industrial energy efficiency with bosch rexroth - …€¦ · bosch rexroth wholly-owned subsidiary...
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Industrial Energy Efficiency with Bosch Rexroth
Scott C. HibbardV P Technology
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V.P. TechnologyBosch Rexroth
Bosch Rexroth
Wholly-owned subsidiary of Robert Bosch GmbH
Merger of Mannesmann Rexroth with Bosch’s Automation TechnologyTechnology
All relevant technology forDrive, Control and Motion,
Worldwide presence
For industrial and factory automation, and mobile applications
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
2Electric Drives and Controls
The Company – Within the Bosch Group
Bosch GroupRevenue: € 46.3 billion
Employees 1/1/2008: 271,300
Consumer Goods & Building Services
Industrial Technology
Automobile T h l Building Services
EngineeringTechnology
Bosch Rexroth 1)
Technology
Packaging Technology
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1) Bosch Rexroth AG (Bosch wholly owned)
The Company – Bosch Rexroth Data
Figures for 2007
Total revenue€ 5,356 million
Total employees32,981
Research and development
Investments
Germany:€ 1,507 million
Europe minus Germany:
Germany:17,905
Europe minus Germany:
total:€ 250 million
Cost share of revenue:
total:€ 377 million
Cost share of revenue:y
€ 2,136 million
Americas:€ 849 million
Asia/RoW:
y8,032
Americas:3,308
Asia/RoW:
revenue:4.7 %
revenue:7.0 %
Asia/RoW:€ 864 million
Asia/RoW:3,736
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Bosch Rexroth in the Americas
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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The Company – The Products
Electric Lineardrives andcontrols
motion technology
Gears Assemblytechnologies
Hydraulics, industrial
Pneumatics
Hydraulics, Service
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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mobileService
The Company – The Markets
Industrial and factory automation as well as mobile applications
Rexroth services are used worldwide in nearly all industriesin nearly all industries ...
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Energy Efficiency in Industry
Total System Design
I d t hi iIn order to achieve maximum energy efficiency, the various technology disciplines must interact perfectly where intelligent solutions arewhere intelligent solutions are concerned.
The intelligent interlinking of differentThe intelligent interlinking of different individual measures achieves the highest possible savings – no single technology can meet the efficiencytechnology can meet the efficiency targets alone.
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Design Scope for Energy Efficient Automation Solutions as a Function of Product Life Cycle
ConceptConcept DesignDesign EngineeringEngineering CommissioningCommissioning Production /Production /OperationOperation
:T8 WZWG1 X100G2 X200
ModernizationModernization
ency
PartPartProgrammingProgramming
ProcessProcessOptimizationOptimization
G2 X200 G1 Y250G1 X150:
RunoffRunoffProgrammingProgrammingMechanical Mechanical DesignDesign
ElectricalElectricalDesignDesign
Mechanical Mechanical ConceptConcept
AutomationAutomationConceptConcept RetrofitRetrofit Product Product
OverhaulOverhaul
U f
nerg
y E
ffici Use of energy
efficient motiontechnology aspart of machine overhaulGreatest Opportunity
uenc
e on
En
Optimization of Machine OperationVi E A l i T l
To effect energy efficiencyIs in the design phase, usingEnergy efficient motionDevices in connection withM h i
Influ Via Energy Analysis ToolsMechatronic
System optimization
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Machine Life Cycle
An Example …
Power Supply Servo or VF D i
Motor
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(AC ► DC) Drive(DC ► AC)
Example: Energy Savings via power sharing with Optimized Machine Cycles
Thermoforming Machine:
• 2 presses
C ti l M ti P fil O ti i d M ti P filPress 1 Press 2
p• Toggle-linkage Mechanism
Pre
ss 1
Pre
ss 1
Conventional Motion Profile Optimized Motion ProfileEnergy Savings:
•Shift timing of the press
Pre
ss 2
t
Pre
ss 2
tmotion Profiles
•Energy balance between the two drives
•Reduce the peak power
Ener
gy
Ener
gy
tt
Reduce the peak power requirements from the 3-phase
•Optionally use the heat for th Th f i P
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E
t
E
t
the Thermoforming Process
Energy Efficiency in Industry
Rexroth – Combined Know-how
R th i id ll iti d t ff thRexroth is ideally positioned to offer therequired energy efficient systems – by means of drive and controltechnologies from a single source,g g ,combined with the required know-how.
Th R th k t t i d i iThe Rexroth key to sustained increase inenergy productivity:
Speed-variable pumpsIntelligent pressure control valvesIntelligent servo drivesMiniaturization
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Low-friction linear guides
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 onp p , y p gcontrol tasks.Increase in efficiency – Energy savings
Clear reduction in idle-running power –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 oilLess energy/heat transfer into the oil, meaning less cooling requiredPositive impact on heat regulation, energy consumption and costs
Noise reduction thanks to spontaneously controlled and lower speeds.
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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p y pReduction in installed power.
Product Examples
Industrial Hydraulics – Bus Module withEnergy-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 powerShorter response times due to voltage reduction.Fault diagnostics for each output / channels can beswitched off individually in the event of a faultMore than one valve can be connected to each bus
d l ti t b i th d d!
P
module – summation current being thus reduced! Lower heat generation of solenoids= Increase in service life, lower cooling costs
t
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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t
Product Examples
Industrial Hydraulics –Pumps and Axes
Pressure-flow-controlled pumps with integrated bus-enabled p p gmotion control permits precise power controlAxial piston pumps with improved mechanical-hydraulic efficiency consume less energy.gyEnergy savings in continuous, hi-performance applications by quickly switching between high and low pressure (example: punching & stamping machines)
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Product Examples
Pneumatics – Valve Series LS04
Th t di i d i i l i dThe compact dimensions and minimal 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 thepneumatic drivepneumatic drive. Furthermore, this solution also also shortens cycle times.
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Product Examples
Pneumatics – Pressure Regulator ED-Series
Th i ht f th i ht t k d ti bThe 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 valve technology. p p gy
The intelligent open-loop control directly at the locationrequired guarantees reliable repetitive accuracy fortypical pneumatic tasks such as weight compensation,force compensation, print run control, paint- or lacquer-dosing 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.
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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position or cylinder speed.
Product Examples
Linear Technology – Roller Rail Guides
E ffi i t d t t l l f i ti ffi i t f 0 01Energy efficient due to extremely low friction coefficients of a mere 0.01 percent.
Reduction in friction of more than 90 percent in heavy load applicationsReduction 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 energy-optimized design.
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Energy Savings with De-central Drive technology in a Mechatronic System Design
+Inverter (Drive) Inverter (Drive) together with
Control SectionControl Section integrated in the
IndraDrive MI
+Control SectionControl Section integrated in the
ServomotorServomotor
A single cableA single cable forggPower Supply (DC) & Communication
Daisy-chaining of up to 20 Mi’sup to 20 Mi’s& up toup to 18 kW18 kW Continuous Continuous PowerPower is possible
Integrated Motion/LogicIntegrated Motion/Logic
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programming using any IEC 61131-3 (PLC) languages
Energy Savings with De-central Drive technology in a Mechatronic System Design – Before & After
To ControlTo Control
Conv. Drives in a CabinetSensors
Servo Motors
SensorsTo Control
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Power Supply/Interface in a Cabinet IndraDrive Mi De-central Drive
Energy Savings with De-central Drive technology in a Mechatronic System Design
Regenerative Regenerative Power SupplyPower SupplyReturn excess energy to the power lines.
S
DC BusDC BusElectrical connection for energy exchange between motoring and generating dri es
Additional SavingsAdditional SavingsComponent reduction (Cable, Cabinet, Connectorization, etc.) Reduced cooling demand in
Energy Savingsapprox. 20%*
generating drivesEnergy Savingsapprox. 15% *
cabinet (unit size, energy costs) Reduced impact on plant cooling (units, energy costs)
Energy Savings approx. 2%*
Auxiliary Capacitor Auxiliary Capacitor
gy g pp
yyModuleModuleBuffers short term excess energy
Energy Savings S h (P M ) MS h (P M ) MEnergy Savingsapprox. 3%* Synchronous (Perm. Magnet) MotorsSynchronous (Perm. Magnet) Motors
High Energy NdFeB-permanent magnets in rotor, low-loss pole windings.
Energy Savings approx. 3%*
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* Typical Energy Savings Amounts given, actual savings depends upon application and may be higher or lower (“Your Results May Vary”)
gy g
Energy Optimization ExamplePackage Sorter for a Parcel Service Company
ApplicationScan parcels for destinationSort and send parcels to trucksp
System Automation GoalsGentile motion for packages & mechanicsmechanicsEnergy efficient total solution
21 largesorter lanes
20 smallsorter lanes
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for packages up to32 kg
for packages up to5 kg
Energy Savings Calculations for ExamplePackage Sorting Line using Decentralized Drives
“Before” System Energy Requirements: 18.5 kW18.5 kW
Energy savings withRexroth Automation Solution
RegenerationElimination of cabinet air conditioningthrough use of decentralized drivesEnergy buffering in Capacitor ModulesEnergy buffering in Capacitor ModulesEnergy sharing via DC BusReduced primary energy requirement(less cable, smaller cabinets)Hi h ffi i PM tHigh-efficiency PM motors
Annual energy savings6.5 kW6.5 kW
(=(= --35 %)35 %)Total Energy SavingsAnnual energy savings(operating 24 Hrs/Day, 365 Days/Year)
CO2-reduction (0.613 kg CO2/kWh*)
( ( 35 %)35 %)
57 Mega W57 Mega W--HH35 tons35 tons
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23Electric Drives and Controls *Energy mix in Germany per GEMIS Version 4.2 for 2004
Conclusion
Every Contribution Counts
N t h l t ll th ffi i t t it it iNo technology can meet all the efficiency targets 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 measuresvariety 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 , gsystem 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.
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
24Electric Drives and Controls
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
25Electric Drives and Controls
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