Speed Variable Pump Drives Technology

Jan Komsta
Bosch Rexroth
September 2012

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 Saving energy and increasing productivity

Variable-speed pump
drives offer:
 Reduced energy consumption

 Reduced average noise

 Compact drive size

 Reduced cooling requirements for

oil

 High robustness

 Intelligent hydraulic drive

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 Motivation, market drivers: Energy costs

Average price electrical energy

12
European Union (EU 15)
11 Source: Eurostat
10
9 EURO CENT

8
7
6
5 Average price electrical energy
1995 1998 2001 2004 2007 2010
USA
Source: www.eia.gov/electricity/data/state

US CENT

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 Motivation, market drivers: Energy costs

Total Cost of Ownership (TCO)

80 ... 95 % AC motor 1 kW
5 year operation
Commissioning
Training Energy costs
Spare parts approx. 5,950 $ (96%)
Maintenance
Staff costs Acquisition costs
Taxes approx. 250 $ (4%)
Insurances

5 ... 20 %
Energy
Retrofit
Machine
Disposal
&
Equipment ...

Investment Operating
costs costs

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 Drive Technology Choices

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 w/o 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

Noise
Energy efficiency
Multiple consumers not
Variable speed possible (or very difficult)
motor drive Electro-mechanic Power density

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 System Solutions

Efficiency Dynamics Costs

M Fixed speed motor

3~ + fixed pump

M Fixed speed motor

3~ + variable pump

M Motor + VFD
3~ + fixed pump

M Motor + VFD
3~ + variable pump

M Servo Motor + Drive

3~ + fixed pump
(for large drives)

M Servo Motor + Drive

3~ + variable pump
(for large drives)

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 Energy saving… but how?

Conventional systems
α
n=constant
 Constant speed AC motor with variable
displacement pump (i.e. pressure
compensated)

 Flow rate is a function of swivel angle α:

VP ( )  n vol
Q
1000
α  0% : α  100 %:
 Motor torque is a function of swivel angle, Vp(α) = 0 Vp(α) = max
α, and pump pressure, p:

p VP ( )
M
20   mech. n= constant Vp(α)

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 Energy saving… but how?

Conventional systems: overall efficiency

Motor Efficiency [%]

Pump Efficiency [%]

Overall pump efficiency
for n= constant

Load of Motor M/M_nominal [%] Swivel Angle [%]

Swept volume Swivel angle

V~α Low pressure

p V ( )
M
20   mech. High Pressure

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 Energy saving… but how?

Conventional systems:
overall efficiency
 Efficiency of conventional system
is low during partial load
operation:

 Pressure Holding
 Idling
Pressure holding  For α <40-50%
Q, p Qsys/min

High saving potential!

n= const. Vp(α)

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 Energy saving… but how?

1. Fixed displacement 2. Variable disp. pump 3. Fixed/ var. disp. pump

pump Constant speed Variable speed
Constant speed

M M M
60 Hz 60 Hz

Energy saving
Losses
Total energy Losses Losses
Total energy
Useful energy Useful energy Total energy Useful energy

Motor heating
Throttling losses
Pump losses
eliminated Minimized / no power
Throttling losses (valve)
consumption during
Less power
Lowest efficiency partial load operation
consumption during
during partial load
partial load operation
operation

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 Saving energy and increasing productivity

Sytronix – Bosch Rexroth Variable-Speed Pump

Sytronix
Basic performance Advanced performance High performance

FcP 5000 DFEn 5000 SvP 7000

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 Saving energy and increasing productivity

Sytronix – FcP 5000

Performance FcP 5000 Sample application
basic dynamics energy
Machine tool
basic accuracy efficient

Control functions
pressure control

Flow control

force control Constant pressure system

System  basic performance required
speed control  pressure control
P
U
position control

Quadrants
pressure
3~
1 M
flow 3~

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 Saving energy and increasing productivity

Sytronix – DFEn 5000

Performance DFEn 5000 Sample application
advanced dynamics energy
Wood working machine
advanced accuracy efficient

Control functions
pressure control

Flow control

force control System

speed control
P
U
position control Constant pressure system
n_CMD
 advanced performance required
Quadrants
 pressure control
pressure
3~
2 1 M
flow 3~

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 Saving energy and increasing productivity

Sytronix – DFEn 5000

 Based on variable displacement pump A10VSO, pressure + stroke
control
 Frequency converter (HCS03)
 Standard motor (inverter duty)
 Advanced dynamics
 p/Q-control
speed
Maintain high pump
and motor efficiency,

swivel angle α>80%

flow

swivel angle

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 Saving energy and increasing productivity

Sytronix – SvP 7000

Performance SvP 7000 Sample application
high dynamics energy
Press brake
high accuracy efficient

control functions
pressure control

Flow control

force control System

speed control
P
U
position control
s
Quadrants Axis control
n
pressure  high performance required
SG
 force control
3~
2 1 M  speed control
flow 3~  position control
3 4

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 Saving energy and increasing productivity

Sytronix – SvP 7000

Internal Gear Pump PGH (Fixed Displacement Pump)

• Very high efficiency

• High drive speed
• Low pressure ripple
• Low noise
• Low mechanical inertia

Synchronous servo motor

• High dynamics
• Low mechanical inertia
• High power density

Servo frequency converter HCS03

• Dedicated flow and pressure controller (p/Q)
• Leakage detection/ compensation
• Safety functions; i.e. torque limitations, anti-cavitation
protection…

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 Saving energy and increasing productivity

SvP 7000 Pressure Control

pressure
 High accuracy pressure control 150bar

 Pressure rise and fall times equal

(T95% < 150ms at oil volume < 5 l)

 No overshoot or undershoot

10 bar T95%= 150ms

3000 rpm
low RPM during pressure hold

speed
-3000 rpm
0s 1.5 s

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 Saving energy and increasing productivity

SvP 7000 Flow Control

 High Dynamics improve cycle time
 Flow control response twice as fast
as conventional hydraulic pumps Flow Up Down

T25% 15 ms 10 ms
 Can save approximately 400ms per T50% 26 ms 18 ms
cycle (i. e. 5% improvement in an 8s T75% 36 ms 24 ms

cycle) T100% 57 ms 35 ms

 High repeatability due to high System example SVP-SF-1X/075-S2

accuracy speed control

Up Down
 High accuracy at very low flows
 Leakage detection and compensation
T25% T50% T75% T100% T25% T50% T75% T100% time

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 Functionality and Requirements

< 7,5 kW >7,5 to 37 kW >37 to 60 kW >60 kW

1 Axis- Presses
control, p/Q, Pos
p/Q, Pos

Dynamics
50ms

p/Q Dynamics
control Injection molding Die casting
150ms
machine

Dynamics Presses
300ms

2 Constant
Dynamics Machine
pressure
300ms tools
system
Metallurgy Bulk material
Marine & Handling
Wood, paper
Offshore

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 Functionality and Requirements

< 7,5 kW >7,5 to 37 kW >37 to 60 kW >60 kW

1 Axis-
control, p/Q, Pos SVP 7000
p/Q, Pos

Dynamics
50ms

DFEn 5000
p/Q Dynamics
control 150ms

Dynamics
300ms

2 Constant
Dynamics
pressure
300ms
system

FcP 5000

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 Noise Reduction with Speed Variable Pump

Full load
-5dB(A)
2

1 2 Variable pump
Noise [dB(A)]

Part load Axial piston pump A10

71cc
-20dB(A) 50 bar
1750 RPM
1

Sytronix constant pump

RPM
Internal gear pump PGH
1 Partial load (pressure holding) 40 cc
50 bar
2 Full load (max flow rate) 75 - 3000 RPM

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 Application Example: FcP 5000 for Machining Center

Conventional drive solution:

• 5.5kW motor
• Control pump 250 bar / 13 l/min
• Fixed displacement pump for filter/cooler
Energy consumption 24.600 kWh/Yr

source: www.sw-machines.de Rexroth Sytronix solution Energy

System Design
• 4.0 kW motor
• Variable speed pump drive Sytronix Efficient
• 6cc internal gear pump Components

Sytronix FcP 5000

• Return line filter/cooler Energy
on Demand

Energy consumption 13.620 kWh/Yr

Savings 10,980 kWh/Yr

CO2-prevention*
1,537 €/Yr **
6.7 tons/Yr
– 45 %
* Energy mix, Germany according to GEMIS version 4.2 in year 2004: 0,613 kg CO2/kWh
** electricity tariff 0,14 €/KWh incl. 3,592 ct/KWh EEG-allocation

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 Application example – Die Casting Machine

Conventional solution: Advanced solution:

 Constant speed drive  Rexroth SvP variable-speed
(11 kW motor) with fixed pump drive
displacement pump

 50 to clamp force
 7.5 s cycle time

Energy consumption:
Energy saving
10.1 kW 83.2 % 1.7 kW

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 Application example – Rubber Injection Machine

Conventional solution: Advanced solution:

 Constant speed drive(15 kW  Rexroth SvP variable-speed
motor, load sensing) with pump drive
SYDFE pump

 50 to clamp force
 7.5 s cycle time

Energy consumption:
Energy saving
2.9 kW 72.3 % 0.8 kW

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 Sytronix SVP 7000 Application

Press Brake

Machine Information
 Press brake 135t
 cycle time: 15sec

Requirements
 Equip both hydraulic axis with controlled servo
variable pump drive (SvP)
 Use existing interfaces

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 Sytronix SVP 7000 Application

Press Brake – Conventional Solution

HMI

PLC

Control block
power unit Control block

U U
x x

Control block Control block

with safety with safety
functionality functionality

Safety control

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 Sytronix SVP 7000 Application

Press Brake – New Solution

HMI

PLC

Control block Control block

 Servo motor MSK
 Digital servo drive HCS02
 Axial piston pump A10
U (4-quadrant) U
x x
 Control block w/ switching
and safety valves
Control block Control block
with safety with safety
functionality functionality

Safety control

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 Sytronix SVP 7000 Application

Press Brake – Positioning Accuracy

Conventional System SvP System A10 (6ccm)

Fast Advance
fast return

Forming speed

hold time

(zoom of target position) (zoom of target position)

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 Sytronix SVP 7000 Application

Press Brake - Energy Consumption

Conventional System SvP System A10 (6ccm)
60 400
axis position axis position
P[kW] / E[Wh]

50
300

P[kW] / E[Wh]
40

x [mm]
x [mm]
200
30 power
energy energy
20 100

power 10
0
0
-100
5 t [s] 10 15 t [s]
Maximum electric power:
19kW 22kW
Total energy per cycle:
32,6Wh 19,2Wh
Stand-by power:
1,85kW 0,55kW

• Energy savings approximately 40% for typical press cycle

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 Saving energy and increasing productivity

Thank You
Energy efficient Efficient Energy Energy
system design components recovery on demand

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 Saving energy and increasing productivity

Jan Komsta
Tel: 610-694-8547
Mobile: 610-216-9034

[email protected]

www.boschrexroth-us.com

www.boschrexroth.com/sytronix

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 Saving energy and increasing productivity
Application example: Ingersoll CM Systems, S-8255

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