This smog is getting more and more rampant, how to arm yourself to deal with this weather full of polluted particles? Air filters help you protect yourself from PM2.5 and clean your air. Here, Lenze servo technology comes in. With Lenze servo technology, the output of air filters has increased by 70%! The editor will take you to have an in-depth understanding.
This is a success story for Lenze in Germany. The Keilmann Group in Frankfurt, Germany, used Lenze servo controllers for their next-generation air filter production system, which achieved 70 percent more output than the previous inverter drive system. This new type of production facility produces well-known bag filters, which are widely used in air handling systems. This filter consists of a series of filter material plates that are cut into a waist curve and bound together. The Lenze servo controller controls the feeding and discharging of these materials, as well as dynamic positioning control of up to 10 needles per second.
Bag filters are used in 3 to 12 pairs fixed in a frame to form a shape with one end open. This 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 the pharmaceutical industry, medical, paint ovens, clean rooms and general air conditioning ventilation. The filter material used is usually fiberglass or synthetic. Whichever of these two materials is used, it is important to guarantee that it is low density and relatively soft. This presents a major challenge for precise material handling at different speeds. Considering the precise synchronization and positioning of the needles, Keilmann opted for Lenze servo technology.
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 edges with a precisely positioned seam and cut the bags to a fixed length before being sent to the stockpiling area. Multi-needle stitching stations can achieve up to 10 stitches per second and thread lengths ranging from 20 to 60 mm between the two fabrics of the material. In order to ensure that the needle enters the material cleanly and does not tear the suturing station, the entire process needs to be precisely synchronized with the movement of the filter material.
For this purpose, the Lenze drive solution uses servo controllers from the 9400 series, bus connection via CANopen, and synchronization with the help of the "e-axis" software. The solution uses a Lenze MCS synchronous servo motor with low inertia and a peak torque that is four times higher than that of a conventional motor. The MCS synchronous servo motors are no longer combined with conventional planetary gears, but are combined with Lenze's GKR bevel gear units. Designed to resemble a worm gear unit, the GKR is based on bevel gears with an efficiency of more than 94 percent, with virtually no wear and extremely low swing clearance, making it less costly than planetary gear designs.
To ensure fast data processing, we integrated the positioning system into the Lenze 9400 servo controller. On the cross-cutting machine, which is responsible for separating the material web into the different filter bags, KSL chose the Lenze "flying saw" drive solution as an off-the-shelf technology module, enabling 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 Lenze FAST application, which includes a wide range of proven technology modules with a clear structure and high performance.
With the help of the Lenze servo system, the KSL FPS300 bag filter 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 40 bags with a length of 600 mm per minute. This success story is the result of a combination of Lenze's many years of drive and automation expertise and industry experience with Keilmann's many years of expertise in nonwovens.
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