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Wind Energy

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Wind Energy

We`ve got the hang of it.

Situation.

Renewable energy production is becoming increasingly important, especially wind turbines. With a hub height of 60 meters and 1.5 megawatts of power, wind turbines that were originally considered to be enormous are now standard and built worldwide using German technology. In order for the turbines to work perfectly as well as cost-effectively, the optimum balance between torque and speed must be found. For this, it is necessary to be able to adjust the rotor blades. It’s not enough to turn the head of the turbine into or out of the wind. In case of high wind speeds, rotor blade adjustment is an additional way to apply the brakes effectively and an important safety aspect.

PROBLEM.

All three rotor blades must always be aligned synchronously, because excessive forces can otherwise act on a single blade. This means the rotor blade adjustment must have a central control system that is also guaranteed to function even in case of power failure. To make the task even more difficult, the hub is only accessible from the outside. On the shaft of the rotor, only a few contacts are available on the slip ring for establishing a connection. A control system via the hub and accommodation of rotor blade technology in the nacelle are therefore not possible. On-site installation in the hub is not practical and economical due to the height and difficult accessibility.

SOLUTION.

The entire rotor blade adjustment system is supplied with electrical power just through the slip rings, so only a few contacts of the slip ring are necessary. A central control box coordinates the rotor blade positions, which are each adjusted by their own drive control. This includes a battery pack to maintain control capability in case of power failure. Everything is modular and ready to plug in. All connections are pre-tested on a specially designed test station with contact force monitoring, eliminating errors and ensuring fast commissioning.

The central control module connects the individual drive controls with a single connector kit in each case. These align the rotor blade with a servomotor. The pre-fabricated installation can be quickly incorporated into the hub on the ground. Supply, signals and bus are consolidated in a single robust plug connector. The rotor blade is completely installed electrically in no time.

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Case Study EN

Robotics

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Robotics

This arm is smart.

SITUATION.

Robots are an indispensable part of the industry and are used in many different areas. The number of required axes, that is, the number of ways in which the system can move varies greatly. Each application has custom requirements which sometimes places high demands on the technology of the ‘robot hand’. Holding and guiding a welding head, for example, has different requirements than the transfer of an entire vehicle body to a conveyor line.

PROBLEM.

Depending on the application, the robot has different axis configurations, requiring several connection configurations. There is limited space in the installation channel inside the robot arms, precluding the use of prepared heavy-duty plug connectors. This results in custom installations and cutting the prefabricated cables to length. The robot hand must also be individually equipped electrically, pneumatically and hydraulically. This results in installation times of up to four hours.

SOLUTION.

The solution is intelligent standardisation that covers the most common options. Ready-made cable sets are designed for six axes. A pair of cables for the other servomotor with encoder is added only if there is a seventh axis. For the robot hand, work is carried out in the arm with a cable set with circular plug connectors, which lead into a flange socket of a heavy-duty plug connector. Convenient, flexible and easy to maintain. The flange socket is additionally equipped with a control element for the brake. The throughput time is reduced to 30 minutes. The bottom line: Many variants – one solution!

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Case Study EN

Machine engineering

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Engineering

CHANCE OVER MACHINES QUICKLY, SAVING TIME AND MONEY.

SITUATION.

In the printing industry, feeder machines overlay printed sheets of paper in the correct sequence and feed them through a conveyor belt for finishing, including stapling and punching. Since magazines have different numbers of pages and paper configurations, the machines have to be convertible in order to be able to vary the type and number of feeder stations. The systems are subject to heavy soiling, because the paper has to be slightly powder-coated.

PROBLEM.

A lot of hard work is required to convert the feeder machine for a new order. Configuration of the feeder stations requires that several lines be connected per station. Finally, the supply voltage, control signals and a data bus must be connected to each feeder station. For an order with six feeder stations, it takes up to one hour before the system is restarted. During this time, 20,000 magazines could have been produced. A lot of money is lost due to long changeover times. Another disadvantage: the standard format of the existing control box is cubic, which has a disruptive effect on the system design.

SOLUTION.

Sangel designed a pre-installed comprehensive package for the new machine generation. The individual feeder stations are now connected with a single line with only one plug connector for the power supply, the control signals and the bus connection. The connector is designed for heavy-duty operation appropriate to the operating conditions and is good for 10,000 mating cycles, ensuring operation for about 20 years. Only then will the connection set need to be replaced. The operator reduces the time required for the changeover process per feeder station from twelve minutes to two minutes. The newly designed control box is now a fully integrated housing part instead of a disruptive attachment. A plug-in design for transferring the supply reduces the diagnostic effort in the event of an error. A coordinated installation module replaces many individual parts. The module is pre-installed and tested. As a result, we reduced installation time by 45 minutes for each station production and by 15 minutes for each commissioning. Per feeding station!

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Case Study EN

Loading crane

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Loading crane

WE LOVE PROBLEMS – YOURS, FOR EXAMPLE.

SITUATION.

There are many companies who upgrade trucks with mobile cranes resulting in an enormous number of variations in terms of individual customer requirements. These customers require a wide variety of solutions when it comes to weight class, control type, motion sequence and attachment location. To meet these requirements, the cranes have to be custom designed and manufactured.

PROBLEM.

The custom equipment increases manufacturing times and storage costs. Every order has to be examined and analysed in detail. The control units must be custom-built, order picking for individual parts has to be conducted, and the wiring must be done according to the wiring diagram. It is only possible to identify installation errors after successful installation of the control system and the peripherals (sensors and actuators). Commissioning of the vehicle is delayed, and the technology team must implement adjustments under ergonomically unfavourable conditions. Installation on the vehicle takes up to six hours, with much of the time taken up with searching for parts and getting oriented.

SOLUTION.

The large number of variants is analysed with regard to the control properties to find where there are overlaps. This area of overlap is expanded with common equipment options. Additional installation space is taken into account for the requirements of exotic add-ons. A jumper module takes over the wiring tasks. Variants can be consolidated with a pre-installed housing with populated circuit board and connected cable set. Despite minor additional costs for installed-but-unused options, the savings clearly prevail. The pre-installed and pre-tested control modules are in stock and installed within 90 minutes. The commissioning phase is shortened by 120 minutes on average, because there are fewer delays caused by errors.

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