Extrusion International 3-2023

41 Extrusion International 3/2023 to each other. They are connected to each other by a rigid yet elastic chain or V-belt. The faces of the chain or V-belt transfer torque by engaging positively or friction- ally into the cone pulleys in the radial direction. Each of the pulleys is arranged on its shaft to allow diagonal displacement. A mechanically, electrically, or hydrauli- cally adjustable rocker permits infinite adjustment of the distances between the pairs of cones, causing dis- placement of the flexible chain or V-belt. This changes the effective transmission diameter of the pulley pairs and, as a result, the transmission ratio. A common bicy- cle dérailleur exemplifies mechanical adjustment of the transmission ratio with all of its benefits and drawbacks. Electronic stepless drive system A stepless drive consists of a planetary transmission, whose sun gear is driven by an electric motor, and ring gear, driven by a second electric motor, with output over the planet gear’s bearing. The electronic part of the drive system is characterized by a torque balanc- ing system to provide a tight/slack connection without excessive tolerance, slippage, and vibration. Electronic adjustment of the transmission ratio is seen on high- speed winding systems in the cable and wire industry, in slowmotion and as a speed- and diameter-adjustable process. In those cases, the cable or wire is the rigid but flexible element. In this way, all of the disadvantages of mechanically stepless transmissions known from the lit- erature and in automobile forums are eliminated. The results: There is no need to produce high lateral forces; wear to the chain, cone pulley pairs, and axes is elimi- nated, since these are not present; and there is no rub- ber band effect during acceleration or shifting. Optimizing a system's ecological footprint As awareness of sustainability issues continues to ex- pand, particularly in regards to climate protection, it is no wonder that industrial and manufacturing compa- nies regularly assess the optimization potential of their systems. But where, specifically, can they make real progress? An electronically stepless drive system is a good place to start and well suited for dynamic applications where a wide range of drive speeds and torques is re- quired. Examples include winding machines; extruders; presses with high, low, and precision gears; conveyors with high, low, and idle gears; applications where high breakout torque is needed; and of course automobiles. Energy savings of more than 40% over conventional drive systems can be achieved. The potential is massive, comparable with that of shifting transmissions of the In- dustry 2.0 and 3.0 eras. Summary of benefits: • Energy costs minimized with optimization of drive performance on motor-driven applications (like a wind- er or extruder); • Optimization of generator output on generator- driven machines like unwinders; • Standardization of drive components on individual machines or system; within a department; in a plant or company; or entire industries; • Standardization of new services, products, and busi- ness models driving innovations in IoT for “networking and digital transformation in drive technology"; • Valuable contributions to energy efficiency and con - servation of resources (material andweight savings) and the larger shift away from fossil fuels to clean energy; • Better than DIN EN 61800-9-2 with optimized gear ratios. Kabel.Consult.Ing Reststrauch 55, 41199 Mönchengladbach, Germany Juan Carlos González Villar, gonzalez@kabelconsulting.de www.kabelconsulting.de Lower ecological footprint (©iStock-ID:1305361225) Mechanically stepless transmission (©Fa. Hako-Lehrmittel) Electronic stepless drive system (©Kabel.Consult.Ing)