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Bretzel GmbH uses YASKAWA’s Sigma-5 servodrive system for customer-specific requirements

Photo by Yaskawa Electric Europe GmbH

Photo by Yaskawa Electric Europe GmbH

A mechanical and apparatus engineering provider demonstrates that it is possible to equip CNC machines according to specific customer requirements using servodrive systems and corresponding inverter drives. As a result, the operating company is able to achieve a high level of dynamics and accuracy during milling.

When equipping CNC milling machines according to customer requirements, Bretzel GmbH Antriebs- und Elektrotechnik, based in Eschborn, relies on the EtherCAT capable Sigma-5 servodrive system from YASKAWA. The drive solution sets standards in terms of dynamics and accuracy.

Bretzel uses Sigma-5 servomotors from YASKAWA’s SGMAV series to drive the axes of the CNC machines. The Sigma-5 servo system is a servodrive that consists of servomotors, servo amplifiers and the powerful Sigma-Win+ engineering tool. The series includes rotary motors, direct drives and linear motors. The standard types combine positioning precision of at least 1 µm with short positioning times.

Servomotors ensure precise and low-wear operation

As a highly dynamic system, Sigma-5 enables the shortest possible processing times. Moreover, motor operation is very precise and practically wear-free. An absolute 20-bit encoder system with over 1 million increments per motor rotation, continuously and extremely accurately records the actual position of the motor. The compact dimensions and low-inertia design make extremely high levels of acceleration possible.

Thanks to the auto-tuning function for automatic drive optimisation, an automatic filter function that suppresses vibration, Sigma-5 motors also operate quietly and have low vibration levels at low speeds. This not only ensures optimal operation, even in high-precision applications, but also reduces wear and tear on machines, which in turn has a positive impact on life-cycle costs. The user-friendly Sigma Win+ software allows simple and fast commissioning and diagnosis of Sigma-5 components. There is no need for manual adjustments or specialised technical expertise. For example, the autotuning algorithm lets you perfectly align two axes in high-performance machines in less than two seconds – instead of the usual eight seconds.

Servodrives combined with EtherCAT interface

Modular interfaces with EtherCAT, CANopen, POWERLINK and MECHATROLINK II and III, which allow the integration of Sigma-5 servomotors in comprehensive automation solutions, are also available. The solution adopted by Bretzel combines the Sigma-5 servo system with an EtherCAT interface. This is made possible by SGDV series 1 × 230 V servo controllers with an EtherCAT option board. The load and logic voltages can be connected separately. The controllers offer approved Safe Torque Off, which makes it possible to safely shut the controllers down in an emergency, even if a load voltage is present. This fast EtherCAT real-time bus system offers maximum performance with simultaneous full access to all controller registers and status information. Moreover, it allows the NC control unit to execute multi-axis, synchronous, interpolated path movements.

Setting up synchronised, distributed drive systems

Devices communicate via the manufacturer-independent, standardised protocol CANopen (CoE = CANopen over EtherCAT). The EtherCAT CoE interface makes it possible to setup synchronised, distributed drive systems with a high level of reliability and a high data transmission rate, thus enabling three-dimensional milling movements with extremely high contour accuracy.

In addition to Sigma-5 technology, another Yaskawa component can be found in the customised CNC milling machines at Bretzel GmbH: a compact V1000 vector-controlled inverter drive controls the spindle. Where permanent magnet motors offer precise and secure control, this inverter drive represents a solution that is as reliable as it is efficient. With its highly dynamic current vector control (open loop vector), it optimally drives both induction motors and permanent magnet synchronous motors in an output range of 100 W to 15 kW.

It reaches the rated torque even at very low speeds. The V1000 can deliver up to 400 Hz output as standard. On a 2-pole spindle this corresponds to a synchronous speed of 24,000 rpm. There is a software variant with up to 1000 Hz for higher speed spindles. Introduced as the smallest compact drive in the world, the V1000 takes up very little space. At Bretzel GmbH, the servodrive system and the compact inverter make it possible to equip CNC machines according to specific customer requirements. Resulting in dynamics and accuracy.

For more information, please visit http://www.yaskawa.eu.com