Lenze's new international sales structure

Systematic quality planning
How Lenze meets stringent customer needs
lenze group customer magazine
Optimizing right from the start
Planning reliability and efficient concepts with the Drive Solution Designer
Precision for the packaging industry
In action: 8400 HighLine Inverter Drives with integrated positioning control
24
2010

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Contents
News
4 Ingenious connection system
Reinforcement for America
Setting the course for the
future
A brilliant phenomenon
5 More IP65 inverters
Experts for Lenze automation
Small servo, large effect
Cover feature
6 United for success
teChNology
10 A growing family of distributed
inverters
12 New three-phase AC motors for
inverter operation
oN the job
14 Electricity from wave power
16 Precision power distribution in
all axes
18 Integrated systems for new
machinery directive
20 A perfectly dosed solution for
administering medications
22 Flexibility in production – as
clear as glass
speCial report
24 Lenze’s new logistics concept
Energy efficiency
26 In pursuit of energy efficiency
Around the world
28 Lenze’s growth in South
America
the future
30 Closer to the customer:
Lenze’s new international sales
structure
regular features
31 Puzzle
33 Service, publication details
34 Trade fair dates
Dear Reader,
One of the most famous statements the Greek philosopher Heraclitus is
reputed to have made was that “everything flows”. This brilliantly simple
thought was his attempt to encapsulate the never-ending process of
creation and change. As specialists in drive and automation technology,
we naturally understand this “concept of motion” very well. But we also
feel the need to modify it somewhat: because we can influence this
process of change and give direction to our own development. And in
that spirit we have been very active in the last few months and have – to
the benefit of our partners and customers – set certain things in motion.
Perhaps the most noteworthy item in this context is the largest internal
training program me our company’s history, which we look upon as “setting
the course for the future” (p. 4). Added to that are our new global
logistics concept (p. 24) and our new European sales structure (p. 30). All
three measures serve the purpose of company-wide synchronisation and
optimisation of internal and external processes, something that will give
Lenze customers the benefit of even more planning certainty.
Some especially efficient products, such as the new 8400 motec motor
inverter (p. 10 – 11) or the new MF L-force three-phase AC (p. 12 – 13), have
also given new impetus to our product portfolio.
The cover feature (p. 6 – 9) and the extensive “on the job” reports, which
come to you from the energy supply sector, the automotive industry,
logistics, the pharmaceutical industry, and a thermal insulation manufacturer,
discuss how Lenze products have proven themselves in practice
and how successfully the teamwork between Lenze and its partners has
worked. You may also find interesting our Global Report, which takes you
to Brazil this time.
I hope you enjoy reading this edition.
Dr. Erhard Tellbüscher
Chairman of the Board of Management, Lenze SE
Content/editorial
3

4
Lenze News
Ingenious connection
system
The newly developed, compact Lenze 1000 I/O system
made its debut in 2009. Just a few weeks later,
a number of extensions to the modular system for
connecting and controlling sensors and actuators
were presented at the SPS/IPC/DRIVES, all of which
are available immediately. These include a module
with two (EPM-S306) or four (EPM-S309) digital
outputs, each of which can deliver 2A of current,
and modules for connecting thermocouples and
ones that provide counters and relays or an SSI
interface.
This makes the 1000 I/O system current one of the world’s most
effective and advanced decentralised I/O systems. In addition,
the separation between the connection level and the electronics
in all modules considerably lowers the cost of production, commissioning,
and maintenance of machines and systems.
Setting the course for the future
When there is a crisis, Lenze uses the time to keep the company moving
ahead and further improve existing processes. One focus is the standardisation
throughout the company of internal and external processes –
with the goal in particular of establishing a uniform portfolio and project
management structure.
To achieve this, Lenze has set up the company’s largest internal training
program to date. The company uses its spare manpower capacity during
short-time hours at its Gross Berkel and Extertal locations. The employees
are trained by in-house speakers. Some of the central subjects are business
process, portfolio, quality, and project management, as well as the
design and development of system solutions. Through this continuing
education program Lenze is able to generate wide-ranging know-how
from which our customers will benefit in the future across the board. It
further improves the company’s consulting services, and its customers
enjoy the benefits of a cooperative partnership that affords maximum
planning certainty.
Reinforcement for America
On 1 February 2010 Charles W.
Edwards took over management
of Lenze’s business operations in
the U.S. He is the new General
Manager and CEO of Lenze
Americas Corporation and AC
Tech Corporation. In this capacity,
Edwards is also a member of the
Lenze Executive Committee.
Charles W. Edwards brings to his work extensive knowhow,
experience, knowledge of the market, and strong
managerial skills. Edwards, who has a Bachelor of Science
degree in electrical and computer engineering and a
Master of Science degree in engineering management,
has in the past worked for Rockwell, Woodhead and Molex.
As vice president for sales and marketing at the latter
company, he was responsible for international sales.
The Lenze Group is very pleased to welcome this outstanding
new addition and looks forward to working with
Charles W. Edwards to promote the company’s successful
development in the American market.
A brilliant phenomenon
Small, compact, intelligent, inexpensive. At this year’s
Hanover trade fair, Lenze presents the EL 103, a new HMI
panel to expand the EL 100 series. Equipped with a brilliant
3.5-inch TFT display (LED backlighting), the device has,
despite its compact frame, Ethernet, USB, and CAN inter-
faces. It also has an SD card slot for memory expansion.
Like the other devices in the EL 100 series before it, this
panel is available with an optional Soft PLC, including
maintenance-free UPS for backing up PLC data. With Visi-
WinNET® the EL 103 offers in addition easy-to-use visu-
alisation functions for representing process values, bars,
text, graphics. A language switch that can be used anywhere
in the world, a cleverly designed signalling system,
and a powerful recipe management function round out
the visualisation functions. The device is particularly well
suited for use where space is limited.

More IP65 inverters
The Lenze AC Tech range of SMV frequency
inverters with IP65 enclosure has been extended
with 4 new powers up to 22 kW. The new models
are at 11, 15, 18.5 and 22 kW and suit installation
in wet and dirty environments, saving the cost
of a panel enclosure.
Matching the smaller models in the range, these
higher power inverters feature the EPM memory
chip, built in RFI filters and excellent sensorless
vector performance. Communication options
include CANopen, Ethernet IP, DeviceNet for the
American market and PROFIBUS for Europe.
Where inverters are to be installed outdoors,
polycarbonate casings are available to give longterm
résistance to UV. The SMV IP65 inverters
have another strength with extremely compact
dimensions. Even with their high protection
casings, footprints are remarkably small – for
example 204 x 254 mm at 7.5 kW.
Small servo, large effect
The second generation of 930K fluxxtorque servo drives
has now made efficient, decentralised drive concepts
feasible in the tightest spaces. With a power range of
120 W to 440 W, the units are available for low and extralow
voltages. In the course of product evolution, Lenze
has also redesigned the synchronous servo motors used.
Approximately 20 % less volume with the same power
and increased efficiency speak for themselves. Added to
that is extended functionality, including more control
capabilities for actuators and sensors through the integrated
digital and analogue I/Os, integration in EtherCAT
networks, and feedback with single- and multi-turn
absolute value encoders. In combination with the integrated
positioning control, including a path program for
processing up to 64 waypoints, the 930K fluxxtorque
servo drive becomes a small, precise positioning drive.
An expensive control system in the background is not
Experts for
Lenze Automation
In early January 2010, Dr. Thomas Cord took
over the management of Lenze Automation
GmbH. He succeeds Frank Maier, who has
joined the Board of Management of Lenze
SE. With Dr. Cord, Lenze is pursuing its
strategy of positioning itself more promi-
nently as a specialist in automation tech-
nology. “I am very pleased that we were
able to attract Dr. Cord”, says Frank Maier.
“His many years of experience and his expertise in marketing
automation solutions will move Lenze a long way forward
towards its goal of becoming a key player in the automation
market.”
Dr. Cord emphasises the central importance of his field for Lenze.
“By merging control and drive technology, our customers will
realise genuine added value through the clear simplification of
the engineering solution.”
necessary. The series can be operated easily and quickly
with the free parameter setting software and the Speed-
Tec connection system.
Servo Drives 930K fluxxtorque
news
5

6
United for success
It is a long road that leads from a promising new idea to a machine design, a finished prototype, and
ultimately a product that is ready for mass production. How that road is travelled is critical to the
success of the machine or system. On the one hand, the spirit of innovation must be given free rein if
market needs are to be grasped and solutions realised to meet them. On the other hand, the develop-
ment process must be designed to run as efficiently as possible. Lenze supports its partners in both
respects with its specialised expertise, testing capabilities, and drive and automation solutions cus-
tomised to individual requirements.

“In just two months we implemented a new automation
concept. It was a feat we never would have been able to
pull off in such a short time without Lenze’s vigorous
support”, recalls Udo Stentenbach, managing director of
Rosink GmbH + Co. Maschinenfabrik. Working with Lenze,
Rosink re-engineered its machines that coil slivers of
textile thread, known as “can coilers”.
“From the moment the project began, both sides profited
from the close collaboration – our customers, the mass
producers of machines, and Lenze itself”, explains Jürgen
Langner. He is the director of the Automation Systems
Projects division at Lenze, whose role is to make Lenze’s
know-how in the field of drives and automation available
to the machine and system builders for project development
purposes. “Customer projects afford us the opportunity
to further develop technologies and push ahead
with new developments. In so doing, we often put into
use for the first time new components and systems that
have already undergone our own exhaustive tests and
achieved marketability”, Langner explains. “In this way, we
gain valuable experience with the new products, most of
which then go into mass production.”
A basis of trust
Mutual trust is essential if collaboration is to be successful
over the entire duration of a project. “The central element
is the transfer of know-know”, says Langner. “Both
our customers and we ourselves must feel confident that
our expert knowledge is not going to be disclosed to the
competition.” “For us, the certainty that we can rely on
Lenze’s absolute discretion was the basis for our work
together”, says Udo Stentenbach in confirmation.
If there is already a basis of trust, the next thing that is
needed is a common definition of goals and a clear
understanding of precisely which services are to be performed.
“The fundamental division of labour is of course
usually the same”, Langner explains. “While the machine
builder is focused on its mass-production machine series
or its system module, our attention is centred on visualisation,
control systems, and drive units.” The importance
“In just two months, we implemented a new automa-
tion concept. It was a feat we never would have been
able to pull off in such a short time without Lenze’s
vigorous support.”
of this close matching of functions has been demonstrated
in the more than 400 projects that the Automation
Systems Projects division has engaged in with
machine builders over the last six years. The clear division
of labour and, for instance, the conscious definition of
interim goals have gone a long way to significantly reduce
development times. The project with Rosink, mentioned
earlier, is a good example of that.
Cover Feature
7

Cover Feature
8
Innovation through teamwork
The starting point was an intensive collaboration that
began as early as in the design phase. “The goal of the
project was to increase the performance of existing
applications by re-engineering the machine and to
develop new application areas. It became clear to us relatively
quickly that the conventional rotational drive technology
could no longer provide a solution to the more
demanding requirements. An innovative advance in the
direction of linear motor technology was needed”, reports
Udo Stentenbach. Rosink then created a working prototype
made up of components from many vendors, and
was already exhibiting it at trade fairs. Wishing to
develop it to the point where it would be ready for mass
production, however, Rosink sought a partner that could
offer a solution from a single source. This is where Lenze
entered the picture. “We had already gained experience
with linear technology”, recalls Jürgen Langner. The two
project partners decided to approach the replacement of
the entire control system – including the drives – with a
feasibility study first. Lenze took charge of designing the
drive components, while Rosink took care of the mechanical
design and building a model. Tests and performance
measurements were conducted in Lenze’s drive technology
laboratory. The system as a whole was then commissioned
in-house by Rosink.
“Preliminary testing under realistic conditions gives
us direct feedback on our newest systems and com-
ponents. The application-related know-how we gain
through this process is then incorporated into our
development and improvement process.”
Realistic preliminary tests
The laboratory at the Lenze headquarters in Gross Berkel
has not only extensive testing facilities for proving, ageing
and performance measurements, but also a special
application test division. Here, Lenze employees are able
to work with customers as they conduct preliminary
testing, take measurements, and run practical tests on
real machines together. The knowledge gained in this
way is then available even before the prototype of a
machine is made. “This gives the mechanical engineer
the opportunity, as it were, to develop the basic principles
of his machine”, explains Langner. “And from these trials
we get some very realistic feedback about our newest
systems and components. The application-related knowhow
we gain through this process is then incorporated
into our development and improvement process.”
This ability to conduct extensive preliminary testing has
proven invaluable over at Rosink as well, where the
machine control system from the feasibility study
achieved the target specifications – the required oscillation
frequency of 6.25 cycles per second was validated
with a drive combination of a linear motor and a 9400
servo controller. At the same time, the staff at both
companies were able to familiarise themselves with the
technology. “We decided right after the feasibility study
to adopt the machine control system unchanged and to
implement the automation concept with Lenze”, recalls
Udo Stentenbach. “That was the starting signal for series
production.”

On-site support
A clear division of labour is a guarantor of efficiency in
the second phase as well, which as a rule is led by the
mechanical engineer. “As is the case with a lot of customers,
with Rosink we had a very short timeframe. Once we
had worked out the concept together, we therefore
developed the basis for control and visualisation with
Lenze. There was a transfer of know-how to the Rosink
staff during the commissioning process, so that Rosink
was then able to continue this work on its own”, relates
Jürgen Langner. Lenze was closely involved even during
commissioning. “We discussed all of the results openly
and directly implemented final improvements in the
automation concept at the last minute.”
An important success factor, particularly in this and in
the last project phase, the commissioning at the end
customer’s premises, is the assistance of the relevant
Lenze sales company. “Our project teams are always made
up of sales colleagues and colleagues from our division,
Automation Systems Projects”, Langner emphasises.
“That, of course, is of particular importance in international
projects, because our sales colleagues are where
our customers are and speak their native language.
Moreover, they are well acquainted with the customers
and their industry, which naturally improves the quality
of our collaboration. On the other hand, we are very close
to the development processes and are able to contribute,
not only our test infrastructure, but Lenze’s entire potential
for innovation.”
“For us, the highlight is always the ability to experience
first-hand how the end customer rates the solution.
This helps us develop a better understanding of the end
customer’s perspective, which we then apply to the
next project.”
Many projects are crowned by the joint commissioning
of the first machine at the facility of the end customer.
Lenze employees were also present for the first delivery
of Rosink’s can coilers. “For us the highlight is always the
ability to experience first-hand how the end customer
rates the solution”, explains Langner. “In this case, too, we
got a lot of confirmation of the automation concept we
chose – and even some suggestions already for further
development. This helps us develop a better understanding
of the end customer’s perspective, which we then
apply to the next project.”
Early teamwork pays off
• Reduction of development times
• Lowering of development costs
• A clear assessment of risks
• Early validation of the machine
• Use of the latest Lenze products ensures the longest possible
product life cycles
Cover Feature
9

10
A growing family of decentralised inverters
The 8400 protec series from drive and automation specialist Lenze made its debut at the SPS/IPC/
Drives 2009. It has been only a few months since that event, and already there are additions to the
family. The 8400 motec motor inverter is the latest useful addition to this range of products. With its
functionality, this compact version marks an advance in decentralised drive technology that is a victory
particularly for intralogistic enterprises such as warehouse & airport businesses. Mechanical engi-
neers in general are also enthusiastic about its clean, ergonomic design.
From left to right: Thomas Fässler, Operations and Project Coordination; Peter Blatter,
product manager; and Kurt Raymann, director of Decentralised Drives.

An efficient platform: the 8400 motec and 8400 protec
bring decentralisation to the 8400 inverter drive series
While the 8400 protec incorporates safety technology
that offers an impressive array of functions and easy-touse
diagnostic capabilities, the new 8400 motec scores
points with its compact and economical structure, not to
mention its successful combination with a geared motor
and flexible options, which Lenze offers as a complete
“drive package”.
Something for everyone
The products in the 8400 series of inverters have been
designed with the demands and wishes of our customers
in mind and are therefore available at present in two
versions with different functional specifications. The
following design types are currently available:
• 8400 protec, designed for 0.75 to 4.0 kW, with interfaces
for CANopen and PROFIBUS/PROFINET
• 8400 motec, 0.37 to 1.5 kW, with AS-i, CANopen and
PROFIBUS (powers will steadily increase)
Common strengths
Despite the differences in their features, the individual
members of this family of products have much in common,
as one would expect. They all reflect Lenze’s emphasis
on compatibility, user friendliness, and efficiency on
all levels. Because its connection system is designed for
compatibility, for example, the same plug connections
can be used for mains, fieldbus, and safety components.
Their operation is handled uniformly through the same
keypad, commissioning and diagnostics through Lenze’s
L-force Engineer software. Users are also sure to be
pleased by the strong “plug & drive” concept inherent in
these units, which are always “ready to use” thanks to
their factory-installed options and available accessories.
Use of this product family becomes even more compelling
when one considers that its comprehensive system compatibility
increases efficiency more or less automatically.
The 8400 motec drive package
Thanks to the precisely matched set of components –
motor, gearbox and inverter – the 8400 motec motor
inverter is a compact, energy-efficient package that offers
the best “cost per kW” values. The drive package consists
specifically of the following components and their advantages
as described:
• L-force 8400 motec
Mounting directly on the motor yields cost advantages
resulting from, for example, elimination of the shielded
motor cable. The integrated VFCeco energy-saving func-
tion enables a substantial increase in motor efficiency
in partial load operation.
• L-force MF three-phase AC motor
These motors, which are specially optimised for inverter
operation, are up to two frame sizes smaller than
traditional three-phase AC motors. They exceed the
minimum efficiency ratings for efficiency class IE2 and
have a wide range of speed settings.
• L-force gearbox
Mounting the right-angle and coaxial gearboxes on the
motor creates an extremely compact unit. The high
efficiency of the gearbox reduces energy losses to
almost negligible levels.
System integration
Even the base unit provides extremely cost-efficient support
for looping through 400 V. The large selection of
built-on modules makes this possible even for the plug-in
version, both when it is in motor mounting position and
when it is mounted on a wall near the motor. As a result,
any number of installation concepts can be quickly and
easily implemented.
Simple commissioning
The 8400 motec is designed for commissioning without
the use of PC software, thanks to the three potentiometers
and DIP switch that are installed. But even tricky
problems can be resolved, thanks to the keypad and the
L-force Engineer. The easy-to-see illuminated surface
makes a quick initial diagnosis possible even under difficult
installation conditions.
teChnologY
11

12
New three-phase AC motors
for inverter operation
More power costs more money. Electromechanical solutions have become a thing of the past. As a
specialist in drive and automation technology, Lenze has developed the new MF L-force three-phase
AC motors as part of its innovative drive package. These motors offer high energy efficiency, more
dynamic performance and power density, and a wide range of speed settings at astonishingly low
initial costs.
The controlled operation of electric motors is gaining
more and more ground. More than 30 % of new installations
are now equipped with inverter technology. In the
past, either traditional three-phase AC motors or classic
servo motors, synchronous or asynchronous, were used
for this mode of operation. And, until recently, there was
no solution in sight that would unite the advantages of
both types of motors.
Three-phase AC and servo motors compared
Normal three-phase AC motors are produced in large
quantities and have a relatively simple construction,
hence a low cost price. However, they are usually operated
on 50 Hz or 60 Hz mains or designed for the conditions
on such networks. If used for frequency inverter
operation, then it is often with nothing more than a better
type of winding insulation. The result is a lower
power density. Compared to a servo motor of the same
power, three-phase AC motors are larger with lower
dynamic performance. The setting range within which
they can be operated with a frequency inverter at a constant
torque is approximately 1 : 15.
By contrast, servo motors are designed for a wide setting
range and high dynamic performance. They are considerably
more compact than three-phase AC motors of the
same power. Their high efficiency means equally high
energy efficiency. Unfortunately, these are advantages
that can be enjoyed only if one accepts the substantially
higher purchase price.
Until recently there was no ideal motor for the many
controlled drives that did not require the extremely high
dynamic performance of a servo motor. The usual practice
was to resort to a traditional three-phase AC motor with
winding suitable for a frequency inverter. The actual
potential for frequency inverter operation went unused.

Left: drive package with GKR
geared motor.
Lenze closes the gap
With its MF L-force three-phase AC motors specially
optimised for frequency inverter operation, Lenze has
demonstrated for the first time what these motors are
really capable of. Their compactness, dynamic performance,
variability and efficiency are all impressive.
The new MF motors are up to two frame sizes smaller
than a traditional three-phase AC motor of the same
power. In frame size 71, for example, they have a rated
power of 1.5 kW. It would take a normal three-phase AC
motor in frame size 90 to deliver the same power. The
lower axis height results in a reduced moment of inertia
compared to a motor optimised for mains operation. The
dynamic performance of the MF L-force three-phase AC
motor puts it between a servo motor and a normal threephase
AC motor.
The setting range of the L-force three-phase AC motor is
about 1 : 24 (without field weakening). Hence the motor
is similar to a servo motor in that it can be used at highly
variable speeds.
The MF three-phase AC motors exceed the minimum
efficiency standards for efficiency class IE2. The lower
moment of inertia as compared to standard motors further
reduces energy consumption when speeds are varied.
To realise all these advantages, Lenze put to further good
use the extensive, perfectly fitting building blocks familiar
from its MD/MH L-force three-phase AC motors, such
as motor feedback systems, surface and corrosion protection
packages, and a wide range of spring-applied brakes.
As compared to many servo motors, the spring-applied
brakes offer a further advantage when maintenance work
is required: while the permanent magnetic brakes used
in servo motors often serve merely as holding brakes, the
spring-applied brakes in the new L-force three-phase AC
motors are easily accessible, can be readjusted repeatedly,
and can be used also as service brakes, for example
in storage and retrieval units.
Even better in a drive package
To realise the advantages of the optimised three-phase
AC motors in complete drive systems, Lenze has put
together a package that offers the new 8400 motec
motor inverter and the L-force gearbox along with the
motors. The distributed frequency inverter mounted on
the motor and the integrated right-angle or coaxial
gearbox lead to compactness.
The entire drive package also stands out by virtue of the
high energy efficiency of all of its components. In addition
to the high efficiency of both gearbox and motor, the
8400 motec frequency inverter offers intelligent adjust-
ment of the magnetising current in VFCeco mode. In
partial load operation in particular, three-phase AC motors
have always been supplied with a higher magnetising
current than operating conditions required. By contrast,
VFCeco operation adjusts the magnetisation of the load,
thereby reducing energy consumption by up to 30 %.
20 % lower acquisition costs
The MF L-force three-phase AC motors are the first to
exploit the potential of using frequency inverters. As
compared to normal three-phase AC motors, the result is
a substantial performance increase, including high energy
efficiency and a compactness and dynamic performance
similar to those associated with servo motors. The 8400
motec distributed frequency inverters and the L-force
gearbox, which form the ideal drive package in combination
with the motor, help achieve these advantages.
The real main attraction, however, is the purchase cost.
As compared to a 50 Hz three-phase AC motor of equal
power (the most reasonable solution in terms of cost to
date), the price has been lowered by more than 20 %. A
pay-back analysis of the type used in the case of highlyhigh
efficiency motors is no longer necessary.
teChnologY
13

14
Electricity from wave power
Ocean waves represent an enormous reservoir of energy. The World Energy Council conservatively
estimates their usable potential at 2000 TWh worldwide if existing technologies are fully realised
in areas with good wave conditions. If sites with less ideal wave condiitons also are included, the
potential increases to 15,000 TWh. One of the research and pilot projects currently underway to make
this energy source usable is being conducted by Harvesting Technologies, for which the Swedish sys-
tem integrator Avalon, working with Lenze, has developed effective and revealing simulations. The
central element is a 9300 series servo controller with integrated cam technology.
From a statistical point of view, average wave states can
be determined for locations near the coast, and the equipment
used can then be optimised according to these
states. Tides, winter storms, mild summer breezes – everything
has an effect on the surface of the sea. “A wave
power station must therefore be designed to be as flexible
as possible so that it can follow these changes as
dynamically as possible”, emphasised Svante Logeke,
product manager at Avalon. But how can waves be simulated
as authentically as possible so that conclusions can
be drawn and applied to future power stations? This was
The functional principle behind the Swedish “Ocean Harvester”, a 50 kW
model of which is to be tested at sea in 2011.
the question that Ocean Harvesting Technologies had to
answer with its test facility. Wave models developed by
Blekinge Technologieinstitut were used as the basis. The
Swedish system integrator Avalon designed and constructed
the test rig with the crucial support of the
Swedish Lenze company.
The motion concept
The test facility has been designed to create robust systems
with which wave energy on the oceans can be
harvested as efficiently as possible. The patented principle
of the Ocean Harvester uses a buoy-like construction that
is kept in place by an anchor cable attached to the seabed.
When a wave causes an upswell, the buoy rises and thus
reaches a higher energy level. This is used in two ways.
First, the anchor cable directly drives an initial drum,
which in turn feeds in a forward direction a mechanical
power takeoff integrated into the buoy, driving a generator.
Next, a second drum with a cable connected to a
counterweight is rotated in a direction that raises the
counterweight while maintaining a constant torque in
the power take-off. When the buoy descends in the next
trough between waves, the input shaft in the power takeoff
is prevented from reversing while the counterweight
continues to drive the generator with previously stored
kinetic energy. In this way, the oscillating movement of

the sea is “evened out” in terms of energy, enabling a
continuous and smooth load on the generator. This
ensures that energy is converted efficiently and that the
electricity generated is of grid-compliant quality. At the
same time, the size and cost of the components are
reduced.
Lenze technology makes waves
The energy harvesting capabilities of the planned wave
power station were put to the test on dry land using
computer simulation and a test rig, where electronic
cams – integrated into Lenze’s 9300 series servo controllers
– simulated the intensity and frequency of ocean
waves. The central challenge of a drive task usually performed
by means of cam technology consists in continuously
re-adapting speeds and travel distances along a
time axis. Seen from this point of view, cams are predestined
to simulate waves. What results in gentle travel
profiles that cause little wear on the machinery in industrial
applications is used by Ocean Harvesting to imitate
nature. On the electro-mechanical side, asynchronous
servo motors from Lenze’s MCA series – combined with a
highly precise planetary gearbox – are used. Since up to
eight cams can be stored in the drive controller, it is possible
to change over between these curves with no delays
during tests. Stretching and compression of the curves
also makes fine adjustments to the process quite easy. For
these adjustments, Lenze provides the cam editor. This
tool can be used to enter and import motion profiles,
characteristics and cams, which can be optimised with a
few clicks of the mouse.
Electronic cams
Compared to mechanical solutions, motion
trimming by means of software functions is
easier, more flexible and reliably reproducible if
electronic cams are used. Another advantage is
the ability to change over to other motion profiles
in less than one millisecond because the
different curves are available immediately from
the drive controller’s memory. Lenze has implemented
this form of motion control in the
controllers of the Servo Drives 9400, ECS and
9300 Servo series as “drive-based automation”
and offers complete drive solutions combined
with the electro-mechanical equipment.
Good prospects in any weather
The simulations that were conducted were so compelling
that the energy supply company E.ON decided to support
the project. “Lenze’s comprehensive know-how and broad
range of products have played an important part in the
success of the test facility”, summarised Svante Logeke,
product manager at Avalon. Ocean Harvesting is now
designing a model for sea trials which will be deployed in
2011. This model will have a rated power output of 50 kW.
The unit is designed to adjust to the most adverse conditions.
If the sea state exceeds the capacity of the wave
energy converter, the excess energy is “spilled” to avoid
overloads in the system. “This way, we can ensure stable
power production in a wide range of conditions”, explained
Mikael Sidenmark, CEO of Ocean Harvesting.
“Lenze’s comprehensive know-how and broad range of
products have played an important part in the success
of the test facility.”
Svante Logeke, product manager at Avalon
Wave power farms are also highly scalable. A large
number of wave energy converters can be deployed in
arrays until the desired capacity has been achieved, typically
in the 100 to 200 MW range. Wave power farms can
also be integrated with offshore wind power farms. Wind
and wave power do not compete for the same energy
resources but complement one another ideally. On the
whole, the prospects of harvesting power from the sea
are therefore very promising.
At a glance
The task
• To build a test rig for simulating ocean waves
Solution
• Effective and revealing test rig that realistically simulates
dynamic ocean wave motions
Products
• 9300 servo controller with electronic cams
• MCA asynchronous servo motors combined with a highly
precise planetary gearbox
• Cam editor for entering and optimising motion profiles,
characteristics and cams
www.oceanharvesting.com
on the job
15

16
Precision power distribution in all axes
The test benches of the Austrian specialist DAM do not have as much as two minutes within which
to put gearboxes through their paces during the quality assurance tests run by automotive manufac-
turers and suppliers. In terms of rotational speed and torque, these systems demand the ultimate in
performance from the Lenze servo motors deployed within them.
Whether all-wheel drive, four-wheel drive, quattro, or
4 x 4 – automobile manufacturers advertise claims that
agility and traction are significantly improved by modern
transfer gearboxes with electronically controlled multiple
disc clutches. The underlying principle is the variable
distribution of the drive torque between front and rear
wheels. To ensure that this works continuously, a quality
assurance program for the gearboxes is indispensable.
For this purpose, Dynamic Assembly Machines Anlagenbau
GmbH (DAM) in the Austrian town of Gleisdorf produces
highly specialised test benches. And it relies on
drive technology from Lenze.
Audible quality
“Every 90 seconds, a gearbox ‘falls’ from the assembly
line”, explains Robert Fandler, one of the managing directors,
along with Gerald Matzer, of DAM. As they are
checked, noise generation provides important information
as to whether the units, which weigh from 30 to 75 kg, are
of the desired quality. “Noises are a reliable indicator of
assembly defects or defectively produced components”,
says Matzer. For this test procedure, the Lenze drives in the
test bench must provide high rotational speeds: at the
input end, up to 7,500 rpm with torque from − 250 to
+ 250 Nm; at the output end, up to 2,500 rpm with torque
from − 700 to + 700 Nm. Considerably higher forces are
involved during clutch tests: forces of up to 1,600 Nm are
reached in the 0 to 700 rpm range. The central question is
always, are the forces being transferred from the multiple
disc clutches precisely and without slippage?
“In terms of mechanics and control technology, we went
to the limit. No one knew exactly where that was before-
hand. This is where our close collaboration with the
Lenze development department proved to be extremely
valuable.” Gerald Matzer, managing director of DAM
A universal test bench for the pilot production
stage
While separate test systems are used for noise and
clutches in series production, things are set up differently
in the pilot production stage. “For this purpose, we
have developed a universal test bench that covers noise
and characteristics tests.” The analytical procedures
must be close-to-production so that they can be transferred
one-to-one to higher numbers later on. In this
respect the DAM universal test bench is a versatile link
between the development phase and the beginning of
series production. Hence the test bench also has the
flexibility that allows refitting, and it offers various
gearbox fixings and contact possibilities for the motor
control devices.

The machine concept
DAM and Lenze have together designed the drive tech-
nology used in the universal test bench to achieve the
maximum expected performance data. For this reason,
servo controllers in Lenze’s 9400 servo drives series with
a power output of 370 kW were used, even though the
asynchronous motors used have a power output of only
105 kW. To achieve the high torque without a gearbox, a
motor current of 690 A is needed. At this operating point,
the asynchronous motors are working, at 3.4 Hz, virtually
in short-circuit operation. “In terms of mechanics and
control technology, we went to the limit. No one knew
exactly where that was beforehand”, recalls Gerald Matzer.
“This is where our close collaboration with the Lenze
development department proved to be extremely valuable.”
The specialist for drive and automation technology
had already developed the first setting in the laboratory.
“As a rule, the system deviations that occur under high
performance conditions have to be kept under control, but
so do the costs. Working as a team with Lenze, we were
very successful in accomplishing this”, Matzer sums up.
The test preparations
Together for one solution: Robert Fandler, Robert
Gradischnig und Gerald Matzer (left to right).
The test system is loaded by means of an articulated
robot. The test oil is then automatically filled, and the
actuators, sensors, and drive and output flanges are connected.
Three drives are required for the actual test
process, one as the driving force before the transfer
gearbox, another two in generator mode as a breaking
force on the two outputs of the gearbox. Because the
currents are high even at minimal speed, the three asynchronous
machines are forced ventilated. The drive
solution developed is supplied as a complete package by
Lenze Anlagentechnik of Enns, Austria. This also includes
the implementation of the control cabinet and commissioning.
In the test bench, the drive control is connected
to the programmable logic controller through a PROFIBUS
connection. The visualisation runs on a separate IPC. DAM
uses the servo controller as a speed and torque actuating
drive and as a gateway. “Through the integrated inputs
we collect bearing temperatures, among other things,
and transmit them by fieldbus to the master computer.
In addition, we save all quality-relevant values in a database
to provide unbroken product traceability”, explains
Robert Fandler.
Energy efficiency by DC bus connection
Apart from its flexibility and precision, what also sets the
universal test bench apart is its cost effectiveness. While
in gearbox test benches the main drive assumes the role
of the internal combustion engine, another two motors
simulate the resistance of the wheels at the output end.
The obvious thing to do, then, is to operate the controllers
via a DC bus connection. “Consequently, what we draw
from the mains is purely to replace the power loss
replacement”, emphasises Robert Fandler in describing
the energy efficiency of the DAM test bench technology.
At a glance
The task
• To develop a universal test bench of maximum and precise
performance
Solution
• Design and implementation of the desired universal test bench
with the utmost energy efficiency
Products
• 9400 servo drives with 370 kW power output and regenerative
module
• Asynchronous motors with 105 kW power output
www.d-a-m.cc
on the job
DAM test bench: The efficient and reliable drive
solution is provided by Lenze as a complete package.
17

18
Integrated systems for the new machinery
directive
Ever faster, ever more productive, ever stronger. That, in a nutshell, is the current trend in handling
technology and logistics. The new European Machinery Directive is intended to ensure that safety
doesn’t get a raw deal. Klug GmbH integrierte Systeme has come up with a mechatronic solution
that ensures safety in compliance with the directive but with no loss of convenience and at com-
parable costs. And the 9400 servo drives from Lenze play a central role.

The storage and retrieval units used in logistics systems
operate at speeds of up to six metres per second. Ambros
Kienberger is convinced that “To operate with such
dynamics as safely as possible, a uniform safety concept
is needed”. He is in charge of handling the logistics
projects for which Klug is the general contractor. The
9400 Servo Drives are an essential component within the
control system. They are integrated via a PROFIBUS connection
with the PROFIsafe protocol. Future Ethernet
standards can also be integrated.
The interplay of mechatronic elements
As the Klug company explains, successful safety solutions
are best achieved with mechatronic systems. “The perfect
interplay of software, electronics, drive controllers, and
electromechanics with the motor, including the feedback
system, is crucial”, emphasises Michael Weiherer, director
of automation technology at Klug. The intensive project
work with Lenze was guided by three primary objectives:
to achieve a higher level of safety to protect the machines
and their human operators in accordance with the EU
standard, to maintain ease of operation, and to achieve
these objectives at comparable costs. The solution that
was implemented and approved by the inspection association
TÜV Süd is a pathbreaking one. “Thanks to the
farsighted teamwork with Lenze, we now have a tested
and comprehensive safety standard that can be applied
across all industries”, Kienberger says with evident satisfaction.
“If we take the level of automation as the benchmark,
safety engineering with the Machinery Directive is
now just catching up technologically and conceptually”,
Michael Weiherer adds. Because systems or machine
modules are being driven ever more frequently to their
physical performance limits, “worst case studies are
unavoidable.”
Always under control
The primary purpose of all safety functions is to safely
limit the motion of the drive on command or in the event
of an error. The stop functions are therefore among the
most important. According to the situation, the drive is
shut down – in the form of the “safe torque off” function
(STO), with which the energy supply to the motor is safely
interrupted. The 9400 servo drives provide this function
with the SM100 safety module fitted in the drive controller.
The yellow module is inserted in a slot reserved for
safety equipment. The sensors are then connected
directly to the safety module. If more extensive safety
functions are required, the functionally more highly
scaled SM301 module is used. With this, for example, the
speeds and positions of the travelling and hoist drives in
storage and retrieval units can be safely recorded and
monitored. Integrating the safety functions into the drive
controller offers many advantages over conventional
solutions. “Drive-based safety” gives greater clarity to the
form in which the safety technology is implemented, and
it simplifies the system structure. One of the positive cost
aspects is the avoidance of external components (safety
switch, speed monitor, guards, or a second sensor system
for “safely limited speed”). From a functional point of
view, the faster shutdown on command or in the event of
an error means an increase in safety, since no points of
separation with contacts are required. Because the safety
technology provides status information available in the
servo inverter and, therefore, in the PLC, there is also an
improvement in the diagnostic possibilities.
Securing competitive advantages
The Klug example proves that real competitive advantages
can be achieved with innovative solutions in the context of
the new machinery directive. Those who are quick to adapt
to the new directive will have an easier time of marketing
their systems in Europe. If unpleasant surprises are to be
avoided during commissionings in 2010 and beyond, it
makes sense to begin working with drive specialists as
early as in the planning phase. For this reason, Lenze is
actively helping to implement and interpret the directive
within the associations VDMA (Verband Deutscher
Maschinen- und Anlagenbau e. V.; German Engineering
Association) and ZVEI (Zentralverband Elektrotechnik- und
Elektronikindustrie e. V.; Central Association of the German
Electrical and Electronics Industry). “We are involved and
always up to date particularly in the classification of drives
in the application areas ‘components/modules’ or ‘incomplete
machines’”, emphasises engineer Martin Grosse,
product manager for safety engineering at Lenze.
New machinery directive
As of 28 December 2009, the new Machinery Directive 2006/42/
EU applies to all machines, replacement equipment, safety
components, load handling devices, chains, cables and lifting
belts, removable cardan shafts, incomplete machines and construction
site lifts for people and/or goods. Once a machine has
been built, the machine manufacturer is responsible for certifying
that it is in compliance with the directive’s requirements by
attaching the CE mark to it. The new Machinery Directive
2006/42/EU does not introduce any sweeping changes but does
change a large number of details and in the Declaration of
Conformity. Its scope of application has been more clearly
defined, particularly by separating it from the Low Voltage Directive
and including construction site lifts and load handling
devices, which previously were mentioned only in Appendix I.
on the job
19

20
A perfectly dosed solution for administering
medications
Medications must be taken in the proper dose and at the right time. It is easy to lose track of medica-
tions if there are several that must be taken at the same time. Pharmacies can solve this problem by
blistering pharmaceuticals individually, but the expense of doing so is prohibitive. That’s why med-
i-tec GmbH, using tested and innovative Lenze products, has developed a semi-automatic device that
packs medications precisely, reliably, and safely.
In times of demographic change, the elderly make up a
steadily increasing portion of the population. Today, there
are already approximately four million people over the
age of 80 living in Germany. A large part of this popula-
tion segment must take several medications at different
times of the day. Pills are easily forgotten, taken at the
wrong time, or confused with one another. According to
health experts, the cumulative costs of such behaviour,
which the medical profession refers to as “non-compli-
ance”, exceed those caused by smoking. Hence, there is a
correspondingly keen demand for solutions that would
prevent such errors.
Previous solutions to the problem
Blister packaging medications individually has the best
chance of success. This method combines all of a patient’s
prescribed medications into units, packs them in small
plastic wraps or capsules, and labels them. Pharmacists
who wish to offer their customers this service find that
repackaging is very costly. Previously, providing the
medications (usually for a week at a time) and the tracking
and documentation required for safety reasons could
be handled only manually or according to the “four eyes”
principle. The typical pharmacy had the resources to
serve, at most, 150 patients for seven days. The fullyautomatic
devices developed for blister packaging are too
expensive for these businesses and do not begin to make
economic sense until 500 or more blisters are processed
per week.
“Reliability and ease of maintenance are crucial,
because we cannot put the patient’s supply at risk.”
Guido Faßbender, product manager
The innovative med-i-box
With the help of industrially proven automation products
from Lenze SE, med-i-tec GmbH has now succeeded in
developing a semi-automatic device that closes the existing
gap between manual and fully-automatic blister
packaging. The med-i-box is remarkable for its performance
capabilities and low purchase price. In addition, it
takes up little space and operates efficiently and reliably.
Thanks to these features, the machine can process from
50 to 500 blisters per week. “Reliability and ease of maintenance
are crucial, because the patient’s supply cannot
be put at risk”, explains Guido Fassbender, who, as product

manager for med-i-tec GmbH, is responsible for the medi-box
and helped develop it. “This was also one of the
reasons why we used Lenze technology. It showed no loss
of performance, even under the harshest conditions and
with constant use.” “Because the replacement parts will
be available for years to come, the safety of this investment
is also guaranteed”, adds Sven Vieten, who, as an
electronics specialist, expedited the development of the
med-i-box.
Modular throughout
Even the unlikely eventuality of a component failure has
been provided for. “It was important to us to design the
machine so that it would be modularly structured
throughout. The affected part of the unit can be replaced
in no time according to the “plug & play” principle. Production
can then continue immediately. The Lenze concept
of system modules has served extremely well here,
as it is based on an extensive range of products that are
perfectly matched to one another”, says Vieten. This was
especially important for the implementation of the medi-box,
since the unit was to consist as much as possible
of market-tested subsystems. The standard commercial
laser printer used to print the inserts and the matrix
printer used to label the blisters were to be integrated
through an Ethernet connection, as was the weighing
unit, which forms part of the integrated, multi-stage
monitoring system for the blister packaging process and
requires a serial interface in the med-i-box.
Lenze technology in operation
Lenze’s CPC 2700 industrial PC is the brains of the med-ibox.
Even its basic version has all of the required interfaces
and, with its outstanding computing power, provides
fast results for the application developed under .NET and
for Microsoft Windows XP Multilanguage.
The integrated bus of the CPC 2700 provides two CAN
interfaces. The first of these is used to connect Lenze’s
servo motor and drive combination through its factoryintegrated
CAN interface to the IPC. This combination
actuates the heat press, which, after the filling process is
completed, uses film to heat seal the weekly blister cards
used by med-t-tec, which contain 35 cavities (tablet
compartments). The fail-safe standard bus serves also as
a communication medium for the specially developed
med-i-box object recognition system, which detects
tablets down to one millimetre in size and ensures that
the compartments are filled correctly. Linked to the sec-
ond CAN interface are two bus coupler modules of the I/O
system, through which the purely digital signals from the
switches or sensors are activated and collected. For the
I/O, our choice was the new 1000 I/O system from Lenze.
“We were thoroughly impressed by this technology
because of its compact design, the reduced wiring time,
and the separation of wiring and electronics levels”, says
Sven Vieten.
All of the med-i-box’s operations are handled through a
touch panel from the Lenze Command Station. The large
screen provides the ideal support for the intuitive and
clear user interface, allowing users to fill all of their orders
ergonomically and error-free. This has been confirmed
with CE certification of the production model of the
machine and the positive TÜV assessment of the med-ibox
prototype.
Individual blister packaging of tablets with the med-i-box: a valuable aid for
the proper administration of medications.
At a glance
The task
• To create a reliable and easily maintained automation system
for a blister packaging machine for pharmacies
Solution
• A robust automation solution made with Lenze components
Products
• CPC 2700 industrial box computer
• 1000 I/O system
• Command station designed to customer specifications
www.med-i-tec.com
on the job
21

22
Flexibility in production – as clear as glass
Modern thermal insulation with its sandwich structure reduces heating costs. To prevent variable rates
of material expansion from creating tears as temperatures fluctuate, the insulation is made with glass
fibre mesh. Menzel Maschinenfabrik specialises in equipment that permanently fixes the glass fibre
mesh by impregnating it. The newest machines use Lenze 9400 servo drives, whose modularity pro-
vides the ideal support for the flexible Menzel systems. They also score points for energy efficiency.
Optimised energy absorption, high tensile strength,
alkali resistance: these are three essential characteristics
that a glass fibre fabric must have when installed under
exterior plaster. “If we were to neglect to fix the mesh lath,
the fibres would slip. Cracks would form in the plaster as
a result”, explains engineer Helmuth Gossler from the
technical sales department at Menzel. In the fixation
process, a latex-like suspension provides the impregnation
and protects the fibres from the high pH values in the
plaster. The consistent coating with the “padding” process
is the crucial quality characteristic in the production process.
Without it, the material would quickly disintegrate.
The drive concept
In the company’s production facilities in Bielefeld, the
padding module assumes the role of master drive as a
speed-controlled draw roll. The drive solution was developed
jointly by Menzel and Lenze. It consists of a combination
of 9400 servo drives and a standard three-phase
AC motor with a helical-bevel gearbox from Lenze’s GKS
series. Another servo controller builds up the precisely
defined fabric tension with tensioning mechanism 1,
which is positioned in front of it. The important thing
here is the high setting range in combination with a very
precise control quality. The 9400 servo drives have control
elements for exact synchronism. They greatly reduce the
angular displacement from the master drive. The high
resolution in combination with an acceleration feedforward
control achieves precise motor control that balances
speeds and reacts faster in the event of lag errors. The
feedback from the prevailing torques is provided through
tension measuring stations. “Because the technical characteristics
of the fabric are subject to international
standards, precision is an absolute must”, explains Ekhard
Neuman, director of design. “For product traceability the
tensions are therefore documented. In addition, the unit
enables us to store these tensions as a product recipe.”
“We can also literally build our systems over several
floors in one building. For that sort of thing, we can
always rely on our partnership with Lenze.” Dipl.-Ing.
Helmuth Gossler, Technical Sales
More energy efficiency
Because tensioning mechanism 1 operates in generating
mode – which means that it converts braking energy into
electric current – the servo controllers are connected to
one another in the control cabinet via a DC bus. The situation
is similar with the combination of winder and
unwinder at the beginning and end of the impregnation
process. In Menzel systems, fabric 2.2 m to 3.2 m in width
travels through a temporary storage unit after the
unwinding process. This buffers the material during roll

Left: Peter Menzel and Helmuth Gossler
(from left to right) are satisfied with the
jointly implemented drive solution.
changing, thus providing continuous material to the
liquid polymer bath. A pair of rollers then squeezes the
excess liquid down to a defined dimension. The heating
section above it dries the fabric sufficiently that it will no
longer adhere to the next roller. It then goes to the main
dryer, in which the impregnation completely polymerises
at 140° to 160° C. The speed reached at this stage, which
depends on the strength of the material, is set by tensioning
mechanism 3 at the output end of the circulating
air dryer. The required control of the geared motor is also
provided by a Lenze servo controller. To save energy consumption
by the dryer as well, 8400 inverter drives of the
StateLine series control the speed of the ventilation fans.
The inverters in the new series were the favoured choice
because of their integrated safety technology (safe torque
off) and their ease of integration into the whole system.
Once the fabric has left the circulating air dryer, printing
units provide it with markings and the manufacturer’s
logo. It then proceeds once more to a temporary storage
unit, after which two rollers wind up the fabric. These,
too, are driven by standard three-phase AC motors with
a helical-bevel gearbox and 9400 servo drives.
Data processing and safety technology
Menzel uses PROFIBUS DP for the central communications
connection between the PLC and the drive controllers.
All of the sensor data are also sent through it. The
company uses the 9400 servo drives as a gateway. “We
read in the sensor data through the drive's analogue
inputs. They are, after all, already on board as standard
components”, explains Ekhard Neumann. The 9400 servo
drives reserve a plug-in slot for “drive based safety”. At
Menzel, the SM 100 module with the safe torque off (STO)
feature is used here. Thus, when activating a light curtain,
operating in set-up mode, or changing rollers, the drives
for each area can be switched torque free. Because, with
drive-based safety technology, this is done directly in the
inverter by interrupting the pulse pattern of the optocoupler,
the drives can be shut down and started up again
faster. Operating times in the safety section are optimised
The extreme flexibility of Menzel’s system is supported by the modular
concept of Lenze’s 9400 servo drives.
in this way. An SM301 module also is available for
extended safety functionality.
Modularity is a plus
Thanks to the modular structure of the 9400 servo drives
and the integrated safety technology, the Lenze drive
solution provides ideal support for the design principle
– one that is geared to maximum flexibility – on which
the Menzel systems are based. “We can also literally build
our systems over several floors in one building”, says
Helmuth Gosslar proudly in reference to previously
implemented projects and their design flexibility, which,
according to Menzel, is unique in the international market.
“For that sort of thing, we can always rely on our
partnership with Lenze, which offers us the best advice,
supply and services, as well as ever more extensive application
know-how.”
At a glance
The task
• To optimise a glass fibre impregnation system
• To provide support for the system’s modularity
• To lower energy costs
Solution
• A highly reliable flexible drive concept
• Integrated safety technology reduces maintenance times
and costs
• Increased energy efficiency through conversion of braking
energy
Products
• 9400 servo drives with integrated safety technology (STO)
• 8400 inverter drives with integrated safety technology (STO)
• Standard three-phase AC motors with GKS gearboxes
www.menzel.net
on the job
23

24
Lenze’s new logistics concept
Lenze customers are internationally active. They expect short delivery times, the entire spectrum of
products in uniform quality, and good service. To satisfy and exceed these expectations, Lenze has
developed a new, global logistics concept that in the future will provide for maximum customer satis-
faction with five logistics centres located around the world. One such logistics centre, inaugurated in
2009 in Ruitz, France, demonstrates how effective and efficient the new logistics concept already is.
“Our logistics centres in China, Germany, France, and, in
the future, Austria and the U.S. are dedicated to making
the process of supplying our customers as smooth as
possible and providing reliable service everywhere in the
world. The five logistics centres constitute a globally
integrated system and serve pre-defined distribution
regions”, reports Dr. Karsten Zeugträger, director of logistics
at Lenze Operations.
The overall guiding principle
“All of Lenze’s logistics centres around the world operate
according to uniform and high product and process quality
standards, and they combine all of the functions
necessary for that purpose”, explains Dr. Zeugträger. In
addition to the traditional logistics areas of incoming
goods, storage, forwarding, scheduling and order fulfilment,
there are also the assembly areas, where customdesigned
products such as geared motors are assembled
for Lenze customers and 8400 and 9400 L-force drives are
configured.
In the logistics centre in Germany, for example, there are
two teams at the Extertal (motor and gearbox fabrica-
tion) and Gross Berkel (electronic equipment fabrication)
locations who work hand-in-hand on behalf of the customer.
At present, the logistics centre in Asten, Austria is
being reorganised. The logistics centre in Uxbridge in
America is in the process of organisation. The Chinese
logistics centre in Shanghai went into operation in 2007.
And the new French logistics centre in Ruitz started up on
4 May 2009.

State-of-the-art logistics
With the support of the most advanced technology,
Lenze’s entire product portfolio is delivered from Ruitz to
customers in Western Europe – on request in complete,
all-in-one shipments. Individual, customer-specific product
combinations are also possible, with the shortest
turnaround times for assembly and dispatch.
Our service enjoys the support of a uniform freight for-
warding and delivery concept, which we implement with
a strong trans-regional partner. The customer profits
from a carefully thought-out master plan that covers
everything up to and including final delivery. Three large
European logistics centres in particular – Hameln, Asten,
and Ruitz – are combined into a very tight supply and
delivery network to ensure fast delivery to customers and
the availability of Lenze technology.
Lenze technology inside
With an efficiency reminiscent of Lenze drive and automation
technology, construction of the entire logistics
centre in Ruitz was completed between March 2008 and
April 2009. This logistics centre is managed by Francis
Kopp. Well-trained staff ensure that deliveries to customers
are on time – with the support of efficiently planned
Our logistics centre in Ruitz, France.
Automatic small parts warehouse. Packing areas for geared motors.
processes and the software tailored to them for stock
picking and shipping. Naturally, Lenze technology is also
used in the new centre, including 8400 frequency inverters
in the paint shop. Materials handling equipment of
the enamelling system, 9300 servo inverters in the TGW
small parts warehouse, motec motor inverters in the
container handling equipment – and, in every area, every
imaginable type of geared motor. After all, Lenze has
already worked for many logistics customers and offers,
in addition to the relevant industry expertise and application-related
know-how, powerful and energy-efficient
products for this area.
Conclusion
“Thanks to our global network of logistics centres with
their universal and uniform processes, we are able to keep
a well-sorted stockpile of our materials. Combined with
the worldwide coordination between the five logistics
centres, this ensures flexibility in our supply capabilities.
Moreover, a regular exchange of information and experience
among the colleagues in the individual logistics
centres also contributes to the steady improvement of
our processes”, observes an optimistic Dr. Karsten, who
was also the project manager for the construction of the
new centre.
speCial report
25

26
In pursuit of energy efficiency
As a magazine for drive and automation technology customers, we wanted to cast a little more light
on the subject of “energy efficiency in mechanical engineering”. With that in mind, we interviewed
Professor Dr. Wilfried Hofmann, who holds the chair for “Electrical Machines and Drives” at the Elec-
trotechnical Institute of the Technical University of Dresden.
Dr. Hofmann, how important is the contribution of the
industry to energy efficiency or climate protection?
In a highly developed country such as Germany, the
industry consumes 50 % of the electrical energy that is
generated. With the current energy mix, electricity gen-
eration is responsible for 30 % of total CO 2 emissions,
which makes the industry responsible for 15 %. The indus-
try’s contribution becomes relatively less significant
when you consider other serious climate sinners such as
agriculture and private transport. Only a comprehensive
climate protection plan based on increased efficiency,
therefore, will prove effective. But because the industry
also provides components and equipment for power
generation and other segments such as households,
transport and trade, it occupies a position of direct and
indirect responsibility on both sides.
Where are the technical limits here at this time?
If we go by the latest current figures before the financial
and economic crisis of 2007 – compiled by AG Energiebilanzen/VDEW
and IfE TU München – 63 % of generated
electricity went to energy conversion through electrical
drives, 26 % to processes, 5 % to lighting, and 4 % to
information and communications. In concrete terms, this
means that energy amounting to 143 TWh (32 % gener-
ated power) was converted in electrical drives alone. Of
these 143 TWh, at least a third, or 50 TWh, could be saved
through energy efficiency measures, which is equivalent
to the energy use of ten fossil fuel power station units.
What economic disadvantages does energy efficiency
bring?
For the vendors of drive technology, manufacturing
highly efficient industrial motors entails added costs
because of the more sophisticated technology and
increased expenditure for materials. The customer is
going to have to be willing to pay more for energy efficiency
in the future as well. But when set off against
operating costs, the result is a plus for the customer. For
the manufacturer, it can even become a competitive
advantage.
Where is there future potential, generally and specifically,
for savings?
The general savings potential for drive technology are
currently estimated at 20 % from process optimisation,
10 % from the use of variable speed drives, and 3 % to 5 %
from improving the effectiveness of motors. While the
smaller values can be predicted fairly accurately, the
potential savings from process optimisation always have

to be considered separately for each industry or machine.
For compressors, for example, there would be an esti-
mated efficiency gain of 15 % through variable speed
drives, 12 % through optimised control, and 2 % through
improved motor technology. Apart from electrical drive
technology, another 20 % is expected through heat recov-
ery and 7 % through optimised compressors. Even more
striking is the pressure for energy savings in the case of
fans and ventilation systems, where 90 % of total costs
are attributable to energy. Savings of 30 % are possible
even here. We haven’t had any reliable figures for the
machine tools and manufacturing equipment industry,
but, in the case of actuating drives alone, lost energy
could be reduced by up to 40 % through optimum motion
control combined with downsizing.
How much potential savings could really be realised
through increased use of inverters?
What the frequency inverter has going for it is that it
enables the speed variability of drives, from which we can
project potential energy savings of 15 TWh. If your calculations
include the generally predicted potential savings of
another 30 TWh from process optimisation (using 2007
figures as a basis), which would require the use of variable
speed drives in most cases, you end up with the equivalent
of the energy input of nine fossil fuel power station
units.
How important will regenerative modules be in the
future?
Once people have subjected a lot of applications to more
rigorous calculations, I think that regenerative modules
will increase in importance. It should be obvious that they
make sense in hoists, lifts, rolling mill drives, test benches,
and centrifuges, where there is a quantifiable savings
potential of approximately 3 %. But the customer benefits
from power recovery only if he is compensated for it
(through smart metering) or is able to reuse the recovered
energy itself.
Is there really anything to be gained from “downsiz-
ing”? What happens if downsized architectures are
forced to deliver more than they were designed for?
I consider downsizing a very intelligent method of saving
energy, because it creates the closest possible link between
the design and control of machines and systems and
brings out previously “hidden reserves”. It does, however,
require greater transparency and accuracy in planning,
something which can be achieved only if manufacturers
and customers work closely together.
Thinking realistically, what possibilities for development
do you see in connection with the introduction of
minimum efficiency levels through the EuP Directive?
It is to be expected that synchronous technology will
continue its advance and that even mains-operated systems
will increasingly be equipped with permanent
magnet synchronous motors, unless there is an intervening
scarcity of resources in the case of rare earth magnetic
materials.
Thinking idealistically, what is your vision of the
perfect drive and automation technology?
Nothing is perfect! But we can attempt to approach the
ideal. Then I would envision a highly compact and efficient
inverter technology built entirely with power semiconductors
that would remain functional up into the high temperature
range. At a minimum, the motors would be
designed to be permanent-magnet-excited and have a
more intelligent cooling system, maybe even better master
the partial load range, using HTSC materials, than has been
the case. The control system would be uniformly sensorless,
i.e. would function without rotary transducers, and it
would go through a self-learning process to the most
energy-efficient operating mode.
Sources:
VDE study: Effizienz- und Einsparpotentiale elektrischer Energie in Deutschland,
Frankfurt 2007;
ECPE study: Verbesserung der Energieeffizienz – Einsparpotentiale durch
Leistungselektronik, Nürnberg 2008
Dr. Wilfried Hofmann, university professor and
qualified engineer
energie eFFiCienCY
Born in 1954, graduated in 1978 as a
qualified engineer (Diplom-Ingenieur)
from the Technical University of Dresden,
promoted in 1984 to doctor of
engineering (Dr.-Ingenieur) at the
Technical University of Dresden, 1982 –
1989 industrial activity with drive
manufacturer Elektroprojekt und Anlagenbau
Berlin, 1990 – 1992 senior
assistant at the Technical University of
Dresden, 1992 – 2007 C4 professor of
electrical machines and drives at the Technical University of
Chemnitz, since 2007 W3 professor of electrical machines and
drives at the Technical University of Dresden, VDE/ETG departmental
head for electrical machines and drives, mechatronics,
regular member of the Saxon Academy of Science in Leipzig and
of the German Academy of Science and Engineering
27

28
Lenze’s growth in South America
For more than ten years now, Lenze SE has been working closely with AC Control in São Paulo, Brazil.
This partnership took on a new quality when Lenze became the company’s majority shareholder in
early 2010. Since then, the German drive and automation specialist has stepped up its activities in
South America and has high expectations of one of the world’s strongest markets for the automotive
industry.
The unbridled joie de vivre that culminates in a wild and
extravagant carnival; the coffee-complexioned beauties
on the Copacabana; the immense tropical rain forest; the
much sought-after football artists … It’s easy to become
rhapsodic when thinking about Brazil. But for us Brazil
has another, more important side. Brazil is an economic
powerhouse. In the Americas its economic output is
second only to that of the U.S. The centre of these economic
activities is the largest Brazilian city of all. We are
referring not to Rio de Janeiro, but to São Paulo, which is
also home to Lenze’s South American partner AC Control.
The perfect location
Eighty kilometres from the Atlantic Ocean lies São Paulo
in a high basin of the rivers Rio Tietê and Rio Pinheiros,
795 metres above sea level. Mass immigration from Portugal,
Italy, Lebanon, Japan, and Germany has given the
city a distinctly multicultural feel and a cosmopolitan
outlook. São Paulo is the largest of Latin America’s industrial
urban areas. Some 1,000 German companies are
active in greater São Paulo, which is indeed the superlative
it appears to be, for this is the location of the largest
concentration of German industrial companies anywhere
in the world. After Germany, Brazil is, among other things,
the largest market for the German automotive industry.
German drive and automation technology is accordingly
very much in demand, for which reason Lenze SE sees
great potential here and is discovering that São Paulo is
the ideal place to expand its activities. A better time of
entry could not have been chosen, as both the financial
market and the domestic market have long since overcome
the global economic crisis.
Bridgehead AC Control
AC Control has been Lenze’s service and sales partner in
South America for twelve years. Under the management
of managing director Antonio Paes, this company, which
specialises in mechanical engineering and automotive
products, has seen its business flourish. It is a family-run
company in which Paes enjoys the energetic support of

his wife and daughter. At present, there are 15 employees
on the payroll of AC Control (ACC) in São Paulo. Antonio
Paes will be going into a well-earned retirement in a few
years, which is the reason why Lenze, looking ahead,
acquired a controlling interest in ACC on 1 January 2010.
Antonio Paes remains on the job, where he continues to
manage the company’s business; as a second managing
director, Lenze SE has appointed Frank Schlüter. AC Control
will soon be renamed Lenze do Brasil Automacao.
The South America strategy
With the expansion of its activities in São Paulo, Lenze SE
naturally aims to share in the rapid growth in the Latin
American market. In doing so, the internationally-oriented
company is also meeting the needs of European
machine manufacturers and automotive customers that
Since 1 January 2010 Lenze has been the majority share-
holder in AC Control. On 13 January, Frank Schlüter (right)
symbolically handed over the check to the company's
founder, Antonio Paes.
On a growth trend: In the offices of AC Control, the takeover was greeted with a sparkling wine toast, as
is customary in Brazil.
are active in Brazil. They would like to have in South
America, as elsewhere, a cooperative relationship and
service that combine the internationally accustomed
proximity to customers, reliability, and know-how of the
quality typical of Lenze.
Lenze SE also plans to invest more and more heavily in
developing Brazil as its main trade base for all South
American projects. The very intensive cooperation with
Metaltex, another Brazilian sales partner, also fits in with
these plans. The Metaltex company was formed in 1958,
and it, too, is located in São Paulo. The owner-managed
company is very active in the components and automatic
sector and has a nationally active, energetic engineering
and sales team. Lenze’s product portfolio and the
Metaltex line of products complement each other perfectly.
And some of the Brazilian company’s executive
staff have already been guests in Germany for product
training to become better acquainted with the country.
Outlook
With the expansion of its activities in Brazil, Lenze can
offer its customers a strong and reliable partnership for
Latin America. Apart from its extensive drive and automation
know-how, the company attaches much importance
to the proximity to its customers. “Lenze Automation
Days” are planned for 1 June 2010, an event that all major
customers will be attending. A day later, on 2 June 2010,
São Paulo will be the scene of the South America Conference,
where, apart from ACC and Metaltex, all other Lenze
partners based in South America will be introduced.
worldwide
29

Future
30
Closer to the customer:
Lenze’s new international sales structure
In the wake of globalisation – and particularly as a result of the current slumps in the industrial-
ised nations – many machine manufacturers are re-orienting themselves. Lenze is responding to this
trend with a new, powerful sales structure. We spoke with Dr. Matthias Kirchherr, vice president of
sales & marketing for Europe, on the direction of the company’s future sales activities.
Dr. Kirchherr, what is at the core
of the new sales structure?
Our customers are becoming
internationally oriented, both
within Europe and globally. Lenze
has already taken this step in
many parts of the world. Apart
from Europe, we have our own
local organisations in the U.S.,
China and, beginning this year, in
Brazil. The bundling of our activities
in the European, American,
and Asian regions is new. It enables
us to offer our international
customers substantially better support, increase their
efficiency, and promote joint product and sector initiatives.
Our managers in the various countries are involved
in global projects, such as developing Lenze’s global
account management. The joint development within
Europe of strategies and themes for products and sales
makes it easier for customers to work with Lenze across
regions. The customer profits from a range of services
that is consistent all across Europe.
What goals are you pursuing with the new organisational
structure?
With our European sales division we are taking more
vigorous steps to improve our position as a first-class
solution partner in the field of drive and automation
technology. Our customers are taking a very positive view
of this. For instance, the CEO of a machine manufacturing
group from the food sector described Lenze as the only
vendor that clearly understood, in its contacts with the
customer, the customer’s international business goals
and its desire for a uniform technological platform. Also
that put together a comprehensive offer. Such understanding
was the result of teamwork among various
Lenze companies.
What will change for the customer with the new
structure?
At first glance, nothing. Their contacts in the various
countries will remain the same. But these same contacts
will soon have recourse to a whole network of European
application engineers. If international connections are
necessary, we can exchange information with colleagues
in other regions faster and ensure support there. For this
gain in sales quality we are bringing all of our know-how
from every kind of market and our international network
to bear. In this way, we are helping customers who are
concentrating more heavily on growth regions, for example
in Asia to lower their costs and increase the quality of
their systems.
And how does that work in concrete terms?
Very simple: We become actively involved in our customers’
programmes. For planned cost reductions, we bring
our drive solution concepts into play (drive optimisation,
custom-fitting products and services, customer-specific
product combinations). The result may be, for example,
that our customers standardise their drive technology,
thereby deriving cost and quality benefits in their own
production processes. Other programmes might be
downsizing initiatives or the development of engineering
expertise in the growth markets of Asia. At the same
time, we work on our customers’ regular update with
new products and services to make their systems faster
and more efficient and their own customers more
competitive as a result.

Sudoku Puzzle
This time we have prepared a more difficult Sudoku puzzle. As usual, the numbers between one and
nine must, first of all, be inserted into the grids so that each number occurs only once in each line,
each column and in each of the nine squares. Use the three correct numbers from the pale blue boxes
to take part in our prize draw.*
Please send us your solution by 31 July 2010.
This time we are raffling three iPods touch.
These offer 8 GB of storage, plenty of room
for your thousands of pictures or songs.
Compatible with more than 140,000 apps
but also makes a convenient companion if all
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7
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2
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* Lenze employees and their relatives are not allowed to take part in the prize draw.
The following have each won a colour lamp:
• Awanes Markarian, Seidenader Maschinenbau GmbH,
Markt Schwaben, Germany
• Patrick Schopfer, STS Industrie SA, Yvonand, France
• Dr. Matthias Smolke, Von Ardenne Anlagentechnik GmbH,
Dresden, Germania
Congratulations!
6
3
8
2
1
6
4
3
8
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1 7
you want to do is play games, e-mail or surf the Web. The
iPod is also a multimedia all-rounder that comes with
Wi-Fi and the standard 802.11 b/g for fast Web access.
Have fun with the Sudoku!
Winners of DriveIn No. 23
6
puzzlE
31
Fax reply
CompaNy
NamE
StrEEt
poStCodE
towN
CouNtry
phoNE
Fax
E-mail
Solution to the Sudoku puzzle
Please enter here the three numbers in the
pale blue boxes in the Sudoku:
Ordering the magazine
International: +49 (0) 51 54/82 16 05
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Information material
If you would like more information about the following
subjects, simply complete this form and return it to us.
L-force decentralised drive technology
L-force three-phase AC motors MF
L-force energy saving solutions
L-force I/O system controls 1000
L-force controls HMI series El 100

Service
Our experts are there for you 24 hours a day.
We can assist you wherever you might be.
Fault analysis and troubleshooting, spare
parts supply, maintenance and repair. You can
reach a nearby service location from more
than 30 countries by calling 008000 24 hours
(008000 24 46877).
Tel.: Electronics: +49 (0) 51 54/82-11 11
Helpline
Tel.: Mechanics: +49 (0) 51 54/82-16 26
Fax: +49 (0) 51 54/82-11 12
E-mail: service@Lenze.de
Publication details
Published by
Lenze SE, Postfach 10 13 52, 31763 Hameln, Germany
Editors
Harald Hilgers (responsible for content),
Ines Oppermann
Staff on this edition
Joachim Becker, Ralf Brünger, Robert Gradischnig,
Univ.-Prof. Dr. Wilfried Hofmann, Petter Hollertz,
Dr. Matthias Kirchherr, Axel Köller, Wolfgang Krauß,
Jürgen Langner, Sören Mirbach, Johanna Mohrmann,
Kurt Raymann, Wolfgang Schenk, Frank Schlüter, Thorben
Steinmann, Bernd Wieners, Dr. Karsten Zeugträger
Contact
Telefon: +49 (0) 51 54/82-15 12, Drivein@Lenze.de
Text/design/typesetting
Kaiserberg Kommunikation GmbH, Duisburg
Printing
Goerres Druckerei
Picture credits
Cover picture: Thorsten Sienk;
Lenze: p. 3, 4, 5, 11, 12, 19, 24, 25, 27, 30;
Thorsten Sienk: p. 6 – 9; motec: p. 10; Avalon: p. 14 (u.);
DAM: p. 16 – 17; Klug: p. 18; med-i-tec: p. 20 – 21;
Menzel: p. 22 – 23; Lenze AC Control: p. 29; Apple: p. 31;
Shutterstock: p. 14 (top), 26, 28
Trade fair dates
Visit us: we exhibit at many international trade fairs.
You will find our complete trade fair schedule on the Internet
at www.Lenze.com.
April
HMI 2010
19.–23.04.10
Hannover, Germany
June
Drives & Controls
08.–10.06.10
Birmingham, England
September
AUTOMATIK 2010
07.–09.09.10
Brøndby, Denmark
Motek
13.–16.09.10
Stuttgart, Germany
MSV – Internationale
Maschinenbaumesse
13.–17.09.10
Brünn, Czech Republic
OctOber
Aandrijftechniek
05.–08.10.10
Utrecht, the Netherlands
Factory & Process Automation
20.–21.10.10
Brussels, Belgium
Matelec
26.-29.10.10
Madrid, Spain
nOvember
FMB – Zuliefermesse
Mechanical engineering
03.–05.11.10
Bad Salzuflen, Germany
IAS
09.–13.11.10
Shanghai, China
SPS/IPC/Drives
23.–25.11.10
Nuremberg, Germany
Lenze SE
Postfach 10 13 52
31763 Hameln
Germany
Tel.: +49 (0) 51 54/82-0
Fax: +49 (0) 51 54/82-28 00
Lenze@Lenze.de
www.Lenze.com
13315581 EN