Lenze highlights servo-like performance without classic servo technology

With the IE5/IE6 Motor Drive System and the i650 motec, the company presented a decentralised drive solution that delivers servo-like performance while creating more freedom in machine design. The presentation centred on how packaging machines can be made more efficient, adaptable and easier to engineer without compromising on precision.

With innovative drive technology, Lenze sets new standards in the sensorless control of industrial applications. The focus at interpack 2026 was on the i650 motec frequency inverter, which, in combination with the m550/m650 synchronous motor, offers a powerful and energy-efficient solution for demanding applications. The i650 motec impresses with its integrated Logic PLC and a positioning function that enables independent motion control without a higher-level controller. This makes the system suitable for various applications such as conveyor drives, lifting applications or positioning axes.

The sensorless open-loop control enables particularly precise torque control. A starting torque of up to 300 percent from 0 rpm enables safe starting at full load without any motor feedback. This means that continuous operation can be designed more precisely by using the overload capability. The precise rotor position detection ensures that even demanding motion tasks can be carried out precisely and reproducibly. At the trade fair stand, Lenze used a lifting application to demonstrate a direct comparison between closed loop and sensorless open loop and showed how servo-like performance can be achieved without additional sensors.

The ability to dispense with the encoder significantly lowers initial costs, reduces the likelihood of malfunctions and simplifies mounting.

The i650 motec also offers integrated safety functions such as Safe Torque Off (STO) and Safe Torque Off over CIP, helping to ensure machine and personnel protection. The system is also set to be expanded with further encoderless safety functions such as Safe Limited Speed (SLS), making the solution suitable for future regulatory requirements while also providing additional investment security. Particularly demanding applications, for example in the packaging or beverage industry, benefit from sensorless and precise positioning via the SLSM algorithm. In this way, the system achieves the accuracy of a closed control loop without feedback from the motor or special cabling.

The elimination of feedback systems, complex cables and superfluous hardware results in an extremely resource-efficient and compact system that simplifies installation and commissioning and significantly reduces maintenance costs.

Energy efficiency and transparency included

The Motor Drive System also stands out in terms of energy efficiency: the highly efficient motor reduces motor losses by up to 60 percent. In combination with the powerful gearboxes and the decentralised frequency inverter, which feeds excess energy back into the mains, this results in a consistently efficient drive package. Via the integrated IO-Link Master, machine operators can also access high-quality information from the machine sensors and thus benefit from greater system transparency.

With the IE5 and IE6 Motor Drive System, Lenze shows that high performance, easy handling and flexible machine architectures do not require a classic servo. The sensorless controlled synchronous motor delivers the dynamics and precision of a closed control loop while remaining as uncomplicated as an asynchronous motor. For machine builders in the packaging industry, this opens up new opportunities to use power specifically where it is needed and to design machines that are economical, compact and future-proof.