ABB has developed a new electric drive technology called DriveIT Direct Drive, which significantly improves the overall efficiency of paper machines by implementing the mechanical components in a completely new way: without gears and pulse generators. The key advantages of the Direct Drive solution include: improved drivability of the paper machine without resonance phenomena caused by shafts and gear clearances, reduced design, installation, and maintenance costs, lower energy consumption due to decreased total losses.
The Direct Drive system replaces conventional gearboxes with a motor directly coupled to the paper‑machine section, eliminating pulsed encoders and reducing the number of mechanical parts. ABB highlights lower engineering and installation costs, better runnability, higher availability, reduced maintenance and energy savings.
The solution uses radial‑flux permanent‑magnet motors and ABB ACS 600 converters, offering speeds from 300 rpm to 600 rpm and power ratings up to 99 kW. Test results show identical measured and calculated motor speeds and smooth torque response, confirming the benefits of tacholess operation and high efficiency.
| Drive power | 90 kW |
|---|---|
| Section powers | 37 kW and 99 kW |
| Section speeds | 600 rpm and 425 rpm |
| Indrive speed range | 300 rpm to 600 rpm |
| Conventional geared motor speed | 1500 rpm to 1800 rpm |
| Converter type | ABB ACS 600 |
| Motor design | radial flux permanent‑magnet rotor |
| Power factor | almost unity |
| Efficiency | high |
| Energy cost reduction | lower energy costs |
The Direct Drive lowers plant engineering and installation costs, improves runnability, increases availability, reduces maintenance and energy costs.
Direct Drive requires motor speeds between 300 rpm and 600 rpm, compared with 1500 rpm–1800 rpm for conventional geared drives.
The system uses ABB ACS 600 converters, available in air‑cooled and water‑cooled versions.