Conversion of master drives to Sinamics G120
IFG Exelto, located on the former Domo site, is a producer of PP staple fibres (PolyPropylene) with applications in floor covering, automotive, geotextiles and construction (concrete fibres). These fibres are spun 24 hours a day on five fibre lines in Zwijnaarde. The spinning pumps are crucial for the quality of the fibres.
|Motion Control, Power Quality
Conversion results in energy efficiency
The spin pumps of these lines were driven by Masterdrives frequency inverters. This Siemens technology has proven its worth for many years, but since the end of 2020 it is no longer supported. This makes it difficult to obtain parts and carry out repairs. An additional problem was that communication between the frequency inverters was done via Simolink, another Siemens technology that once caused a stir, but has since been replaced by more user-friendly systems. ATS was still one of the only integrators familiar with this.
So it was high time to modernise one of the five fibre lines. At the same time, the released parts can be used to depower the other lines.
ATS Group proposed to switch to the modular, multi-functional Sinamics G120 variable speed drives. These could drive the existing spin pump motors, but it was suggested to replace the outdated and sub-optimal motors with the synchronous Simotics reluctance motors. These are in fact perfectly matched to the Sinamics frequency control, which means that this frequency controller requires less power. This higher energy efficiency, even at part load, quickly pays for itself.
Simolink was also replaced by the more accessible Profibus communication technology that was already in place.
"ATS thinks along with us. They know our installed base through and through and guide us to the most suitable solutions on the market." - Jeroen Kuypers, Head of Technical Services IFG Exelto.
After a conversion of barely a week, ATS Group also performed a grid analysis: the new installation consumes up to 41% less energy (at nominal conditions), which of course also helps IFG Exelto to meet their targets in the energy management agreement.
ATS Group was responsible for:
- Analysis and configuration of current drivetrain and line drive
- Mechanical, electrical and software installation of drivetrain and line drive
- Analysis of current grid contamination and influence of new configuration by Power Quality