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Rexroth variable speed pump
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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
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.
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
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.
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
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.
Energy and the Environment Current Challenges
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
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.
Energy and the Environment Current Challenges
Growth in energy costs will continue
5
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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)
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.
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
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.
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
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.
Pump selection
Fixed or variable displacement?
M mechpVpM
=20
17
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.
Pump selection
Fixed or variable displacement?
mech
pVpM
=
20)(
M
Pump displacement is reduced A10 VZO pump with two-point control
Reduced load torque during pressure holding
18
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
Engineering: System Simulation
System simulation verify your ideas
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
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.
Engineering: System Simulation
System simulation verify your ideas
Various process variables (speed, position, pressure, power, pump speed etc)
Evaluation of the simulation: Productivity (cycle time) Dynamic behavior Efficiency
26
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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