1. Introduction
HIPERFACEDSL® (Digital Servo Link) represents the digital age in the evolution of motor/drive communication. This interface requires very few connecting cables because fail-safe data transmission can be achieved directly through the motor cable during motor feedback – a first in the field. Communication data is modulated onto the power supply voltage of the servo feedback encoder: such as the EKS36 single-turn or EKM36 multi-turn servo feedback encoder. Furthermore, data from other sensors (such as winding temperature sensors) can be transmitted via digital motor feedback protocols. Electric drive systems with motor encoders and integrated HIPERFACEDSL® interfaces are visually distinctive, with the entire system consisting of only a single device plug.
2. Significantly reduce costs and installation work.
This design allows the entire system to use only a single motor cable, up to 100 meters long. Since encoder cable kits and their associated installation are no longer needed, the amount of wiring work that mechanical engineers must perform can effectively be reduced by half. Depending on the number of drives used on machines employing HIPERFACEDSL® interface servo feedback encoders (such as the SICK EKS36 single-turn or EKM36 multi-turn servo feedback encoders), the entire drive system provided to mechanical engineers will be significantly cheaper. Unnecessary components naturally occupy less space, an advantage that benefits not only machine manufacturers' material reserves but also the machines themselves, as the energy transmission chain requires less space, and cable trays can be made smaller. Furthermore, the space required for cable covers and cables in the control cabinet can be greatly reduced, allowing for the use of smaller and cheaper control cabinets.
3. New opportunities for energy saving and size reduction
Thanks to the reduction in plugs, cables, and peripheral hardware, the size of servo drives is constantly shrinking. This is crucial in applications where the drive must move as part of a dynamic process, where smaller size and lighter weight mean that devices such as robots require less kinetic energy. Moreover, these dynamic applications, like static ones, offer mechanical engineers another advantage: reducing drive size without compromising the machine's power rating. In some applications, servo drives can be smaller than in others, leading to increasingly compact machines in certain industries that are very space-saving for on-site installations, even in very small areas. Generally, lower power rating drives are more cost-effective – a fact that certainly pleases machine manufacturers' designers and finance personnel.
4. Improve availability by minimizing the risk of failure and providing status monitoring capabilities.
The evolution of the HIPERFACE® interface from a hybrid (analog/digital) to the purely digital HIPERFACEDSL® has minimized the number of cables required between the inverter and the servo feedback encoder. Correspondingly, less installation work is required, reducing potential sources of failure and significantly lowering the risk of technical problems (even statistically speaking). This is one reason why HIPERFACEDSL® improves machine availability. Mechanical engineers can develop and provide customized condition monitoring functions for their customers in the servo drive and surrounding area. In addition to digital signal transmission, E²PROMs can be used as electronic model tags, enabling automatic drive parameterization for servo feedback encoders such as the EKS36 and EKM36. Motor specifications, serial numbers, part numbers, and other data facilitating quick inspection or replacement can be stored here and used to automatically adjust the drive to adapt to motor parameters. For mechanical engineers, the ability to record a wide range of motor data via the servo feedback encoder throughout the machine's operation (typically several years) and use this data for diagnostics and preventative maintenance (as part of continuous condition monitoring via HIPERFACEDSL®) is highly attractive. Not only can these objectives be achieved directly on the machine in the field, but users can also remotely access the machine (down to the motor shaft) at any time using the DSL diagnostic tool PGT-11-S and data transmission via a network interface. This remote diagnostic option provides rich remote monitoring data for preventative maintenance through features such as lifecycle histograms. During operation, the servo feedback encoder records and measures numerous physical parameters, including power consumption, revolutions, speed, temperature, and all variations of these parameters. The status and expected development direction of the drive and machine can then be derived from these parameters. Condition monitoring enables machine manufacturers to achieve two goals: first, machine protection by using fast-response safety systems such as emergency stop switches to avoid costly secondary failures. Combined with sensor data analysis, destructive factors and causes of damage can also be analyzed. The second goal of condition monitoring is to optimize machine efficiency, thereby maximizing product availability. Continuous condition monitoring has significant potential for saving operating costs because critical machine components do not require preventative inspection and replacement; and their entire lifecycle can be fully utilized without wasting still functional parts. At the same time, the status information of the drive is also the basis for forming necessary maintenance measures to coordinate with factors such as production schedule or planned machine downtime.
5. Future-proof integrated SIL security and advanced technologies
HIPERFACEDSL® is a future-proof communication standard. This means that, in terms of security, data transmission via HIPERFACEDSL® is certified to achieve performance levels up to SIL3 (IEC 61508 standard) or e (EN ISO 13849-1 standard). SICK's EKS36 and EKM36 servo feedback encoders are servo feedback encoders capable of achieving SIL2 or d performance levels, ensuring that digital motor/encoder interfaces can, in principle, be used in safe applications. Mechanical engineers can achieve the same level of safety as their end users (machine operators) in terms of safety features and compliance with machine instructions and related standards, as shown in Figure 1.
Figure 1
Generally speaking, HIPERFACEDSL® offers mechanical engineers an opportunity to compete for their services: to stand out from the competition through new interface technology and its corresponding advantages, and to provide greater added value to today's customers – needs that will only increase in the future. Furthermore, this means that upgrading to HIPERFACEDSL® will be a safe investment.
6. HIPERFACEDSL®: Dedicated to green drives and machine technology
For years, even decades, energy efficiency has been an area with tremendous potential for innovation in drive technology, as motors and drives consume the vast majority of energy in industrial applications: they account for 66% of total consumption, equivalent to over 151 TWh (Germany) or 656 TWh (Europe). Research by ZVEI (German Association of Electrical and Electronic Manufacturers) indicates that in Germany alone, drive technology could reduce energy consumption by 22 TWh (approximately 15%). This energy saving is enough to power over 5.5 million homes, reduce CO2 emissions by 12,500,000 tons, or cut several power plants off the grid—all achievable in Germany alone. Against this backdrop, HIPERFACEDSL® technology truly contributes to the creation of green drive and machine technology. It boasts the advantage of less copper consumption due to the reduced need for plug and cable materials. Not only does the smaller drive size contribute to energy savings, but the weight and size of servo drives also decrease accordingly, meaning less kinetic energy is required to move them. Condition monitoring also contributes to excellent sustainability. Simultaneous monitoring of processes and machines not only provides maximum protection for people, machines, and the environment nearby, but also maximizes the utilization of components throughout their entire lifecycle. The fact that the HIPERFACEDSL® concept meets future needs means that tomorrow's technologies can be utilized now, and resource waste can be avoided through advancements in sensor technology. HIPERFACEDSL® also drives the evolution from asynchronous motors to more energy-efficient synchronous motors, as shown in Figure 2.
Figure 2
In summary, electric servo drive systems with the HIPERFACEDSL® interface offer a wide range of advantages and opportunities for mechanical engineers who choose an innovative strategy.
