Energy Efficient Actuation - Schaedler Yesco€¦ · The Global Leader in Actuator Technology...
Transcript of Energy Efficient Actuation - Schaedler Yesco€¦ · The Global Leader in Actuator Technology...
The Global Leader in Actuator Technology
Energy Efficient Actuation
Good for the Environment. Good for Business.
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NEED FOR CHANGE
ACTUATION TECHNOLOGIES
COMPARISON OF EFFICIENCIES
APPLICATION EXAMPLES
CONCLUSION
AGENDA:
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Energy Efficiency…
■ Not just about being “green” or environmentally friendly
■ Can produce significant cost savings to the business
■ Can address increasing regulatory mandates (cost avoidance)
■ Can lead to benefits beyond energy cost savings
The Need for Change
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The Need for Change
Industrial Sector ■ Account for over 20% of US energy
consumption (41% world-wide)
■ And, uses 25% + of the Electric
Power generated
Transportation / Mobile
Equipment Sector ■ Addressing EPA Tier IV regulations
■ Concerned about cost & availability of
fossil and alternative fuel sources
Source: U.S. Energy Information Administration
0 10 20 30 40 50
Residential/Commercial
Industrial
Transportation
Electric Power Generation
US Energy Consumption by Sector
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90.0%
92.0%
94.0%
96.0%
98.0%
100.0%
2HP 150HP
Electric Motor TCO
Purchase Price
Installation/Maintenance
Energy Cost
The Need for Change
Energy Costs Represent the
Largest Portion of Equipment
Total Cost of Ownership (TCO)
for Many Industrial
Applications*
Other factors driving the move to electric
actuation:
■ Environmental Concerns (oil leaks, disposal,
etc.)
■ Operator Safety (noise)
■ Performance (precision and repeatability)
■ Down Time (maintenance and support)
*Source: U.S. Energy Information Administration
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The Need for Change
Efficiency-focused Investment Increasing
US DOE indicates:
■ 40% of industrial applications lacking in use of energy efficient technologies
■ 50% of industrial applications not using some form of control to mange
motor-based applications
Source: Energy Efficiency & Technology Magazine & DOE web site
Yes 43%
No 57%
Are You Engaged in an Energy Efficiency Engineering Program?
6%
41%
37%
16%
Do You Anticipate More Energy Savings Programs?
No More Projects
More Projects in 6Months
More Projects in 12Months
More Projects in 24Months
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Typical Actuation Technologies
HYDRAULIC PNEUMATIC ELECTRIC
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Hydraulic Actuation
Pro’s ■ High power density
■ Low component acquisition cost
■ Moderate to high stiffness
■ Moderate speed
■ Mature, well understood technology
■ Numerous suppliers
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Hydraulic Actuation
Con’s ■ Moderate accuracy / repeatability
■ Installation / maintenance complexity
■ High installation cost (labor)
■ Time to commission
■ Expensive (TCO)
■ High maintenance
■ Low energy efficiency
■ Low scalability / modularity
■ Messy (environmental impact)
“The annual cost of one slow leak
can amount to nearly $1,000 per year
in make-up fluid, clean-up and
disposal costs alone.” Source: www.empire-cat.com
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Pneumatic Actuation
Pro’s ■ Low component acquisition cost
■ High speed
■ Mature, well understood technology
■ Numerous suppliers
Con’s ■ Low to moderate power density
■ Low accuracy / repeatability
■ Low energy efficiency
■ Low stiffness
■ Time consuming to install
■ Moderate scalability / modularity
■ High maintenance
■ High noise
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Pneumatic Actuation – Hidden Costs
Cost to Run Compressor: ■ Installed compressor capacity = 1,500 cfm
■ Average demand = 1,000 cfm
■ Operates 24 x 7, 50 weeks / year
■ Electricity cost = $0.068 / kWh
■ Compressor duty cycle = 75%
■ 4.5 cfm compressor capacity requires 1 compressor
HP
Total Running Cost = $107,000 / yr
Cost of Commonly Found Problems: ■ On average, 30% of air is wasted
■ 30% of $107,000
Cost of Wasted Energy = $32,100 / yr Source: Norgren – “How to improve energy efficiency”
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Electric Actuation
Pro’s ■ High speed + high force
■ High accuracy / repeatability
■ High Scalability / Modularity / Flexibility
■ High Energy Efficiency
■ High System Stiffness
■ Medium to High Power Density
■ Reduced Maintenance / Down Time
■ Eliminates Hydraulic Fluid / Air Leaks
■ Lower operating cost (TCO)
■ Reduced Ambient Noise
■ Easy to Install
Con’s ■ Higher component acquisition cost
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Actuation Technology Scorecard
Attribute Hydraulics Pneumatics Electrics
Power Density High Low Medium to High
Precision Medium Low High
Energy Efficiency Low Medium High
Cleanliness Low Medium High
Maintenance High Medium Low
Installation Costs Medium to High Medium to High Low
Scalability Low Medium High
Component Cost Medium Low Medium to High
TCO* Medium High Low
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Comparison of Technology Efficiencies
Comparative Testing by University of Kassel ■ Founded in 1971 as a multi-disciplinary teaching and research
university based in Kassel, Germany
■ The University of Kassel is characterized by diverse and
networked competencies across the domains of nature,
technology, culture and society
■ Over 160 research programs to date have been conducted by UNI-
Kassel
■ Testing funded by University of Kassel
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Comparison of Technology Efficiencies
Test Set Up
3 Technologies
■ Pneumatic
■ Hydraulic
■ Electro-mechanical (with integrated
servo motor)
Test Conditions
■ 1000 N of force exerted by each
actuator
■ 150 mm stroke
■ 1.7 sec/cycle
Photo courtesy of UNI-Kassel
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Comparison of Technology Efficiencies
Results
Consumption Factors
■ Electric = 1
■ Pneumatic = 4.4x
■ Hydraulic = 10.3x
Energy Conversion
(efficiency)
■ Electric = 90%
■ Pneumatic = 77%
■ Hydraulic = 57% 0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Hydraulic Pnuematic Electric
Energy Conversion (% Efficiency)
0.0
1000.0
2000.0
3000.0
4000.0
5000.0
6000.0
7000.0
8000.0
9000.0
Hydraulic Pnuematic Electric
Energy Consumption (Kwh)
* Study and Test Data by UNI-Kassel, 2012
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Application Examples
Case Study: Fastening
Press
Challenges
■ Provide High Production Capacity
at Lower Cost
■ Decrease Set Up Time
■ Reduce Environmental Impact
Results
■ Higher Productivity at Lower Cost
■ Lower Maintenance / More Up Time
■ Self-contained Machine / Scalability
0
100
200
300
400
500
600
700
800
900
0
1000
2000
3000
4000
5000
Electric Hydraulic
$/y
ea
r
Un
its
/ye
ar
(00
0s
)
Machine Comparison by Technology
Production Output Energy Cost/year
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Application Examples
Case Study: Injection
Molding Machine
Challenges
■ Higher Precision
■ Faster Cycle Times
■ Lower Energy Cost
Results
■ Quieter Operation
■ Increased Uptime
■ Scalable Solution
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Electric Hydraulic
kw
h/k
g m
ate
ria
l
Injection Molding Machine
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Benefits of Converting to Electric Actuation
Higher Efficiency Equating to:
■ Lower Energy Consumption
■ Lower Cost to Operate
■ Higher Productivity
Additional Benefits:
■ Lower Installation and Maintenance Costs
■ Modularity / Scalability (cost to change)
■ Reduced Environmental Impact (noise, leaks, disposal of fluids, etc.)
■ Lower Total Cost of Ownership (install, operate, maintain, repair)
Conclusion
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