Empower Your Drives with Real-Time, Customized Innovation
Unlock the full potential of your motor and drive systems with ABB Crealizer™, an open software platform seamlessly integrated into ABB drives’ operating system. Designed to overcome the limitations of programming traditional controller applications, Crealizer™ enables you to create, validate, and deploy customized solutions with microsecond precision (125/250 μs).
From analyzing drive parameters in high resolution data within the frequency domain using off-the-shelf FFT (Fast Fourier Transforms) algorithms to optimizing energy storage systems with Optimal Grid Control or eliminating defects in metals production, Crealizer™ delivers unmatched flexibility, speed, and reliability.
With real-time data access, advanced programming capabilities, and a collaborative ecosystem, Crealizer™ empowers you to innovate on your terms, reduce costs, and drive operational excellence.
Ready to transform your drive systems?
Key challenges faced in industry
Complex Integration
Turning innovative ideas into rapid prototypes is daunting due to intricate automation integration. For instance, implementing a new control algorithm to enhance production line efficiency requires complex coding to align with existing drive systems. Traditional Programmable Logic Controllers (PLCs), reliant on rigid IEC 61131-3 languages like Ladder Logic, introduce delays and errors, complicating safe validation. Crealizer’s open software platform streamlines this with intuitive C++ or MATLAB Simulink programming, pre-built applications, and real-time monitoring, enabling faster, reliable prototyping without PLC complexities.Performance Optimization
Achieving energy efficiency and performance in motor and drive systems is vital, especially for adapting to variable loads, like pumps in a water treatment plant. PLCs, slowed by processing delays and limited functionality, struggle with real-time adjustments. Crealizer, executing at 125µs or 250µs directly on the drive, uses high-level programming and analytics for swift, precise optimization, eliminating PLC lag.Maintenance and Troubleshooting
Reliable automation hinges on high-frequency monitoring of parameters like temperature and vibration to prevent failures in demanding industrial settings. PLCs, constrained by rigid languages and processing limitations, restrict real-time visibility into drive systems. Crealizer empowers teams with advanced tools, leveraging its platform’s intuitive programming and real-time analytics for precise anomaly detection, surpassing the limitations of traditional PLCs and DCS systems.How Crealizer™ Works
Crealizer™ streamlines the journey from idea to impact through a three-stage workflow:
Create
Create or co-create new solutions or benefit from existing ones.The possibilities are endless using either PLC standard IEC 61131, high-level language C++, or model-based coding from Matlab/Simulink
Validate
Simulate & Validate: Test in virtual environments (Virtual Drive Plus) or HIL setups (DriveLab). Simulate scenarios like load variations or environmental disturbances to refine performance.
Realize
Realize your new solution within your Drive or fleet. Discover existing solutions on our dedicated online platform and reuse it for your Drive. Make your solution available for others and publish it on our webpage.
Key benefits
Crealizer™ delivers tangible advantages for your operations:
Accelerated Innovation
Prototype and deploy solutions in minutes, free from firmware constraints. For example, a new control algorithm can be tested and implemented without waiting for drive updates.Cost Efficiency
Reduce reliance on additional PLCs or controllers, simplifying system architecture. This lowers both capital and operational costs.Risk Mitigation
Validate solutions in virtual environments (e.g., ABB Virtual Drive Plus) or hardware-in-the-loop (HIL) setups (e.g., DriveLab), ensuring reliability before deployment.Proactive Maintenance
Monitor high-frequency parameters to detect issues early, preventing costly downtime in de-manding environments like mining or marine.Environmental Impact
Optimize energy usage, potentially reducing electricity consumption through real-time efficiency mapping.Crealizer™ redefines what’s possible
Embedded in ABB drives, this platform provides instant access to high-resolution data, enabling rapid prototyping, precise control, and seamless deployment of tailored solutions. Whether you’re a system integrator designing custom torque strategies for marine propulsion or an engineer optimizing conveyor efficiency in mining, Crealizer™ puts the power of innovation at your fingertips.
Technical data
Crealizer™ is engineered for precision and flexibility.
Microsecond Precision
Four cyclic tasks (125/250 μs, 500 μs, 2 ms, 10 ms) plus a background task for real-time control and data acquisition, surpassing PLC limitations.Programming Power
Supports C++ and MATLAB/Simulink, with access to libraries for AI (e.g., TensorFlow), signal processing, and control systems. Unlike CODESYS-based IEC languages, Crealizer™ enables complex applications like predictive maintenance.Data Access
Direct access to drive parameters and read-only access to the event system, integrating seam-lessly with existing setups without external hardware.Memory Allocation
6 MB of memory to support robust algorithms and real-time analytics.Debugging Tools
Parameter writing, log files, and crash dump tools for efficient troubleshooting.Cybersecurity
SL-1 compliant with signed applications, ensuring secure deployment.Compatibility
Integrates with Drive Composer for the new UCU based ACS drive for seamless deployment and Virtual Drive Plus/DriveLab for simulation.Discover Crealizer software platform
ABB Crealizer™ delivers proven flexibility and efficiency in multiple applications
Potential Real-World Use Cases
Crealizer™ delivers proven results across industries, as highlighted in the handouts and sales presentation
- Challenge: A metals plant faced uneven sheet thickness, chatter marks, and tension variability due to 50 Hz roller vibrations, speed fluctuations, and torque spikes. PLCs’ 10 ms scan cycles couldn’t address these rapid issues.
- Solution: Engineers used Crealizer™ to build a digital twin in MATLAB/Simulink, validating active vibration control and a custom torque loop coded in C++. The solution was deployed via Drive Composer with low-speed commissioning for safety.
- Result: Defect rates dropped, thickness variation improved, and surface defects fell, slashing rework costs and boosting customer satisfaction.
- Challenge: Older motors in harsh environments lacked real-time efficiency data, making energy optimization difficult. Manual data collection was laborious and incomplete.
- Solution: Crealizer™ analyzed voltage, current, and temperature to generate motor-specific efficiency maps in real time, without additional sensors. For example, a manufacturing plant mapped efficiency across a motor fleet to identify optimization opportunities.
- Result: Operators adjusted loads and conditions, potentially cutting energy use, reducing operational costs and environmental impact.
- Challenge: Empty conveyor runs in mining operations wasted energy and accelerated wear on belts and rollers, driving up costs. Manual monitoring was error-prone, and scheduled operations led to inefficiencies.
- Solution: Crealizer™ implemented real-time monitoring of motor current and speed, automatically slowing or stopping conveyors during empty runs.
- Result: Reduced energy consumption, lower maintenance costs, and improved material flow, enhancing overall productivity.
- Challenge: Mechanical resonances and electrical harmonics went undetected due to low sampling rates, risking equipment failure. For example, a motor’s torque signal showed signs of resonance, but PLCs couldn’t analyze it in real time.
- Solution: Crealizer™ extended drive functionality with an FFT application capturing high resolution data, analyzing signals like current or torque to identify problematic frequencies.
- Result: Proactive adjustments (e.g., speed changes or damping) prevented failures, with high-frequency sampling unlocking insights unattainable with PLCs or external sensors.
- Challenge: Marine vessels required tailored power control to maintain optimal propulsion and reduce cavitation risks, which PLCs couldn’t handle due to limited real-time flexibility.
- Solution: Crealizer™ enabled system integrators to design custom torque behavior, adjusting drive outputs in real time to match sea conditions.
- Result: Improved vessel efficiency, reduced cavitation risks, and enhanced operational reliability.
Crealizer™ vs. Traditional Solutions
Traditional approaches—PLCs, manual monitoring, or external sensors—are often inadequate.
Crealizer™ leverages the drive as a sensor, eliminating extra hardware while providing high-frequency, real-time insights. Its open platform, support for advanced programming, and ecosystem collaboration make it a future-proof solution for evolving industrial needs.
- PLCs: Slow scan cycles (10-50 ms) and basic logic miss rapid events like vibrations or torque spikes. For example, PLCs failed to address 50 Hz roller vibrations in metals production.
- Manual Monitoring: Labor-intensive and error-prone, requiring technicians to collect data physically, often missing critical insights. For instance, manual checks missed empty conveyor runs in mining.
- External Sensors: Adding dedicated measurement systems (e.g., vibration sensors) increases costs and complexity, when drives already provide rich data.
- Offline Analysis: Low sampling rates and delayed processing fail to capture transient events, limiting diagnostic accuracy (e.g., missing resonance peaks in motor signals).
What do our users say
As a startup, Contextere was able to quickly build an application within the Crealizer ecosystem. Our development team found the SDK intuitive and straightforward, enabling us to focus on solving real customer problems rather than wrestling with integration. Crealizer provides a powerful platform that empowers developers to deliver solutions that truly enhance the end-user experience, and we are excited to be part of this innovative ecosystem.
Gabriel Batstone, CEO & Co-founder