Energy Efficiency in Industry with Bosch Rexroth · Mannesmann Rexroth with ... Rexroth 4EE –...
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Transcript of Energy Efficiency in Industry with Bosch Rexroth · Mannesmann Rexroth with ... Rexroth 4EE –...
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Energy Efficiency in Industry with Bosch Rexroth
A5
Scott C. HibbardV.P. TechnologyBosch Rexroth
23-Jun-2009
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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 %
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Bosch Rexroth in the Americas
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Bosch Rexroth – The Products
Hydraulics,mobile
Hydraulics, industrial
Gears
Electric drives andcontrols
Linearmotion
technology
Assemblytechnologies
Pneumatics
Service
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Bosch Rexroth – The Markets
Industrial and factory automation as well as mobile applications
Rexroth services are used worldwide in nearly all industries ...
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Principle 2: Energy Recovery
Power Supply
(AC DC)
Servo or VF Drive
(DC ◄► AC)
Motor
Driving
Generating
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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).
© Bosch Rexroth AG 2007: Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
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
© Bosch Rexroth AG 2007: Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
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.
© Bosch Rexroth AG 2007: Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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