© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Motion control application – A novel approach with
servo pump systems
ENERGY EFFICIENCY ON HYDRAULICS
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Culture
Miss ion:
▪ The company 's miss ion is to prov ide a Mot ion Cont ro l and power t ransmiss ion technologica l cont r ibut ion to
▪ Indust r ia l OEM market
▪ Renewable energy
▪ Elect r ic mobi l i ty
prov id ing innovat ive so lut ions that respect the env i ronment and energy eff ic iency.
Market :
▪ We are serv ing
▪ customers range f rom medium to large s ize thank to qual i ty - process, long term avai lab i l i ty
▪ customers smal l s ize range thank to f lex ib i l i ty and dynamic react ions
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© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Corporate values
Customer satisfaction:
▪ It is what ownership and management demands to
their employees and partners. The company has
obtained quality and process certifications both in the
industrial and automotive fields (ISO 9001 - IATF).
Environment:
▪ Intended as a territory but also as a workplace
(together they contribute to people's health)
Energy - efficiency
▪ A commitment and attention to the concept of
continuous improvement designing efficient and
energy saving products and solutions
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© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
From mechanics to electronics; our path towards mechatronics
▪ In order to contribute to the respect and care
of the environment we have analyzed for
years all the solutions whose movement can
be carried out with an electric actuator.
▪ There are applications where an electric
actuator would be a technically and
economically NOT sustainable compared to a
hydraulic solution.
▪ Combining our experience with experts in
hydraulics, we design a Mechatronic solution
to improve the performance in terms of
▪ Energy Efficiency
▪ Motion control quality4
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Servo pump as efficient hydraulic Technology
▪ Generally speaking, the servo pump is a gear pump that allows to regulate the flow rate and the pressure according to the number of revolutions of the pump
▪ The use of servo pumps allows real -time control of the flow and/or pressure of a system directly from the motor, without the use of valves.
▪ Energy savings (more than 70 percent)
▪ Noise savings (up to -20dB)
▪ Thanks to the Built in Servo pump Controller algorism in a frequency inverter, it is possible to manage and reduce cycle times of a system.
▪ A permanent magnet motor operates over a wide range of speed (flow) and torque (pressure) without excessive consumption or overheating. Applications are even more dynamic.
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© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Conventional vs Servo Pump
09 /2021 6
3 ph
Variable
Pump
Constant
Pressure
LOADMain
Voltage
Electric
Motor
3 ph
Electric
Motor
VSD
Main
Voltage
Heat dissipation
Oil Passage
Resistance
Heat dissipation
throttling to
adjust actuator
speed
Heat dissipation
Pressure
adjustment
Energy
Consumption
Motor running
continuously @
Nominal Speed Heat extraction
by using cooling
systems
Potential energy recovery
Servo
Pump
A conventional hydraulic system for Motion
Control dissipates energy at every stage of the
cycle
while Servo Pump system regulates speed
and torque (Flow and Pressure) by using
energy only when necessary
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Conventional hydraulics Motion Application
Considering a dissipative type system as
▪ Pressure and Flow in the circuit are set at the
nominal value necessary to perform any movement.
▪ To manage the speed of the actuator is necessary
throttle which means “just dissipation” instead of
“regulation”
▪ The Oil temperature reach high value. In order to
keep the Oil within certain range, an Oil colling
system is required (additional energy dissipation).
▪ The tank sizing is normally 3/5 time the pump flow
(e.g. 100L pump flow >> 300 – 500L Oil)
09 /2021 7
3 ph
Variable
Pump
Constant
Pressure
LOADMain
Voltage
Electric
Motor
Heat dissipation
Oil Passage
Resistance
Heat dissipation
throttling to
adjust actuator
speed
Heat dissipation
Pressure
adjustment
Energy
Consumption
Motor running
continuously @
Nominal Speed Heat extraction
by using cooling
systems
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Servo Pump Efficient Hydraulics Motion Control
▪ In principle the system requires fewer classic valves
that’s why we can say that system is less complex.
▪ Having simpler circuit and run the pump on demand
makes Hydraulic power loss in the system is lower.
▪ The level of heat introduced into the hydraulic
system is lower so your cooling system is simpler
▪ The tank sizing is normally 0,5/1 time the pump flow
(e.g. 100L pump flow >> 50 – 100L Oil)
▪ Oil Operating temperature is lower
▪ Components longer service life
▪ Hydraulic system has high reliability and
availability with positive impact on the
productivity of your machine.
09 /2021 8
LOAD
3 ph
Electric
Motor
VSD
Main
Voltage
Potential energy recovery
Servo
Pump
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Quality on Motion Control even with Hydraulics
▪ Thanks to the dedicated Servo pump Control algorism, actuator cycle times can be drastically shortened
(High bandwidth of the system).
▪ Due to Low mass moment of inertia of the internal gear pump and motors, Highly dynamic control can be
achive (Accurate pressure control) .
09 /2021 9
Easy Commissioning!!
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Is energy efficiency economically sustainable?
09 /2021 10
Actuator
Cost
Hydraulic
Control Cost(Valves for regulation)
(Throttle valves)
(security)
Electrical
Cost(Control Cabinet)
(Motor)
(Pump)
Energy
Cost
Hydraulic
circuit cost(Tank)
(Pipes)
(Connections)
(Heat exchanger)
(Accessories)
Life-time
Cost(filtering system)
(fire hazard - cooling)
(Oil life-time)
(Frequency)
OEM End User
Considering a system which
needs an Actuator who runs
100L/min with a pressure
100 bar
Conventional
Servo Pump
28% 60% 4%
Same
50%30%
cost estimates based on the examples given. for the same application, there could be numerous technical solutions that would definitely have an impact on costs
PQ Control shift Easier circuit Easier Circuit
Component life-time
© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
Application example
▪ Injection molding machine
▪ Blow molding machine
▪ Die-casting machine (Al & Mg)
▪ Metal forming presses
▪ Hydraulic presses
▪ Press feeding systems
▪ Trimming presses
▪ Sheet processing machine
▪ Punching machines
▪ Nibbling machine
▪ Notching machine
▪ Sheet shears
▪ Recycling presses
▪ Fuel pumps for gas turbine
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© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.
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