speed variable pump drives technology
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9/6/2012 | DCUS/SET1 | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Speed Variable Pump Drives Technology
Jan Komsta
Bosch Rexroth
September 2012
1
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the event of applications for industrial property rights.
Saving energy and increasing productivity
Variable-speed pump
drives offer:
Reduced energy consumption
Reduced average noise
Compact drive size
Reduced cooling requirements for
oil
High robustness
Intelligent hydraulic drive
2
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Motivation, market drivers: Energy costs
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9
10
11
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1995 1998 2001 2004 2007 2010
Average price electrical energy
European Union (EU 15) Source: Eurostat
EURO CENT
3
Average price electrical energy
USA
Source: www.eia.gov/electricity/data/state
US CENT
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Total Cost of Ownership (TCO)
Motivation, market drivers: Energy costs
Machine
&
Equipment
Investment
costs
Operating
costs
Commissioning
Training
Spare parts
Maintenance
Staff costs
Taxes
Insurances
Energy Retrofit
Disposal
...
80 ... 95 %
5 ... 20 %
AC motor 1 kW
5 year operation
Acquisition costs
approx. 250 $ (4%)
Energy costs approx. 5,950 $ (96%)
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Drive Technology Choices
drive power transmission Properties
Constant speed
electric motor classic hydraulics
Hydraulic pump control motor /
cylinder Power density, robustness
Controllability
Multiple consumers possible
Noise
Energy efficiency
Force transmission Spindle drive
Electro-mechanic Variable speed
motor drive
Controllability
Noise
Energy efficiency
Multiple consumers not
possible (or very difficult)
Power density
Hydraulic pump motor /
cylinder Power density, robustness
Controllability
Multiple consumers possible
Energy efficiency
Noise
variable speed pumps
w/o valves
Variable speed
motor drive
5
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System Solutions
(for large drives)
Servo Motor + Drive
+ variable pump
Motor + VFD
+ variable pump
Fixed speed motor
+ fixed pump
Motor + VFD
+ fixed pump
Fixed speed motor
+ variable pump
Efficiency
(for large drives)
Servo Motor + Drive
+ fixed pump
Costs Dynamics
M 3 ~
M 3 ~
M 3 ~
M 3 ~
M 3 ~
M 3 ~
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the event of applications for industrial property rights.
Energy saving… but how?
Conventional systems
Constant speed AC motor with variable
displacement pump (i.e. pressure
compensated)
Flow rate is a function of swivel angle α:
Motor torque is a function of swivel angle,
α, and pump pressure, p:
n=constant
α 0% :
Vp(α) = 0
α 100 %:
Vp(α) = max
α
1000
)( volP nVQ
.20
)(
mech
PVpM
Vp(α) n= constant
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Energy saving… but how?
Conventional systems: overall efficiency
Swivel Angle [%] Load of Motor M/M_nominal [%]
Overall pump efficiency
for n= constant
Pu
mp
Eff
icie
ncy
[%
]
Mo
tor
Eff
icie
ncy [
%]
.20
)(
mech
VpM
Low pressure
High Pressure
Swept volume Swivel angle
V ~ α
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Energy saving… but how?
Conventional systems:
overall efficiency
Efficiency of conventional system
is low during partial load
operation:
Pressure Holding
Idling
For α <40-50%
High saving potential!
Q, p
n= const. Vp(α)
Pressure holding
Qsys/min
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Energy saving… but how?
10
1. Fixed displacement
pump
Constant speed
2. Variable disp. pump
Constant speed
3. Fixed/ var. disp. pump
Variable speed
M 60 Hz
M 60 Hz
M
Useful energy
Losses Total energy
Useful energy
Losses Total energy
Throttling losses
eliminated
Less power
consumption during
partial load operation
Useful energy
Losses Total energy
Minimized / no power
consumption during
partial load operation
Motor heating
Pump losses
Throttling losses (valve)
Lowest efficiency
during partial load
operation
Energy saving
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Saving energy and increasing productivity
SvP 7000
Basic performance High performance Advanced performance
FcP 5000 DFEn 5000
Sytronix
Sytronix – Bosch Rexroth Variable-Speed Pump
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Saving energy and increasing productivity
12
Sytronix – FcP 5000
Constant pressure system
basic performance required
pressure control
pressure control
Flow control
force control
speed control
position control
Control functions
Performance
Quadrants
1 flow
pressure
Machine tool
FcP 5000
System
Sample application
energy
efficient
M 3~
3~
P U
basic dynamics
basic accuracy
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Saving energy and increasing productivity
13
Sytronix – DFEn 5000
Constant pressure system
advanced performance required
pressure control
pressure control
Flow control
force control
speed control
position control
Control functions
Performance
Quadrants
1 flow
pressure
Wood working machine
DFEn 5000
System
Sample application
2
energy
efficient
M 3~
3~
P U
n_CMD
advanced dynamics
advanced accuracy
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Sytronix – DFEn 5000
Based on variable displacement pump A10VSO, pressure + stroke
control
Frequency converter (HCS03)
Standard motor (inverter duty)
Advanced dynamics
p/Q-control
Saving energy and increasing productivity
speed
flow
swivel angle
Maintain high pump
and motor efficiency,
swivel angle α>80%
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Saving energy and increasing productivity
15
Sytronix – SvP 7000
Axis control
high performance required
force control
speed control
position control
Press brake
SvP 7000
pressure control
Flow control
force control
speed control
position control
control functions
Performance
Quadrants
1 2
4 3
flow
pressure
System
Sample application
energy
efficient
M 3~
3~ SG
n
s
P U
high dynamics
high accuracy
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Sytronix – SvP 7000
Saving energy and increasing productivity
Internal Gear Pump PGH (Fixed Displacement Pump)
• Very high efficiency
• High drive speed
• Low pressure ripple
• Low noise
• Low mechanical inertia
Synchronous servo motor
• High dynamics
• Low mechanical inertia
• High power density
Servo frequency converter HCS03
• Dedicated flow and pressure controller (p/Q)
• Leakage detection/ compensation
• Safety functions; i.e. torque limitations, anti-cavitation
protection…
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SvP 7000 Pressure Control
Saving energy and increasing productivity
High accuracy pressure control
Pressure rise and fall times equal
(T95% < 150ms at oil volume < 5 l)
No overshoot or undershoot
pressure
10 bar
150bar
speed
3000 rpm
-3000 rpm
T95%= 150ms
0 s 1.5 s
low RPM during pressure hold
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SvP 7000 Flow Control
Saving energy and increasing productivity
High Dynamics improve cycle time
Flow control response twice as fast
as conventional hydraulic pumps
Can save approximately 400ms per
cycle (i. e. 5% improvement in an 8s
cycle)
High repeatability due to high
accuracy speed control
High accuracy at very low flows
Leakage detection and compensation
Flow Up Down
T25% 15 ms 10 ms
T50% 26 ms 18 ms
T75% 36 ms 24 ms
T100% 57 ms 35 ms
time T25%
System example SVP-SF-1X/075-S2
T50% T75% T100% T25% T50% T75% T100%
Up Down
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Functionality and Requirements
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Constant
pressure
system
Dynamics
300ms
p/Q, Pos
Marine &
Offshore
Metallurgy Bulk material
Handling Wood, paper
1
2
Axis-
control,
p/Q, Pos
p/Q
control
Dynamics
50ms
Dynamics
150ms
Dynamics
300ms
< 7,5 kW >7,5 to 37 kW >60 kW >37 to 60 kW
Machine
tools
Presses
Presses
Die casting Injection molding
machine
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Functionality and Requirements
20
Constant
pressure
system
Dynamics
300ms
p/Q, Pos
1
2
Axis-
control,
p/Q, Pos
p/Q
control
Dynamics
50ms
Dynamics
150ms
Dynamics
300ms
< 7,5 kW >7,5 to 37 kW >60 kW >37 to 60 kW
DFEn 5000
SVP 7000
FcP 5000
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Noise Reduction with Speed Variable Pump
21
RPM
Variable pump
Axial piston pump A10
71cc
50 bar
1750 RPM
Sytronix constant pump
Internal gear pump PGH
40 cc
50 bar
75 - 3000 RPM
Part load
-20dB(A)
Full load
-5dB(A)
No
ise
[d
B(A
)]
1
2 1
2
1
2
Partial load (pressure holding)
Full load (max flow rate)
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Application Example: FcP 5000 for Machining Center
22
* Energy mix, Germany according to GEMIS version 4.2 in year 2004: 0,613 kg CO2/kWh
** electricity tariff 0,14 €/KWh incl. 3,592 ct/KWh EEG-allocation
Rexroth Sytronix solution
• 4.0 kW motor
• Variable speed pump drive Sytronix
• 6cc internal gear pump
• Return line filter/cooler
Energy consumption 13.620 kWh/Yr
– 45 % Savings 10,980 kWh/Yr
1,537 €/Yr **
CO2-prevention* 6.7 tons/Yr
source: www.sw-machines.de
Energy
on Demand
Efficient
Components
Energy
System Design
Sytronix FcP 5000
Conventional drive solution:
• 5.5kW motor
• Control pump 250 bar / 13 l/min
• Fixed displacement pump for filter/cooler
Energy consumption 24.600 kWh/Yr
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Application example – Die Casting Machine
23
Conventional solution:
Constant speed drive
(11 kW motor) with fixed
displacement pump
Advanced solution:
Rexroth SvP variable-speed
pump drive
50 to clamp force
7.5 s cycle time
Energy consumption:
10.1 kW 1.7 kW Energy saving
83.2 %
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Application example – Rubber Injection Machine
24
Conventional solution:
Constant speed drive(15 kW
motor, load sensing) with
SYDFE pump
Advanced solution:
Rexroth SvP variable-speed
pump drive
50 to clamp force
7.5 s cycle time
Energy consumption:
2.9 kW 0.8 kW Energy saving
72.3 %
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Sytronix SVP 7000 Application
25
Requirements
Equip both hydraulic axis with controlled servo
variable pump drive (SvP)
Use existing interfaces
Machine Information
Press brake 135t
cycle time: 15sec
Press Brake
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Sytronix SVP 7000 Application
26
PLC
U x
U x
PLC
Safety control
power unit
Control block
with safety
functionality
Control block Control block
U x
U x
U x
Control block
with safety
functionality
Press Brake – Conventional Solution HMI
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Sytronix SVP 7000 Application
27
Press Brake – New Solution
Servo motor MSK
Digital servo drive HCS02
Axial piston pump A10
(4-quadrant)
Control block w/ switching
and safety valves
HMI
PLC
U x
U x
PLC
Safety control
Control block
with safety
functionality
Control block Control block
U x
U x
U x
Control block
with safety
functionality
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Sytronix SVP 7000 Application
28
Press Brake – Positioning Accuracy Conventional System SvP System A10 (6ccm)
(zoom of target position) (zoom of target position)
Fast Advance
hold time
Forming speed
fast return
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Sytronix SVP 7000 Application
29
Press Brake - Energy Consumption
t [s]
P[k
W] / E
[Wh]
axis position
power energy
SvP System A10 (6ccm)
x [m
m]
5 10 15
0
10
20
30
40
50
60
5 10 15-100
0
100
200
300
400
t [s]
P[k
W] / E
[Wh] axis position
power
energy
Conventional System
x [m
m]
Maximum electric power:
19kW 22kW
Total energy per cycle:
32,6Wh 19,2Wh
Stand-by power:
1,85kW 0,55kW
• Energy savings approximately 40% for typical press cycle
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Saving energy and increasing productivity
30
Energy efficient system design
Efficient components
Energy recovery
Energy on demand
Thank You
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the event of applications for industrial property rights.
Saving energy and increasing productivity
Jan Komsta
Tel: 610-694-8547
Mobile: 610-216-9034
www.boschrexroth-us.com
www.boschrexroth.com/sytronix
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Saving energy and increasing productivity
Application example: Ingersoll CM Systems, S-8255