variable speed pump komsta powerpoint presentation

11.19.2013 | DCUS SET | Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Sy

Jan Komsta, Ph.D. Bosch Rexroth 11.19.2013 Chicago

Variable Speed Pump Drives for Industrial Machinery System Considerations

1


Variable Speed Pump Drives for Industrial Machinery

Why speed variable pumps?

Reduced energy consumption

Reduced average noise

Compact power unit Reduced cooling requirements for oil

High robustness

Intelligent hydraulic drive

2


Energy and the Environment Current Challenges

Policy assumptions for 2020* USA

23%** share of renewables in electricity generation

European Union

20 % reduction in greenhouse gas emissions compared with 1990

China

40 % reduction in CO2 intensity compared with 2005

Russia

15 % reduction in greenhouse gas emissions compared with 1990

Brazil

36 % reduction in greenhouse gas emissions compared with no measures

India

20 % reduction in CO2 intensity compared with 2005

Energy consumption is the driver New Policies Scenario, World Energy Outlook 2012

** By 2035

3



Manufacturing systems life cycle costs (TCO)

Machinery &

Equipment

Investment costs Operating costs

Initial startup

Training

Spare parts

Maintenance

Labor costs

Taxes

Insurances

Energy Modernization

Disposal

...

80...95 %

5...20 %

Three phase motor 1 kW 5 year running time

Cost price ~ $250 (4%)

Energy costs ~ $5.950 (96%)

Example

4



Growth in energy costs will continue

5


Technology Change

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

with /without valves

Variable speed motor drive

6


Energy saving potential

Full motor speed during part load operation.

Pump mechanical losses caused by high rotation speed

Lower motor and pump efficiency during part load operation

High throttling losses caused by proportional valves

Technology Change

Classic Solution

Motor losses

Pump losses

Throttling losses

Useful energy

Total energy

M

7


Energy saving potential

No throttling losses from proportional valves

40-70% speed reduction during part load operation

Increased pump and motor efficiency during part load operation

Reduced pump losses by lowering average motor RPM

Additional inverter losses

Technology Change

Variable Speed Pump Drives

Inverter losses

Pump losses

Useful energy

Motor losses

Total energy

M

8


System Solutions

(esp. for >60kW)

VFD + PM motor* + variable pump

VFD + AC motor + variable pump

AC motor + fixed pump

VFD + AC motor + fixed pump

AC motor + variable pump

Efficiency

(esp. for >60kW)

VFD + PM motor* + fixed pump

Costs Dynamics

M

M

M

M

M

M

* permanent magnet synchronous motor

9


System Considerations: Pump Selection

Which pumps are suitable for variable speed operation?

???

Speed range Pressure range Direction of rotation Pump efficiency Pump noise Flow and pressure pulsation Pump inertia Quadrants of operation

10


Pump speed and pressure limitations Pump selection

Noise limit

- Motor Fan

- Pump (high frequency) temporary

operation possible (i.e. for gear pumps)

Pressure cont.

Cavitation Power lowest speed for continuous operation (i.e. for gear pumps)

p [b

ar]

n [RPM]

Pressure int.

Highest efficiency

11


Noise reduction Pump noise depends on:

Pump construction Speed and pressure

Noise Reduction

40

50

60

70

80

0 1000 2000 3000

Pum

p no

ise

leve

l in

dB(A

)

Pump RPM

Axial piston pump Internal gear pump

40

50

60

70

80

0 1000 2000 3000 Pump RPM

Axial piston pump p= 50 bar

p= 200bar

12


Pump selection

Quadrants of operation

- Flow

+ Flow

pressure

Pump operation

Pump operation

Motor operation

Motor operation

- Flow

+ Flow

pressure

Pump operation

Pump operation

Motor operation

Motor operation

Internal gear pump e.g. PGH

Axial piston pumps e.g. A10 FZG / VZG (for closed circuits)

Axial piston pumps e.g. A10 VZO

13


Pump selection

Mechanical inertia / dynamics

Internal gear pump+PM Motor Axial piston pump+PM Motor

0%

20%

40%

60%

80%

100%

120%

140%

060 075 100 120 150 190 240 300

Mec

hani

cal i

nert

ia

Maximum Flow (LPM)

Distribution of mechanical inertia of the pump drive 100% = total mechanical inertia of system using internal gear pump

0%

20%

40%

60%

80%

100%

120%

140%

060 075 100 120 150 190 240 300

Maximum Flow (LPM)

PM Motor

Pump

Coupling

14

0%

20%

40%

60%

80%

100%

120%

060 075 100 120 150 190 240 300

Mec

hani

cal in

ertia

Maximum Flow (LPM)


Pump selection

Direct coupling

Internal gear pump+PM Motor PM Motor Pump

Reduced inertia

Reduced mechanical inertia Better dynamics (higher acceleration capabilities) Higher efficiency Less mounting space (no bell-housing)

Direct coupling

Sytronix SVP 7000

15


Pump selection

Fixed or variable displacement?

Power consumption for pressure holding

Source: Prof. S. Helduser*, Elektrisch-hydraulische Systemtechnik, O&P 1/2006

*IFD, Technical University Dresden, Germany

0

1

2

3

4

5

6

7

8

0 50 100 150 200 250

Inpu

t Pow

er P

(kW

)

Pressure p (bar)

Variable displacement pump, n=1500 RPM

Variable displacement pump + VFD

Fixed displacement pump + VFD

M

M

M

16


Pump selection


M mechpVpM

=20

17


Pump selection


mech

pVpM

=

20)(

M

Pump displacement is reduced A10 VZO pump with two-point control

Reduced load torque during pressure holding

18


Pump selection

Performance curve VFD + self-ventilated AC motor

Axial piston pump with two-point control - A10VZO-EZ4

Fixed displacement internal gear pump- PGH

19

Pump pressure Pump Pressure

Pump speed Pump speed

- Continuous VFD operation

Vgmax max. pump displacement Vgmin min. pump displacement

EZ4


Energy Saving

Consider overall efficiency

M

PMMs drive efficiency

Load

Tor

que

Speed

Pump efficiency

Spe

ed

Pump pressure

Adapt pump displacement to operate in preferred working points

20


Energy Saving by Reducing Motor Speed

Energy saving during stand-by/ idling

0

0.5

1

1.5

2

2.5

3

3.5

4

0 200 400 600 800 1000 1200 1400 1600

Inpu

t Pow

er P

(kW

)

Motor speed n (rpm)

Power consumption of electric motor during standby/ idle Pump size 100cc 40 HP AC motor 600 PSI, 0.25 GPM flow (pilot oil)

M

Sytronix DFEn 5000

21


Energy Saving by Reducing Motor Speed

Energy saving by reducing motor speed

Power consumption of electric motor during pressure holding (Q=0 GPM)

= Hydraulic Output Power / Electric Input Power pump A4 125cc 100 HP AC motor

0

2

4

6

8

10

12

0 1000 2000 3000 4000

Inpu

t Pow

er P

(kW

)

Pressure p (PSI)

Variable displacement pump+VFD

Variable displacement pump, @ 1800 RPM

0.40

0.50

0.60

0.70

0.80

5 15 25 35 45

Effic

ienc

y

Q (GPM)

Efficiency @2200 psi

Variable displacement pump+VFD

Variable displacement pump, @1800 RPM

Sytronix DFEn 5000

22


Engineering: System Sizing in SytronixSize

Machine load cycle (p/Q/t)

Select the pump type and size

Investigate drive working points, drive utilization factors, RMS power

23


Engineering: System Simulation

System simulation verify your ideas

Model of hydraulic actuators, valves, process forces, lines, etc.

Closed loop control algorithm

Speed Variable Pump HPU

24




Internal gear pump model, including efficiency (working point dependent)

VFD, firmware and p/Q control algorithm

Model of PMM Servo Motor with Torque-Speed characteristics

25




Various process variables (speed, position, pressure, power, pump speed etc)

Evaluation of the simulation: Productivity (cycle time) Dynamic behavior Efficiency

26


Sytronix: Bosch Rexroths Variable Speed Pump Drives

Preconfigured Sets

Sytronix FcP

Sytronix

27

Pressure and flow control

Basic dynamics

Sytronix SVP

Pressure and flow control Force and velocity control Position control

High dynamics

Sytronix DFEn

Pressure and flow control Power control

High dynamics & high power

Custom Solutions

Custom system functions Pressure and flow control Force and velocity control Position control

SvP 7000 High performance

Axis control high

performance required

force control speed control position control

injection molding machine

press brake

11.19.2013 | | DC-IA/PJ-HDC Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

System Variants- SVP

SvP 7000

pressure control flow rate control force control speed control position control

control functions

high dynamics

high accuracy energy efficient

performance

quadrants

1 2

4 3 flow

pressure

system

sample application

n

s

3~

3~ SG

P U

M

Axis control high performance

required pressure control flow rate control

28

SvP 7000 High performance


System Variants- SVP

pressure

10 bar

150bar

speed

3000 rpm

-3000 rpm

T95%= 150ms

0 s 1.5 s

low RPM during pressure hold

29

DFEn Advanced performance

Axis control advanced performance

required pressure control flow rate control

constant pressure system advanced performance

required pressure control


System Variants- DFEn

pressure control flow rate control force control speed control position control

control functions

advanced dynamics

advanced accuracy

energy efficient

performance

quadrants

1 flow

pressure

injection molding machine

paper

DFEn 5000

system

sample application

nCMD

2

2 independent hydraulic circuits

possible

M 3~

3~

P U

30

Variable speed mode and constant speed mode

11.19.2013 | Abteilung | Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

System Variants- DFEn

speed

flow

swivel angle

speed

flow

swivel angle

constant speed mode variable speed mode

31


Solution examples

Slide title

1 n=const 2 n=const 3 n=var. 4 n=var. 5 n=var.

AC motor + 2x fixed pumps

AC motor + variable pump

VFD +AC motor + fixed pump

VFD +AC motor + variable pump (hydr. control)

VFD +AC motor + variable pump (electric control)

6 n=var. 7 n=var. 8 n=var. 9 n=var. 10 n=var.

VFD +AC motor + variable pump + fixed pump

VFD +PMM motor + fixed pump

VFD +PMM motor + fixed pump

2x VFD +2x PMM motor + 2x fixed pump

VFD +PMM motor + variable pump (hydr. control)

32


Compact Hydraulic Axis Solution examples: Compact Axis

Position accuracy 1 m

Max. press force up to 6200 kN (over the entire press stroke)

Pressure control 0.3 bar

Rapid speed forward and return 1000 mm/s

Safety functions up to Performance Level e, SIL3

Stroke 450 mm, max. 3000 mm

The hydraulic circuit completely integrated into the module

33


Cross Technology System Integration

HPUs and actuators go smart and efficient

MLC Process control

IAC-R

sercos

Smart HPU with Sytronix

Sytronix Compact Axis

Electro Mechanical Actuator

Electro hydraulic linear cylinder

Process/ Motion Control

Integrated automation bus for real time communication

IndraDrive MLD Open platform for integration of advanced control and monitoring functions

Actuators matching different applications

Smart HPU Compact and modular design wide range of sensors

34


Increased efficiency Application Injection Mould Machine

Sytronix DFEn 5000

New Machine ]

Efficient Components

Energy on Demand

Energy System Design

Former solution: - Standard hydraulic solution DFEC - Asynchronous motor fixed rpm - Installed power: 11 kW -75 kW - operation: 24h/240days

Sytronix solution:

Customer requirements: Energy saving

Optimal pressure/ flow control Reduced cooling capacity Reduced noise level Energy efficient system for master master

double pump configuration

10,000 kWh 1,000 EUR 3,900 kg CO2

-34%

Comparison / Saving:

Machine size : From 110 up to 430 Ton.

0.028 0.018

10.9 0.7

Energy consumption per year [Mio. kWh

CO2 emission per year [to]

35


Increased Efficiency Application Injection Mould Machine

Energy consumption per cycle [kWh]

Energy consumption per year [Mio. kWh]

CO2 emission per year [to]

4,9

3,2

- 34 % Savings per year: 10,000 kWh, 1,000 EUR ** 3900 kg CO2 ***

base: ** 10ct/kWh *** 240g / kWh electrical motor power 11kW

former solution Rexroth Sytronix solution

4.9

3.2

0.028

0.018

10.9

0.7

36


Application Injection Molding Machine Field tests: Reduced operating power constant vs. variable speed DFE systems

55 ton closing force, 45 cc pump, 11kW motor: Cycle time 8s: 10% Cycle time 25s: 20% Cycle time 60s: 45%

160 ton closing force, 100 cc pump, 30kW motor: Cycle time 10s: 8% Cycle time 20s: 32% Cycle time 40s: 44%

140 ton closing force, 71 cc pump, 15kW motor: Cycle time 27s: 45%

Application Injection Mould Machine

250 ton closing force, 140cc + 64cc (regenerative) pump, 55kW motor with accumulator: Cycle time 20s: 8%

270 ton closing force, 140cc + 71cc (regenerative) pump, 55kW motor: Cycle time 45s: 30%

37

Advantages


Summary

Energy saving Depending on the application cycle, variable speed pump drives from Rexroth can reduce energy consumption by 10 to 80 %. Low energy consumption results in reduced energy costs and lowers the users Carbon Footprint.

Noise Level Reduction Noise is reduced during partial load operation as a result of lower pump RPM. Average noise reductions of up to 20 dBA can be achieved. Installation costs may be reduced if sound insulation designs are not needed

Reduced Cooling In many applications, cooling may not be required on the hydraulic power unit since high operating efficiency reduces hydraulic system heating

38

Advantages


Summary

Less Mounting Space

Hydraulic and Electric standard components

Forward Looking Technology

Eliminating system cooling allows for a more compact design, reduced complexity and lower cost .

Variable speed pump drives utilize standard hydraulic components.

Variable speed pump drives can help customer requirements for energy conservation.

Easy Integration of flexible control functions Advanced diagnosis and monitoring can help avoid costly machine failures.

39


Thank you for your attention! Jan Komsta Manager, New Technologies & Simulation (DCUS/SET1) Tel: +1 610-694-8547 Mobile: +1 610-216-9034 [email protected]

Sytronix DFEn 5000

40

SyWhy speed variable pumps? Policy assumptions for 2020*Manufacturing systems life cycle costs (TCO)Growth in energy costs will continueSlide Number 6Energy saving potentialEnergy saving potentialSlide Number 9Slide Number 10Pump speed and pressure limitations Noise reductionQuadrants of operationMechanical inertia / dynamics Direct coupling Slide Number 16Slide Number 17Slide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 23System simulation verify your ideasSystem simulation verify your ideasSystem simulation verify your ideasSlide Number 27Slide Number 28Slide Number 29Slide Number 30Slide Number 31Slide titleCompact Hydraulic AxisHPUs and actuators go smart and efficient Increased efficiencyIncreased EfficiencyApplication Injection Molding MachineSlide Number 38Slide Number 39Slide Number 40

variable speed pump komsta powerpoint presentation

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