Variable Speed Pump Komsta Powerpoint Presentation

Sy Variable Speed Pump Drives for Industrial Machinery – System Considerations

Jan Komsta, Ph.D. Bosch Rexroth 11.19.2013 Chicago

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11.19.2013 | DCUS SET | © Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Variable Speed Pump Drives for Industrial Machinery

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* USA

European Union

Russia

China

India

Brazil

23%** 20 % 15 % 40 % 20 % 36 % share

reduction

reduction

reduction

reduction

reduction

of renewables in electricity generation

in greenhouse gas emissions compared with 1990

in greenhouse gas emissions compared with 1990

in CO2 intensity compared with 2005

in CO2 intensity compared with 2005

in greenhouse gas emissions compared with no measures

Energy consumption is the driver •New Policies Scenario, World Energy Outlook 2012 •** By 2035

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Manufacturing systems life cycle costs (TCO) 80...95 % Initial startup Training Spare parts

Energy costs

~ $5.950 (96%) Cost price ~ $250 (4%)

Maintenance Labor costs Taxes Insurances

5...20 % Machinery & Equipment

Investment costs 4

Energy Modernization Disposal ...

Operating costs

Three phase motor 1 kW 5 year running time

Example



Growth in energy costs will continue

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Technology Change drive

power transmission Hydraulic pump

Constant speed electric motor

with /without valves

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Electro-mechanic

Power density, robustness Controllability Multiple consumers possible Noise Energy efficiency

motor / cylinder

variable speed pumps Force transmission

Variable speed motor drive

motor / cylinder

classic hydraulics Hydraulic pump

Variable speed motor drive

control

Properties

Spindle drive

Power density, robustness Controllability Multiple consumers possible Energy efficiency Noise

Controllability Noise Energy efficiency Multiple consumers not possible (or very difficult) Power density


Technology Change

Energy saving potential  Classic Solution

M Motor losses Pump losses

Total energy

 Full motor speed during part load operation.  Pump mechanical losses caused by high rotation speed  Lower motor and pump efficiency during part load operation  High throttling losses caused by proportional valves

Throttling losses

Useful energy

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Technology Change

Energy saving potential  Variable Speed Pump Drives

M Inverter losses Motor losses

Pump losses

Total energy

 No throttling losses from proportional valves  40-70% speed reduction during part load operation  Increased pump and motor efficiency during part load operation  Reduced pump losses by lowering average motor RPM  Additional inverter losses

Useful energy

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System Solutions Efficiency

M

AC motor + fixed pump

M

AC motor + variable pump

M

VFD + AC motor + fixed pump

M

VFD + AC motor + variable pump

M

VFD + PM motor* + fixed pump

M

Dynamics

VFD + PM motor* + variable pump

* permanent magnet synchronous motor

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Costs

(esp. for >60kW)

(esp. for >60kW)

System Considerations: Pump Selection

Which pumps are suitable for variable speed operation?         

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Speed range Pressure range Direction of rotation Pump efficiency Pump noise Flow and pressure pulsation Pump inertia Quadrants of operation …

???


Pump selection

Pump speed and pressure limitations Power

p [bar]

lowest speed for continuous operation (i.e. for gear pumps)

Pressure int. Pressure cont.

Noise limit - Motor Fan

Highest efficiency

temporary operation possible (i.e. for gear pumps) n [RPM]

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Cavitation


- Pump (high frequency)

Noise Reduction

Noise reduction  Pump noise depends on:  Pump construction  Speed and pressure

Pump noise level in dB(A)

… 80

80

70

70

60

60 Axial piston pump Axial piston pump

50

p= 200bar

Internal gear pump

40

40 0

1000

2000

Pump RPM

12

p= 50 bar

50

3000

0

1000

2000

Pump RPM


3000

Pump selection

Quadrants of operation + Flow Motor operation

Pump operation

pressure

Pump operation

Motor operation

- Flow

Internal gear pump e.g. PGH

Axial piston pumps e.g. A10 VZO

+ Flow Motor operation

Pump operation

pressure

Pump operation

Motor operation

Axial piston pumps e.g. A10 FZG / VZG (for closed circuits)

- Flow

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Pump selection

Mechanical 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

Mechanical inertia

Pump 140%

140%

120%

120%

100%

100%

80%

80%

60%

60%

40%

40%

20%

20%

0% 060

075

100

120

150

190

Maximum Flow (LPM)

14

240

300

Coupling PM Motor

0% 060

075

100

120

150

190

240

Maximum Flow (LPM)


300

Pump selection

Direct coupling  Reduced mechanical inertia  Better dynamics (higher acceleration capabilities)  Higher efficiency  Less mounting space (no bell-housing) Direct coupling Pump

Internal gear pump+PM Motor 120%

PM Motor

Mechanical inertia

100%

Reduced inertia

80% 60% 40% 20%

Sytronix SVP 7000

0% 060

075

100

120

150

190

240

300

Maximum Flow (LPM)

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Pump selection

Fixed or variable displacement? 8

Input Power P (kW)

M

Variable displacement pump, n=1500 RPM

7 6

Variable displacement pump + VFD

5

Fixed displacement pump + VFD

M

4 3

M

2 1 0 0

50

100 150 Pressure p (bar)

200

250

Power consumption for pressure holding Source: Prof. S. Helduser*, ‘Elektrisch-hydraulische Systemtechnik’, O&P 1/2006 *IFD, Technical University Dresden, Germany

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Pump selection

Fixed or variable displacement?

M =

17

p ⋅ Vp 20 ⋅ π ⋅ η mech

M


Pump selection

Fixed or variable displacement? Pump displacement is reduced A10 VZO pump with two-point control

Reduced load torque during pressure holding

M =

18

p ⋅ Vp (α ) 20 ⋅ π ⋅ η mech

M


Pump selection

Performance curve VFD + self-ventilated AC motor Fixed displacement internal gear pump- PGH Pump pressure

Axial piston pump with two-point control - A10VZO-EZ4 Pump Pressure

EZ4

Pump speed

Pump speed

- Continuous VFD operation

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Vgmax– max. pump displacement Vgmin – min. pump displacement

Energy Saving

Consider overall efficiency Pump efficiency

Load Torque

Adapt pump displacement to operate in preferred working points

Speed

PMM’s drive efficiency

Pump pressure

Speed

20

M


Energy Saving by Reducing Motor Speed

Energy saving during stand-by/ idling 4

Input Power P (kW)

3.5 3

M

2.5 2 1.5 1 0.5 Sytronix DFEn 5000

0 0

200

400

600 800 1000 Motor speed n (rpm)

1200

1400

1600

Power consumption of electric motor during standby/ idle  Pump size 100cc  40 HP AC motor  600 PSI, 0.25 GPM flow (pilot oil) 21


Energy Saving by Reducing Motor Speed

Energy saving by reducing motor speed Variable displacement pump+VFD

Efficiency @2200 psi Variable displacement pump, @ 1800 RPM

0.80

10 0.70

8

Efficiency

Input Power P (kW)

12

6 4

0.60

Variable displacement pump+VFD

0.50

2 0

Variable displacement pump, @1800 RPM

0.40 0

1000

2000 Pressure p (PSI)

3000

Power consumption of electric motor during pressure holding (Q=0 GPM)

4000

5

15

25 Q (GPM)

35

45

η = Hydraulic Output Power / Electric Input Power

 pump A4 125cc  100 HP AC motor Sytronix DFEn 5000

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Engineering: System Sizing in SytronixSize Machine load cycle (p/Q/t)

Select the pump type and size

Investigate drive working points, drive utilization factors, RMS power … 23


Engineering: System Simulation

System simulation – verify your ideas Model of hydraulic actuators, valves, process forces, lines, etc. Closed loop control algorithm

Speed Variable Pump HPU 24



System simulation – verify your ideas Internal gear pump model, including efficiency (working point dependent) VFD, firmware and p/Q control algorithm Model of PMM Servo Motor with Torque-Speed characteristics

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System simulation – verify your ideas Various process variables (speed, position, pressure, power, pump speed etc…)

Evaluation of the simulation:  Productivity (cycle time)  Dynamic behavior  Efficiency

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Sytronix: Bosch Rexroth’s Variable Speed Pump Drives Sytronix Preconfigured Sets Sytronix FcP

Sytronix SVP

•Pressure and flow control

•Pressure and flow control •Force and velocity control •Position control

Basic dynamics

High dynamics

Sytronix DFEn

•Pressure and flow control •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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System Variants- SVP

SvP 7000 – High performance SvP 7000

performance high dynamics

injection molding machine

energy efficient

high accuracy

sample application

control functions pressure control flow rate control force control

system

speed control

U

quadrants

2

n

SG 3~

1 flow

3 28

4

press brake

s

position control pressure

P

Axis control  high performance required  pressure control  flow rate control

3~

M

Axis control  high performance required  force control  speed control  position control

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 in the event of applications for industrial property rights.

System Variants- SVP

SvP 7000 – High performance pressure 150bar

10 bar

T95%= 150ms

3000 rpm

low RPM during pressure hold

speed

-3000 rpm 0s

29

1.5 s


System Variants- DFEn

DFEn – Advanced performance DFEn 5000

performance advanced dynamics advanced accuracy

2 independent hydraulic circuits possible

energy efficient

sample application injection molding machine

control functions pressure control

Axis control  advanced performance required  pressure control  flow rate control

flow rate control force control

system

speed control U

position control

paper

P

nCMD

quadrants pressure

2

3~

1 flow

30

3~

M

constant pressure system  advanced performance 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

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11.19.2013 | Abteilung | © Bosch Rexroth AG 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Solution examples 1

Slide title n=const

2

n=const

3

n=var.

4

n=var.

5

n=var.

AC 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 (electric control)

6

7

8

9

10

n=var.

VFD +AC motor + variable pump + fixed pump

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n=var.

VFD +PMM motor + fixed pump

n=var.

VFD +PMM motor + fixed pump

n=var.

2x VFD +2x PMM motor + 2x fixed pump

n=var.

VFD +PMM motor + variable pump (hydr. control)


Solution examples: Compact Axis

Compact Hydraulic Axis The hydraulic circuit completely integrated into the module Max. press force up to 6200 kN (over the entire press stroke) Pressure control ± 0.3 bar Stroke 450 mm, max. 3000 mm Rapid speed forward and return 1000 mm/s 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 MLC Process control

Process/ Motion Control Integrated automation bus for real time communication

sercos

IndraDrive MLD Open platform for integration of advanced control and monitoring functions

IAC-R

Smart HPU Compact and modular design wide range of sensors Actuators matching different applications Electro hydraulic linear cylinder

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Smart HPU with Sytronix

Sytronix Compact Axis

Electro Mechanical Actuator


Application Injection Mould Machine

Increased efficiency ]

New Machine

Machine size : From 110 up to 430 Ton.

Sytronix DFEn 5000

Former solution: - Standard hydraulic solution DFEC - Asynchronous motor fixed rpm - Installed power: 11 kW -75 kW - operation: 24h/240days Customer requirements:

Energy saving

Sytronix solution:    

Optimal pressure/ flow control Reduced cooling capacity Reduced noise level Energy efficient system for master – master double pump configuration

Comparison / Saving: Energy consumption per year [Mio. kWh 0.028 0.018

CO2 emission per year [to]

10.9 0.7

10,000 kWh 1,000 EUR 3,900 kg CO2

-34% 35


Energy System Design Efficient Components Energy on Demand


Increased Efficiency

former solution Rexroth Sytronix solution

Energy consumption per cycle [kWh]

Energy consumption per year [Mio. kWh]

10.9

0.028 4.9

CO2 emission per year [to]

0.018

4,9

0.7

3.2

3,2

Savings per year:

base: ** 10ct/kWh

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10,000 kWh, 1,000 EUR ** 3900 kg CO2 ***

- 34 %

*** 240g / kWh electrical motor power 11kW



Application – Injection Molding Machine Field tests: Reduced operating power constant vs. variable speed DFE systems 160 ton closing force, 100 cc pump, 30kW motor: 

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: 

Cycle time 20s: 8%

270 ton closing force, 140cc + 71cc (regenerative) pump, 55kW motor: 

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Cycle time 45s: 30%


Summary

Advantages Energy saving Depending 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 sound insulation designs are not needed

Reduced Cooling In many applications, cooling may not be required on the hydraulic power unit since high operating efficiency reduces hydraulic system heating

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Summary

Advantages Less Mounting Space Eliminating system cooling allows for a more compact design, reduced complexity and lower cost .

Hydraulic and Electric standard components Variable speed pump drives utilize standard hydraulic components.

Forward Looking Technology Variable speed pump drives can help customer requirements for energy conservation.

Easy Integration of flexible control functions Advanced diagnosis and monitoring can help avoid costly machine failures.

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Thank you for your attention! Jan Komsta Manager, New Technologies & Simulation (DCUS/SET1) Tel: +1 610-694-8547 Mobile: +1 610-216-9034 [email protected] Sytronix DFEn 5000

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Variable Speed Pump Komsta Powerpoint Presentation

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