Energy Saving Hydraulic Drive

PDAC 2014
11.19.2013 | DCUS SET | © Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
1 the event of applications for industrial property rights.
PDAC 2014
SEnergy
Sy
E saving
i hydraulic
h d li drives
di
Energy and the Environment – The Drivers
Manufacturing systems life cycle costs (TCO)
80...95 % Energy costs

~ $5.950 (96%)
Initial startup
Training Cost price
Spare parts ~ $250 (4%)
M i t
Maintenance
Labor costs
Taxes
Insurances
5...20 % Energy
Modernization
Machineryy
& Disposal
Three phase motor 1 kW
Equipment ... 5 year running time
Investment costs Operating costs Example
Energy and the Environment – The Drivers
Growth in energy costs will continue
Technology Change and reduction in hydraulic expertise
drive power transmission Properties

Hydraulic pump control motor / Power density, robustness
cylinder
Controllability
Multiple consumers possible
Noise
Constant speed Energy efficiency
electric motor classic hydraulics
Hydraulic pump with /without valves

motor / Power density, robustness
cylinder Controllability
Multiple consumers possible
Energy efficiency
Variable speed Noise
motor drive variable speed pumps
Force transmission Spindle drive Controllability

N i
Noise
Energy efficiency
Multiple consumers not
Variable speed possible (or very difficult)
motor drive Electro-mechanic
Electro mechanic Power density
Technology Change
Energy saving potential

 Classic Solution
 Full motor speed during part load

operation.
M
 Pump p mechanical losses caused byy
high rotation speed
Motor losses  Lower motor and pump efficiency
during part load operation
Pump losses  High throttling losses caused by
proportional valves
Total
energy Throttling losses
Useful energy
Technology Change
Energy saving potential

 Variable Speed Pump Drives
 No throttling losses from proportional

valves
M
p
 40-70% speed reduction during
gppart
load operation
Inverter losses
 Increased pump and motor efficiency
Motor losses during part load operation
 Reduced pump losses by lowering
Pump
p losses
average motor RPM
 Additional inverter losses
Total
energy
U f l energy
Useful
Pump selection
Quadrants of operation
+ Flow
Motor operation Pump operation
pressure
Pump operation Motor operation Internal gear pump Axial

A i l piston
i t pumps
e.g. PGH e.g. A10 VZO
- Flow
+ Flow
Motor operation Pump operation
pressure
Pump operation Motor operation Axial piston pumps

e.g. A10 FZG / VZG (for closed circuits)
- Flow
Fl
Noise Reduction
Noise reduction
 Pump noise depends on:
 Pump construction
 Speed and pressure
…
80
80
oise level in dB(A)
70
70
60 60
Axial piston pump
Pump no
Axial piston pump p= 50 bar

50 50
Internal gear pump p= 200bar
40 40
0 1000 2000 3000 0 1000 2000 3000
Pump RPM Pump RPM
Variable Speed Pump Drives for Industrial Machinery
Hydraulic applications for pconstant ,

e.g. conventional technology for HPUs
Variable Speed Pump Drives for Industrial Machinery
Traditional Pump Motor Group

ciency [%]
ciency [%]
Effic
Effic
Load of Motor M/M_nenn [%] Swivel Angle [%]
Swept volume Swivel angle V

V~α
LP
HP
Sytronix - Variable Speed Pump Drives
Energy saving for constant pressure systems

 Typical flow rate profile for pconstant (e.g. technology for HPUs)
 High energy saving potential
 Reduced motor speed  decreasing of installed energy
 Using components in ideal degree of efficiency
High energy saving potential
A li ti
Application for
f pconstant
Energy Saving by Reducing Motor Speed
Energy saving by reducing motor speed

Variable displacement pump+VFD
12 Efficiency @2200 psi
Variable displacement pump, @ 1800 RPM 0,80
10
Inputt Power P (kW)
8 0,70
Effficiency
6 0,60 Variable displacement
4 pump+VFD
0,50
2 Variable displacement pump,
@1800 RPM
0 0,40
0 1000 2000 3000 4000 5 15 25 35 45
Pressure p (PSI) Q (GPM)
Power consumption of electric motor during η = Hydraulic Output Power / Electric Input Power
pressure holding (Q=0 GPM)
 pump A4 125cc
 100 HP AC motor
S
Sytronix DFEn 5000
Sytronix - Variable Speed Pump Drives
Potential for energy savings

Q
p
Pressure
sys
hold mode Max. flow rate
Max
Qsys/min Qsys/max
η syys [%]
Comparison of conventional and
variable speed drives:
Energy saving in pressure hold
mode and reduced flow up to 80% Sytronix
(depends on cycle time and basic
rate of Qsys/min ).
Q / Q nenn [%]
System Variants- SVP
SvP 7000 – High performance

performance SvP 7000 sample application
high dynamics energy
injection molding machine
high accuracy efficient
control functions
pressure control
Axis control
flow rate control  high
g pperformance
required
force control  pressure control
system
 flow rate control
P
speed control U p
press brake
s
position control
Axis control
quadrants n  high
performance
pressure
SG required
3~
2 1 M  force control
flow 3~  speed control
 position control
3 4
11.19.2013 | | DC-IA/PJ-HDC© Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
15 in the event of applications for industrial property rights.
System Variants- SVP
SvP 7000 – High performance

pressure
150bar
Important !!
Pressure control
at reduced speed
10 bar T95%= 150ms
low RPM during pressure hold
speed
0s 1.5 s
System Variants- DFEn
DFEn – Advanced performance

performance DFEn 5000 sample application
advanced dynamics energy
2 independent injection molding machine
hydraulic circuits
advanced accuracy
y efficient possible
control functions
pressure control
Axis control
flow rate control  advanced performance
required
force control system  pressure control
 flow rate control
speed control
paper
p p
P
U
position control
nCMD
quadrants
pressure
3~ constant pressure system

2 1 M  advanced performance
flow 3~
required
 pressure control
System Variants- DFEn
Variable speed mode and constant speed mode

constant speed mode variable speed mode
speed
speed
flow
flow
swivel angle
swivel angle
11.19.2013 | Abteilung | © Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
Application: John Lewis
Log loading device J. Lewis

Aggregate before retrofit
 Pressure p = 120 bar by 60 l/min/pump with 120 l/min by 1800 rpm
 „Pressure
Pressure controlling“
controlling via pressure limitation valve
Energy consumption 44.000 kWh/a
Sytronix SVP 7000 Energy

 Internal gear pump on servomotor via FU System Design
 4 Liter accumulator for safeguarding 97 bar Efficient
 selectable throttle point for min. speed of the pump Components
Energy
e gy
on Demand
Energy consumption 4.000 kWh/a
Saving 40.000 kWh/a
CO2-Saving*
5.600 €/a **
24,5 t/a
– 71 %
* Energy mix, germany concerning GEMIS version 4.2 in the comparison year 2004: 0,613 kg CO2/kWh
** Current price 0,14 €/KWh incl. 3,592 ct/KWh EEG-allocation, 24h/day, 260 days/year
Thank you for your
attention!
Rodney Trail
Bosch Rexroth Canada

Industry Sector Manager SET23
Canadian Sytronix Manager
Sytronix DFEn 5000

Energy Saving Hydraulic Drive

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Energy Saving Hydraulic Drive

Uploaded by

Copyright:

Available Formats

PDAC 2014

Manufacturing systems life cycle costs (TCO)

80...95 % Energy costs

Investment costs Operating costs Example

Growth in energy costs will continue

drive power transmission Properties

Hydraulic pump with /without valves

Force transmission Spindle drive Controllability

Energy saving potential

 Full motor speed during part load

Energy saving potential

 No throttling losses from proportional

Motor operation Pump operation

Pump operation Motor operation Internal gear pump Axial

Motor operation Pump operation

Pump operation Motor operation Axial piston pumps

Axial piston pump p= 50 bar

Hydraulic applications for pconstant ,

Traditional Pump Motor Group

Swept volume Swivel angle V

Energy saving for constant pressure systems

High energy saving potential

Energy saving by reducing motor speed

Potential for energy savings

SvP 7000 – High performance

SvP 7000 – High performance

10 bar T95%= 150ms

low RPM during pressure hold

DFEn – Advanced performance

3~ constant pressure system

Variable speed mode and constant speed mode

Log loading device J. Lewis

Energy consumption 44.000 kWh/a

Sytronix SVP 7000 Energy

Saving 40.000 kWh/a

Bosch Rexroth Canada

Sytronix DFEn 5000

You might also like