Industrial Energy Efficiency with Bosch Rexroth - …€¦ · Bosch Rexroth Wholly-owned subsidiary...

Industrial Energy Efficiency with Bosch Rexroth

Scott C. HibbardV P 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.

1Electric Drives and Controls

A5

V.P. TechnologyBosch Rexroth

Bosch Rexroth

Wholly-owned subsidiary of Robert Bosch GmbH

Merger of Mannesmann Rexroth with Bosch’s Automation TechnologyTechnology

All relevant technology forDrive, Control and Motion,

Worldwide presence

For industrial and factory automation, and mobile applications



The Company – Within the Bosch Group

Bosch GroupRevenue: € 46.3 billion

Employees 1/1/2008: 271,300

Consumer Goods & Building Services

Industrial Technology

Automobile T h l Building Services

EngineeringTechnology

Bosch Rexroth 1)

Technology

Packaging Technology



1) Bosch Rexroth AG (Bosch wholly owned)

The Company – Bosch Rexroth Data

Figures for 2007

Total revenue€ 5,356 million

Total employees32,981

Research and development

Investments

Germany:€ 1,507 million

Europe minus Germany:

Germany:17,905

Europe minus Germany:

total:€ 250 million

Cost share of revenue:

total:€ 377 million

Cost share of revenue:y

€ 2,136 million

Americas:€ 849 million

Asia/RoW:

y8,032

Americas:3,308

Asia/RoW:

revenue:4.7 %

revenue:7.0 %

Asia/RoW:€ 864 million

Asia/RoW:3,736



Bosch Rexroth in the Americas



The Company – The Products

Electric Lineardrives andcontrols

motion technology

Gears Assemblytechnologies

Hydraulics, industrial

Pneumatics

Hydraulics, Service



mobileService

The Company – The Markets

Industrial and factory automation as well as mobile applications

Rexroth services are used worldwide in nearly all industriesin nearly all industries ...



Energy Efficiency in Industry

Total System Design

I d t hi iIn order to achieve maximum energy efficiency, the various technology disciplines must interact perfectly where intelligent solutions arewhere intelligent solutions are concerned.

The intelligent interlinking of differentThe intelligent interlinking of different individual measures achieves the highest possible savings – no single technology can meet the efficiencytechnology can meet the efficiency targets alone.



Design Scope for Energy Efficient Automation Solutions as a Function of Product Life Cycle

ConceptConcept DesignDesign EngineeringEngineering CommissioningCommissioning Production /Production /OperationOperation

:T8 WZWG1 X100G2 X200

ModernizationModernization

ency

PartPartProgrammingProgramming

ProcessProcessOptimizationOptimization

G2 X200 G1 Y250G1 X150:

RunoffRunoffProgrammingProgrammingMechanical Mechanical DesignDesign

ElectricalElectricalDesignDesign

Mechanical Mechanical ConceptConcept

AutomationAutomationConceptConcept RetrofitRetrofit Product Product

OverhaulOverhaul

U f

nerg

y E

ffici Use of energy

efficient motiontechnology aspart of machine overhaulGreatest Opportunity

uenc

e on

En

Optimization of Machine OperationVi E A l i T l

To effect energy efficiencyIs in the design phase, usingEnergy efficient motionDevices in connection withM h i

Influ Via Energy Analysis ToolsMechatronic

System optimization



Machine Life Cycle

An Example …

Power Supply Servo or VF D i

Motor



(AC ► DC) Drive(DC ► AC)

Example: Energy Savings via power sharing with Optimized Machine Cycles

Thermoforming Machine:

• 2 presses

C ti l M ti P fil O ti i d M ti P filPress 1 Press 2

p• Toggle-linkage Mechanism

Pre

ss 1

Pre

ss 1

Conventional Motion Profile Optimized Motion ProfileEnergy Savings:

•Shift timing of the press

Pre

ss 2

t

Pre

ss 2

tmotion Profiles

•Energy balance between the two drives

•Reduce the peak power

Ener

gy

Ener

gy

tt

Reduce the peak power requirements from the 3-phase

•Optionally use the heat for th Th f i P



E

t

E

t

the Thermoforming Process

Energy Efficiency in Industry

Rexroth – Combined Know-how

R th i id ll iti d t ff thRexroth is ideally positioned to offer therequired energy efficient systems – by means of drive and controltechnologies from a single source,g g ,combined with the required know-how.

Th R th k t t i d i iThe Rexroth key to sustained increase inenergy productivity:

Speed-variable pumpsIntelligent pressure control valvesIntelligent servo drivesMiniaturization



Low-friction linear guides

Product Examples

Industrial Hydraulics – Speed-Variable Pump Drive (DvP)

Speed on demand – reduction of motor speed and thus pump power during pauses or in part-load operation, yet without impacting onp p , y p gcontrol tasks.Increase in efficiency – Energy savings

Clear reduction in idle-running power –Clear reduction in idle running power in part-load mode / zero stroke the drive goes into “stand-by function”.Less energy/heat transfer into the oilLess energy/heat transfer into the oil, meaning less cooling requiredPositive impact on heat regulation, energy consumption and costs

Noise reduction thanks to spontaneously controlled and lower speeds.



p y pReduction in installed power.

Product Examples

Industrial Hydraulics – Bus Module withEnergy-saving Function for Relay Valves

Controlled energy cut-off during pauses in operation with the aid of field bus technology. Up to 66 % less power consumption (reduced to minimum level required)Uses PWM to control effective powerShorter response times due to voltage reduction.Fault diagnostics for each output / channels can beswitched off individually in the event of a faultMore than one valve can be connected to each bus

d l ti t b i th d d!

P

module – summation current being thus reduced! Lower heat generation of solenoids= Increase in service life, lower cooling costs

t



t

Product Examples

Industrial Hydraulics –Pumps and Axes

Pressure-flow-controlled pumps with integrated bus-enabled p p gmotion control permits precise power controlAxial piston pumps with improved mechanical-hydraulic efficiency consume less energy.gyEnergy savings in continuous, hi-performance applications by quickly switching between high and low pressure (example: punching & stamping machines)



Product Examples

Pneumatics – Valve Series LS04

Th t di i d i i l i dThe compact dimensions and minimal space required means the valve system can be positioned in the direct vicinity of the actuators.

Directly mounted onto moving parts due to low weight.

The concentration of pneumatic functions in an extremely confined space prevents pressure losses, which can occur from the long tubing lengths required from the control cabinet to thepneumatic drivepneumatic drive. Furthermore, this solution also also shortens cycle times.



Product Examples

Pneumatics – Pressure Regulator ED-Series

Th i ht f th i ht t k d ti bThe right pressure for the right task reduces energy consumption by up to 25%. ED-Series pressure control valves permit sensitive pressure control. They combine digital closed-loop control electronics with innovative proportional valve technology. p p gy

The intelligent open-loop control directly at the locationrequired guarantees reliable repetitive accuracy fortypical pneumatic tasks such as weight compensation,force compensation, print run control, paint- or lacquer-dosing and press-fit processes.

The pressure control valves can, in open and closed loop operation, control force, flow rate, motor speed,position or cylinder speed.



position or cylinder speed.

Product Examples

Linear Technology – Roller Rail Guides

E ffi i t d t t l l f i ti ffi i t f 0 01Energy efficient due to extremely low friction coefficients of a mere 0.01 percent.

Reduction in friction of more than 90 percent in heavy load applicationsReduction in friction of more than 90 percent in heavy-load applications when compared with conventional sliding bearings. Drive systems can be built to a smaller and thus more energy-optimized design.



Energy Savings with De-central Drive technology in a Mechatronic System Design

+Inverter (Drive) Inverter (Drive) together with

Control SectionControl Section integrated in the

IndraDrive MI

+Control SectionControl Section integrated in the

ServomotorServomotor

A single cableA single cable forggPower Supply (DC) & Communication

Daisy-chaining of up to 20 Mi’sup to 20 Mi’s& up toup to 18 kW18 kW Continuous Continuous PowerPower is possible

Integrated Motion/LogicIntegrated Motion/Logic



programming using any IEC 61131-3 (PLC) languages

Energy Savings with De-central Drive technology in a Mechatronic System Design – Before & After

To ControlTo Control

Conv. Drives in a CabinetSensors

Servo Motors

SensorsTo Control



Power Supply/Interface in a Cabinet IndraDrive Mi De-central Drive

Energy Savings with De-central Drive technology in a Mechatronic System Design

Regenerative Regenerative Power SupplyPower SupplyReturn excess energy to the power lines.

S

DC BusDC BusElectrical connection for energy exchange between motoring and generating dri es

Additional SavingsAdditional SavingsComponent reduction (Cable, Cabinet, Connectorization, etc.) Reduced cooling demand in

Energy Savingsapprox. 20%*

generating drivesEnergy Savingsapprox. 15% *

cabinet (unit size, energy costs) Reduced impact on plant cooling (units, energy costs)

Energy Savings approx. 2%*

Auxiliary Capacitor Auxiliary Capacitor

gy g pp

yyModuleModuleBuffers short term excess energy

Energy Savings S h (P M ) MS h (P M ) MEnergy Savingsapprox. 3%* Synchronous (Perm. Magnet) MotorsSynchronous (Perm. Magnet) Motors

High Energy NdFeB-permanent magnets in rotor, low-loss pole windings.

Energy Savings approx. 3%*



* Typical Energy Savings Amounts given, actual savings depends upon application and may be higher or lower (“Your Results May Vary”)

gy g

Energy Optimization ExamplePackage Sorter for a Parcel Service Company

ApplicationScan parcels for destinationSort and send parcels to trucksp

System Automation GoalsGentile motion for packages & mechanicsmechanicsEnergy efficient total solution

21 largesorter lanes

20 smallsorter lanes



for packages up to32 kg

for packages up to5 kg

Energy Savings Calculations for ExamplePackage Sorting Line using Decentralized Drives

“Before” System Energy Requirements: 18.5 kW18.5 kW

Energy savings withRexroth Automation Solution

RegenerationElimination of cabinet air conditioningthrough use of decentralized drivesEnergy buffering in Capacitor ModulesEnergy buffering in Capacitor ModulesEnergy sharing via DC BusReduced primary energy requirement(less cable, smaller cabinets)Hi h ffi i PM tHigh-efficiency PM motors

Annual energy savings6.5 kW6.5 kW

(=(= --35 %)35 %)Total Energy SavingsAnnual energy savings(operating 24 Hrs/Day, 365 Days/Year)

CO2-reduction (0.613 kg CO2/kWh*)

( ( 35 %)35 %)

57 Mega W57 Mega W--HH35 tons35 tons


23Electric Drives and Controls *Energy mix in Germany per GEMIS Version 4.2 for 2004

Conclusion

Every Contribution Counts

N t h l t ll th ffi i t t it it iNo technology can meet all the efficiency targets on its own – it is rather the sum of each individual measure that counts.Considerable savings can be made by the intelligent interlinking of a variety of measuresvariety of measures.Greater efficiency reduces energy costs, meaning that investments can pay for themselves within a short period of time.However, there is one consideration throughout the service life of a , gsystem that may or may not endorse the decision made after procurement costs have been taken into account. – Cheap products offer one-off savings; efficient products pay every day. Rexroth offers the essential products and modules and supports both in the project design phase and in optimization of auxiliary processes.





A4

Industrial Energy Efficiency with Bosch Rexroth - …€¦ · Bosch Rexroth Wholly-owned subsidiary...

Documents

Transcript of Industrial Energy Efficiency with Bosch Rexroth - …€¦ · Bosch Rexroth Wholly-owned subsidiary...