Servo technology increases the output of air filters by 70%.

This is a success story for Lenze Lenz in Germany. The Keilmann Group in Frankfurt, Germany, selected Lenze servo controllers for the production of their new generation of air filters, achieving a 70% higher output than the previous inverter drive system. This new type of production equipment produces well-known bag filters, which are widely used in air handling systems. The filter consists of a series of filter panels that are cut into waist curves and bound together. The Lenze servo controller controls the feeding and discharging of these materials, as well as dynamic positioning of up to 10 hands per second.

Bag filters are used in 3 to 12 pairs fixed in a frame to form a shape with one end open. This method of installation greatly increases the surface area, allowing it to remove dust from the air with minimal pressure loss. It is used in a wide range of applications, including pharmaceutical occupations, medical, paint ovens, clean rooms and general air conditioning ventilation. The filter material used is usually glass fibre or synthetic. Whichever of these two types of guessing is used, it is important to ensure that it is low density and relatively soft. This presents a major challenge for accurate data processing at different speeds. Considering the need for accurate synchronization and positioning of the needles, Keilmann turned to Lenze servo skills.

The upper and lower lengths of the material are pulled from a single reel to the sewing area, where the multi-needle stitching station in the sewing area sews it into the fabric in various lengths and is then held in place with a hot melt adhesive. The next step is to close the edge by a precisely positioned seam and cut the filter bag to a fixed length before being sent to the stockpiling area. The multi-needle stitching station can produce up to 10 stitches per second and the thread length between the two fabrics varies from 20 to 60 mm. In order to ensure that the needle enters the data cleanly and does not tear the suturing station, the entire process needs to be accurately synchronized with the movement of the filtered data.

For this purpose, the Lenze Drive Solution uses the 9400 series servo controllers, which are bus-connected via CANopen and synchronized with the help of the "e-axis" software. The program uses LenzeMCS synchronous servo motors with low inertia and four times more peak torque than conventional motors.

The MCS synchronous servo motors are no longer combined with conventional planetary gears, but are combined with Lenze's GKR bevel gear units. The GKR, which resembles a worm gear unit, is based on a bevel gear with a power of more than 94 percent, with almost no wear and tear, and extremely low swing clearance, making it less costly than planetary gear planning.

In order to ensure fast data processing, we integrated the positioning system into the Lenze9400 servo controller. In its role as a cross-cutting machine that separates the web into different filter bags, KSL chose the Lenze "Flying Saw" drive solution as its off-the-shelf skill module to complete the continuous movement of the fabric instead of a cushioned start-stop movement. The Flying Saw software is one of the motion modules of the LenzeFAST application, which includes a wide range of proven skill modules with a clear structure and high functionality.

With the help of the Lenze servo system, KSLFPS300 filter bag system has benefited a lot. The initial target was 20 m/min, but Lenze achieved 24 m/min, a 70 percent increase in output compared to the previous system, and was able to produce 40 bags with a length of 600 mm per minute. This success story is the result of the combination of Lenze's many years of drive and automation expertise and his many years of expertise in nonwovens.

Servo technology increases the output of air filters by 70%.

Servo technology increases the output of air filters by 70%.

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