Making logistics smart and crisis-proof

Successive crises have put increasing emphasis on intralogistics. But the challenges (and opportunities) are not minus. There are more goods in stock, new distribution channels are popping up, costs have dropped, consumers expect a more sustainable supply chain, factories run 24/7, long interruptions for maintenance no longer exist, there is not enough staff anymore, delivery reliability is crucial... In short, intralogistics makes the difference in the market. Through the interplay between automation, drive technology and digital engineering, Lenze's technology is taking up this gauntlet to optimize processes and develop new business models. The goal? A smart warehouse.

Let's start at the beginning. Moving goods through production is right up the alley of horizontal conveyors. You find them in all sectors, in all shapes and sizes. The new generation of decentralized servo drives from Lenze, the i series motec, lends itself perfectly to this task. It responds to the demands made on modern systems: reduced engineering time through minimal variations and at the same time maximum energy savings. Using the EASY System Designer, you design the perfect drive system that is up to 30% more economical. This newly developed component can be either motor or wall mounted for output power from 0.37 to 45 kW. 

The integrated regeneration unit provides additional savings. The regenerative energy is not lost in braking resistors, but is fed back into the power grid without additional hardware costs. In addition, the servo drive can control synchronous motors without sensors.

Drive system as a sensor

The IO-Link master functionality reduces what is required in terms of cabling. But users can also capture data from the servo controller and pass it on to a higher-level system. By scanning the digital name tag, users can quickly access product data and the Lenze Information Hub. Thanks to the integrated oscilloscope function, the drive system actually acts as a sensor in conveyor technology. The motor current is recorded in high resolution. With that data, companies know exactly what is going on in the system. 

In the next step, they can then discover why it happens, in order to eventually predict what will happen and when it will happen. For this, Lenze relies on a combination of the IT and OT worlds, of IT expertise and experience in intralogistics. This makes it possible to optimize production lines, reduce costs and establish new digital business models.

Higher machine availability

A second consequence of the interaction between IT and OT is the asset management and ticketing system for higher machine availability. For this purpose, Lenze has developed a specific portal that is directly connected to the machines. If an error occurs, the machine can automatically generate a ticket to inform the maintenance technician. In it, he can read which component is involved, which model and variant it is, what the serial number is, and where exactly the component is installed within the topology of the machine. This eliminates the possibility of incorrect information or outdated documentation. The information comes directly from the PLC, which always displays the most current status. Since it is an independent platform built on open standards, products other than Lenze can also be included. For example, sensors from specialist SICK are already part of this solution.

Making machines modular

Another digital solution that simplifies engineering is FAST. With the software engineering modules of Lenze FAST, automation specialists can bundle ready-to-use functions for latest-generation warehouse cranes, for example. Lenze FAST helps developers assemble machines in a modular way. 

This saves engineering time and takes systems to the next level because users now have an expandable basic framework for machine applications. Key control commands can be executed independently of the higher-level controller, and the graphical user interface makes commissioning particularly easy. The integration of customer-specific know-how or additional functions is possible thanks to the open IEC 61131 environment.