High flexibility thanks to a large modular system

The following sample application shall demonstrate how optimally matched, individual drive solutions with short delivery times emerge from the comprehensive NORD modular gear unit system. This is possible due to the great production depth of the NORD products: All key modules and components of the drive solutions such as gearing, housing, windings and drive electronics are not only installed by NORD DRIVESYSTEMS but also developed, tested and manufactured in its own facilities. The idea of a modular system not only characterises the industrial gear units but is also the basis for the normal gear motor sizes for different industries such as intralogistics, food and beverage or bulk goods handling – as currently reflected in the new high-efficiency portfolio – and for the universally applicable NORD drive electronics.

Together with NORD frequency inverters and motors, industrial gear units from the modular MAXXDRIVE® system for tailor-made drive solutions form a powerful drive team, combining power and intelligence. MAXXDRIVE® industrial gear units allow for various individual options up to industry-specific special solutions. The numerous versions and components offer almost infinite possibilities for individualisation – always based on the customer requirements. The application example of an electromechanically operated bascule bridge illustrates the performance and design possibilities of the NORD portfolio, from industrial gear units to electronic drive technology. High torques are required to open and close a bascule bridge weighing many tons. At the same time, the bascule bridge moves very slowly and just before the end (landing) positions, the movement must be exactly dosed to avoid any damage to the structure and mechanics.

A complete solution thanks to engineering

Such a drive concept does of course not automatically emerge from the modular system. Here, application engineering from NORD DRIVESYSTEMS comes into play: It supports the client with the application development, and develops and manufactures a drive solution according to his requirements and needs – completely ready to be installed and commissioned. What are the requirements for a bridge drive unit? Unquestionably, it shall require low maintenance and achieve a maximum service life. It must open and close several times a day – reliably under all weather conditions. If a component should fail, emergency operation must be possible and in case of repair, a quick replacement of the faulty drive components must be ensured. In the end (landing) positions, in particular when the bridge is raised, the drive system shall be locked.

Industrial gear units – subject to design

The suitable electric motor, the right industrial gear unit and the frequency inverter for the fine adjustment of the drive behaviour are selected from the portfolio based on the required physical parameters such as drive power, torque and speed. This is completed by a separate brake for safe stop in any position – even with disassembled motor – and an auxiliary geared motor for very slow levelling speed, emergency and maintenance operation. If necessary, manual operation of the auxiliary gear unit by hand wheel must be possible. All components receive corrosion protection according to environmental conditions and – easy to commission and transport – will be delivered as a fully assembled drive system on a common frame. NORD has developed its own software for the calculation and selection of suitable drive systems. Even if the optimal gear unit size has been determined, the modular MAXXDRIVE® industrial gear unit system still offers a wide variety of possible combinations. This is where the application-specific knowledge of our NORD engineers comes into play for the selection of the optimal option.

Wide portfolio for tailor-made individualisation

MAXXDRIVE® industrial gear units are manufactured in 11 sizes as three- or four-stage right-angle gear units and two- or three-stage parallel gear units. In addition to this universally applicable standard series, the industrial gear unit portfolio comprises the following series:

• MAXXDRIVE® XT
  Two-stage right-angle gear units that deliver high performances with low speed ratios, e.g. for conveyor belts. An integrated axial fan and structural adjustments such as an optimised cooling airflow eliminate the need for an external cooling system.
• MAXXDRIVE® XD
  Three- or four-stage parallel gear units, which due to an extended centre distance make maximum installation space for a U-shaped arrangement (input and output on the same side of the gear unit), e.g. for use in bucket elevators. The housings are optimised for external loads; an inspection cover facilitates maintenance.
• MAXXDRIVE® XJ
  Three-stage right-angle gear units that due to an additional input shaft position (“J-Mount”) ensure maximum flexibility and freedom of design.

Based on the modular system, NORD plans complete and customised drive systems for heavy-duty operation with short delivery times. This is based on a comprehensive range of frequency inverters, motors, gear units and attached components such as couplings, brakes, cooling options, base frames and many other options. For example, various versions of input and output shafts, mountings, sealing systems, back stops, auxiliary gear units, cooling equipment and sensors for condition monitoring are available.

The NORDAC ON is available in two versions: NORDAC ON was designed for use with asynchronous motors, whereas NORDAC ON+ is intended for combination with synchronous motors and supplements the NORD high-efficiency portfolio around the new IE5+ motor generation, and with the DuoDrive geared motor. Both modular system versions of the inverter have an integrated Ethernet interface and are thus ideally equipped for integration into modern automation systems. Whether for PROFINET NET, EtherNet/IP or EtherCAT – the required protocol can be easily set via parameters. All connections are pluggable for a quick, easy and error-minimised installation, commissioning and maintenance on site. The equipment comprises a diagnostic interface, four digital inputs and, with the NORDAC ON+, an encoder interface. Functional safety (STO) and internal braking resistors for dynamic start/stop processes are optionally available.

Scalable functions for each drive application

According to the philosophy of a modular system, all NORD inverters principally allow for a flexible configuration and scalability in function and equipment. This way, they can be flexibly adjusted to any application. They are quick to install, easy to operate and compatible with all common bus systems and controls. Useful features like the PLC functionality for drive-integrated functions, an energy-saving function for partial load operation, the POSICON positioning control, integrated brake choppers for 4-quadrant operation and functional safety with STO and SS1 ensure high functional use. The inverters perform open-loop or closed-loop, and are designed for operation with asynchronous and synchronous motors. The precise current vector control ensures optimal torque in a wide variety of load and speed situations. The consistency of the entire NORDAC product family ensures a comparable function range, uniform operation, and common options for all NORD frequency inverters.