IMAGINE Engineering GmbH develops innovative solutions based on new technologies in the field of mechanical engineering – with a focus on engineering of hygienic equipment – and process technology. The company’s competencies range from early concept development, mechanical design and automation to functional validation and delivery of machine components as well as complete systems. In addition to development orders for reputable customers, IMAGINE Engineering also works on its own product developments.

The goal of the project, which was funded by the German Federal Ministry of Economics and Climate Action (BMWK), was to combine two process steps in hermetic, hygienic screwing and sealing. For this purpose, InduTwist combines two process tools in a single operation – one for tightening the screw caps onto the package and one for induction sealing. 

The new system required a space-saving installation solution on the drive side, and the frameless servo motor also required a large hollow shaft diameter for guiding the induction welding head. The selected motor from the cyber^® kit line with an outer diameter of 85 mm and a voltage class of 60 VDC also offers a maximum torque of up to 8 Nm – and thus enough power to tighten the caps with the desired torque of 3 Nm.

The tightening torque applied for screwing can be controlled very precisely thanks to the high current resolution of the cyber^® simco^® drive 2 servo drives. In addition, all torques for each bundle are also read out and evaluated. This way, the processes of screwing and sealing are already monitored during production. The drive solution is completed by a DIN rail power supply unit of the cyber^® power supply series.

The most important advantages include the high design flexibility resulting from the elimination of housing and bearing. Compact dimensions, the reduction in weight, and unsurpassed power density thanks to a torque-optimized motor design with best-in-class performance data enable space-saving yet highly dynamic drive solutions, e.g. in conjunction with the new cyber^® simco^® drive 2 servo drive family. These servo amplifiers are not only among the most space-saving components, but also offer the best connectivity to many fieldbus environments thanks to their Multi-Ethernet-Interface. They are also open for different encoder and motor feedback solutions.

And these solutions are completed by the efficient DIN rail power supply units of the cyber^® power supply series with various versions offering efficiencies of more than 95%. They also offer high power potentials thanks to a high overload factor, which they can provide as additional energy reserves.

The product kit of the cyber^® kit line small is characterized by a special design of the stators – 24 individual teeth are plugged into a round shape and cast with a high copper filling factor. As a result, the servo motors achieve continuous torques significantly exceeding the values of comparable motors on the market. Another unique feature of this type of frameless motor is the large hollow shaft. In robot axes and other space-critical designs, this allows feeding cables as well as compressed air, vacuum, fiber optic, and laser lines through it for space-saving implementation. 

Compact, sufficiently high torque density, large hollow shaft and available at the right time – in the InduTwist project, the frameless servo motors of the cyber^® kit line made a precision landing in terms of application-critical parameters. In addition, the motors are available in staggered lengths and power levels, making them suitable for future applications with larger screw cap applicators. 

In general, the cyber^® kit line offers a flexible design in identical-contour variants with 60 V or 600 V and a wide range of options. Maximum flexibility with cyber^® simco^® drive 2 servo drives: Service-friendly 48 V supply voltage, clean motor control, high current resolution and control quality as well as compatibility with different feedback systems and fieldbus connections allow generous combination and testing of different system designs. In addition, the servo drives enable self-testing during operation for short-term optimization. This perfect one-stop drive solution is then completed by perfectly-matched power supply units.