When performance doesn't need a servo

Increasing performance demands on machinery are noticeably transforming the packaging industry. OEMs face the challenge of designing machines that are more compact, material-efficient, and cost-effective, while simultaneously ensuring high flexibility in machine architecture. With the IE5/IE6 motor drive system featuring the i650 motec, Lenze presents a decentralized drive solution offering servo-like performance, opening up greater design flexibility for modern packaging machines. Under the banner "Move Stronger," Lenze demonstrates how motion in packaging machines can be made more powerful, efficient, and adaptable—aiming to consistently combine dynamic response with precision.

Lenze is setting new benchmarks in sensorless control for industrial applications through innovative drive technology. At the heart of this is the i650 motec frequency inverter; combined with the m550/m650 synchronous motor, it delivers a high-performance, energy-efficient solution for demanding applications. The i650 motec stands out thanks to its integrated Logic PLC and a positioning function that enables autonomous motion control without the need for a higher-level controller. This makes the system suitable for a variety of applications, such as conveyor drives, lifting applications, and positioning axes.

Sensorless open-loop control enables exceptionally precise torque regulation. A starting torque of up to 300 percent—available from 0 rpm—allows for a reliable start under full load without the need for motor feedback. This means that continuous operation can be designed more precisely by leveraging the system's overload capability. Precise rotor position detection ensures that even demanding motion tasks are executed with accuracy and repeatability. At its trade fair booth, Lenze uses a lifting application to demonstrate a direct comparison between closed-loop and sensorless open-loop control, illustrating how servo-like performance can be achieved without additional sensor hardware.

Eliminating the need for an encoder significantly lowers initial costs, reduces the likelihood of malfunctions, and simplifies installation. Furthermore, the i650 motec offers integrated safety functions such as Safe Torque Off (STO) and Safe Torque Off over CIP, ensuring protection for both machinery and personnel. Future updates will add more encoderless safety functions—such as Safe Limited Speed ​​(SLS)—making the solution ready for upcoming regulatory requirements and providing additional investment security. Particularly demanding applications, such as those in the packaging or beverage industries, benefit from precise, sensorless positioning via the SLSM algorithm. This allows the system to achieve closed-loop accuracy without the need for motor-side feedback or specialized cabling.

By eliminating feedback systems, complex cabling, and unnecessary hardware, the result is a highly compact, resource-efficient system that simplifies installation and commissioning while significantly reducing maintenance requirements.

Energy efficiency and transparency included

The motor drive system also sets benchmarks for energy efficiency: the highly efficient motor reduces motor losses by up to 60 percent. Combined with high-performance gearboxes and a decentralized frequency inverter that feeds excess energy back into the grid, the result is a consistently efficient drive package. Additionally, the integrated IO-Link master allows machine operators to access high-quality data from machine sensors, thereby benefiting from greater system transparency.

With its IE5 and IE6 motor drive systems, Lenze demonstrates that high performance, ease of use, and flexible machine architectures do not require a traditional servo system. The sensorless-controlled synchronous motor delivers the dynamics and precision of a closed-loop system while remaining as straightforward to use as an asynchronous motor. For machine builders in the packaging industry, this opens up new possibilities for applying power precisely where it is needed and for designing machines that are cost-effective, compact, and future-proof.