The new DC Platform will be on display at LogiMAT in Stuttgart in February. It is suitable for standard applications, but also enables systems with Industry 4.0 functionality in order to take account of the trend towards increasing networking. Smart manufacturing and smart logistics were also a topic at the premiere of the DC Platform in Hinwil, Switzerland. Under the motto "Driving the Future", Interroll presented the product innovation for the first time at the beginning of December last year at a joint event to mark its long-standing collaboration with the Sauber motorsport racing team. "We both manage extremely complex processes," Jens Karolyi emphasized the common ground between the two companies, which have been working together in partnership since 2012.

Zero pressure accumulation conveying
With the zero pressure accumulation conveyor, the individual zones can be driven individually. It is also possible to switch off the motors individually when there is no package on the corresponding conveyor zone. This improves the energy efficiency of the system. The advantage of Zero Pressure Accumulation (ZPA) is that the packages do not touch each other, preventing any damage caused by collisions.

Motorized roller at the heart
One of the central components of the DC Platform are the RollerDrive EC5000 motorized rollers, which offer a number of technical innovations compared to the already established RollerDrive EC310. In addition to a 24V version, they are also available as 48V technology. "In the past, RollerDrives were always supplied with 24 VDC. Neighboring products such as light sensors or PLCs are also supplied with 24V, so there was no need for a supply with a different voltage level. The market for motorized rollers will nevertheless develop in the direction of 48 VDC," explains Daniel Heinen, Global Product Manager for Rollers and RollerDrive at Interroll. Three power levels are also available - 20 watts, 35 watts and 50 watts. The 35 watt version is compatible with existing systems. For heavy goods, a version with a diameter of 60 millimetres is also available in addition to the 50 millimetre version. The RollerDriveEC5000 is also available in versions with protection classes IP54, IP66 and for deep-freeze applications.

Foresight protects against surprises
With the new bus interface, Interroll is also focusing on predictive maintenance with the DC Platform. "The innovative bus interface (CANopen) offers a wealth of possibilities and is the entry into Industry 4.0. This RollerDrive version informs the user when it has reached its statistical end of life. In important parts of the system, operators can now react proactively in quiet times," says Daniel Heinen. The analog interface, on the other hand, is compatible with the predecessor of the EC5000 and can therefore easily be used for any spare parts. With its control systems, Interroll addresses different applications. While the DriveControl 2048 is suitable for standard applications with a small number of RollerDrives, the MultiControl, as a multi-protocol capable four-zone controller, enables simple to extremely sophisticated applications - from autonomous conveyors with integrated logic to conveyors with customized PLC programming via fieldbus communication.

Put to the test
According to the company, Interroll has tested the DC Platform for more than 10 million hours at its competence center in Wermelskirchen. Extensive load and endurance tests were carried out to ensure the reliability of the DC Platform. "Our test facilities run around the clock. We leave nothing to chance. We have put the new DC Platform through its paces in every conceivable application scenario - the products and their assemblies and individual parts have been tested for several million hours in total," reports Armin Lindholm, Managing Director of Interroll Engineering GmbH.

The company relies on the built-to-order principle for the production of the DC Platform. This allows short delivery times to be achieved even for the smallest batch sizes. This is made possible by intelligent processes based on the Interroll Production System (IPS). This allows them to be identified by their serial number even years later." Interroll would also like to gradually build up the necessary production processes and systems in America and Asia.