Extrusion International 3-2023

40 Extrusion International 3/2023 DRIVE TECHNOLOGY Optimizing System Efficiency and Ecological Footprint The past several decades have seen impressive refinements to gearboxes for industry and automobiles. Engineers have developed innovative approaches to problem-solving, such as transmission solutions optimized for specific tasks, greater integration of electronic submodules, new functionality, and the ability to network transmissions with other machine components. These changes are reflected in the IP as well. During the past ten years, several patents have been published that describe ways to reduce the ecological footprint of machines and vehicles. N ew and refined transmissions are now expected to be more reliable, stay in service longer, take up less space, optimize weight and efficiency, and generally re - duce costs in pursuit of lower energy consumption and lower harmful emissions. Terms like CO 2 reduction, de- carbonization, and carbon footprint are now widely dis- cussed. The increasing integration of peripherals and sub- modules into transmissions has resulted inmore compact, lighter, and more reliable units. This article discusses how the use of commercially available, modular drive systems can avoid oversized mechanical, electrical, and electronic drive assemblies and optimize a system’s CO2 footprint, while simultaneously opening up new opportunities for manufacturers and operators of thesemachines and even facilitating innovative IoT business models. Complete drive with high variability: “Extrusion line for medical cables” To keep up with the expectations of modern medi- cine, cables used in medical systems must exhibit a range of special characteristics. These requirements in- fluence not just the design, where space is always at a premium, but also hygienic and safety qualities. Inno- vative production methods and cutting-edge materials play large roles in fulfilling these elevated expectations. But what about the ecological footprint of such com- plex and technically demanding systems? Extrusion lines for medical cables consist of one un- winding and one winding machine (constant output drives). These machines are characterized by a great deal of variability as a result of dynamic winding di- ameters and torques since winding machines have the same torque characteristics as automobiles. The same is true for extruder drives (constant torque drive), where- by variability is due to inconsistent shear strengths and temperatures required to process the common plastics. The third highly variable drive is the positioning drive for layered winding of finished cable. In this case, the spool starts at its minimum, empty weight and finishes at its maximum, fully wound weight. It is also important to consider the moment of inertia ratio between the positioning machine and drive motor in order to ensure good regulation and control. This inevitably results in oversizing. The need for drives to produce high torque at start-up is another reason for oversizing. Mechanically stepless transmissions Amechanically stepless transmission consists primarily of two pairs of cone pulleys installed on parallel shafts (driving and driven shafts) that can be displaced relative State-of-the-art drivetrain (©Kabel.Consult.Ing) Drivetrain with electronic stepless drive system (©Kabel.Consult.Ing) Extrusion line for demanding cables (©Kabel.Consult.Ing)