Industrial Energy Efficiency with Bosch Rexroth. Scott C. Hibbard V.P. Technology Bosch Rexroth 1 A5

Transcription

1 Industrial Energy Efficiency with Bosch Rexroth Scott C. Hibbard V.P. Technology Bosch Rexroth 1 A5

2 Bosch Rexroth Wholly-owned subsidiary of Robert Bosch GmbH Merger of Mannesmann Rexroth with Bosch s Automation Technology All relevant technology for Drive, Control and Motion Worldwide presence For industrial and factory automation, and mobile applications 2

3 The Company Within the Bosch Group Bosch Group Revenue: 46.3 billion Employees 1/1/2008: 271,300 Automobile Industrial Consumer Goods & Technology Technology Building Services Engineering Bosch Rexroth 1) Packaging Technology 1) Bosch Rexroth AG (Bosch wholly owned) 3

4 The Company Bosch Rexroth Data Figures for 2007 Total revenue 5,356 million Total employees 32,981 Research and development Investments Germany: 1,507 million Germany: 17,905 total: 250 million total: 377 million Europe minus Germany: 2,136 million Americas: 849 million Europe minus Germany: 8,032 Americas: 3,308 Cost share of revenue: 4.7 % Cost share of revenue: 7.0 % Asia/RoW: 864 million Asia/RoW: 3,736 4

5 Bosch Rexroth in the Americas 5

6 The Company The Products Electric drives and controls Linear motion technology Gears Assembly technologies Hydraulics, industrial Pneumatics Hydraulics, mobile Service 6

7 The Company The Markets Industrial and factory automation as well as mobile applications Rexroth services are used worldwide in nearly all industries... 7

8 Energy Efficiency in Industry Total System Design In order to achieve maximum energy efficiency, the various technology disciplines must interact perfectly where intelligent solutions are concerned. The intelligent interlinking of different individual measures achieves the highest possible savings no single technology can meet the efficiency targets alone. 8

9 Design Scope for Energy Efficient Automation Solutions as a Function of Product Life Cycle Concept Design Engineering Commissioning Production / Operation Modernization : T8 WZW G1 X100 G2 X200 G1 Y250 G1 X150 : Mechanical Concept Automation Concept Mechanical Design Electrical Design Programming Runoff Part Programming Process Optimization Retrofit Product Overhaul Influ uence on En nergy Efficiency Greatest Opportunity To effect energy efficiency Is in the design phase, using Energy efficient motion Devices in connection with Mechatronic System optimization Optimization of Machine Operation Via Energy Analysis Tools Use of energy efficient motion technology as part of machine overhaul Machine Life Cycle 9

10 An Example Power Supply (AC DC) Servo or VF Di Drive (DC AC) Motor 10

11 Example: Energy Savings via power sharing with Optimized Machine Cycles Thermoforming Machine: 2 presses Toggle-linkage Mechanism Press 1 Press 2 Conventional Motion Profile Optimized i Motion Profile Energy Savings: Press 2 Press 1 Energy t t Press 2 Press 1 Energy t t Shift timing of the press motion Profiles Energy balance between the two drives Reduce the peak power requirements from the 3- phase Optionally use the heat for the Thermoforming Process t t 11

12 Energy Efficiency in Industry Rexroth Combined Know-how Rexroth is ideally positioned to offer the required energy efficient systems by means of drive and control technologies from a single source, combined with the required know-how. The Rexroth key to sustained increase in energy productivity: Speed-variable pumps Intelligent pressure control valves Intelligent servo drives Miniaturization Low-friction linear guides 12

13 Product Examples Industrial Hydraulics Speed-Variable Pump Drive (DvP) Speed on demand reduction of motor speed and thus pump power during pauses or in part-load operation, yet without impacting on control tasks. Increase in efficiency Energy savings Clear reduction in idle-running power in part-load mode / zero stroke the drive goes into stand-by function. Less energy/heat transfer into the oil, meaning less cooling required Positive impact on heat regulation, energy consumption and costs Noise reduction thanks to spontaneously controlled and lower speeds. Reduction in installed power. 13

14 Product Examples Industrial Hydraulics Bus Module with Energy-saving Function for Relay Valves Controlled energy cut-off during pauses in operation with the aid of field bus technology. Up to 66 % less power consumption (reduced to minimum level required) Uses PWM to control effective power Shorter response times due to voltage reduction. Fault diagnostics for each output / channels can be switched off individually in the event of a fault P More than one valve can be connected to each bus module summation current being thus reduced! d! Lower heat generation of solenoids = Increase in service life, lower cooling costs t 14

15 Product Examples Industrial Hydraulics Pumps and Axes Pressure-flow-controlled pumps p with integrated bus-enabled motion control permits precise power control Axial piston pumps with improved mechanical-hydraulic efficiency consume less energy. Energy savings in continuous, hi-performance applications by quickly switching between high and low pressure (example: punching & stamping machines) 15

16 Product Examples Pneumatics Valve Series LS04 The compact dimensions i and minimal i space required means the valve system can be positioned in the direct vicinity of the actuators. Directly mounted onto moving parts due to low weight. The concentration of pneumatic functions in an extremely confined space prevents pressure losses, which can occur from the long tubing lengths required from the control cabinet to the pneumatic drive. Furthermore, this solution also also shortens cycle times. 16

17 Product Examples Pneumatics Pressure Regulator ED-Series The right pressure for the right task reduces energy consumption by up to 25%. ED-Series pressure control valves permit sensitive pressure control. They combine digital closed-loop control electronics with innovative proportional p valve technology. The intelligent open-loop control directly at the location required guarantees reliable repetitive accuracy for typical pneumatic tasks such as weight compensation, force compensation, print run control, paint- or lacquerdosing and press-fit processes. The pressure control valves can, in open and closed loop operation, control force, flow rate, motor speed, position or cylinder speed. 17

18 Product Examples Linear Technology Roller Rail Guides Energy efficient i due to extremely low friction coefficients i of a mere percent. Reduction in friction of more than 90 percent in heavy-load applications when compared with conventional sliding bearings. Drive systems can be built to a smaller and thus more energyoptimized design. 18

19 Energy Savings with De-central Drive technology in a Mechatronic System Design IndraDrive MI Inverter (Drive) together with Control Section integrated in the Servomotor + A single cable for Power Supply (DC) & Communication Daisy-chaining of up to 20 Mi s & up to 18 kw Continuous Power is possible Integrated Motion/Logic programming using any IEC (PLC) languages 19

20 Energy Savings with De-central Drive technology in a Mechatronic System Design Before & After To Control Conv. Drives in a Cabinet Sensors Servo Motors To Control Sensors Power Supply/Interface in a Cabinet IndraDrive Mi De-central Drive 20

21 Energy Savings with De-central Drive technology in a Mechatronic System Design Regenerative Power Supply Return excess energy to the power lines. Energy Savings approx. 20%* DC Bus Electrical connection for energy exchange between motoring and generating drives Energy Savings approx. 15% * Additional Savings Component reduction (Cable, Cabinet, Connectorization, etc.) Reduced cooling demand in cabinet (unit size, energy costs) Reduced impact on plant cooling (units, energy costs) Energy Savings approx. 2%* Auxiliary Capacitor Module Buffers short term excess energy Energy Savings approx. 3%* Synchronous (Perm. Magnet) Motors High Energy NdFeB-permanent magnets in rotor, low-loss pole windings. Energy Savings approx. 3%* * Typical Energy Savings Amounts given, actual savings depends upon application and may be higher or lower ( Your Results May Vary ) 21

22 Energy Optimization Example Package Sorter for a Parcel Service Company Application Scan parcels for destination Sort and send parcels to trucks System Automation Goals Gentile motion for packages & mechanics Energy efficient total solution 20 small sorter lanes for packages up to 5 kg 21 large sorter lanes for packages up to 32 kg 22

23 Energy Savings Calculations for Example Package Sorting Line using Decentralized Drives Before System Energy Requirements: 18.5 kw Energy savings with Rexroth Automation Solution Regeneration Elimination of cabinet air conditioning through use of decentralized drives Energy buffering in Capacitor Modules Energy sharing via DC Bus Reduced primary energy requirement (less cable, smaller cabinets) High-efficiency i PM motors Total Energy Savings Annual energy savings (operating 24 Hrs/Day, 365 Days/Year) CO 2 -reduction (0.613 kg CO 2 /kwh*) 6.5 kw (= -35 %) 57 Mega W-H 35 tons *Energy mix in Germany per GEMIS Version 4.2 for

24 Conclusion Every Contribution Counts No technology can meet all the efficiency i targets t on its own it is rather the sum of each individual measure that counts. Considerable savings can be made by the intelligent interlinking of a variety of measures. Greater efficiency reduces energy costs, meaning that investments can pay for themselves within a short period of time. However, there is one consideration throughout the service life of a system that may or may not endorse the decision made after procurement costs have been taken into account. Cheap products offer one-off savings; efficient products pay every day. Rexroth offers the essential products and modules and supports both in the project design phase and in optimization of auxiliary processes. 24

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