Powerful controllers, industrial PCs, web panels, monitors - all optimally matched to our automation system and our drives. Let us convince you of our control systems and visualisation options.

c550 controller

The c550 controller enables you to conveniently solve high-end control applications, such as printing machines with many printing units or picker lines with several robots. Thus, modern and modular machine controls can be implemented based on our software modules.

Highlights

• High computing power for demanding motion control in complex machines
• Maintenance-free and more resistant: The battery-free design and the extended ambient operating temperature to 60 °C are the guarantors of a use in all areas of industry
• The engineering tools are the same as for all the other Lenze products which enables you to continue to use the tools you are familiar with
• Optional fieldbus extension
• Ready for state-of-the-art web-based machine visualizations in combination with EASY UI Designer and v450 web panel

Technical data and features

• ProcessorIntel® Core™ i7 2.8 GHz
• Operating system: RT Linux
• Communication:
  • EtherCAT master
  • EtherCAT slave
  • PROFINET IO-Device
  • Ethernet 1000 Mbps

Keeping a better eye on the machine with real-time data: OEE provides a quick and reliable overview of current availability, performance and quality. In addition, downtime tracking offers further possibilities for recording the reasons for machine downtimes.

Die Lenze OEE-Lösung basiert auf den größtenteils ohnehin verbauten Komponenten und ist skalierbar – von einer lokalen Ausführung bis in die Cloud.

When the drive becomes a sensor: We are illustrating how smart Condition Monitoring can be realised that provides extensive information about the "state of health" of machines and plants without the need for any additional, costly sensor technology.

Collecting and interpreting the available data is already a sound way of monitoring the condition of machines. This requires a deeper understanding of the machines and processes so as to generate meaningful information from the "bare" data. Analyses based on Machine Learning (ML) and AI can help identify anomalies faster. In this showcase we show this and visualize the evaluation result with the help of a digital twin.

 Model-based or data-based? Two options for optimal results

Model-based approach: Here the measured actual values are compared with those resulting from the assumed mathematical/physical description of the machine. If certain patterns are detected or tolerances are exceeded, this is interpreted as an anomaly.

Data-based approach. A machine learning algorithm learns the normal state of the system based on the measured data, for example motor speed, acceleration, torque, position and current consumption. The real values are compared with this learned description to detect deviations.

Model-based approach: Here the measured actual values are compared with those resulting from the assumed mathematical/physical description of the machine. If certain patterns are detected or tolerances are exceeded, this is interpreted as an anomaly.

Data-based approach. A machine learning algorithm learns the normal state of the system based on the measured data, for example motor speed, acceleration, torque, position and current consumption. The real values are compared with this learned description to detect deviations.

Control system or cloud?Here the data is evaluated

The two Condition Monitoring approaches differ not only in terms of their concept. The question as to how this data is evaluated also has different answers. The model-based evaluation usually takes place on the control system because it does not require any significant computing power. ML and AI analyses used for data-based evaluations are normally implemented as a Cloud application.

Lenze's portfolio gives the OEM complete freedom of choice. This includes a number of different three-dimensional PLCs for model-based Condition Monitoring. Data-based evaluation can also be carried out locally if the powerful c750 cabinet controller is used. Alternatively, a route to the Cloud can be provided using the x500 gateway. Combined with the x4 platform, mechanical engineers have a turnkey Cloud solution that covers not only Condition Monitoring but also remote maintenance for the machine and user-friendly Asset Management.

Without additional sensor technologySimply use existing sources

The trick with this solution is to extract the added information value from data sources that are already available. No additional sensors are needed Lenze provides pre-tested algorithms for various applications and helps mechanical engineers turn their process expertise and knowledge of machines into a Condition Monitoring model that will improve efficiency.

Solution examples

Typical textile applications solved with an integrated automation platform consisting of modular software and scalable hardware as well as reliable drive systems.

So that your machine runs like clockwork: Yarn Spinning

• Easy and precise control as well as modification of the yarn count, due to the use of servo systems in the stretching machines
• Maximum flexibility with regard to bobbin shape due to recipe-controlled variation of the lift-to-wind ratio.
• Greater productivity due to fully automatic and therefore fast adaptation when the material is changed
• Energy saving due to optimised dimensioning and DC coupling
• High degree of robustness due to compensation of short interruptions of the power supply
• Always informed due to feedback of production data and energy consumption in real time

From standard to something special: Yarn Finishing

• Flexible and modular machine design due to distributed, synchronised controllers as well as optional drives and I/O cells
• Easy engineering due to verified application templates for the traversing drive as well as the drawing and thread transport systems
• Cost-efficient temperature control with short set-up times and, thanks to fewer cycles, self-adapting due to integrated temperature controllers in the I/O modules
• Best yarn quality due to highly precise control of tensile force
• Innovative visualisation with database link for purposes of quality control and documentation

Always a clean solution: Washing

• EtherCAT-Teilnehmer Easy control due to touch panel with visualisation - no additional PLC needed
• Space-saving due to the use of a servo inverter with double axis modules
• Cost-saving due to motors running parallel on one axis
• An I/O system with temperature sensor card for temperature control inside the PLC; this makes additional hardware controllers superfluous
• Use of an EtherCAT valve island, which considerably reduces the number of additional I/O modules
• Remote maintenance with transparent access to EtherCAT nodes

For high quality patterns: Printing

• Easy engineering due to uniform software environment for visualisation, printing roller drives and variable speed drives
• Support of modular machine concepts based on a configuration for a maximum number of colours with optional nodes
• High printing precision due to synchronised servo axes
• High plant availability due to possibility of using an alternative printing axis in the event of a printing unit fault or failure

Easy solutions for complex applications: Stenter

• Synchronisation of the axes due to easy parameter setting
• Additional synchronisation modules are unnecessary
• Integrated motion functions such as
  • CAM
  • Register
  • Electronic shaft
  • Winding
  • Dancer control
• Easy integration into higher-level standard PLC structure due to flexible communication interfaces

Anything is possible in the cloud - our x4 remote service platform proves how machine automation works. Simply connect your machine to the cloud via our x500 IoT gateway and easily add value to your service, reduce downtime and increase productivity.

x500 IoT gateway

We at Lenze know: mechanical and plant engineering has its own challenges. Because customers are demanding ever more flexible machines with more productivity and less downtime at the same time. Remote Services offer a simple, safe and reliable way of establishing connections to your machines – anytime, anywhere. Easily add value to your service, reduce downtime and increase productivity with the help of the available IoT x510, x520, x530 and x540 gateways. This allows the online connection to be made in accordance with the existing firewall.

Highlights

• Gateway via LAN, WLAN or 4G for easy integration into the system periphery
• Create your personalized dashboards for a simple overview of operations
• Connect your machine to the cloud in just a few minutes

Technical data and features

• Communication: LAN, WLAN, 4G und EtherNet/IP
• Connections: 4x LAN, 1x WAN, 1x USB 2.0, 1x Digital Input

x4 remote service platform

Anything is possible in the cloud – the x4 remote service platform proves how machine automation works. Simply connect your machine to the cloud via the x500 IoT gateways and easily add value to your service, reduce downtime and increase productivity. With this platform, machine and plant monitoring can be brought into a cloud environment without specific IoT knowledge. It allows access from anywhere with Internet enabled devices. Functions such as data dashboards and alarm functions with powerful condition monitoring services are available.

Highlights

• IoT made easy, machine control without programming knowledge
• Create your personalized dashboards for a simple overview of operations
• Data controlling in the cloud ensures secure information, e.g. through two-factor authentication