Energy Efficiency in Industry with Bosch Rexroth - …€¦ · Mannesmann Rexroth with Bosch’s Automation Technology ... Rexroth 4EE – Rexroth for Energy Efficiency. 4 effective

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Energy Efficiency in Industry with Bosch Rexroth

A5

Scott C. HibbardV.P. TechnologyBosch Rexroth

03-Sep-2009


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Bosch Rexroth

Is a wholly-owned subsidiary of Robert Bosch GmbH

Is a result of the merger of Mannesmann Rexroth with Bosch’s Automation Technology

Covers All relevant technology forDrive, Control and Motion

Is dedicated to industrial and factory automation, and mobile applications

Has a worldwide presence


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Bosch Rexroth 1)

Packaging Technology

The Company – Within the Bosch Group

Bosch GroupRevenue: € 45.1 billion

Employees 1/1/2008: 281,700

Consumer Goods & Building Services

Engineering(€11.9B)

Industrial Technology

(€6.7B)

1) Bosch Rexroth AG (Bosch wholly owned)

Automobile Technology

(€26.5B)

2008 figures


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The Company – Bosch Rexroth Data

Bosch Rexroth AG 2008 Figures

Total revenue€ 5,882 million

Germany:€ 1,705 million

Europe minus Germany:€ 2,329 million

Americas:€ 897 million

Asia/RoW:€ 950 million

Total employees35,309

Germany:18,701

Europe minus Germany:8,423

Americas:3,474

Asia/RoW:4,711

Research and development

total:€ 263 million

Cost share of revenue:4.5 %

Investments

total:€ 568 million

Cost share of revenue:9.7 %


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Bosch Rexroth in the Americas


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Bosch Rexroth – The Products

Hydraulics,mobile

Hydraulics, industrial

Gears

Electric drives andcontrols

Linearmotion

technology

Assemblytechnologies

Pneumatics

Service


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Bosch Rexroth – The Markets

Industrial and factory automation as well as mobile applications

Rexroth services are used worldwide in nearly all industries ...


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Energy and Environment in Focus at Bosch Rexroth

Renewable energy production (wind, solar, ocean)

Innovative Drive and Control Solutions from RexrothBenefits for the User and the Environment

Energy efficient drive and control solutions for the field of factory automation

Fuel efficiency and emissions reduction for commercial vehicles and mobile applications


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Energy Efficiency Solutions for Production Equipment

Drives &Controls

Motors CylindersClamping HMI Transfer Modules

BallScrews

Components

Valves

Efficient components, systems & software enable high energy savings potential in production machinery and systems

Systems & Software

Variable Speed Pump Systems Pneumatic SystemsMulti-Axes

SystemsConveyor-Systems


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Basic Principles to Optimize Energy Efficiency Rexroth 4EE – Rexroth for Energy Efficiency

4 effective principles for energy efficient solutions

Efficient Components

Products and Systems with optimum efficiency

Energy Recovery

Recovery and storage of surplus energy

Energy on Demand

Demand-based energy usage, Stand-by-Mode

Energy ConsciousSystem Design

Total system design, perfect project engineering, simulation & consulting

Concept Design Engineering Startup Production/usage Modernization

…. Work in the total machine life-cycle

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Principle 1: Efficient Components

High efficiencyservo drive controller

Brushless PWM principle permanent magnet motor design 97 % Efficiency

Energy efficient Drive & Control Technology

Energy Saving Valve Bus Modules

Throttles power back after valve actuation Uses PWM technology Up to 66% lower power consumption

Volume-optimized pneumatic valves

Reduce line losses using cylinder-integrated valves

Up to 30% air savings

Roller blocks Roller bearing technology with low friction

coefficient replaces conventional sliding way technology


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Principle 2: Energy Recovery

Power Supply

(AC DC)

Servo or VF Drive

(DC ◄► AC)

Motor

Driving

Generating


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Principle 3: Energy on Demand

Speed-Variable Pump Drive (SvP)

Speed on demand – reduction of motor speed and thus pump power duringpauses or in part-load operation,without impacting control tasks.

Increase in efficiency – Energy savings Clear reduction in idle-running power –

in part-load mode / zero stroke thedrive goes into “stand-by function”.

Less energy/heat transfer into the oil, meaning less cooling required

Positive impact on heat regulation, energy consumption and costs Noise reduction thanks to spontaneously controlled and lower speeds. Reduction in installed power (size of components).

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Principle 4: Energy Conscious System Design

Cycle Time Analysis Tool

Machine &ProcessAnalysis

Multi-Channel /Multi ProcessAnalysis

Example: Machine Tool

Control/ HMI

Peripherals

Drives

Linear-technology

Pneumatics

Hydraulics

Energy Analysis Tool

Machine Overview Energy-

Oscilloscope Energy Analysis

Machine &ProcessOverview


Regenerating Supplies Returns decel energy

back to linesEnergy Savings ca. 20%

Example: Decentralized Drive Technology

Additional Savings Less resources: Cable,

cabinets etc. Reduced Cooling

requirement inside the cabinets and plant

Common DC Bus Energy exchange between

driving & generating motorsEnergy Savings ca. 15%

Synchronous motors High energy permanent

magnets on the rotor, enhanced stator wiring.

Energy Savings ca. 3%

Reduction of primary energy consumption in Producing the

equipment System lay-out Daily production

Capacitor Modules Energy BufferingEnergy Savings ca. 3%

* The figures shown represent typical values. The actual savings can be higher or lower, depending on the actual application.


Example: Plastic Molding Press with SvP

Conventional OEM Drive Application:Hydraulic fixed displacement pump with 2 control blocks and pressure valveMain process: 67,067 kWh/aSecondary process (cooling): 44,774 kWh/aEnergy intake of the plastic molding press: 111,861 kWh/a

Rexroth Automation Solution with Energy Savings Speed variable pump Energy Recovery via drive power supplies

with line regeneration Highly efficient synchronous servo motors

Energy intake of the plastic molding press : 24,965 kWh/aMain process: 17,704 kWh/aSecondary process (cooling): 7,261 kWh/a

Energy savings: 86,895 kWh/a (-78%)CO2 Reduction (0.613 kg CO2/kWh*): 53 t

*Energy mix, Germany according to GEMIS Version 4.2, reference 2004


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Ensemble of Measures for Energy efficient Systems

Demand controlled pneumatic valves

Cycle time analysis tool

Energy analysis tool

Regenerative power supplies

Efficient electric motors

low friction roller blocks

Variable speed hydraulic pumps

System oriented approach

Decentralized drive technology

www.boschrexroth-us.com/sustainable

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Energy Efficiency in Industry with Bosch Rexroth - …€¦ · Mannesmann Rexroth with Bosch’s Automation Technology ... Rexroth 4EE – Rexroth for Energy Efficiency. 4 effective