This is how to optimize your rail applications with the right motors for the highest demands.
What exactly is a high inertia motor and why is it so important for tension control in railway systems?
A high inertia motor is characterized by a high moment of inertia . This property allows it to act like a mechanical buffer and resist rapid changes in load or torque. For railway systems, this means a more stable and consistent rail tension, which reduces production downtime due to material fractures or quality issues.
What specific advantages do high inertia motors offer in applications such as film or paper processing?
In these industries, high inertia motors minimize tension fluctuations, which is critical for product quality. They allow for precise control of material tension, reduce material damage, and can lower the scrap rate by up to 10%.. In coating systems, deviations from the target tension are often minimized to under ±1%..
For which types of rail systems and materials are high inertia motors particularly suitable?
They are ideal for systems with high rail speeds (over 600 m/min) and where large material rolls are unwound. Industries such as the paper industry, film extrusion and coating as well as the textile industry (e.g., in weaving machines for technical textiles) benefit significantly. They are also advantageous in the processing of sensitive materials such as thin films or non-woven fabrics due to their gentle power delivery.
What should be considered when selecting a high inertia motor for a specific system?
Important criteria include the matching of the motor inertia moment to that of the system (often a ratio of 1:1 to 1:5 to the load inertia), the required peak torque to cover pulling force and acceleration, as well as a precise controllability, which is typically ensured by modern servo motor controllers. Environmental conditions also play a role.
How does ATEK Drive Solutions support companies in the implementation of high inertia motors?
ATEK acts as a system provider for the complete industrial drive train.We provide not only high-performance servo motors but also suitable gear boxes and brakes. Our strength lies in customized special solutions and a modular system, which allows for a high variety of configurations and fast delivery times. Comprehensive technical consulting is also part of our service.
Can high inertia motors contribute to energy efficiency in production facilities?
Yes, modern high inertia motors, especially in conjunction with efficient servo controllers, can reduce the energy consumption compared to older technologies by up to 15%.This reduces operating costs and the CO2 footprint of the facility.
What role do servo motor controllers play in combination with high inertia motors?
A powerful servo motor controller is critical for the full precision of the high inertia motor. It enables active vibration damping and a rapid error correction (often in the range of 2-4 milliseconds), which is essential for constant, accurate rail tension.
High inertia motors are essential for precise tension regulation in industrial rail systems, as they compensate for load fluctuations due to their high moment of inertia, thereby significantly improving the product quality and can reduce scrap rates, for example, by up to 10%. können.
The combination of high inertia motors with modern servomotors and controllers enables the highest precision even at speeds over 600 m/min, which can increase production efficiency, for example, in printing companies by 5-7% and reduce material losses in coating systems by 3-5%. ATEK Drive Solutions offers as a system supplier
ATEK Drive Solutions bietet als Systemanbieter complete, often customized drive solutions with high inertia motors, gear boxes, and brakes that can be quickly configured through a modular system and shorten commissioning times by up to 20%. Learn how high inertia motors are revolutionizing tension control in rail systems and what advantages they offer for your applications.
Tension control in rail systems places the highest demands on the components used. High inertia motors play a crucial role in this. Are you looking for the perfect drive solution for your rail application? Contact us at können.
Erfahren Sie, wie Hochträgheitsmotoren die Spannungsregelung in Bahnsystemen revolutionieren und welche Vorteile sie für Ihre Anwendungen bieten.
Die Spannungsregelung in Bahnsystemen stellt höchste Anforderungen an die eingesetzten Komponenten. Hochträgheitsmotoren spielen dabei eine entscheidende Rolle. Sie suchen die perfekte Antriebslösung für Ihre Bahnanwendung? Kontaktieren Sie uns unter ATEK Drive Solutions for a personalized consultation!
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Introduction to high inertia motors for tension controls
Production downtimes due to incorrect rail tension, e.g., in films, incur high costs. High inertia motors counteract this. The high moment of inertia stabilizes against rapid load changes, as when unwinding large material rolls (diameter >1m).
Even ±5% tension fluctuations affect product quality, for instance, in multicolor printing. As a mechanical buffer, the high inertia motor minimizes these fluctuations and can reduce the scrap rate by up to 10%. See also efficient unwind brakes..
At system speeds of over 600 meters per minute it is essential for stable tension control. A high inertia motor for tension controls, often combined with servo motors, increases precision.Functioning and benefits of high inertia motors
A high inertia motor resists sudden speed changes due to stored kinetic energy. This acts similarly to a flywheel, smoothing out torque irregularities and cushioning acceleration ramps (e.g., 0-1000 rpm in <500 ms) without tension fluctuations. For additional safety, electromotors with an integrated brake.
- store kinetic energy to bridge sudden speed changes.
- Flywheel-like effect to smooth torque irregularities.
- Compensation of acceleration ramps (e.g., 0-1000 rpm in <500 ms) without tension fluctuations.
- Reduction of deviations from the target tension in coating systems to under ±1%.
- Significant reduction of material losses (3-5%) and ensuring homogeneous product quality.
- Fine adjustability of pulling force, ideal for sensitive materials such as non-woven fabrics (20 g/m²).
In coating systems, they minimize deviations to under ±1% of the target tension.. This significantly reduces material losses of 3-5% and ensures homogeneous product quality, highlighting the effectiveness of high inertia motors for tension control in rail systems. The proper design of the safety brake is also important.
The fine adjustability, often with intelligent controllers, precisely adjusts the pulling force to material requirements, even for sensitive non-woven fabrics (20 g/m²). Our hydraulically controlled torque brakes provide suitable solutions.Areas of application in rail systems
In paper mills (rail speeds up to 2000 m/min) a high inertia motor ensures calm and stability, prevents tearing and can reduce machine stoppages. The use of a high inertia motor for tension controls in these rail systems increases production efficiency, for example, in printing companies by 5-7%. This also optimizes downstream logistics processes..
In the processing of the thinnest films (e.g., 10 micrometers) during extrusion or coating, the gentle, stable power delivery is ideal, to achieve defect rates below 0.5% – a core function that high inertia motors for tension control in rail systems. stands out. Our industrial brakes support such processes.
In weaving machines for technical textiles, such as airbag fabrics, they ensure consistent yarn tension for uniform structures and improve the quality of produced textiles by up to 15%.Selection criteria for high inertia motors
The selection requires coordination: The inertia moment of the motor must be matched to that of the system (guideline ratio of motor to load inertia 1:1 to 1:5 for dynamic applications). The correct sizing is essential for the optimal function of a high inertia motor for tension controls in railway systems.. Our modular system provides flexibility.
- The inertia moment of the motor must be precisely matched to that of the system (guideline ratio 1:1 to 1:5).
- The peak torque of the motor must be able to cover the maximum pulling force and required acceleration.
- Modern servo motors can temporarily deliver 2 to 3 times their rated torque for dynamic requirements.
- A powerful servo motor controller is crucial for full precision and active vibration damping.
- The controller must enable rapid error correction, ideally in the range of 2-4 milliseconds.
- The flexibility provided by modular systems can be helpful in adjustments.
Critical factors are peak torques: The torque must cover maximum pulling force and acceleration (e.g., rail 0-300 m/min in 2s). Modern servo motors provide 2 to 3 times their rated torque for this. Electronic braking systems complement this.
Full precision requires a powerful servo motor controller for active vibration damping and rapid error correction (2-4 ms). You can find such systems in our ATEK servo motors..ATEK Drive Solutions: Your partner for drive solutions.
ATEK Drive Solutions offers a complete industrial drive train as a system provider from a single source: matched Gear Boxes, brakes, and high-performance servomotors. System integrations can reduce commissioning time by up to 20%. Discover our suitable industrial brakes.
Our modular system enables millions of configurations for quick, economical solutions, even for specific high-inertia motor requirements, often with adaptations in 4-6 weeks. Learn about the ATEK modular system.
Experienced engineers provide comprehensive advice, analyze your requirements – from track width to process speed – and determine the ideal drive configuration, including the optimal high-inertia motor for tension control in your rail systems, taking into account important safety aspects.Future perspectives and innovations
Future developments include sensor integration into the drive for adaptive voltage regulation in real-time, which can improve process stability (e.g., with recycling materials) by 5-8%. Such advancements will further optimize the performance of high inertia motors for tension control in rail systems. . Modern electronic brake systems are part of this intelligent future.
Energy efficiency is central: Modern high-inertia motors reduce energy consumption by up to 15% compared to older technologies, which reduces costs and CO2 footprint. Our electric motors with brakes are consistently designed for efficiency.
Networking and data analysis enable condition monitoring and predictive maintenance, thereby reducing unplanned downtimes by up to 20% and extending the lifespan of components, such as bearings in a high-performance servomotor, is extended.
