Compact DS4 Synchronous Motors For Dynamic Industrial Applications

Industrial plants such as injection moulding and textile machines require drive systems that combine a high power density with a broad speed range to efficiently control dynamic processes. To meet these technical demands for acceleration and compactness, Baumüller is introducing the new DS4 generation of three phase synchronous motors at the SPS Smart Production Solutions trade fair.

System Architecture And IPMSM Technology
Conventional servomotors often reach structural limits in highly dynamic applications. The DS4 series addresses this challenge through its design as Interior Permanent Magnet Synchronous Motors (IPMSM). In this manufacturing process, the magnets are buried in the rotor lamination, which leads to a more compact design while simultaneously increasing performance. The reduced use of materials lowers the mechanical inertia of the rotor, enabling faster acceleration and deceleration sequences in cyclic processes. The liquid-cooled motors are initially offered in frame sizes 100 and 132, while frame size 160 is in preparation.

Energy Efficiency And Downsizing
The operating costs of production machines are largely determined by energy consumption in continuous operation. The DS4 motors achieve an efficiency of up to 97 percent over the entire working range, which leads to a direct reduction in energy requirements. By providing optional additional overall lengths and the high power density of the IPMSM architecture, plant constructors can perform a downsizing of the drive train. A physically smaller motor takes over the work of previous, larger generations, significantly reducing both the space required in the machine and the investment costs.

Integration In Injection Moulding Machines
In plastics processing, short cycle times and precise injection processes are crucial for throughput. The DS4 motors feature a broad speed range specifically designed for the operation of speed-increased high-flow pumps in injection moulding machines. These pump systems enable higher injection speeds and contribute to a significant shortening of machine cycle times. The high dynamics and increased efficiency of the drive unit pave the way for improved overall plant productivity.

Additional Context
This section contains technical specifications and competitive benchmarking that were not included in the original product announcement.

The integration of Interior Permanent Magnet Synchronous Motors (IPMSM) marks an industrial benchmark in drive technology, as the buried magnets improve the field weakening capability of the motor and thus expand the usable speed range compared to surface-mounted magnets (SPM). Comparable highly compact synchronous motors from manufacturers such as Siemens or Bosch Rexroth also rely on forced liquid cooling in this performance segment to dissipate thermal power loss during continuous overload cycles. An efficiency of 97 percent qualifies electrical drives for the highest efficiency classes. Against the backdrop of increasingly stringent European ecodesign directives, this represents a mandatory technological prerequisite to sustainably reduce the Total Cost of Ownership (TCO) in energy-intensive production environments and minimise the carbon emissions of end users.

Edited by Maria Brueva, Induportals editor - adapted by AI.

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