SViblS dP Di f Id tilV yariable Speed Pump Drives for ... · PDF fileSViblS dP Di f Id tilVyariable Speed Pump Drives for Industrial Machinery – System Considerations JK tPhDJan

SV i bl S d P D i f I d t i lSyVariable Speed Pump Drives for Industrial Machinery – System Considerations

J K t Ph DJan Komsta, Ph.D.Bosch Rexroth

Drive for Technology Expo Hanover Park IL April 15 16 2014

04.15.2014 | DCUS SET | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Drive for Technology Expo, Hanover Park, IL, April 15-16, 2014

1

Variable Speed Pump Drives for Industrial Machinery

Why speed variable pumps?Why speed variable pumps?

Reduced energy consumption

Reduced average noise

Compact power unit

Reduced cooling requirements for oil

High robustness

Intelligent hydraulic drive

04.15.2014 | DCUS SET | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.2

Energy and the Environment – Current Challenges

Policy assumptions for 2020*Policy assumptions for 2020USA European

Union China Russia Brazil India

23%** 20 % 40 %15 % 36 %20 %23%share

of renewables in electricity

20 % reduction

in greenhouse

40 % reduction

in CO2intensity

15 % reduction

in greenhouse

36 % reduction

in greenhouse gas emissions

20 % reduction

in CO2intensity y

generation gas emissions compared with 1990

compared with 2005

ggas emissions compared with 1990

compared with no measures

compared with 2005

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


•** By 2035

3


Manufacturing systems life cycle costs (TCO)Manufacturing systems life cycle costs (TCO)

80...95 % Energy costs~ $5.950 (96%)

Initial startupTraining

Spare partsM i t

Cost price~ $250 (4%)

$5.950 (96%)

MaintenanceLabor costs

TaxesInsurances

Machinery

EnergyModernization

5...20 %y

& Equipment

Investment costs Operating costs

Disposal...

Three phase motor 1 kW5 year running time

Example


Investment costs Operating costs Example

4


Growth in energy costs will continueGrowth in energy costs will continue


Technology Change

drive power transmission Propertiesdrive power transmission PropertiesHydraulic pump control motor /

cylinderPower density, robustnessControllability Multiple consumers possible

Constant speed electric motor classic hydraulics

Noise Energy efficiency

Hydraulic pump motor /cylinder

Power density, robustnessControllability Multiple consumers possibleEnergy efficiency

with /without valves

Variable speed

Force transmission Spindle drive ControllabilityN i

Noisevariable speed pumps

Variable speed motor drive

Electro-mechanicVariable speed

motor drive

Noise Energy efficiency

Multiple consumers not possible (or very difficult) Power density


Electro mechanicmotor drive Power density

6

Energy saving potentialTechnology Change

Energy saving potential Classic Solution

Full motor speed during part load operation. Pump mechanical losses caused by

Mp y

high rotation speed Lower motor and pump efficiency

during part load operation High throttling losses caused by

Motor losses

Pump lossesproportional valves

Throttling lossesTotal

energy

Useful energy


Energy saving potentialTechnology Change

Energy saving potential Variable Speed Pump Drives

No throttling losses from proportional valves 40-70% speed reduction during part

Mp g p

load operation Increased pump and motor efficiency

during part load operation Reduced pump losses by lowering

Inverter losses

Pump losses

Motor losses

average motor RPM Additional inverter losses

p

U f l

Total energy

Useful energy


System Solutions

Efficiency CostsDynamics

AC motor+ fixed pump

AC motor

M

M

VFD+ AC motor

fi d

+ variable pumpM

M

VFD+ AC motor + variable pump

+ fixed pump

Mp p

(esp for >60kW)

VFD+ PM motor* + fixed pump

M

(esp. for >60kW)

VFD+ PM motor* + variable pump

(esp. for >60kW)

M


* permanent magnet synchronous motor

9

System Considerations: Pump Selection

Which pumps are suitable for variable speedWhich 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 …


Pump speed and pressure limitationsPump selection

Pump speed and pressure limitations

CavitationPowerlowest speed

Pressure int

Pressure cont.

lowest speedfor continuous operation (i f

int.

Noise limit

- Motor Fan

(i.e. for gear pumps)

bar]

Hi h t ffi i - Pump (highfrequency)temporary

operation possible

p [b Highest efficiency

possible (i.e. for gear pumps)


n [RPM]

11

Noise reductionNoise Reduction

Noise reduction Pump noise depends on:

Pump construction Speed and pressure …

70

80

dB(A

)

70

80

60

70

oise

leve

l in

Axial piston pump

60Axial piston pump

p= 50 bar

40

50

0 1000 2000 3000

Pum

p no Axial piston pump

Internal gear pump

40

50

0 1000 2000 3000

p= 50 bar

p= 200bar


Pump RPM Pump RPM

12

Pump selection

Quadrants of operationQuadrants of operation+ Flow

Pump operationMotor operation

pressure

A i l i t

- Flow

Pump operation Motor operation

+ Flow

Internal gear pump e.g. PGH

Axial piston pumpse.g. A10 VZO

pressure

Pump operationMotor operation

Fl

Pump operation Motor operation Axial piston pumpse.g. A10 FZG / VZG (for closed circuits)


- Flow

13

Pump selection

Mechanical inertia / dynamicsMechanical inertia / dynamics

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

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

100% total mechanical inertia of system using internal gear pump

100%

120%

140%

tia

100%

120%

140%

PM

PumpCoupling

40%

60%

80%

100%

Mecha

nical ine

r

40%

60%

80%

100% Motor

0%

20%

060 075 100 120 150 190 240 300

Maximum Flow (LPM)

0%

20%

060 075 100 120 150 190 240 300

Maximum Flow (LPM)


Pump selection

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

Di t li

120%

Internal gear pump+PM MotorPM MotorPump

Direct coupling

60%

80%

100%

anica

l inertia

PM Motor

Reduced inertia

0%

20%

40%

060 075 100 120 150 190 240 300

Mecha

Sytronix SVP 7000

Maximum Flow (LPM)


Pump selection

Fixed or variable displacement?Fixed or variable displacement?

7

8

Variable displacement pump, n=1500 RPM M

4

5

6

wer

P (k

W)

Variable displacement pump + VFD

Fixed displacement pump + VFD M

2

3

4

Inpu

t Pow

M

0

1

0 50 100 150 200 250Pressure p (bar)

Power consumption for pressure holding Source: Prof. S. Helduser*, ‘Elektrisch-hydraulische Systemtechnik’, O&P 1/2006

*IFD Technical University Dresden Germany

Pressure p (bar)


IFD, Technical University Dresden, Germany

16

Pump selection


Mmech

pVpM

20


M

17

Pump selection


Pump displacement is reduced

A10 VZO pump with two-point control

Reduced load torque during pressure holding

mech

pVpM

20)(

M


M

18

Pump selection

Performance curvePerformance curveVFD + self-ventilated AC motor

Axial piston pump with two point controlFixed displacement internal Axial piston pump with two-point control - A10VZO-EZ4

Fixed displacement internal gear pump- PGH

Pump pressure Pump Pressure

EZ4

Pump speed Pump speed Vgmax– max. pump displacement

Vgmin – min. pump displacement


- Continuous VFD operation displacement

19

Energy Saving

Consider overall efficiencyConsider overall efficiencyPMM’s drive efficiency

Pump efficiency

peedAdapt pump displacement to

Torq

ue

SpAdapt pump displacement to

operate in preferred working points

Load

Pump pressure

M


Speed

20

Energy Saving by Reducing Motor Speed

Energy saving during stand-by/ idlingEnergy saving during stand by/ idling

3.5

4

2

2.5

3

ower

P (k

W)

M

0.5

1

1.5

Inpu

t Po

0

0.5

0 200 400 600 800 1000 1200 1400 1600Motor speed n (rpm)

Sytronix DFEn 5000

Power consumption of electric motor during standby/ idle Pump size 100cc 40 HP AC motor

600 PSI 0 2 GPM fl ( il il)


600 PSI, 0.25 GPM flow (pilot oil)

21

Energy Saving by Reducing Motor Speed

Energy saving by reducing motor speedEnergy saving by reducing motor speed

10

12Variable displacement pump+VFD

Variable displacement pump, @ 1800 RPM 0.80Efficiency @2200 psi

4

6

8

10

t Pow

er P

(kW

)

0.60

0.70

ffici

ency

Variable displacement pump+VFD

0

2

4

0 1000 2000 3000 4000

Inpu

t

Pressure p (PSI)

0.40

0.50

5 15 25 35 45

Ef

Q (GPM)

pump+VFD

Variable displacement pump, @1800 RPM

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

η = Hydraulic Output Power / Electric Input Power

Pressure p (PSI) Q (GPM)

pump A4 125cc 100 HP AC motor

S


Sytronix DFEn 5000

22

Engineering: System Sizing in SytronixSize

Machine load cycle (p/Q/t)Machine load cycle (p/Q/t)

Select the pump type and size

Investigate drive working points,drive utilization factors, RMS power


RMS power …

23

Engineering: System Simulation

System simulation – verify your ideasSystem simulation verify your ideas

M d l f h d liModel of hydraulic actuators, valves, process forces, lines, etcetc.

Closed loop control algorithm

Speed Variable Pump HPU


HPU

24



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

VFD, firmware and p/Q control algorithmp/Q control algorithm

Model of PMM Servo Motor with Torque-Speed characteristics




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

d t )speed etc…)

Evaluation of the simulation:P d ti it ( l ti ) Productivity (cycle time) Dynamic behavior Efficiency


Sytronix: Bosch Rexroth’s Variable Speed Pump Drives

SytronixPreconfigured Sets

Sytronix FcP Sytronix SVP Sytronix DFEn

•Pressure and flow control •Pressure and flow control •Pressure and flow controlPressure and flow control

Basic dynamics

•Force and velocity control•Position control

High dynamics

•Power control

High dynamics & high power

Custom Solutions

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


SVP – High performanceSystem Variants- SVP

SVP High performance

injection molding machineSvP 7000

high dynamics

high accuracyenergy

efficient

performance sample application

pressure control

flow rate control

control functions

g accu acy

Axis control high performance

press brake

flow rate control

force control

speed control

systemP

U

g prequired

pressure control flow rate control

Axis control high

performance

p

position control

quadrantspressure

n

s

SGrequired

force control speed control position control

12

43flow 3~

3~SG

M

04.15.2014 | | DC-IA/PJ-HDC© Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.28

SVP – High performanceSystem Variants- SVP

SVP High performancepressure

150bar

10 bar

3000 rpmT95%= 150ms

low RPM during pressure hold

speed-3000 rpm0 s 1.5 s

low RPM during pressure hold


1.5 s

29

DFEn – Advanced performanceSystem Variants- DFEn

DFEn Advanced performance

advanced dynamics

advanced accuracyenergy

efficient

performanceinjection molding machine

DFEn 5000 sample application2 independent

hydraulic circuitspossible

Axis control advanced performance

pressure control

flow rate control

control functions

y

advanced performance required

pressure control flow rate control

flow rate control

force control

speed control paper

system

position control

quadrantspressure

p p

nCMD

PU

constant pressure system advanced performance

required pressure control

1flow

2 M3~

3~


Variable speed mode and constant speed mode

System Variants- DFEn

Variable speed mode and constant speed mode

constant speed mode variable speed mode

speed

speed

flow

speed

swivel angle

flow

swivel angle


Solution examples

Slide title1 n=const 2 n=const 3 n=var. 4 n=var. 5 n=var.Slide titleAC 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 (electriccontrol)

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

VFD +AC motor+ variable pump + fixed

VFD +PMM motor+ fixed pump

VFD +PMM motor+ fixed pump

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

VFD +PMM motor+ variable pump (hydr+ variable pump + fixed

pump+ fixed pump + fixed pump + 2x fixed pump + variable pump (hydr.

control)


Compact Hydraulic AxisSolution examples: Compact Axis

Compact Hydraulic Axis

The hydraulic circuit completely integrated into the d l

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

module

(over the entire press stroke)

Pressure control ± 0.3 bar

St k 450 3000

Rapid speed forward and return 1000 mm/s

Stroke 450 mm, max. 3000 mm

Position accuracy ± 1 µm

Safety functions up to Performance Level e, SIL3


Cross Technology System Integration

HPUs and actuators go smart and efficient g

MLCProcess control

Process/ Motion Control

sercos

Integrated automation bus for real time communication

I d D i MLD

IAC-R

IndraDrive MLDOpen platform for integration of advanced control and monitoring functions

IAC RSmart HPU Compact and modular design wide range of sensors

Smart HPU with

Sytronix Compact

ElectroMechanical

Electrohydraulic

Actuators matching different applications


withSytronix

pAxis

MechanicalActuator

hydrauliclinear cylinder

34

Increased efficiencyApplication Injection Mould Machine

Increased efficiencyNew Machine

]

Former solution:- Standard hydraulic solution DFEC- Asynchronous motor fixed rpm

I t ll d 11 kW 75 kW- Installed power: 11 kW -75 kW - operation: 24h/240days

Customer requirements: Energy savingMachine size :

Sytronix solution:

requirements: gy g

Optimal pressure/ flow control Reduced cooling capacity

Machine size :From 110 up to 430 Ton.

Sytronix DFEn 5000

Energy

g p y Reduced noise level Energy efficient system for master – master

double pump configuration

Comparison / Saving:

EfficientComponents

Energy D d

Energy System Design

10,000 kWh1,000 EUR3,900 kg CO2

34%

Comparison / Saving:

0.0280.018

10.90.7

Energy consumption per year [Mio. kWh

CO2 emission per year [to]


on Demand-34%

35

Increased EfficiencyApplication Injection Mould Machine

former solutionIncreased Efficiency

Energy consumption Energy consumption CO2 emission

former solutionRexroth Sytronix solution

gy pper cycle [kWh]

gy pper year [Mio. kWh] per year [to]

4 9

0.028

0 018

10.9

0 74,9

3,2

4.9

3.2

0.018 0.7

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

3900 kg CO2 ***


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

36

Application – Injection Molding MachineApplication Injection Mould Machine

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

160 ton closing force, 100 cc pump, 30kW motor:

55 t l i f 45 11kW t

Cycle time 10s: 8% Cycle time 20s: 32% Cycle time 40s: 44%

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

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

250 ton closing force 140cc + 64cc (regenerative) pump 55kW motor with accumulator: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:C l ti 45 30%


Cycle time 45s: 30%

37

AdvantagesSummary

Advantages

Energy savingDepending on the application cycle variable speed pump drives from Rexroth canDepending 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 user’s “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 p ysound insulation designs are not needed

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


AdvantagesSummary

AdvantagesLess Mounting SpaceEliminating system cooling allows for a more compact design, reduced complexity and

Hydraulic and Electric standard components

g y g p g , p ylower cost .

Variable speed pump drives utilize standard hydraulic components.

Forward Looking TechnologyVariable speed pump drives can help customer requirements for energy conservation.

Easy Integration of flexible control functionsEasy Integration of flexible control functionsAdvanced diagnosis and monitoring can help avoid costly machine failures.


Thank you for yourThank you for your attention!

Jan Komsta

Manager, New Technologies & g gSimulation (DCUS/SET1)

Tel: +1 610-694-8547Mobile: +1 [email protected]

Sytronix DFEn 5000


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SViblS dP Di f Id tilV yariable Speed Pump Drives for ... · PDF fileSViblS dP Di f Id tilVyariable Speed Pump Drives for Industrial Machinery – System Considerations JK tPhDJan