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SV i bl S d P D i f I d t i lSyVariable Speed Pump Drives for Industrial Machinery – System Considerations
J K t Ph DJan Komsta, Ph.D.Bosch Rexroth
Drive for Technology Expo Hanover Park IL April 15 16 2014
04.15.2014 | DCUS SET | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Drive for Technology Expo, Hanover Park, IL, April 15-16, 2014
1
Variable Speed Pump Drives for Industrial Machinery
Why speed variable pumps?Why speed variable pumps?
Reduced energy consumption
Reduced average noise
Compact power unit
Reduced cooling requirements for oil
High robustness
Intelligent hydraulic drive
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Energy and the Environment – Current Challenges
Policy assumptions for 2020*Policy assumptions for 2020USA European
Union China Russia Brazil India
23%** 20 % 40 %15 % 36 %20 %23%share
of renewables in electricity
20 % reduction
in greenhouse
40 % reduction
in CO2intensity
15 % reduction
in greenhouse
36 % reduction
in greenhouse gas emissions
20 % reduction
in CO2intensity y
generation gas emissions compared with 1990
compared with 2005
ggas emissions compared with 1990
compared with no measures
compared with 2005
Energy consumption is the driver•New Policies Scenario, World Energy Outlook 2012
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•** By 2035
3
Energy and the Environment – Current Challenges
Manufacturing systems life cycle costs (TCO)Manufacturing systems life cycle costs (TCO)
80...95 % Energy costs~ $5.950 (96%)
Initial startupTraining
Spare partsM i t
Cost price~ $250 (4%)
$5.950 (96%)
MaintenanceLabor costs
TaxesInsurances
Machinery
EnergyModernization
5...20 %y
& Equipment
Investment costs Operating costs
Disposal...
Three phase motor 1 kW5 year running time
Example
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Investment costs Operating costs Example
4
Energy and the Environment – Current Challenges
Growth in energy costs will continueGrowth in energy costs will continue
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Technology Change
drive power transmission Propertiesdrive power transmission PropertiesHydraulic pump control motor /
cylinderPower density, robustnessControllability Multiple consumers possible
Constant speed electric motor classic hydraulics
Noise Energy efficiency
Hydraulic pump motor /cylinder
Power density, robustnessControllability Multiple consumers possibleEnergy efficiency
with /without valves
Variable speed
Force transmission Spindle drive ControllabilityN i
Noisevariable speed pumps
Variable speed motor drive
Electro-mechanicVariable speed
motor drive
Noise Energy efficiency
Multiple consumers not possible (or very difficult) Power density
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Electro mechanicmotor drive Power density
6
Energy saving potentialTechnology Change
Energy saving potential Classic Solution
Full motor speed during part load operation. Pump mechanical losses caused by
Mp y
high rotation speed Lower motor and pump efficiency
during part load operation High throttling losses caused by
Motor losses
Pump lossesproportional valves
Throttling lossesTotal
energy
Useful energy
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Energy saving potentialTechnology Change
Energy saving potential Variable Speed Pump Drives
No throttling losses from proportional valves 40-70% speed reduction during part
Mp g p
load operation Increased pump and motor efficiency
during part load operation Reduced pump losses by lowering
Inverter losses
Pump losses
Motor losses
average motor RPM Additional inverter losses
p
U f l
Total energy
Useful energy
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System Solutions
Efficiency CostsDynamics
AC motor+ fixed pump
AC motor
M
M
VFD+ AC motor
fi d
+ variable pumpM
M
VFD+ AC motor + variable pump
+ fixed pump
Mp p
(esp for >60kW)
VFD+ PM motor* + fixed pump
M
(esp. for >60kW)
VFD+ PM motor* + variable pump
(esp. for >60kW)
M
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* permanent magnet synchronous motor
9
System Considerations: Pump Selection
Which pumps are suitable for variable speedWhich pumps are suitable for variable speed operation?
Speed range Pressure range
??? Direction of rotation Pump efficiency Pump noise Flow and pressure pulsation Pump inertia Quadrants of operation …
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Pump speed and pressure limitationsPump selection
Pump speed and pressure limitations
CavitationPowerlowest speed
Pressure int
Pressure cont.
lowest speedfor continuous operation (i f
int.
Noise limit
- Motor Fan
(i.e. for gear pumps)
bar]
Hi h t ffi i - Pump (highfrequency)temporary
operation possible
p [b Highest efficiency
possible (i.e. for gear pumps)
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n [RPM]
11
Noise reductionNoise Reduction
Noise reduction Pump noise depends on:
Pump construction Speed and pressure …
70
80
dB(A
)
70
80
60
70
oise
leve
l in
Axial piston pump
60Axial piston pump
p= 50 bar
40
50
0 1000 2000 3000
Pum
p no Axial piston pump
Internal gear pump
40
50
0 1000 2000 3000
p= 50 bar
p= 200bar
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Pump RPM Pump RPM
12
Pump selection
Quadrants of operationQuadrants of operation+ Flow
Pump operationMotor operation
pressure
A i l i t
- Flow
Pump operation Motor operation
+ Flow
Internal gear pump e.g. PGH
Axial piston pumpse.g. A10 VZO
pressure
Pump operationMotor operation
Fl
Pump operation Motor operation Axial piston pumpse.g. A10 FZG / VZG (for closed circuits)
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- Flow
13
Pump selection
Mechanical inertia / dynamicsMechanical inertia / dynamics
Distribution of mechanical inertia of the pump drive 100% = total mechanical inertia of system using internal gear pump
Internal gear pump+PM Motor Axial piston pump+PM Motor
100% total mechanical inertia of system using internal gear pump
100%
120%
140%
tia
100%
120%
140%
PM
PumpCoupling
40%
60%
80%
100%
Mecha
nical ine
r
40%
60%
80%
100% Motor
0%
20%
060 075 100 120 150 190 240 300
Maximum Flow (LPM)
0%
20%
060 075 100 120 150 190 240 300
Maximum Flow (LPM)
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Pump selection
Direct couplingDirect coupling Reduced mechanical inertia Better dynamics (higher acceleration capabilities) Higher efficiency Less mounting space (no bell-housing)
Di t li
120%
Internal gear pump+PM MotorPM MotorPump
Direct coupling
60%
80%
100%
anica
l inertia
PM Motor
Reduced inertia
0%
20%
40%
060 075 100 120 150 190 240 300
Mecha
Sytronix SVP 7000
Maximum Flow (LPM)
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Pump selection
Fixed or variable displacement?Fixed or variable displacement?
7
8
Variable displacement pump, n=1500 RPM M
4
5
6
wer
P (k
W)
Variable displacement pump + VFD
Fixed displacement pump + VFD M
2
3
4
Inpu
t Pow
M
0
1
0 50 100 150 200 250Pressure p (bar)
Power consumption for pressure holding Source: Prof. S. Helduser*, ‘Elektrisch-hydraulische Systemtechnik’, O&P 1/2006
*IFD Technical University Dresden Germany
Pressure p (bar)
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IFD, Technical University Dresden, Germany
16
Pump selection
Fixed or variable displacement?Fixed or variable displacement?
Mmech
pVpM
20
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M
17
Pump selection
Fixed or variable displacement?Fixed or variable displacement?
Pump displacement is reduced
A10 VZO pump with two-point control
Reduced load torque during pressure holding
mech
pVpM
20)(
M
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M
18
Pump selection
Performance curvePerformance curveVFD + self-ventilated AC motor
Axial piston pump with two point controlFixed displacement internal Axial piston pump with two-point control - A10VZO-EZ4
Fixed displacement internal gear pump- PGH
Pump pressure Pump Pressure
EZ4
Pump speed Pump speed Vgmax– max. pump displacement
Vgmin – min. pump displacement
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- Continuous VFD operation displacement
19
Energy Saving
Consider overall efficiencyConsider overall efficiencyPMM’s drive efficiency
Pump efficiency
peedAdapt pump displacement to
Torq
ue
SpAdapt pump displacement to
operate in preferred working points
Load
Pump pressure
M
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Speed
20
Energy Saving by Reducing Motor Speed
Energy saving during stand-by/ idlingEnergy saving during stand by/ idling
3.5
4
2
2.5
3
ower
P (k
W)
M
0.5
1
1.5
Inpu
t Po
0
0.5
0 200 400 600 800 1000 1200 1400 1600Motor speed n (rpm)
Sytronix DFEn 5000
Power consumption of electric motor during standby/ idle Pump size 100cc 40 HP AC motor
600 PSI 0 2 GPM fl ( il il)
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600 PSI, 0.25 GPM flow (pilot oil)
21
Energy Saving by Reducing Motor Speed
Energy saving by reducing motor speedEnergy saving by reducing motor speed
10
12Variable displacement pump+VFD
Variable displacement pump, @ 1800 RPM 0.80Efficiency @2200 psi
4
6
8
10
t Pow
er P
(kW
)
0.60
0.70
ffici
ency
Variable displacement pump+VFD
0
2
4
0 1000 2000 3000 4000
Inpu
t
Pressure p (PSI)
0.40
0.50
5 15 25 35 45
Ef
Q (GPM)
pump+VFD
Variable displacement pump, @1800 RPM
Power consumption of electric motor during pressure holding (Q=0 GPM)
η = Hydraulic Output Power / Electric Input Power
Pressure p (PSI) Q (GPM)
pump A4 125cc 100 HP AC motor
S
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Sytronix DFEn 5000
22
Engineering: System Sizing in SytronixSize
Machine load cycle (p/Q/t)Machine load cycle (p/Q/t)
Select the pump type and size
Investigate drive working points,drive utilization factors, RMS power
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RMS power …
23
Engineering: System Simulation
System simulation – verify your ideasSystem simulation verify your ideas
M d l f h d liModel of hydraulic actuators, valves, process forces, lines, etcetc.
Closed loop control algorithm
Speed Variable Pump HPU
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HPU
24
Engineering: System Simulation
System simulation – verify your ideasSystem simulation verify your ideas
Internal gear pumpInternal gear pump model, including efficiency (working point dependent) p p )
VFD, firmware and p/Q control algorithmp/Q control algorithm
Model of PMM Servo Motor with Torque-Speed characteristics
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Engineering: System Simulation
System simulation – verify your ideasSystem simulation verify your ideas
Various process variables (speed, position, pressure, power, pump
d t )speed etc…)
Evaluation of the simulation:P d ti it ( l ti ) Productivity (cycle time) Dynamic behavior Efficiency
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Sytronix: Bosch Rexroth’s Variable Speed Pump Drives
SytronixPreconfigured Sets
Sytronix FcP Sytronix SVP Sytronix DFEn
•Pressure and flow control •Pressure and flow control •Pressure and flow controlPressure and flow control
Basic dynamics
•Force and velocity control•Position control
High dynamics
•Power control
High dynamics & high power
Custom Solutions
•Custom system functions•Pressure and flow control•Force and velocity control•Position control
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SVP – High performanceSystem Variants- SVP
SVP High performance
injection molding machineSvP 7000
high dynamics
high accuracyenergy
efficient
performance sample application
pressure control
flow rate control
control functions
g accu acy
Axis control high performance
press brake
flow rate control
force control
speed control
systemP
U
g prequired
pressure control flow rate control
Axis control high
performance
p
position control
quadrantspressure
n
s
SGrequired
force control speed control position control
12
43flow 3~
3~SG
M
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SVP – High performanceSystem Variants- SVP
SVP High performancepressure
150bar
10 bar
3000 rpmT95%= 150ms
low RPM during pressure hold
speed-3000 rpm0 s 1.5 s
low RPM during pressure hold
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1.5 s
29
DFEn – Advanced performanceSystem Variants- DFEn
DFEn Advanced performance
advanced dynamics
advanced accuracyenergy
efficient
performanceinjection molding machine
DFEn 5000 sample application2 independent
hydraulic circuitspossible
Axis control advanced performance
pressure control
flow rate control
control functions
y
advanced performance required
pressure control flow rate control
flow rate control
force control
speed control paper
system
position control
quadrantspressure
p p
nCMD
PU
constant pressure system advanced performance
required pressure control
1flow
2 M3~
3~
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Variable speed mode and constant speed mode
System Variants- DFEn
Variable speed mode and constant speed mode
constant speed mode variable speed mode
speed
speed
flow
speed
swivel angle
flow
swivel angle
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Solution examples
Slide title1 n=const 2 n=const 3 n=var. 4 n=var. 5 n=var.Slide titleAC motor+ 2x fixed pumps
AC motor+ variable pump
VFD +AC motor+ fixed pump
VFD +AC motor+ variable pump (hydr. control)
VFD +AC motor+ variable pump (electriccontrol)
6 n=var. 7 n=var. 8 n=var. 9 n=var. 10 n=var.
VFD +AC motor+ variable pump + fixed
VFD +PMM motor+ fixed pump
VFD +PMM motor+ fixed pump
2x VFD +2x PMM motor+ 2x fixed pump
VFD +PMM motor+ variable pump (hydr+ variable pump + fixed
pump+ fixed pump + fixed pump + 2x fixed pump + variable pump (hydr.
control)
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Compact Hydraulic AxisSolution examples: Compact Axis
Compact Hydraulic Axis
The hydraulic circuit completely integrated into the d l
Max. press force up to 6200 kN (over the entire press stroke)
module
(over the entire press stroke)
Pressure control ± 0.3 bar
St k 450 3000
Rapid speed forward and return 1000 mm/s
Stroke 450 mm, max. 3000 mm
Position accuracy ± 1 µm
Safety functions up to Performance Level e, SIL3
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Cross Technology System Integration
HPUs and actuators go smart and efficient g
MLCProcess control
Process/ Motion Control
sercos
Integrated automation bus for real time communication
I d D i MLD
IAC-R
IndraDrive MLDOpen platform for integration of advanced control and monitoring functions
IAC RSmart HPU Compact and modular design wide range of sensors
Smart HPU with
Sytronix Compact
ElectroMechanical
Electrohydraulic
Actuators matching different applications
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withSytronix
pAxis
MechanicalActuator
hydrauliclinear cylinder
34
Increased efficiencyApplication Injection Mould Machine
Increased efficiencyNew Machine
]
Former solution:- Standard hydraulic solution DFEC- Asynchronous motor fixed rpm
I t ll d 11 kW 75 kW- Installed power: 11 kW -75 kW - operation: 24h/240days
Customer requirements: Energy savingMachine size :
Sytronix solution:
requirements: gy g
Optimal pressure/ flow control Reduced cooling capacity
Machine size :From 110 up to 430 Ton.
Sytronix DFEn 5000
Energy
g p y Reduced noise level Energy efficient system for master – master
double pump configuration
Comparison / Saving:
EfficientComponents
Energy D d
Energy System Design
10,000 kWh1,000 EUR3,900 kg CO2
34%
Comparison / Saving:
0.0280.018
10.90.7
Energy consumption per year [Mio. kWh
CO2 emission per year [to]
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on Demand-34%
35
Increased EfficiencyApplication Injection Mould Machine
former solutionIncreased Efficiency
Energy consumption Energy consumption CO2 emission
former solutionRexroth Sytronix solution
gy pper cycle [kWh]
gy pper year [Mio. kWh] per year [to]
4 9
0.028
0 018
10.9
0 74,9
3,2
4.9
3.2
0.018 0.7
Savings per year: 10,000 kWh,- 34 %1,000 EUR **
3900 kg CO2 ***
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base: ** 10ct/kWh *** 240g / kWh electrical motor power 11kW
36
Application – Injection Molding MachineApplication Injection Mould Machine
Application Injection Molding MachineField tests: Reduced operating power constant vs. variable speed DFE systems
160 ton closing force, 100 cc pump, 30kW motor:
55 t l i f 45 11kW t
Cycle time 10s: 8% Cycle time 20s: 32% Cycle time 40s: 44%
55 ton closing force, 45 cc pump, 11kW motor: Cycle time 8s: 10% Cycle time 25s: 20% Cycle time 60s: 45%
140 ton closing force, 71 cc pump, 15kW motor: Cycle time 27s: 45%
250 ton closing force 140cc + 64cc (regenerative) pump 55kW motor with accumulator:250 ton closing force, 140cc + 64cc (regenerative) pump, 55kW motor with accumulator: Cycle time 20s: 8%
270 ton closing force, 140cc + 71cc (regenerative) pump, 55kW motor:C l ti 45 30%
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Cycle time 45s: 30%
37
AdvantagesSummary
Advantages
Energy savingDepending on the application cycle variable speed pump drives from Rexroth canDepending on the application cycle, variable speed pump drives from Rexroth can reduce energy consumption by 10 to 80 %.Low energy consumption results in reduced energy costs and lowers the user’s “Carbon Footprint”.
Noise Level Reduction
Noise is reduced during partial load operation as a result of lower pump RPM. Average noise reductions of up to 20 dBA can be achieved. Installation costs may be reduced if p ysound insulation designs are not needed
Reduced CoolingIn many applications cooling may not be required on the hydraulic power unit since highIn many applications, cooling may not be required on the hydraulic power unit since high operating efficiency reduces hydraulic system heating
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AdvantagesSummary
AdvantagesLess Mounting SpaceEliminating system cooling allows for a more compact design, reduced complexity and
Hydraulic and Electric standard components
g y g p g , p ylower cost .
Variable speed pump drives utilize standard hydraulic components.
Forward Looking TechnologyVariable speed pump drives can help customer requirements for energy conservation.
Easy Integration of flexible control functionsEasy Integration of flexible control functionsAdvanced diagnosis and monitoring can help avoid costly machine failures.
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Thank you for yourThank you for your attention!
Jan Komsta
Manager, New Technologies & g gSimulation (DCUS/SET1)
Tel: +1 610-694-8547Mobile: +1 [email protected]
Sytronix DFEn 5000
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