Reliable and Efficient Hydraulics and Pneumatics for Today and Tomor

Transcription

1 Reliable and Efficient Hydraulics and Pneumatics for Today and Tomor Energy Savings Through Proper Use of Pneumatics Date: November 21, 2013 Frank Langro Festo Corporation Director Marketing & Product Management

2 Energy Savings Through Proper Use of Pneumatics Trends System Approach Design & Optimization Energy Saving Steps Summary

3 Trends Changing general requirements are the drivers for energy efficiency ascending energy demand statutory guidelines ascending Energy costs ascending CO 2 -emission

4 Trends Changing general requirements are the drivers for energy efficiency Source: US Energy Information Administration Source: estimation of the Brookings Institution

5 Trends Changing general requirements are the drivers for energy efficiency Source: US Energy Information Administration

6 Trends Changing general requirements are the drivers for energy efficiency Increasing CO2 emissions

7 Trends Changing general requirements are the drivers for energy efficiency

8 Trends Changing general requirements are the drivers for energy efficiency The cheapest energy is what you don't use. Arthur Rosenfeld, nuclear physicist, California Energy Commission As far as I'm concerned, however, it is clear that the concept of premium will be increasingly defined through sustainability in the future. BMW Head Norbert Reithofer Energy savings financed new investments VDI-Nachrichten Nov You don t have to lose your Green, to go Green GREENWORLD RESTORATION, LLC What we need to do is really improve energy efficiency standards, develop in full scale renewable and alternative energy and use the one resource we have in abundance, our creativity. Lois Capps

9 System Approach Energy efficiency requires teamwork Purchasing Design Production Energy efficiency in companies Sales Quality Maintenance Logistics

10 System Approach Energy efficiency requires teamwork Efficiency measures are complex Easy organizational measures can realize clearly improvements Results at its best can be achieved due to an early involvement in planning phase From (industrial) point of view it s possible to realize approx. 15% of saving potential* This potential will be realized very slowly in spite of a high profiability due to the broad disciplines required to achieve * study from Fraunhofer Institute

11 System Approach Energy efficiency requires teamwork No responsible person Failing acceptance Complexity Cultural differences.working fine for years Energy consumption is unknown Differing opinions Lack of ressources Poor relations Too little time Hidden conflicts Internal contests Too little motivation Energy costs not transparent Only theory! Fear and distrust Ignorance

12 Design and Optimization Solutions for a profitable and sustainable future

13 Design and Optimization Energy efficiency = Energy used/benefit in a defined application Example: Consumer goods Application 60 C cotton program Application data 200 cycles a year Energy efficiency based on EN and Directive 95/12/EC Energy efficiency class Example: Machines Application Always different Not standardized Application data Varies customer to customer Application-dependent Energy efficiency can be determined, but not compared Energy efficiency classes are not possible!

14 Design and Optimization Pneumatic and electric drives Simulations compensate expensive empirical testing dimensioning software supports the choice, configuration and dimensioning from the pneumatic active chain. approx. 40% less compressed air consumption approx. 10% less purchase costs No accumualtion of safety factors dimensioning software uses position values, workload and fitting position for designing of drive, gear, motor and controller. Up to 70% energy saving due to reducing of safety factors approx. 20% less purchase costs

15 Design and Optimization Average costs of the generation of compressed air Fixed costs: Depreciation of the investment of the compressed air system Interest rate Cost of the used floor + Variable Costs: Electrical consumption Oil and water consumption Maintenance and repair costs = Avg compressed air costs: $/m $/ft 3 Compressor air intake per year*

16 Design and Optimization Example: Moving a 12 kg block of cheese Distance 250mm 60 cycles/min 300ms cycle time operation: 8h/day 200 days/year Comparison of bore sizes 40mm & 32mm Energy consumption Energy costs per year ( $ / m³) ,77 Nl / cycle (+0,86Nl / Tube) 2,43 Nl / cycle (+0,86Nl / Tube) ~288 $ ~205 $ - 30 % Purchase costs 100% 88 % - 12 %

17 Design and Optimization Example: dimensioning by single components dimensioning axis Supplier 1 Safety factor 2 dimensioning gear Supplier 2 Safety factor 1,5 Dimensioning motor Supplier 3 Safety factor 1,2 consumption per year = kwh Application: Palletizing of a gear part weight: 12 kg; distance: 500 mm 20 cycles/min; cycle time: 1s operation: 8h/day and 200 days/year

18 Design and Optimization Example: dimensioning as a system Application: Palletizing of a gear part wt: 12 kg; distance: 500 mm 20 cycles/min; cycle time: 1s operation: 8h/day & 200 days/yr Nonoptimized dimensionin g safety factor >> 1,5 1,2 energy consumption Optimized dimensionin g 195 kwh/year 60 kwh/ yr - ~70 % purchase costs ~ $5,850 ~ $4,810

19 Design and Optimization Guideline: pneumatic or electric? Application: moving or holding?

20 Design and Optimization Tips: Pressure sensor Continuous control of the system pressure Differential pressure sensor for filter elements The monitoring of filter elements of fine and micro filters alerts in time! economical changing the filter elements exactly on demand Flow sensor for consumption monitoring Measuring the flowrate for monitoring and controlling Logging and controlling of the air consumption

21 Design and Optimization Tips: Integration of sensors in air preparation units Use the exhaust connector of the manual on/off valve P P It is possible to use this connector to measure the consumption of the machine. Switch the valve to the off position Connect the flow sensor to the exhaust thread Input the flow sensor with system pressure ATTENTION: do not disconnect the system pressure at the input of the on/off valve

22 Design and Optimization Tips: Air saving cicuits for vacuum When the required vacuum is achieved, the air saving circuit is activated and the supply of compressed air to the nozzle will be switched off Vac. max Vac. min Vacuum conventional vacuum generator 1 0 saving pressured air

23 Design and Optimization Tips: Vacuum application on a customer machine Actual situation Possibilities for optimization

24 Design and Optimization Tips: Vacuum application on a customer machine cycles/ min Vacuum active time [s] Air consumption [Nl/min] Compressed air costs per day Costs for comp. air per year Maintenance costs 1-shift operation Invest Vacuum pump 1,5kW $1,690 $161 $130 Vacuum nozzle VN-07 2pcs. $ ,5 80 $ $129 $0.00 Vacuum nozzle OVEM 07 w/asc 2pcs $ ,5 28 0,34 $45 $0.00

25 Design and Optimization Tips: High pressure requirement If only for one application, e.g. force fitting, a higher pressure is needed, the adoption of a pressure booster is more efficient rather than increasing the system pressure at the compressor. example 1 pressure 10bar example 2 pressure 6bar + Booster operation costs/m $ $ compressor delivery / 360,000m 3 360,000 m 3 year plus 5% for Booster supply m 3 Costs for compressed air 5,292 $ 4,082 $ the invest of the compressor is considered in the calculation savings $ additional costs (Booster) Return of Invest ~ 13 months 1,300 $

26 Energy Saving Steps Pre-assessment Introduction energy saving in compressed air systems Actual situation Targets and needs Saving potentials Recommended activities Analysis of compressed air generation Air consumption analysis logging and analysis of the electrical consumption of the compressor(s) logging of the air consumption detection of the actual energy costs detection of saving potentials logging and analysis of the air consumption and the leakages from machines and production lines Identifying of improper use of compressed air and possibilities for improvements

27 Energy Saving Steps Leakage-detection reducing pressure drops due to leakages decreasing the consumption of compressed air and also the operational costs increasing the process reliability Analysis of the air quality Optimization of the actual air quality in the compressed air system increasing the machine availability and process reliability decreasing the maintenance costs

28 Energy Saving Steps Design of tubing system, lengths and diameters pressure terminators long pipes small inner diameters cramped tube elbows reductions valves and connectors

29 Energy Saving Steps Design of tubing system, lengths and diameters NEVER!! Long tubes, tube tangles and too many branches

30 Energy Saving Steps Design of tubing system, lengths and diameters The pressure drop is proportional to the tube length and reciprocal proportional D 5!!! P loss ~ Source: Prof. Dr.-Ing Andreas P.Weiß FH Amberg - Weiden EnEffAH Corrective measures: closed circular pipeline instead of pipelines with a dead end correct dimensioning of pipe and hose diameters l D 5

31 Energy Saving Steps Impact of tubing length on energy costs If possible local installation of valve terminals Valves close to the cylinder tube from valve to cylinder DNC-32 long tube PUN-8x1, m DNC-32 short tube PUN-8x1, m air consumption of cylinder air consumption Tube costs of energy / yr ( $ /m³) 0.856Nl/ cycle ~53 $ / year 2.43 Nl/ cycle ~151 $ 0.086Nl/ cycle ~ 5.35 $ / year ~ 204 $ ~ 156 $

32 Energy Saving Steps Create pressure zones activation on both sides with max. system pressure activation with pressure zones cylinder: DNC PPV-A Circuit diagram for a reverse stroke with lower piston power/ speed pressure: moving time: energy costs per annual: additional purchase costs: 6 bar 0.5 s forward 0.5 s reverse 6 bar forward 2.5 bar reverse ~ 205 $ ~ 164 $ ~ 75 $ the additional purchase costs are paid off in less than 2 years

33 Summary Requirements from the market and also new legislations are increasing the awareness of energy efficiency Energy efficiency is team-work Festo our customers company networks Each drive technology has advantages Pneumatic and electric drives are efficient if correctly dimensioned and applied, many ways to make pneumatic technology efficient

34 THANK YOU