Design Considerations for a More Efficient Power Unit Circuit Tom Shickel Manager Marine & Offshore Bosch Rexroth Corporation Tele: 610/ 694-8552 Fax: 610/ 694-8266 1
Hydraulic Drive System Advantages Reliability Maintenance Power Density System Noise Component Longevity Cost of Construction..If properly sized, flushed, and commissioned! 2
Pump Motor Group on Top of Tank - Horizontal Low Noise Accessibility Overall Size Suction Characteristics Fair Good Excellent Fair 3
Mounted Pump Group on Top of Tank- Vertical Low Noise Accessibility Overall Size Suction Characteristics Excellent Fair Excellent Excellent 4
Pump Motor Below the Tank (Overhead Design) Low Noise Accessibility Overall Size Suction Characteristics Good Good Excellent Excellent 5
Motor Pump Group on Side of Tank (L-shape) Low Noise Accessibility Overall Size Suction Characteristics Good Excellent Fair Excellent 6
Design & Procedure Considerations: 1. Electric Motor Sizing 2. Pump Selection 3. Pump Controllers 4. Heat Exchangers 5. Temperature Settings 6. Energy Recovery (HRB, RAHC) 7
Don t oversize the electric motor Some OEM s specify motors sized 20% max requirement Unloaded motors will still draw 1/3 the nameplate HP 8 Linear Motion and Assembly Technologies Nolte Uta 12.03.2010 Abteilung
Energy Saving Potential Classic Solution High throttling losses caused by proportional valves High motor heating caused by current flow. High leakage losses caused by high speed. Full motor speed during part-load operation. High Energy losses caused by releasing pressure overshoot to tank No energy saving potential used in classic (fixed displacement/ speed) hydraulic solutions 9 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
A10VO Parts Piston Shoe Retainer Plate Cylinder Barrel Hydrostatic Bearing Swash Plate Retainer Ball Piston Mechanical Pretension Spring force Distributor Plate 10
A10VO/VSO Control Summary DR pressure compensation control DRG remote pressure control DFR load sensing control DRT offsettable pressure control DFLR torque control (series 31) DFSR summation torque control (series 31) FHD hydraulic pilot flow control (series 31) DFE electronic pressure/flow control (series 31) ED electronic pressure control EP electronic displacement control 11
Pump Control Options Tailored for Specific Operations Variable Displacement Pump Controls: 1. Constant Pressure Control (DR) 2. Load Sensing (DFR) 3. Horse Power Control (DFLR) 4. Integrated Electronic Control (DFEE) 12
Oil Reservoir - Size of Tank 1. Minimum 3x total flowrate per minute 2. Baffle recommended 3. Sufficient time for cooling, settling of particles and aeration 13
Filtration Guidelines 1. Cleanliness level determined by the most sensitive component 2. Pressure and return filters sized sufficiently 3. Breather to be lowest micron filter in system 4. Kidney loop filters 5. Suction filters must have low P bypasses 14
Filter/Cooler Module MFC3, MFN3, MNC3 4-19 HP Removal Pump Flow 3-13 GPM Motor 1500/1800 RPM RA 50127 15
Rear Mounted Heat Exchangers Mounts directly to the back of the main electric motor 1-2 HP Removal Pump Flow 2-3 GPM Pump drain line cooling 16
Hydraulic Fluid - Temperature 1. Suitable viscosity for ambient temperatures and duty cycle 2. Heat exchanger approach temperature is critical for energy conservation 3. Life span of fluid is halved every additional 18 degrees F over 160 degrees F 4. Pumps ideal range of 80 to 170 SUS 5. Pumps intermittent min/max range of 60/4600 SUS 17
Viscosity range for Shell Tellus 32 Temperature (Degrees F) Viscosity (SUS) 210 44 160 60 140 78 120 105 100 167 80 230 60 400 18
Avoid Air Entrainment and Cavitation Design Traps Place air bleed valves at high points of the circuit Optimize pump suction line characteristics Avoid suction strainers when possible Size reservoir adequate for the fluid to settle and deaerate. Use a reservoir baffle design Mount suction lines sufficiently well below lowest level fluid level Insure transmission lines are not undersized!! 19
Pressure Drop in Transmission Lines We recommend the following oil velocities for noise sensitive applications: Suction lines: Not to exceed 3 ft/sec Return lines: Not to exceed 6 ft/sec Pressure lines: 0-400 psi: Not to exceed 9 ft/sec 800 psi: Not to exceed 13 ft/sec 1500 psi: Not to exceed 15 ft/sec Over 1500 psi: Not to exceed 17 ft/sec 20
Manifold Advantages Manifold Mounted Components 1. Elimination of leak points 2. Compact size enable shorter runs between valves and less pressure drop 3. Flexibility for future changes 4. Ease of maintenance 21
After commissioning, all systems will vary efficiency degradation over time depending on fluid and operating conditions are maintained. 22
Hydrostatic Regenerative Braking System Makes Commercial Vehicles Up to 25 Percent More Economical Linear Motion and Assembly Technologies Nolte Uta 12.03.2010 Abteilung 23
Components of the HRB A4VSO Axial Piston Unit + Gearbox Hydraulic Accumulator Pressure Relief Valve Valve Control Block HIC BODAS Controller RC Linear Motion and Assembly Technologies Nolte Uta 12.03.2010 Abteilung 24
Applications High vehicle mass Strong, active deceleration for storing much energy in a short time Frequent accelerating and braking Low rolling resistance for storing maximum braking energy Linear Motion and Assembly Technologies Nolte Uta 12.03.2010 Abteilung 25
RAHC - Rotativ Active Heave Compensation based on BR secondary control technology s U m P T L DR M 3 DR M 3 26
System Description Linear AHC Reduced installed power: LAHCS175: 175 t @ +/- 3.0 m heave & 8 sec period Theoretical net peak power : 3900 kw AHC solution: Passive part compensates the static external load, stores and regenerates energy Active part compensates dynamic effects and losses Installed power : 600 kw Factor 1:6 27
Rexroth Sytronix Variable Speed Pump Technology Title of presentation ML20110512v01 28 Michael Liedhegener 05/12/2011 DCUS/SLE Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
Rexroth Sytronix * * formerly known as BlueHydraulics 29
Rexroth Sytronix Variable Speed Pump Technology Variable Speed Pumps (VSP) Variable Displacement <=> Variable Speed T T 30
Rexroth Sytronix Benefits Slide title Significant noise reduction Potential Energy savings Improved diagnostic capability (SW + sensors) VSP variable speed pump Easy commissioning (Indraworks engineering tool) High accuracy and performance Easy and flexible integration in control system 31 Electric Drives and Controls Tobias Schillinger 6/11/2010 DCC/SIM8 Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
Sytronix - OrientationRexroth Sytronix Product Family Overview Sytronix Systems basic performance Sytronix energy efficient variable speed pump drives advanced performance FcP DFEn SvP high high performance 32 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix Energy Saving Potential Sytronix Variable Speed Pump Drives No throttling losses caused by proportional valves 40-70 % speed reduction during partload operation. Reduction of motor heating caused by reduced current flow. Reduced leakage losses due to lower average speed. Additional inverter losses Saving potential up to 80% compared to classic hydraulic solutions 33 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix Energy Saving Injection Molding Machine Classic solution P EL M 3~ p Q Energy consumption 100 % Variable displacement P EL M 3~ p Q Energy consumption 60 % Variable Speed Pump Sytronix SvP 7000 P EL M 3~ p Q Energy consumption 30 % 34 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix FcP System Components IndraDrive Fc Pressure sensor Fixed Displacement Pump FCS01 HM17 PGF1/2/3 Electric asynchronous motor with external fan Today: Siemens 35 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix FcP Quadrant Operation / Control Functionalities 1 Quadrant Operation -n +p Pump operation internal gear pump +n Control Functionalities Open loop: Flow control or Closed loop: Pressure control -p open loop operation M 36 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix FcP 5000 - Components IndraDrive Fc Frequency Converters Servo Drive Type Power Supply Voltage Input frequency Max. current Nom. Current Nominal current input ambient temperature IndraDrive Fc FCS01 1,5 7,5 kw 3 AC 380 480V 47 63 Hz 8 32 A 4 16 A 5,6 22,4 A 0 to +40 C (Derating up to 50 C) Communication interface analog field bus Compact design High availability Flow rate extension for max. 3s 38 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix FcP 5000 - Components E-Motor Name Motor Type Protection Class Housing Material Cooling Number of pole pairs Power Low-Voltage Motor Asynchronous motor IP55 Aluminum Integrated 4 50 Hz: 4kW 11kW 60 Hz: 4,6kW 12,6 kw Standard asynchronous motor Integrated ventilation / cooling Integrated frequency converter supports Retrofit no changes in control cabinet necessary self-sustaining system 39 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Motor / Pump / Drive Combinations in Comparison Product Name PP PPV FCP DFEn SVP 40
Sytronix FcP - Applications Machine Tool Former solution: Constant rotation system (5.5kW motor) with variable displacement pump Energy saving 24.1 % New solution: Variable-speed pump drive Sytronix FcP - Series-production - 2.175s cycle time Energy consumption: 3.4 kw Energy saving 24.1 % 2.6 2.6 kw kw 42 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Sytronix FcP - Applications Lathe Machine Former solution: Constant rotation system (5.5kW motor) with variable displacement pump New solution: Variable-speed pump drive Sytronix FcP - Series-production - 45s cycle time Energy consumption: 3.7 kw Energy saving 40.5 % 2.2 kw 43 27.07.2011 DC-IA/PJ-HDC Bosch Rexroth AG 2011. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Rexroth Sytronix Summary Advantages of Variable Speed Drives: Energy saving due to variable input speed = Energy on Demand Lower noise level over cycle Lower overall cost of hydraulic equipment (smaller pump, less valves, less or no cooling, smaller reservoir) Higher efficiency requires less installed power and smaller e-motor Commissioning similar to electro mechanical drive (Indraworks) Benefits in efficiency and noise strongly depend on the load cycle of the machine!!! 44
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