Thanks to numerous approvals, SIMATIC MICRO-DRIVE is a servo drive system that can be used worldwide for the safety extra-low voltage range of 24 and 48 V DC. It includes a compact drive controller for relatively straightforward applications and power outputs of up to 280 watts (F-TM ServoDrive), a drive controller for more demanding tasks (PDC, PROFI Drive Control), versatile motors, and industrial-grade connection technology (Fig. 1). As part of a product partnership with Siemens, ebm-papst offers matching motors in various sizes, with different transmissions, integrated encoders, and brakes in power outputs ranging from 50 to 750 watts. Users benefit in a number of different ways, from configuration, parameter setting, and commissioning to diagnostics and maintenance.

Making everything simpler
The robust, electronically commutated BLDC motors from ebm-papst’s modular ECI drive system offer high power density in a compact design and have already proven themselves in many applications across a variety of industries. Today, the motor data stored in the TIA Portal already simplifies project planning in motion control applications. This reduces the amount of engineering work required and ensures consistency within the project, making it much faster and simpler to realize motion control applications.
The SIMATIC MICRO-DRIVE drive controllers can then be used to easily parameterize and commission the drives (Fig. 2). The control system automatically detects the respective drive. During operation, system diagnostics messages provide important information such as the motor temperature, which can be used for things like preventive maintenance. Thanks to the standardized communication based on Industrial Ethernet (PROFIdrive and PROFIsafe), this can be accessed without the need for further technical work, either via the TIA Portal or the control system or via HMI or web server, including remote access if required.

In many cases, safety also plays an important role in drive technology. While the compact F-TM Servo-Drive controller is suitable for applications with straightforward safety requirements (STO) and power outputs of up to 280 watts, the PDC servo controller meets the highest demands with STO, SS1, SLT, SLS, and SSM via PROFIsafe. The combination of servo controller with an ECI drive has already proven itself in automated guided vehicles (AGV) in a wide range of logistics applications, from online retail to automotive production and hospital logistics. If the drives can be seamlessly integrated into the control system of the AGV, the vehicle manufacturer is on the safe side. When communication is running and safety requirements are met, this helps them to create their own safety concept and simplifies the downstream approval of the overall vehicle with the TÜV testing body.
Different power classes for a wide range of applications
The brushless, electronically commutated internal rotor motors from ebm-papst are available in three sizes. With stator lengths of 20 or 40 mm, the ECI-42 motors with a diameter of 42 mm achieve power outputs of 45 to 92 watts at 110 or 220 mNm nominal torque and a nominal speed of 4,000 rpm. With stator lengths of 20, 40, or 60 mm, the larger ECI-63 motors cover the power range from 150 to 370 watts at up to 880 mNm nominal torque and 4,000 rpm nominal speed. Their efficiency is over 90 %. Three stator lengths are also available for the ECI-80 motors. They have a diameter of 80 mm and achieve rated outputs of up to 750 watts.
All versions can be combined with planetary gearboxes in the same size as the motor and equipped with integrated high-resolution encoders, which means applications that require very accurate positioning can also be realized. You can find an example of one such application at Kolbus GmbH, which is using ECI-42 drives as a replacement for an older type of motor in combination with the compact SIMATIC F-TM ServoDrive HF v2 servo drive controller to adjust the format on casemakers – machines used to produce high-quality book cases, files, display cards, calendar backs, and game boards (Fig. 3).

Tailor-made conversion concept for format adjustment process
When considering how best to convert the format adjustment process, the machine builders were looking for highly accurate positioning as well as two other key features: The ability to seamlessly integrate the new motor into the Siemens control environment for the machines, and a 1:1 mechanical replacement for the previous drive solution. This is where b-drives GmbH came into play. As a system partner of ebm-papst, the team from b-drives has more than ten years of experience in the design, regulation, and application of electrical drives, which the machine builders are now benefiting from.

To provide a drive for adjusting the format, we combined an ECI-42 motor with a high-resolution absolute multiturn encoder system from the modular drive kit and a modified worm gear.
Robert Nohr, project engineer at b-drives
Robert Nohr, project engineer at b-drives, explains: “To provide a 1:1 replacement for the previous solution, we combined an ECI-42 motor with 90 watt power output with a high-resolution multiturn encoder system from the modular drive kit, as well as a worm gear that was tailored to this application. The power supply of 48 V was also matched to the application .” (Fig. 4) As there are absolute multiturn encoders on all axes, there is no need for a reference movement after the machine has come to a standstill as the position value is retained.
This resulted in a plug-and-play conversion solution for the machine builders. “Kolbus obtains the compact servo controllers directly from Siemens. A hybrid cable is all that is needed to connect to the motor – it’s connected to the motor using an industrial-grade plug,” adds Robert Nohr (Fig. 5). The F-TM modules from the ET200SP system are integrated in the TIA Portal via a GSD file, after which the motor parameters are set. A TO drive object must also be created as the hardware interface. Depending on the version, Kolbus now uses up to 20 of the ECI-42 drive systems on the casemakers. All those involved in the project are pleased with the result of the conversion and would be pleased to collaborate again on other projects in the future.
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