Selected innovations in brief: Solutions for enhanced efficiency and sustainability

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ABB Dynafin™

ABB Dynafin™ is an industry-first electric propulsion concept that breaks new ground for vessel efficiency. Based on a cycloidal propeller, the technology offers vessel designers unprecedented opportunities for innovation and contributes to shipping industry’s goal of cutting greenhouse gas emissions.

The ABB Dynafin™ solution comprises a cycloidal propeller with individually controlled, vertical blades. Its main elements consist of a main electric motor that powers a large wheel rotating at a moderate 30-80 rounds per minute. This is fitted with multiple vertical blades, each regulated by an individual motor and control system. The blades oscillate in a manner imitating the highly efficient movement of a whale’s tail.

The ABB Dynafin™ configuration has a low height, allowing designers to optimize ship layout. The concept delivers unprecedented propulsion efficiency of up to 85 percent on open water. Compared to a conventional propeller, Dynafin offers an improvement in efficiency of up to 22 percent. Due to its moderate operating speed, mode of action and low pressure pulses, ABB Dynafin™ generates low vibrations and noise, improving comfort and minimizing the impact of underwater radiated noise (URN).

Propulsion and steering forces are generated simultaneously by ABB’s Dynafin™, offering immediate and stepless/gearless variation of thrust and its direction. The concept will initially be made available in the power range of 1-4 MW per unit and aimed at medium-sized and smaller vessels, including ferries for passengers and vehicles, offshore support vessels and yachts.

ABB estimates that the first ABB Dynafin™ prototype to be available in 2025. 

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What if operators could predict the impact of their actions immediately?

Equipment operators can sometimes be cautious about implementing changes. Typically, if the operator changes a set point, eg, setting a water valve to 30 percent, in the plant or via a high fidelity simulation, (s)he must monitor the plant system for many minutes to see what will eventually happen.

What if operators could “experiment” by simulating possible actions and observing the results in real-time? Such a diagnostic tool could revolutionize plant system operation.

Thanks to ABB’s 800xA Simulator What-if, the operator can now safely experiment and receive an immediate response of what will happen in the plant system in response to a planned operator action.

The 800xA Simulator What-if system uses machine learning (ML) to predict process behavior as a result of an operator process change. A Long Short-Term Memory (LSTM) Recurrent Neural Network (RNN) is employed to train using time-series data, resulting in reliable predictions that are presented immediately (<1 s).

The time-series data can be created using historical process data from the plant historian. In addition, the 800xA Simulator system, including a system digital twin, or replica, of the plant control system, employs a high fidelity dynamic process model that can be used to enrich the training of data, thereby resulting in more robust models.

Derived from ABB’s research project, Augmented Operator [1], the 800xA Simulator What-if system will:

• help control room operators to avoid critical situations eg, trips due to high pressure.
• significantly improve overall operational efficiency of the plant.
• address the demographic change in future workforce and operations.
• enable operators to confidently perform changes in larger steps than today for efficient operation.

By giving operators enough time to implement appropriate actions, 800xA Simulator What-if will support plant operators in the daily operation of the plant. 

_{Reference
[1] Ruomu Tan et al., “Smooth Operation”, ABB Review 3/2022, pp. 18 – 23.}

Power extension of random wound lv motor range

Coils in a low-voltage (LV) motor can either be form-wound – with square or rectangular wires arranged systematically – or random-wound, with round wires arranged in a less definite manner. Though more expensive, the former are usually used in motors rated over 1,500 kW for reasons of performance, durability, etc. However, an ABB study revealed a demand for random-wound motors in higher power ranges – eg, in an IEC 500 frame size.

In 2018, a project was started to create a water-cooled series of these motors. The productization of this new series needed only a relatively small investment in new tooling and molds.

After the successful productization of this water-cooled IEC 500, it was natural to create an air-cooled version. Such a product would have a much larger customer base. This water-cooled IEC 500 version was harmonized with ABB’s existing M3BP cast-iron motor product structure to streamline order and delivery processes.

The main new component required was a cast iron frame featuring internal cooling. This frame has two cooling circuits: one internal circuit cooling the rotor through cooling channels and using the frame as a heat exchanger and one external cooling circuit in which air is driven over the cooling fins. These two circuits must work in a perfectly balanced fashion.

The frame design process used computational fluid dynamics (CFD) extensively to simulate the temperature distribution in the motor. Using the simulations, the number and size of the cooling fins on the motor surface could be optimized while keeping sufficient space for internal cooling channels. Prototype motor temperatures match the simulated ones very well.

High-speed motors

The paper-machine vacuum turboblower manufacturer Runtech Systems – a part of the Ingersoll Rand company – was seeking possibilities to enhance its turboblower’s high-speed motor’s efficiency.

The Runtech vacuum turboblower is a direct-driven, high-speed unit operating at up to 600 kW at 10,000 rpm. These devices are widely used in the pulp and paper industry to dry excess water from paper. As impellers are directly fitted to the rotor, rotor dynamics play the biggest role in designing a motor for the application.

ABB was known to Runtech for its advanced rotor manufacturing technology. For example, ABB’s cast aluminium rotors provide a superior power factor and lower losses due to their laminated rotor structure. Therefore, it was natural to form a partnership to create a new motor for the Runtech vacuum turboblowers.

The task was challenging: not only had 600 kW to be squeezed out of a motor size that would normally deliver 200 kW as a standard product, but vibration, bearing lubrication and centrifugal forces also had to be considered. The team created a prototype that featured a split-core stator for enhanced forced cooling, a special IP23 frame, a new rotor core structure and circulating oil lubrication for the ceramic high-speed bearings. Rapid prototyping casting using 3-D printed molds was used to create the cast iron components.

It was immediately evident that the motor’s performance not only achieved the set targets but also delivered an improvement of 1 to 2 percent in total efficiency. Productization of the new motor is complete and ABB has already delivered hundreds of these motors to Runtech. 

Scaling up Ethernet-APL to connect I/OS to DCS and power them over the same link

By addressing the need to power field devices and, simultaneously, provide an easy-to-handle “high speed” communication link for process data, device configuration and diagnostic data, Advanced Physical Layer technology (APL) is bringing Ethernet to the field and beyond for process and chemical industries.

Installation is simple and robust as the devices are connected through a point-to-point link with the APL switch that can be part of a network ring of many devices. Such a scenario provides media redundancy whenever increased availability is important. APL eliminates the need for the traditional I/O modules of programmable logic controllers (PLC) or distributed control systems (DCS) as the controller can access the device data directly, instead of indirectly, via an I/O module that converts analog standard signals and sends them to the central processing format (CPU).

Importantly, this technology is ready just as APL network equipment and field instruments are becoming available on the market. ABB has deployed automation solutions, System 800xA® with PROFINET protocol, for three large scale chemical process plants. In one case, up to 252 field instruments are directly connected through one APL network ring to a controller. Each controller typically handles three Ethernet communication rings: two rings for process devices connected via APL and one ring for Ethernet connected electrical format. Additionally, remote IO connected over the same PROFINET ring is used to collect those auxiliary signals that do not originate from APL enabled devices.

Customers benefit from simplified engineering, robust and uncomplicated installation; the solution also takes up less space in cabinets, compared to classical IO device solutions and earlier fieldbus solutions such as PROFIBUS PA or Foundation Fieldbus. The ease and speed of access to device diagnostic and configuration data results in a faster commissioning- and troubleshooting time. And, by leveraging asset management solutions, life cycle cost is reduced. ABB’s scaled-up Ethernet-APL solution is just what the process and chemical industries need. 

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VD4 evo vacuum ­circuit breaker for MV protection for a smarter greener future

As the electrical smart grid becomes reality, the role of MV circuit breakers is progressing from a simple protection device to an active apparatus able to interact directly with the main installation-specific electrical entities and thereby coordinate operations. This evolution is furthered by demands from public utility companies and private industry for greater continuity of service and a better-quality supply of power, required as the grid must manage bi-directional energy flows from intermittent renewable sources of energy.

ABB recognizes that advancements in control and protection grid components eg, circuit breakers (CB), combined with sensor systems, data analytics, and the use of machine learning-based algorithms could help make the grid more reliable, robust, and intelligent.

Having evaluated their highly successful conventional circuit breaker, VD4, ABB crafted the VD4 evo. This evolutionary solution, released in 2023, is a more energy- and maintenance efficient, cyber-secure intelligent protection system based on the same sterling level of safety and protection provided by the VD4.

Developed with ABB’s established sustainability processes, the VD4 evo CB provides up to a 60 percent improvement in efficiency and up to a 30 percent reduction in unexpected outages. With 15 percent more compactness, VD4 evo provides customers with a complete environmental product declaration (EPD).

The operational effectiveness of VD4 evo is augmented by embedded monitoring and diagnostic features, eg, sensors and the control and monitoring unit (CMU), based on ABB’s proprietary Maxwell platform, that promptly and continuously analyze and communicate the operational status, which is easily viewed on the on-premises Web HMI.

Thanks to the seemless integration of these new smart components for control and diagnostic functions, life management services and operation, ABB improves not only flexibility, efficiency and connectivity with a reduced risk of cyber incursions, but also improves environmental performance, material efficiency, and circularity. Condition-based maintenance enables customers to take targeted recovery actions whenever necessary. Considered overall, VD4 evo helps customers meet the demands of an evolving smart power grid efficiently and reliably, and safely for a digital, greener future. 

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Further information
ABB website, “IEC indoor vacuum circuit breaker VD4”
ABB website, “VD 4 evo. Evolution that empowers”
ABB website, “ABB sustainability – driving progress for a sustainable tomorrow”
ABB website, “Leading the way to a circular economy”

Ethernet-APL for field devices in the ­process industry

The measurement of parameters such as temperature, pressure and flow is essential for monitoring and controlling industrial processes. Moreover, increased energy and material costs and greater environmental awareness drive operators to monitor processes more closely than ever – not a trivial task when even a midscale plant can have as many as 10,000 field devices that measure and report process parameters.

Traditionally, 4 to 20 mA analog current loops, often using the HART protocol, have been employed to transfer data between devices and control rooms. However, current loop characteristics do not match modern communication expectations. The way forward is a new standard: Ethernet-APL.

Ethernet-APL represents the culmination of a decade-long journey in standardization. The standard allows the reporting of far more device parameters and lends itself to the automation of process plant design and operation.

One area in which Ethernet-APL is of particular interest is in potentially explosive environments as its 2-wire intrinsically safe Ethernet (2-WISE) concept limits voltage and current going to the device. Moreover, the power levels allowed in 2-WISE allow devices to perform more complex computations than in the past.

ABB has implemented Ethernet-APL into its FSx430 and FSx450 vortex/swirl flowmeters. These devices also feature a Bluetooth interface that simplifies local access with a secure smartphone app.

ABB will employ Ethernet-APL in other products and introduce further enhancements, such as using PROFIsafe to apply Ethernet-APL and PROFINET for functional safety integrity level (SIL) purposes. 

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Expert knowledge at hand

Sometimes, troubleshooting complex equipment is not just about the equipment itself. Hidden hurdles in the form of product names and local slang expressions can significantly slow a technician’s ability to diagnose and repair a problem. How, for instance, can a novice field operator make sense of a request to repair “the VD4 breaker in outgoing to T11 in TS4 UniGear ZS1 panel”? And things become even more complicated when components from different manufacturers are involved.

In view of these challenges, as well as a declining commitment by many companies to invest in training, ABB has introduced Service Assist, a virtual assistant that provides on-the-spot support and information. Interactions can be via text or voice – in fact, Service Assist can interpret human speech and is particularly versed in electrification network slang. Technicians can request manuals, videos and perhaps most important, augmented reality (AR) guides, which make it possible to troubleshoot problems even if the technician’s experience level is not advanced. Furthermore, the system is not limited to ABB documentation or equipment.

Thanks to Service Assist’s use of AR technology, operational information is presented in the user’s view of his or her real environment, thus making it more practical and easier to understand and act upon, all of which adds up to accelerated resolution of problems and reduced downtime.

Nevertheless, if further assistance is needed, a technician can request a remote support call with an ABB service specialist who can place augmented reality instructions in the operator’s field of view, allowing visual information to enhance voice instructions.

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Convenience comes home

With an eye to improving energy efficiency, convenience and value, ever more homeowners are turning to home automation systems. In view of this, ABB and Busch-Jaeger, a brand of the ABB Group, have introduced the ABB-free@home® flex system, a wireless smart home control platform. Based on a 2.4 GHz wireless Mesh-Network with ABB state-of-the-art encryption and cyber security standards, the platform can address the needs of a single room or be upgraded to control a complete smart home system.

Thanks to its intuitive, user-friendly design, the system enables quick device configuration and digital remote control of various smart functions via Bluetooth® using a smartphone or tablet. The management of blinds, light intensity, and motion detectors can take place individually or be wirelessly networked with up to 32 devices. As a result, scheduling functions and group controls can be easily implemented.

In addition, a System Access Point can accommodate up to 150 wireless sensors or wired devices. Premium and high-end functions include the integration of the ABB-Welcome® door communication system, as well as household and multimedia devices.

In the event that a customer requires support, ABB uses artificial intelligence (AI) and machine learning (ML) to solve queries. The technology leverages data sources from manuals, product documentation, and online communities to train its advanced ML and AI engines to resolve recurring support requests. 

Application examples

Garden: Thanks to a range of lighting scenes, ABB-free@home® flex ­guarantees orientation and safety.
Stairs: The platform offers automatic ­detection of movement and saves energy thanks to its automatic on-off function.
Bathrooms: ABB-free@home® flex ­creates customized lighting ambiences in harmony with natural biorhythms.
Children’s room: ABB-free@home® flex can switch lights on and off and ­offers pre-set lighting scenes such as its Good Night mode, which automatically dims lights on a predefined level.

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Kiln gas sampling with ProKiln

In recent years, the cement industry has seen a significant increase in alternative fuels and raw material (AFR) use. Though beneficial in many ways, AFR presents new challenges for gas analy­sis equipment in the already-harsh environment at the cement kiln inlet. Gas analyzers at the inlet are indispensable as they offer operators valuable information on combustion efficiency and emission levels that help ensure optimal operational efficiency, environmental compliance and effective utilization of AFR.

ProKiln, ABB’s fourth-generation gas sampling probe, allows the effective collection of samples even in hostile kiln inlet environments with high AFR levels. The probe – developed in collaboration with FLO2R, a Danish company with long-established and deep knowledge of kiln inlet measurement – focuses on a more powerful probe cleaning regime and increased mechanical strength.

ABB’s ProKiln’s main component is a 3 m-long, water-cooled probe with an extractive filter at the sample end. Two powerful air blasters provide sample flow and filter cleaning. The probe is installed on a buggy running on a retraction device.

ProKiln was trialed at a Holcim plant in Lägerdorf, Germany. The plant used fuels originating from 17 different AFRs during the trial period, resulting in significant fluctuations of the O₂ and CO process values and giving very light to very heavy scaling. Despite these conditions, the probe functioned reliably in automatic operation and no manual cleaning was required.

The return on investment on this simple and strong probe can easily be justified by preventing kiln stops alone. 

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SACE Infinitus: all-in-one solid-state ­protection for DC grids

The characteristic high efficiency of DC power solutions makes them very effective in the mission to reach carbon neutrality. However, until now, the fast nature of DC short-circuit behavior has made adequate protection and isolation technology difficult to achieve. The answer lies with solid-state circuit breakers (SSCBs), which exploit microsecond-fast disconnection. ABB’s unique SSCB is called the SACE Infinitus – an all-in-one protection solution that integrates power electronics, mechanics, cooling, control, sensing and communication [1]. The SACE Infinitus is the world’s first breaker based on semiconductor interruption technology that complies with IEC 60947-2.

The SACE Infinitus employs reverse-blocking integrated-gate commutated thyristors (RB-IGCTs), having an integral diode in series to protect against reverse voltages. The anti-parallel arrangement of RB-IGCTs enables bidirectional control of currents up to 2.5 kA. Consequently, ABB’s solution features up to 99.9 percent efficiency – a 70 percent reduction in power losses compared with equivalent technologies.

Nevertheless, power losses are still much higher than in conventional circuit breakers, making integrated cooling necessary. SACE Infinitus, therefore, cools with aluminum-nitride cold plates, combining electrical insulation and high thermal conductivity. Thus, the coolant can be the familiar mixture of water and glycol, and deionization is unnecessary.

Breaking times as short as 15 µs at up to 1 kV DC, compared to the tens of milliseconds needed by conventional electromechanical breakers, makes Infinitus the best option for applications where fault currents may exceed 100 kA in a few milliseconds, such as in novel smart industrial DC grids, battery storage systems, electric vehicle infrastructure or bus-ties in DC marine grids. 

_{Reference
[1] A. Antoniazzi et al., “One of a kind,” ABB Review 04/2022, pp. 14 – 19.}

Machine learning solution identifies ­process states in real time

Startup, shutdown, half-load, full-load. In many industries determining the state of any given process is not as easy as one might think. There are many reasons for this. For example, events and or manual operations can cause a change in operating states. Furthermore, the signatures of multiple states usually coexist within a large amount of data, making identification of individual states difficult. Added to this is the fact that many substates can exist within one operating state, thus complicating state determination.

In view of these challenges, ABB has developed ABB Ability™ PlantInsight Operator Assist, a solution that accurately identifies and calculates process states and substates to enable operators to more accurately evaluate and correct production processes. The solution is based on an innovative architecture that uses machine learning (ML) techniques to identify the signatures of operating states, which are derived from unlabeled, historical time series data. The solution can successfully identify states with simple signatures and those that are more complex.

Once the operating states have been identified, the solution analyzes the associated operations and configures state-aware ML models that generate the operating lanes for all, or the most important, operating states, individually. When deployed for online operator support, the solution labels the currently active operating state in a process using online data and applies the corresponding ML model to generate operating lanes for operator support in real-time.

Simultaneously, the solution monitors the drift in the online data, eg, when none of the previously identified states can be applied to the newly generated data, and triggers a retraining workflow such that the new operating states can be identified and the ML models can be updated to account for the new states.

To date, the solution has been verified in several customer use cases based on real-life datasets from chemical production, oil refineries and power plants. 

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A dashboard for energy and asset management

As energy prices rise, infrastructures age and government restrictions on carbon emissions tighten, businesses are turning to digital solutions to help them get the most out of their assets while remaining compliant. ABB Ability™ Energy and Asset Manager has been introduced to meet these needs. A modular, state-of-the-art cloud-based solution, Energy and Asset Manager integrates energy and asset management in a single intuitive dashboard. With real-time visibility into energy use, electrical power quality, and the health of low- and medium-voltage electrical distribution system equipment, the solution helps organizations with multiple small or medium size sites – such as factories, commercial buildings, and datacenters – optimize power consumption and minimize downtime.

The solution’s modules can be purchased separately or together, as needed. Monitoring can also be segmented down to individual pieces of equipment and/or sub-systems, such as an elevator, a single HVAC system, or a production line, enabling users to make informed decisions regarding when to reduce energy consumption, how to limit unplanned downtime and how to use predictive maintenance to detect and proactively address issues before they escalate.

ABB Ability™ Energy and Asset Manager enables customers to receive alerts and make changes anytime from a smartphone, tablet, or PC; keep workers out of hazardous areas thanks to remote diagnostics; and adhere to government standards on carbon emissions.

Built from the ground up to run on Microsoft Azure, ABB Ability™ Energy and Asset Manager offers the highest levels of scalability and security. It can be used standalone or integrated with existing systems using a flexible application interface. All in all, it maximizes performance and safety while minimizing risk and costs. In fact, the solution has helped customers reduce energy and maintenance costs by up to 40 percent. 

_{For more information, a full-length article on this subject will appear in a future issue of the ABB Review.}

Better by half – the DS301C compact circuit breaker

The DS301C, ABB’s new single-phase and neutral residual current circuit breaker with overcurrent protection (RCBO), combines protection against short-circuits, overloads and earth faults in a single-module circuit breaker. The breaker is voltage-independent – ie, it works without an external power source. Compared to traditional two-module breakers, the remarkable space reduction achieved enables smaller electrical panels, more protected circuits and smaller or less-crowded technical rooms in residential, commercial and railway installations. Extensions and retrofits are also made easier.

In contrast to conventional installations, where overcurrent protection is at branch level and earth-fault protection one step upstream, now, with the slim DS301C, a residual fault leads to disconnection of the affected branch only, instead of the whole installation. Such selectivity delivers superior service continuity.

All polymeric parts in this lightweight product are made of recyclable thermoplastic. Furthermore, the “all-in-one” design eliminates the duplicated resistive elements found in setups with miniature circuit breakers or residual current devices. This reduces power losses and cooling requirements. The resulting energy savings are significant over the device’s lifetime. The DS301C is part of the ABB EcoSolutions™ portfolio.

Indicators of contact position as well as earth fault as the cause-of-trip simplify system maintenance. The DS301C is compatible with both busbars and cables, with miswiring-prevention features. Installers also appreciate the clipping system that allows easy product mounting and dismounting without removing busbars from neighboring breakers.

An extensive portfolio of ABB System Pro M accessories will supplement the DS301C and satisfy the needs of elaborate installations. Datasheets and technical information are accessible via a QR code on the front. 

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Meeting the protection and control needs of mv distribution substations with ­centralized and virtualized solutions

To handle the increased complexity and unpredictability of the power grid associated with greater penetration of distributed energy resources, medium voltage (MV) distribution substations with the ability to effectively control and protect the network are becoming increasingly important.

ABB launched the ABB Ability™ Smart Substation Control and Protection for electrical systems SSC600 in 2018, a centralized protection and control (CPC) smart software-oriented solution that concentrates multiple relays into one device: only the process interface functionality remains in the bay-level merging units. By permitting information flow between different components, bays, substations, and related operators, one device performs the tasks of 30 protection relays in the substation.

Thanks to network processing capability, newer management and automation approaches are supported, eg, with routable GOOSE (Generic Object Oriented Substation Events).

Building upon the success of SSC600, ABB launched the world’s first virtualized P&C software, SSC600 SW, in January, 2023. In this virtualized protection and control (VPC) system, software is independent of the hardware. Successfully tested and verified in a MV substation in western Finland, this virtual image of the CPC equaled the real-time performance of ABB’s SSC600, in all ways, eg, during fault clearance. SSC600 SW, combined with merging units, creates an IEC 61850-compliant CPC solution. Customers can now deploy applications and update functions from any vendor on demand, as long as performance requirements are met; hardware is easier to maintain or upgrade and substation life cycle costs are reduced.

With SSC600 or SSC600 SW, MV substations are now able to meet real-time performance for distribution network protection and control as defined by IEC 61850. Modularity of both systems permit flexible modifications and customization. This is an advantage as substation protection needs change in response to an evolving power network. 

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ABB’s motor anomaly detection feature leverages ML to automate ABB Ability™ monitoring services for motors

Recognizing that a motor is behaving “unusually” is important as such behavior may reflect misalignment or impending bearing failure. However, such a deterministic diagnosis is incredibly difficult to achieve: For a motor that runs with a constant load, even tiny variations in speed or vibration might indicate atypical behavior that merits quick attention, whereas large swings in speed and vibration might be typical and expected for another motor in the same fleet with a different application.

Clearly, it is not enough to define “atypical” behaviors for broad classes of motors: providing world-class service requires an understanding of the unique performance characteristics of each individual motor. Responding to this challenge, ABB inaugurated development of its Motor Anomaly Detection Tool for low voltage (LV) motors, an automated cloud-based tool that leverages machine learning (ML) to create a unique behavioral profile for each asset in a fleet that is equipped with ABB Ability™ Smart Sensors – and to alert ABB’s support experts whenever a customer’s motor is operating in a manner that warrants closer attention.

For each motor, the platform builds both long-term ML- and rule-based models that recognize the types of anomalies revealed by subtle changes occurring over weeks or months, along with short-term models that detect rapidly-evolving issues requiring immediate attention. The ML models retrain themselves regularly as fresh data becomes available and present their insights through a unified user interface.

This platform will allow ABB’s remote experts to recognize emerging problems that might otherwise go unnoticed, and enable them to monitor substantially more assets. Such a tool will help maximize a motors’ uptime and efficiency and minimize customers’ total cost of ownership. 

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High-power integrated motor drives

With increasing needs for greater power density, better efficiency and guaranteed tolerance of higher temperatures in electric drive systems, more users are turning to integrated motor drives (IMDs). IMDs offer sizable cost and performance benefits over traditional, separated motor and drive systems. However, thermal and electromagnetic considerations are critical in IMDs, especially at higher powers (over 7.5 kW). ABB has now successfully developed 7.5 kW IMD prototypes that exhibit excellent performance – especially in terms of thermal management and low radiated electromagnetic emission.

The new ultra-compact IMD – ie, an integrated IE5 permanent magnet (PM) motor and drive – is based on customer requirements and helps them save space, energy and cost. By eliminating separate enclosures for the motor and drive and taking away long cable runs, for example, the integrated approach can lower system costs substantially. The removal of cables and their associated electromagnetic noise filters also increases reliability.

The IE5 PM motor’s electromagnetic design reduces losses and uses radial cooling fins and a specially designed fan for better cooling performance. The IMD is IP56-rated, thus is suitable for harsh environments.

A pluggable connection cable between the drive and motor means either can be replaced separately and maintenance is simple.

The design satisfied the customer requirement that the maximum temperature at any point on the frame should be below 80 °C at an ambient temperature of 35 °C. Indeed, the frame temperature is lower than that of ordinary permanent magnet motors, while the efficiency is higher. 

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Unparalleled path accuracy with secondary position control (SPC)

The trend toward product miniaturization and the need to meet ever tighter application requirements in robot automation, eg, for cutting, gluing, sealing, and surface inspection, require robots and robot controllers with greater path accuracy. Building on the TrueMove concept, which provides control for high accuracy robots since the 1990s, ABB is integrating SPC to push the limits of robot accuracy even further.

SPC is an innovative technology that uses arm-side information and conventional measurements from the motor-side in the servo loops. This added functionality furthers the controller’s ability to reject disturbances and uncertainties introduced by the gearbox and those disturbances that originate externally.

The measurements at the gearbox output seem to be a natural way to improve accuracy compared to conventional motor-side sensing. Despite this, actuation and sensing are physically distributed, and as such pose significant challenges to control systems in general and for control of robots specifically [1]. By developing an improved understanding of the gearboxes and measurement systems, and by integrating such capacity with ABB’s advanced model-based controls, ABB could ensure stability and performance of the SPC scheme in the robot’s complete work space, covering its full payload- and speed-range.

Using a Leica AT960 high precision laser tracker (evaluating straight lines and more involved shapes, eg, small circles, hexagons, and rectangles – especially challenging due to high accelerations in corner zones), SPC has been shown to improve path accuracy by 65 percent compared with that achieved by GoFa with conventional motor-side controls. Throughout these tests, GoFa SPC consistently achieved a 3D path accuracy of 0.1 mm in speeds up to 80 mm/s, and a 2D path accuracy of 0.05 mm at speeds up to 40 mm/s – an unparalleled path accuracy to the best of ABB’s knowledge. These path accuracy levels are comparable to the average diameter of a human hair (~75 μm).

Further tests showed that absolute positioning accuracy improves by 50 percent if SPC is used in combination with absolute accuracy. For example, during testing of GoFa, an average absolute error of 0.1 mm and a maximum absolute error of 0.2 mm was achieved.

Based on these successful results, further research and technology development of SPC is underway. With SPC, ABB targets to provide high accuracy to the market and open-the-door for high precision continuous applications. 

_{This topic will be covered in greater depth in an upcoming issue of the ABB Review.}

_{Reference
[1] P. A. Chodavardapu and M.W. Spong, “On noncollocated single control of a flexible link” in Proceedings of the IEEE Conference on Robotics and Automation, Minneapolis, Mn, USA, 22-28 April, 1996.}

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