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This on-demand webinar explores the differences between pneumatic and electric actuators and outline the decision process for successful, efficient, and cost effective deployment. Pneumatics’ performance characteristics, costs and best case application scenarios will be compared to those of electrics. Case studies where pneumatics are preferred to electrics and where electrics are preferred to pneumatics will be analyzed, compared and contrasted. Finally, a pneumatic-electric cost comparison software tool will be presented, an example will be presented using the tool, and the tool is available along with the recording.
Citation preview
Pneumatic or Electric? -How to decide which actuator to use
This webinar will be available afterwards at
www.designworldonline.com
Q&A at the end of the presentation
Hashtag for this webinar: #PvsE
Before We Start
Moderator
Paul J. Heney Design World
Presenter
Bob Kral Bimba Manufacturing
Pneumatic or Electric?
How to decide which actuator to use.
• Criteria to Consider
• Pneumatic o Performance
o Costs
o Best application scenario
• Electric o Performance
o Costs
o Best application scenario
• Case Study: Pneumatic Over Electric
• Case Study: Electric Over Pneumatic
• Freebie: Pneumatic versus Electric Cost Calculator
• Q&A
Agenda
Criteria to Consider
• Performance advantages and disadvantages
• Installation and maintenance costs
• Operating (power) costs
• Productivity gains o Reduced downtime
o Increased capacity
o Labor savings
Pneumatic or electric actuators?
Pneumatic Actuator Performance
Characteristics • High force and speed
• Force and speed are independent and easily adjusted
• Economical to oversize
• Small footprint
• Simple implementation
• Extend and retract only
• System requirements: o Compressor
o Air lines
o Fittings
o Filters
o Regulators
o Lubricators
…which limit where it can be deployed
Pneumatic or electric actuators?
Pneumatic Actuator Costs
• Component costs are low
• Operating costs dominated by compressor power consumption (~76%) o Efficiency is lower at idle
o Idling at no load wastes electric power consumption
o Oversized cylinders and compressors waste money
• Other operating and maintenance costs (~24%)
• Best scenario: o Large scale deployment
o Efficiently sized compressor
o No labor savings or production downtime savings are achievable
Pneumatic or electric actuators?
Electric Actuator Performance
Characteristics • Trade speed for thrust and thrust for speed
• Accurate sizing is critical o Over sizing is expensive
o Under sized actuators will not perform
o Force and speed limits are locked in by design
• Precise control and positioning
• Adapt machines to flexible processes
• “Portable” – install anywhere electric power is available
• More complex to implement
Pneumatic or electric actuators?
• High unit cost
• High replacement cost o Modular designs help minimize replacement costs
o Mechanical wear parts – 3 year life
o Electrical components – 5 to 10 year life
• Low power consumption
• Flexibility can yield cost savings o Eliminate costly downtime
o Eliminate time consuming change-overs
o Not automatic – needs to be designed in
• Best scenario o Smaller scale deployment
o Effects process improvements or cost savings through automation
Pneumatic or electric actuators?
Electric Actuator Costs
Cost of Electricity • Average retail price: 9.74 cents per kilowatt-hour (kWh)
o Residential: 11.3¢ per kWh
o Transportation: 10.7¢ per kWh
o Commercial: 10.4¢ per kWh
o Industrial: 6.8¢ per kWh
• Highest average price of electricity: o Hawaii (29.20¢ per kWh)
o Connecticut (16.95¢ per kWh)
o New York (16.74¢ per kWh)
• Lowest average price: o West Virginia (5.59¢ per kWh)
o Wyoming (5.68¢ per kWh)
o Idaho (5.70¢ per kWh)
Pneumatic or electric actuators?
Compressor Sizing Calculator
Inputs: o Average bore size
o Average stroke length
o Average time for stroke
o Number of cylinders
o % of cylinders that actuate simultaneously
Output: o CFM required
o Find compressor HP using the CFM number and the manufacturer’s specifications
Pneumatic or electric actuators?
Case Study
Pneumatics over Electrics • Pneumatic solution
o 200 HP compressor
• 2,000 hours per year at full load, 93% efficiency ($0.10/kWh)
• When not in use it is off
o 150 pneumatic actuators deployed
• Average unit cost: $50
• Life expectancy: 3 years
• Electric solution o 150 electric actuators deployed
• All-in-one design: includes driver and controller but not DC power supply
• Average unit cost: $1,200
• Life expectancy: 3 years
o Actuator draws 6A fully loaded at 48 VDC; fully loaded 30% of the time
o Actuator draws 3A at 48 VDC 70% of the time
o Power supplies draw 6A at 120 VAC fully loaded, producing 9A at 48 VDC
Pneumatic or electric actuators?
Case Study
Pneumatics over Electrics • Pneumatic solution
o Annual cost of compressed air: $42,237
o Replacement cost of actuators: $2,500 per year
o Total annual cost: $44,737
o Total annual cost per actuator: $298
• Electric solution o Annual cost at full load: $4,320
o Annual cost at idle: $5,040
o Annual operating cost: $9,360
o Replacement cost of actuators: $60,000 per year
o Total annual cost: $69,360
o Total annual cost per actuator: $462
Pneumatic or electric actuators?
Case Study
Pneumatics over Electrics
Pneumatic or electric actuators?
Pneumatic Costs Electric Costs
Electrics over Pneumatics • Pneumatic solution
o 100 HP compressor
• 2,000 hours per year at full load, 90% efficiency ($0.10/kWh)
• When not in use it is idling at 25% power and 85% efficiency
o 20 pneumatic actuators deployed
• Average unit cost: $50
• Life expectancy: 3 years
• Electric solution o 20 electric actuators deployed
• Modular: Motor/actuator and separate controllers
• Average unit cost: $900 for actuator and $1,200 for electronics
• Life expectancy: 3 years for actuators, 10 years for electronics
o Actuator draws 6A fully loaded at 48 VDC; fully loaded 30% of the time
o Actuator draws 3A at 48 VDC 70% of the time
o Power supplies draws 6A at 120 VAC fully loaded, producing 9A at 48 VDC
o Process improvement: Automates a line change
• Saves 2 hours every week for 2 employees at $30/hr each
• Saves 2 hours of lost production: 100 products/hr, $1 per product
Pneumatic or electric actuators?
Electrics over Pneumatics
• Pneumatic solution o Annual cost of compressed air: $21,882 full load
o Annual cost of compressed air: $19,351 at 25% power
o Replacement cost of actuators: $333 per year
o Total annual cost: $41,506
o Total annual cost per actuator: $2,075
• Electric solution o Annual cost at full load: $576
o Annual cost at idle: $672
o Annual operating cost: $1,248
o Replacement cost of electronics: $2,400 per year
o Replacement cost of actuators: $6,000 per year
o Total annual cost: $9,648
o Savings, changeover labor: $6,240
o Savings, lost production: $10,400
o Net results of deployment: $6,992 COST REDUCTION!
Pneumatic or electric actuators?
Case study
Electrics over Pneumatics
Pneumatic or electric actuators?
Pneumatic Costs Electric Costs
Bimba now features a Pneumatic versus Electric Actuator
cost evaluation spreadsheet, which is available for download
from bimba.com
This spreadsheet allows a person to estimate pneumatic and
electric costs, facilitating a comparison and selecting the
correct actuator depending upon the application
Cost Evaluation Calculator
Thank you for attending!
Bimba.com
800-44-Bimba
Questions?
Design World Paul Heney [email protected] Phone:440.234.4531 Twitter:@wtwh_fluidpower
Bimba Manufacturing Bob Kral [email protected] Phone: 708.235.2067
Thank You
This webinar will be available at www.designworldonline.com & email
Tweet with hashtag #PvsE
Connect with Twitter: @Design_World
Facebook: /engineeringexchange
LinkedIn: Design World Group
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