New MDR offers new opportunities for intralogistics

Less complex, more efficient, more flexibility, more power and easier, faster commissioning and maintenance. These were some of the key points in the development of the new MDR (motor driven roller conveyor) recently launched by Lenze. With the MDR o450, the automation solutions specialist wants to be able to offer intralogistics customers even better support.

"The MDR o450 can be integrated directly into existing conveyor systems and delivers an output of 115 watts, making it more than twice as powerful as comparable systems on the market," explains product manager Rune Friis Knutzen. "The motor design works according to the Vernier principle: the motor transfers its rotational energy directly to the transport goods or conveyor via the rotor. It combines a 3-phase AC motor with a lossless magnetic gearbox." So the MDR has no gears, which saves variants. "This makes many processes less complex, such as procurement and design, and maximizes flexibility in operation and maintenance. With less inventory, the user is more flexible and a wide range of solutions can be offered in intralogistics with fewer components." 

24 or 48 V

The MDR operates on 24 or 48 V. "In doing so, we chose not to develop our own control system, but to use a standard interface so that the o450 can be controlled with any control card with 24 or 48 VDC that outputs a control signal from 0 to 10 V. An additional advantage of this over a conventional drive system is that the o450 - after a short training session - can easily be replaced by anyone. A certified electrician is not required for replacement, maintenance or installation."

Twice as powerful

"By design, this motor has significantly lower copper and iron losses, meaning less heat is generated in the roller. This has a positive effect on efficiency because cooler copper windings have lower resistance (and therefore less copper loss). The cooler magnets have higher magnetic flux coupling and therefore can achieve the same torque with a lower current. Depending on the speed, the MDR therefore meets IE7-IE9 efficiency classes and saves the customer up to 30% of energy compared to conventional systems. The o450 can carry up to 30 kg. Even at low speeds, it provides full rated torque, which is advantageous for accelerating transport goods."

Silent

The noise level has also been considered. "We have developed a technology where there are no more mechanical gears. This automatically means that the noise level is much lower. Compare it to a diesel versus an EV car. Thanks to the lower noise level, we ensure better working conditions and less stress for employees in distribution centers."

Compact

A compact design is another advantage, says colleague Tim-Oliver Ricke, global segment manager material handling & logistics. "Thanks to the design, we applied about 30% less active material in the motor. In addition, we have also implemented a special type of magnet that uses 30% less rare earth metals than conventional magnets. This also makes the engine less sensitive to volatile rare earth prices while contributing to its durability."

Better value

Friis Knutzen concludes, "We want to launch an MDR that offers customers many advantages: higher power, high efficiency, low noise, lower variation and voltage flexibility. We want to do that at the same price level as competitors' systems we see on the market today. We believe we can win the market by creating better value for the customer, putting in features that our customers care about to future-proof their processes."