To transmit large amounts of power with a maintenance-free solution, Weidmüller has optimized the proven resonant inductive coupling technology to feed the most powerful motors through an air gap.
The development of smart power transmission solutions is just one stage on the path to the smart factory. In conventional methods, power is manually connected via a plug-in mechanical contact. However, these products require a lot of maintenance and must be replaced frequently, which causes regular production stoppages. These weaknesses are foreign to contactless power transmission, as it far exceeds the flexibility and life cycle of conventional plug-in connections.
“Contactless power transmission is something we are all familiar with. Take electric toothbrushes for example. With this drive system, the brushes are driven without a plug-in connection that is subject to wear”, explains Klaus Leuchs, product manager, by way of comparison.
“Industrial applications benefit greatly from this level of flexibility. Therefore, we have adapted resonant inductive coupling technology to the most demanding industrial environments, which opens up a whole range of new applications by providing high energy density and maximum efficiency.”
High energy density and maximum efficiency
Weidmüller's FreeCon Contactless system transmits up to 240 watts through an air gap; It is a wear-free and particularly efficient solution. This high power transmission capacity allows to extend the range of applications from robotics and rotating systems to non-contact transport systems. High vibrations are not a problem; the system has a transmission distance of up to five millimeters, unique in its performance class.
The connection is established as soon as two modules are placed one in front of the other, remaining stable in the event of rotating movements. This makes it possible to obtain completely new structures in the construction of industrial systems and significantly contributes to optimizing production processes.
FreeCon Contactless facilitates the automation of production thanks to a safe and contactless power transmission, adapted to the needs of the industry and suitable for integration into a control program.
Finally, FreeCon Contactless stands out because all these performance parameters can be implemented in a totally compact design of only 100 x 100 x 47 mm. The system, equipped with IP65 protection, can be installed in practically any industrial environment, with very significant space savings.
But how has Weidmüller managed to combine that level of energy and such a compact format? “Our formula for success is based on innovative thermal management that has enabled designers to achieve efficiency levels of over 90% and effectively reduce heat generation,” reveals Mr. Leuch. "These conditions have allowed us to put into practice the compact design we were looking for."
Knowledge applied in the field
The development of FreeCon Contactless was carried out in close cooperation with leading manufacturers in the German automotive sector. One of the proposals that came out of this partnership resulted in fantastic functionality: as the system is controlled by PLC, the secondary side can be connected or disconnected using the primary. The result is a switchable device suitable for integration into a higher level control program.
Its plug & play capability makes FreeCon Contactless as easy to use as a plug-in connector and can therefore be seamlessly incorporated into existing systems.
Connections that were previously made manually can now be made automatically in an instant, opening up a whole host of new possibilities on the road to the smart factory.
Trouble-free operation with uninterruptible power supplies
Combined with battery modules, Weidmüller uninterruptible power supplies respond to power failures for 30 minutes with a 40 A load.
To keep safety functions, process controls and communications operational – in the wind industry, for example – it is necessary that automated components receive a constant power supply.
In 2010 alone, more than 200.000 power outages lasting more than three minutes were recorded in Germany. Micro outages, typically 200 milliseconds, happen even more frequently.
To this we must add that operations in the companies' own networks can cause cuts or voltage drops when connecting equipment with a large power consumption. The result is costly data loss, rebooting of machines, or even damage to tools and products due to uncontrolled start-up.
“These damages and the consequent losses in production can lead to enormous costs, in the millions of euros,” says Klaus Schürmann, Product Manager at Weidmüller. “Users with high-level automation systems require power solutions that meet their specific application requirements and meet applicable safety levels.”
Innovative battery management
The new UPS control unit combined with a battery module has been specially designed for bridging during long power outages. With the Weidmüller solution, modern battery management and the integrated thermal sensor, optimal charging and increased battery life are guaranteed. Depending on the needs, the battery modules supply up to 40 A for 30 minutes or 1 A for 30 hours.
“Automation components and industrial PCs are normally consumers of 24 V DC, which is why uninterruptible DC power supplies are used in this field.
The modular concept consisting of a power supply and a UPS control unit ensures flexible distribution of the entire load between safe and non-safe circuits. This allows machine builders, for example, to maintain communications at defined points in their facilities. In other applications it is possible to completely avoid downtimes caused by problems in the supply voltage” explains Mr. Schürmann.
Wind energy is another sector, along with machine building, in which uninterruptible power supply solutions play a major role. Installed on the "top-box" board, the modules maintain the security and data communication functions with complete reliability. In this way, critical states of the systems are avoided and process control is maintained.
Focus: Reliable power supply in intelligent automation of local distribution systems from ABB
In the past, the current flow was unidirectional. In other words, electricity was produced at the plant and transported to customers through high, medium and low voltage distribution networks.
Today, distribution system operators face the challenge of increasingly decentralized power generation. Farms and homeowners feed the low voltage networks with the electricity produced in their photovoltaic and wind installations.
Given the great volatility of renewable energies, it is very difficult to predict load curves from one day to the next. In sunny and windy conditions, renewables provide more electricity than usual to the grid. If conventional power plants simultaneously feed the grid, there is a risk of overloads. To answer this question, distribution system operators can lay new cables or invest in smart substations.
Substations are used in the secondary distribution system and consist of gas-insulated medium voltage switchboards, distribution transformers and low voltage switchboards. These substations transform electricity from the medium voltage network with a voltage greater than 1 kV to voltages of 400 V. Among the consumers connected to low voltage outlets of this type are household, workshop and farm appliances.
ABB's FIONA: a solution for measuring, monitoring, controlling and regulating tasks in local distribution switchboards
ABB's FIONA (Functional and Intelligent Substation Automation) provides power distribution system operators with a pre-programmed and scalable solution. FIONA adapts to a large number of customer requirements, from simple recording of readings, short circuits and ground faults to control and regulation tasks. Thanks to its high temperature resistant design and electromagnetic compatibility, FIONA is a particularly suitable solution for medium voltage applications.
“Substations reach high temperatures in summer, so the components of our automation solution must operate in as wide a range of temperatures as possible.
As you can imagine, this condition is especially important in the case of modules responsible for ensuring the uninterruptible supply of power to 24 V consumers,” explains Ulrich Aschenbroich from ABB. "Thanks to its wide temperature range, Weidmüller's uninterruptible power supply meets all our requirements." Temperature compensated charging enables optimum battery charging and ensures reliable operation at extreme temperatures. Temperature compensated battery management ensures a meticulous and correct charging process even at high temperatures. The result is longer battery life and a reliable power supply.
