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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.
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.
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
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.
Energy costs
5...20 %
Machinery & Equipment
Energy
Modernization Disposal ...
Investment costs
4
Operating costs
Example
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.
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.
Properties
Power density, robustness Controllability Multiple consumers possible Noise Energy efficiency
classic hydraulics
Hydraulic pump with /without valves motor / cylinder
Power density, robustness Controllability Multiple consumers possible Energy efficiency Noise
Controllability Noise Energy efficiency Multiple consumers not possible (or very difficult) Power density
Electro-mechanic
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.
Technology Change
M
Motor losses Pump losses
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
Total energy
Throttling losses
Useful energy
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.
Technology Change
M
Inverter losses Motor losses
Pump losses
Total energy
Useful 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
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.
System Solutions
Efficiency Dynamics Costs
M M
AC motor + fixed pump AC motor + variable pump VFD + AC motor + fixed pump VFD + AC motor + variable pump VFD + PM motor* + fixed pump VFD + PM motor* + variable pump
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.
???
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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.
Pump selection
Cavitation
Highest efficiency
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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.
Noise Reduction
Noise reduction
Pump noise depends on: Pump construction Speed and pressure
80 70 60 Axial piston pump
Axial piston pump Internal gear pump 40 0 1000 2000 3000
80
70
60
50
50 40
Pump RPM
Pump RPM
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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.
Pump selection
Quadrants of operation
+ Flow
Motor operation Pump operation
pressure
Pump operation
Motor operation
- Flow + 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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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.
Pump selection
Coupling PM Motor
100% 80% 60% 40% 20% 0% 060 075 100 120 150 190 240 300 Maximum Flow (LPM)
0% 060 075 100 120 150 190 240 300 Maximum Flow (LPM)
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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.
Pump selection
Direct coupling
Reduced mechanical inertia Better dynamics (higher acceleration capabilities) Higher efficiency Less mounting space (no bell-housing) Direct coupling
Internal gear pump+PM Motor
120% 100%
Mechanical inertia
80% 60% 40% 20% 0% 060 075 100 120 150 190
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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.
Pump selection
M M
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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.
Pump selection
M =
p Vp 20 mech M
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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.
Pump selection
M =
p Vp ( ) 20 mech M
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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.
Pump selection
Performance curve
VFD + self-ventilated AC motor Fixed displacement internal gear pump- PGH
Pump pressure
EZ4
Pump speed
Pump speed
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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.
Energy Saving
Load Torque
Speed
Pump pressure
Speed
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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.
Power consumption of electric motor during standby/ idle Pump size 100cc 40 HP AC motor 600 PSI, 0.25 GPM flow (pilot oil)
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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.
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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.
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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.
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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.
Pressure and flow control Force and velocity control Position control High dynamics Custom Solutions
Pressure and flow control Power control High dynamics & high power
Basic dynamics
Custom system functions Pressure and flow control Force and velocity control Position control
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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.
SvP 7000
control functions pressure control flow rate control force control speed control position control quadrants
pressure n
system
U P s
Axis control high performance required pressure control flow rate control press brake Axis control high performance required force control speed control position control
SG
3~
flow
2 3
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1 4
3~
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.
-3000 rpm
1.5 s
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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.
DFEn 5000
2 independent hydraulic circuits possible
energy efficient
control functions pressure control flow rate control force control speed control position control quadrants
pressure U P
system
Axis control advanced performance required pressure control flow rate control paper
nCMD
1
flow
3~ 3~
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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.
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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 AC motor + 2x fixed pumps
Slide title
n=const 2
n=const
n=var.
n=var.
n=var.
n=var.
n=var.
n=var.
n=var.
10
n=var.
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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.
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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.
Process/ Motion Control Integrated automation bus for real time communication IndraDrive MLD Open platform for integration of advanced control and monitoring functions Smart HPU Compact and modular design wide range of sensors Actuators matching different applications
sercos
IAC-R
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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.
Increased efficiency
]
New Machine
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
Energy System Design Efficient Components Energy on Demand
Comparison / Saving:
Energy consumption per year [Mio. kWh 0.028 0.018 10.9
-34%
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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.
Increased Efficiency
Energy consumption per cycle [kWh]
4.9
4,9
3.2
3,2
- 34 %
base: ** 10ct/kWh
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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.
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:
Cycle time 45s: 30%
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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.
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 users Carbon Footprint.
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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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.
Summary
Advantages
Less Mounting Space
Eliminating system cooling allows for a more compact design, reduced complexity and lower cost .
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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.
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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.