Siemens Answers with Products and Solutions for General Motion Control Applications

With a clear focus on the needs of customers, Siemens approach to every application of Motion Control - no matter how general or specific - combines innovation and automation to create best-in-class products and optimal solutions for any machine. Machine builders, system integrators, and end users can leverage Siemens’ broad motion control portfolio as well as a global network, which that includes technical support services, application support services, capable distributors, solution partners, and more.

Why Choose Siemens?

Cost Savings in Configuration, Commissioning, Control and Diagnostics 
Through Totally Integrated Automation

Highly Scalable, Flexible Solutions
With SIMATIC, SIMOTION and SINAMICS that reduce the number of components and complexity of the machine automation systems, and offer greater standardization of parts

Global Footprint
No matter what you import or export, Siemens has the worldwide experience, and that includes local resources in over 190 countries ready with technical resources and spare parts


 

Test stand diagram
Common engine test stand setup

With more than 160 years of industrial application experience, it only makes sense that the world’s leading companies call on Siemens to assist in developing test stand systems. Whether the results are to verify specifications, to confirm manufacturing integrity (end-of-line), durability, reliability, noise, vibration, harshness (NVH), or any other kind of assessment, Siemens has the right products and expertise for any industrial test stand application.

One of the most common scenarios involves using a motor to provide a simulated load against the input force of the part being tested. For example, a durability test stand might be set up by an engine manufacturer to see how long an engine can withstand a specified torque. In this example, a motor controlled by a variable frequency drive would be coupled to the engine. The variable frequency drive would then be programmed to provide a resistance against the motor at a specified torque

Siemens Advantages for Test Stand Applications

  • High response, accurate servo-like performance available to both the motors and drives - SINAMICS S120 / S150 drives have a torque accuracy of 1.5%

  • Speed and torque-consistency (low ripple)

  • Adaptable closed-loop system for maximum torque quality - rotating-field frequencies above 1000 Hz

  • Energy recovery for braking without dangerous current harmonics

  • Type tested and standard design common bus enclosed drive solutions

  • Ability to supply a power-matched motor / drive combination for custom test stand applications

  • As high as 6,000 HP in a low-voltage design

  • Energy exchange in the coupled DC link for multi-axis test stands

  • Where multiple drives are required, a single control unit can control up to 6 drives. This eliminates the need for drive-to-drive communication

  • EMC filters available to eliminate the possibility of noise interference with test stand sensors

  • PROFIBUS, PROFINET, and Ethernet I/P communications available

  • Integrated safety functions, e.g. SLS on entering the test cell

  • Smaller footprint drives and motors

  • Low speed, high torque motors are available to eliminate the need for a gear reducer

  • Motors can be ordered with a KTY84 temperature sensor which is wired to the input on the drive. There is software built into the drive to use the temperature feedback to maintain torque accuracy even while the motor is heating up

  • Siemens drives have free function blocks that can be used to do “bumpless” transfer from speed mode to torque mode and also from torque mode back to speed mode

  • SINAMICS S120 Cabinet Modules are available with customized common bus lineups to minimize problems

  • 12 pulse and 18 pulse drives solutions available


Siemens Products for Test Stand Applications

Drives for Test Stand applications
Both SINAMICS S150 and the S120 Cabinet Modules are high performance drive products. These products offer the best solution when speed and torque accuracy and response is critical. Siemens has other lower performance, lower cost alternatives when the application does not require high performance. For example, a pump test stand or maybe an endurance test stand might not require servo level performance.

SINAMICS Variable Speed Drives

SINAMICS S120 Cabinet Modules are enclosed common bus drives perfect for test stand applications where there is an input motor and an absorbing motor loading a test piece. Allowing for the grouping of several pre-designed modules together, Siemens has used SINAMICS S120 CM for testing gearboxes, couplings, and transmissions. These modules have undergone extensive complete cabinet module testing for shock, vibration, short circuit, heat, load, and mechanical testing, reducing many possible causes of common failures.

SINAMICS S150is an enclosed regenerative drive offering great competitive advantages. For test stands generating large amounts of power, such as when loading an engine or turbine, the SINAMICS S150 employs an active front end to push this power back into your facility. Unlike typical regenerative drives with anywhere from 30 to 50% harmonic distortion which can cause erratic behavior or reduced life for other electrical equipment in the facility, SINAMICS S150 has near perfect harmonics (less than 3% current distortion) so the power generated is “clean."

SINAMICS S150 also has the ability to run at unity power factor or even compensate for poor power factor in other parts of the facility. This can result in improved efficiency and even eliminate fines utilities impose for poor power factor. SINAMICS S150 also has anti-islanding built into the product which can help eliminate concerns from the utility that arise when trying to generate power.

For those test stand OEMs preferring to build unique drive lineups, The SINAMICS S120 modular product is available as a loose chassis to be built into a custom enclosure. The S120 components offer the same performance advantages as far as accuracy and torque response as the S120 Cabinet Modules and SINAMICS S150.

SIMOTICS Motors

Siemens is able to offer low voltage, high horsepower motors up to 5,000HP which enables the solution to stay in the higher performance low voltage system as opposed to lower performance medium voltage systems.

test stand main motor

SIMOTICS M 1PH8 Main Motors
The test stand industry benefits from their low inertia, wide power and speed range, and servo like high-performance. This motor has several speed feedback options that allow for extremely high accuracy.

Air or water-cooled*

test stand torque motor 1fw3

SIMOTICS 1FW3 torque motor
is an excellent example of a low speed, high torque, low voltage motors to eliminate the need for a gear reducer.

Water-cooled*

test stand weiss motor

Weiss Spindle Motors
special motors for high dynamic and minimal moment of inertia

test stand torque motor 1fw6

SIMOTICS 1FW6 torque motor
for high torque applications and precision

Water-cooled*

* In many cases, Siemens liquid cooled motors are supplied to the test stand industry to eliminate motor heat into the room or to achieve high horsepower or speed. Because of their quiet performance, liquid cooled motors also have been the choice when a test stand will need to record the audible noise of a machine.


Siemens Value-Add for Test Stand Engineering

Planning Phase (Vibration Analyses)

Dynamic Designs

Test stands - sizer

Siemens SIZER engineering tool for drives and motors

> Learn more about SIZER configuration tool

Engineering Phase

Integration of Simulink® - Models with SINAMICS or SIMOTION

Test stands - Simulink

> Learn more about Simulink

Advantages

• Processes and control algorithms are modeled and simulated graphically

• Models are compiled into C/C++ code

• The code can then be included in a SINAMICS or SIMOTION project, and called and executed from the DCC

• The targets handle the fully-automatic creation of DCC blocks

• The code generation can be started directly with Simulink

> View this diagram for further illustration

LabVIEW TM - Interface for SINAMICS drives

> Learn more about LabView

Advantages

• The converted functionality permits the control of a SINAMICS G/S drive via a standard PC running LabVIEW TM - No additional hardware is required

• Cycle times up to 8 ms for Windows and up to 1 ms for Real Time Operating System (RTOS) can be implemented

• Predefined VIs (virtual instruments): Standard telegram 1 (speed control), standard telegram 111 (position control), free telegram configuring or communication

> Check out this application example

TPS (Torque Pulse Simulation)

Test stand - tps

Polygon Open Architecture application for internal combustion engine test stands

• The OA application polygon is a mathematical signal generator that generates a periodic signal from predefined values

• The mathematics function can be described as: Output(t, X)=A(t)*Y(X+S(t))+O(t)

• It can be changed at runtime via BICO

• The function runs in the current-controller cycle (Booksize 31.25 µs)

• The signal is generated on the basis of a values table or via a simple cam function that can be imported with as many as 10,000 interpolation points via Excel. These interpolation points are stored as dynamic array in the SINAMICS S120

• The output value Y depends on X, e.g. from the current actual encoder value, position or electrical angle

• Phase and amplitude corrections for the damping or delay compensation in the system are possible

• A signal frequency to above 1 kHz can be attained

Periodic Signal Generation

test stand - periodic signal generation

OA SETPGEN (Open Architecture) application

• Consists of three individual signal generators that can be operated simultaneously

• Generation of sinusoidal, saw-tooth and square wave signals up to 3 rd harmonic

• Amplitude, frequency, phase offset and offset can be changed at runtime

• Signal frequencies of up to 1.6 KHz possible

• Can be changed at runtime via BICO

• The function runs in current controller cycle (Booksize 31.25 µs)

• Interconnectable as supplementary torque, supplementary speed and to analog outputs

> Check out this application example

PROFINET Interface for Data logger PCs

test stand - profinet

Implementation of PROFINET using standard Ethernet interfaces

• Make standard PCs PROFINET-compatible for measured value acquisition

• PROFINET with Real Time (RT) for cycle times as fast as 1 ms

• Ring topology for higher plant availability

• Standard Ethernet interface sufficient

• Sample applications available for Windows

Further information

> PROFINET Driver

Torque Sensor with PROFINET

Test stands - torque sensor

Integration of torque meters into SINAMICS drives systems

• Controlled systems can be established via SINAMICS standard communication

• No EMC issues - signal is digital

• Small controlled systems - no additional signal conversion required

• Cycle times as fast as 1 ms with PROFINET RT

• Cycle times as fast as to 250µs with PROFINET IRT

Manufacturers

> HBM Test and Measurement

> Kistler Instruments


Test Stand Challenges - Siemens Answers

Application Challenge

Siemens Answer

The test stand requires power regeneration

The SINAMICS G and SINAMICS S drives have Smart Line Module and Active Line Module solutions for regeneration

Due to the constant high power regeneration, it is often a challenge dealing with power utilities who do not want power generated back to the grid

SINAMICS S120 Cabinet Modules offer a common bus solution so one motor consumes all power generated by another motor, thus eliminating any regeneration back to the grid

The test stand must run at a very high speed

The SINAMICS S120 family of drives can generate as high as 600Hz to run motors as fast as possible

Due to the huge range of possible tests, the motor products need to be able to handle a very wide speed and power range

Siemens SIMOTICS features a wide variety of motors including Servo, IEC, NEMA, Above-NEMA, and even custom Loher Motors to handle virtually any requirement

Test stands have many data collection sensors that are sensitive and cannot handle the electrical noise emitted by AC drives and motors

The SINAMICS S120 / S150 family of drives has a category C3 line filter standard and an optional category C2 to reduce high frequency interference

The power generated by the test stand could be used by the rest of the plant but the harmonics generated by AC drives can be detrimental to other equipment in the facility

The Active Line Module regenerative solution has extremely low harmonic distortion (<3% THD) compared to standard 6-pulse drives (30-40% THD) in addition to power factor control

Test stand applications require very accurate speed control

The SINAMICS S120 / S150 product along with the SIMOTICS 1PH8 motor using the DRIVE-CLiQsine/cos encoder features speed rise time as fast as 5ms and speed accuracy lower than 0.001% of rated speed

Test stand applications require very dynamic torque response and accuracy

The SINAMICS S120 / S150 product along with the SIMOTICS 1PH8motor which includes a KTY84 temp sensor has motor model algorithm to achieve 0.8 ms rise time and 1.5% torque accuracy