSize 12 Transformers line converters drives motors reductions and motion profiles and mechanics all have their own data input displays When you click on an item in the System configuration tree the input data display will change accordingly 2 3 2 Toolbar The toolbar provides quick access to common functions in MCSize You can find the functions of the toolbar also in the main menu see Table 2 Tip When you move the cursor over a button the help text for that button appears below it Table 2 Toolbar icons Icon Action Opens a new project Opens a project 8 00 0B 0 0 1 000 Saves the project Opens the Print dialog Opens the Ambient Conditions display Opens the Motion profiles display Opens the Network Check display Dimensions the selected item Opens the dimensioning Results display Opens the Graph display Opens the List selected display Opens the User Selection display Menu equivalent File gt New
57. sults The values displayed in the Mechanical results field see Figure 33 are only intermediate results and they are true at the input shaft of mechanics Gearings are not taken into account here Mechanical results Opposing torque Nm fo 015 Equivalent inertia kgm 2 01 50 Figure 33 Mechanical results You can see the items in the Mechanical results field in Table 29 Table 29 Mechanical results Result Explanation Results 63 Opposing torque Nm Intermediate opposing torque for mechanics only Motor and gearings are not taken into account Equivalent inertia Kgm Intermediate inertia at input shaft for mechanics only Motor and gearings are not taken into account 6 1 3 Combined results at driver shaft The combined results for motor selections are displayed in the Combined results field see Figure 34 These results are true at the input shaft of mechanical application Gearings are not taken into account Combined results Max torque Nm Max speed rpm Max power kw RMS torque Nm RMS speed rpm Figure 34 Combined results at the driver shaft You can see the items in the Combined results field in Table 30 Table 30 Combined results display items Item Explanation Max torque Nm Calculated maximum torque for given profile and mechanics Max speed rpm Calculated maximum speed for given profile and
58. t caused by the incline angle Sizing if necessary Load Coupling Leadscrew Figure 25 Lead screw mechanics 51 You can see the input fields for lead screw mechanics in Table 22 Table 22 Lead screw mechanics settings Setting Explanation Load mass kg Enter the total load mass to be transported Table mass kg Enter the mass of the table It has an effect on the value of total inertia and on the frictional forces All the linearly moving parts for example the nut are taken into account here Counter balance mass kg If counterbalance is used enter its mass Note that the acceleration of free fall or 9 82 m s is the natural maximum limit for acceleration when counterbalance is used If no counterbalance is used enter zero value to this input field Lead screw Inertia kgm Enter the screw inertia or use the inertia and mass calculator to define the inertia Coupling inertia kgm Enter the inertia of the coupling between the gearings and the conveyor or use the inertia and mass calculator to define the inertia value This value should also include all additional coupling inertia that is not included in the screw inertia value for example the additional inertia caused by shafts Efficiency Enter the efficiency percentage of lead screw mechanics The losses of lead screw mechanics for example the loss of power due to friction in the beari
59. tarts In many cases this is the diameter of core or reeling drum Coupling inertia kgm Enter the inertia of coupling between the 57 gearing and the winder mechanics or use the inertia and mass calculator to define the inertia value You can add any load side rotating inertia to this input field Core inertia kgm Enter the total inertia of core and shaft or use the inertia and mass calculator to define the inertia value This is the initial value of inertia Efficiency Enter the efficiency percentage of input torque provided to output The efficiency value takes into account the losses of the winder mechanics like bearings Width m Enter the width of material Density kg m Enter material density information It affects the value of inertia Tension N Enter the tensional force that is needed to achieve the desired material tension Opposing force N Enter the sum of any opposing forces that affect the movement of reeled material This force is acting against movement at the surface of the coil 5 7 3 9 Unwinder A centerwind type of mechanics is unwinding material from reel see Figure 30 In this type of winder the center of coil is driven by motor When the positive directions are according to the figure the normal running power is negative and will be shown in second quadrant in torque speed diagram The MCSize assumes that winding starts from maximum dia
60. the inertia and mass calculator to define the inertia value This value should also include all additional coupling inertia that is not included in the driver pulley inertia value for example the additional inertia caused by the shaft Efficiency Enter the efficiency With the efficiency setting you can take into account the loss of torque In MCSize the losses are assumed to happen in the teeth of gears 5 6 4 Gearbox The gearbox is an enclosed gearing that is a planetary gear for the gearing of higher rotation speed see Figure 18 The purpose of a gearbox is to achieve output with high torque and low speed The gearbox is often integrated into the motor Figure 18 Gearbox Sizing 38 You can see the input fields for gearbox gearing in Table 15 Table 15 Gearbox gearing input fields Setting Explanation Inertia kgm Enter the inertia of the gearbox or use the inertia and mass calculator to define the inertia value Typically gearbox manufacturers specify only one value of inertia This inertia is valid at the power input of gearbox Gear Ratio Enter the gear ratio This value defines how the speed of the input shaft is transmitted to the output shaft of the gearbox For example 3 means that three rotations of the input shaft are required for one complete turn of the output shaft Coupling inertia kgm2 Enter the coupling inertia at the power input side of gearing or use
61. the rack and the support These losses are caused by the total weight of the load and the rack This opposing component depends also on the cosine of the incline angle Opposing force N Enter the thrust load that is the sum of forces that effects against the movement of the rack 5 7 3 6 Rotating table A horizontally rotating table is controlled through a shaft and a coupling see Figure 27 The table moves and positions bulk loads Sizing 54 Sizing ed Load Coupling Figure 27 Rotating table mechanics You can see the input fields for rotating table mechanics in Table 24 Table 24 Rotating table mechanics settings Setting Explanation Load mass kg Enter the total load mass to be moved Load center distance m Enter the distance between the center of the table and the center of the weight The radius can be defined as the average of the inside radius and outside radius The inertia of the load depends on its position in relation to the center of the table Table inertia kgm Enter the inertia of the table and the shaft or use the inertia and mass calculator to define the table and shaft inertia value Coupling inertia kgm Enter the inertia of the coupling between the gearings and the rotary table or use the inertia and mass calculator to define the inertia value This value should also include all additional coupling inertia that is not includ
62. ven speed profile will still be used In Table 6 you can see the explanations of abbreviations that are used on the display Table 6 Explanation of abbreviations in Drive load display settings Abbreviation Meaning RMS current Root mean squared value for the whole duty cycle currents Max current The calculated peak value that occurs during the duty cycle Sizing 5 4 2 More complicated inverter profile 25 The text custom is shown in Drive load display s current and duration fields when the Duty type of motion profile is Multiform cyclic Open Inverter profile to see the segmental currents You can also enter the new current for each segment and these values override the calculated values All the other motor data and the given speed profile will still be used Click the icon or select Data gt Motion profile from the menu to open Inverter profile Drive load Duty type Input currents 4 111 TT RMS current 4 Max current 4 Simple cyclic Calculated Calculated currents 4 duration s 1 6667 1 6667 1 6667 F Specifications Name drive Inverter amount 1 Switching frequency 8 kHz Braking chopper Ignored Braking resistor Not considered Figure 10 Drive load input data 5 4 3 Modifying drive specifications You can set the following specifications for the drive the inverter amount type IP class swit
63. ves Click OK to save the ambient conditions information or Cancel to discard the changes Ambient Conditions q x Change the ambient condition values to reflect the operating environment Altitude m fr 000 Temperatures gt Transformer C 40 Inverter C 40 Motor C 40 OK Cancel Figure 5 Ambient conditions window 4 2 Creating new project file To create a new project file use one of the following three methods e Click the toolbar icon 6 e Select File gt New from the menu or e Press the Ctrl N short cut key The name of any new project file is Untitled until you change it You can change the project name when you save the project 4 3 Saving project file To save the project file 1 Click the icon or Select File gt Save Starting a project 18 2 For new projects select a location and type in a name for the project 4 4 Opening saved project To open a saved project 1 Click the icon or select File gt Open 2 Select the project file and click OK The ACSM1 motion control project files have a unique file extension Select the correct extension option mdd from the List of file Types to open these files Starting a project 5 Sizing 5 1 Sizing procedure overview 5 1 1 System configuration tree The System configuration tree displays an overview of the frequency converter system as well as the type designations or names of units in the tr
64. wer of supply unit is shown in function of time The graph illustrates the total DC power of all inverters connected to that supply unit Results Unit name supply unit Selected supply unit ACSM1 204xR 0740 4 Supply unit Time s Figure 44 Supply unit graph display 6 7 User selection User selection functionality is a part of the sizing process and the screen with plenty of computed choices is also a part of the results In the User selection display you can select a smaller or larger unit instead of your current selection made by the software or by your previous other choice selection The selected unit has number 0 and its row is highlighted Smaller units have a negative mark Larger units have a positive mark In this table there are some catalogue values and calculated margins to help with the new selection process In some cases in which the overloads are decisive there are no smaller units in the list Results 74 Results User Selection x Catalogue data Type designation Power kw Icont 4 Margin Imax 4 peak Margin 1 ACSM1 044x 0245 CH 0 75 25 24 53 10 0 l B 6 3 02 CSM1 044 03404 CH 1 1 3 49 6 3 1 4 ACSMI O4eu0945 CH 4 as 372 tft ga 5 ACSMI 048 0120 CH_ 55 2 lex tft ea 6 ACSMI O44x01644CH 75 je es J fg 883 7 _ ACSM1 04Ax 024A cH_ 11 a honz fate ea la ACSM1 04Ax 031A CH_ 15 31 1439 54 1815 lg ACSM1 044x 0404 CH 18 5 40
65. y files to the drive and directory specified by the user The setup program prompts you to install the software to C ProgramFiles DriveWare DriveSize You can change the directory if necessary The set up program also creates a working directory in C ProgramFiles DriveWare DriveSize Projects where all of your projects will be stored If you have problems installing MCSize close any other active programs Restart Windows and do not open any programs before the installation is completed Always disable MCAfee Host Intrusion Prevention System HIPS both while installing and uninstalling Before reinstalling uninstall the old version of MCSize 3 3 Uninstalling To uninstall MCSize 1 Select Start gt Settings gt Control panel 2 Double click Add or remove programs 3 Select the MCSize software from the list and click Remove Installing MC Size 4 Starting a project 4 1 Opening new project In the DriveSize Welcome screen double click the ACSM1 Drives MCSize icon or click Open from the New project selection tab See Figure 2 ia Welcome xi ACSM1 ABB AC5800 ACS 800 ACS550 MotSize DOL SingleDrive MultiDrive SingleDrive ACH550 SingleDrive bh e 4 Figure 2 DriveSize Welcome window On the tabs Existing and Recent you can open projects saved earlier Starting a project 16 4 1 1 First Drive Type dialog opens for a start Select the type of drive you want to start with There is possibility to add

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