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Energioptimerade beprövade system =>Syntronix
Jan Tegevall
Senior Sales Advisor
1
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Bosch Rexroth - Sytronix
2
2015-04-20 | DCSE-Bosch Rexroth | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as
well as in the event of applications for industrial property rights.
Bakgrund - energikostnad
Costs
Energy costs
Cost of IGBT in frequency
and servo inverters:
3
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Förbrukning av elenergi i Sverige
≈40% Industri
(www.energimyndigheten.se)
varav ≈70% elmotorer
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2015-04-20 | DCSE-Bosch Rexroth | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as
well as in the event of applications for industrial property rights.
Life cycle costs - elmotor
Life Cycle Cost
Source: K. Kerns,
Siemens *
*) Information available on www.EETmag.com
1,5 kW
15 kW
110 kW
LCC AC-motor
5
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
AC-motorer i hydraulaggregat
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix i samma hydraulaggregat
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix
Focus applications
Machine
Tools
8
Wood & Paper
Metallurgy
Presses
Die Casting
machines
05.05.2014
Product
Management
© Bosch
2014. Alle
vorbehalten,
auchexploitation,
bzgl. jeder Verfügung,
Verwertung,
Reproduktion,
2015-04-20 || Sytronix
DC-IA/SPI2
| © Bosch
Rexroth |AG
2012. Rexroth
All rightsAG
reserved,
alsoRechte
regarding
any disposal,
reproduction,
editing, distribution,
as well as in
Bearbeitung,
Weitergabefor
sowie
für denproperty
Fall vonrights.
Schutzrechtsanmeldungen.
the event of applications
industrial
Plastic Machines
Hydraulik 2015 och framåt = Sytronix
Hydraulik ”On Demand”
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
Anpassar energiuttaget efter behov (on demand).

Ökar verkningsgraden/minimerar förluster.

Minskar energikostnader / minskar koldioxid (CO₂) utsläpp.

Erhåller en lägre ljudnivå jämfört med konventionell utrustning.

Underlättar fjärrövervakning av utrustningen (4.0).

Minskar inbyggnadsvolymen jämfört med konventionell utrustning.

I vissa fall kan pumpstorlek standardiseras.

Mer flöde med bibehållen pump/motor.

Högre flöde ger kortare cykeltid.

Hydrauliska o elektriska standard komponenter används.

Följer förordningar gällande bullernivåer (EU Directive 2003/10/EC) och
ekodesignkrav för energieffektivisering av elmotorsystem (EU Regulation
(EC) no. 640/2009).
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Hydraulik 2015 och framåt = Sytronix
Grundförutsättningar för att uppnå systemets fördelar
 Sekvens där dellaster är c:a 20-30% av cykeltiden.
 Höga momentana flöden per cykel – minska pumpstorlek.
 Hydraulaggregat som skall placeras nära maskin – minska ljudnivå.
 Vid retrofit:
Öka produktionstakt utan ändring av befintlig motor/pump.
Att befintlig hydraulvätska ej ger varvtalsbegränsningar.
Att utrustning klarar frekvensomformare o låga/höga varvtal.
Rexroth erbjuder support genom hela processen vid retrofit, från
planering till montage och idrifttagning på plats.
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Huvudkomponenter
Slide title
 Asynkronmotor
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Frekvensomformare/omvandlare
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Huvudkomponenter
Slide title
 Synkronmotor (Servomotor)
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Servoförstärkare
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Effekt = Moment * varvtal
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix – Motivation
el. Power kW
4,5
4
Elektrisk effekt (aktiv)
3,5
3
2,5
el. power kW
2
1,5
1
0,5
0
0
200
400
600
800
1000
1200
1400
1600
motor speed
Energiförbrukning av motor
14

30 kW asynkronmotor i ett hydraulaggregat

Obelastad

Frekvensomriktardrift
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix – Motivation
Ljudnivå – Sytronix FcP
 Noise level depends on:
 Pump type
 Rotation speed of hydraulic pump
constant rotation speed
Sytronix FcP
Internal Gear Pump
(constant)
Displacement Axial Piston
Pump
e.g. A10 pump
e.g. PGH pump
75
75
70
65
60
60
55
55
dB(A)
dB(A)
65
50
∆dB~20dB(A)
50
45
45
40
40
35
35
75
250
600
750
1000 1250 1500 1750 2000 2500 3000
Rotation speed (rpm)
15
70
∆dB~10dB(A)
75
250
600
750
1000
1250
1500
1750
Rotation speed (rpm)
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
2000
2500
3000
Bosch Rexroth – 4EE
Rexroth 4EE – Rexroth for Energy Efficiency
Energy
System Design
Inspection
of complete
system,
Engineering,
Simulation,
Consulting.
18
Efficient
Components
Products and
Systems with
optimized
efficency
Energy
Recovery
Recharge
and storage of
excessive
energy
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Energy
on Demand
Demand
controlled
energy input,
Stand-by-Modus
Sytronix
Sytronix – Motivation
 Klassiskt hydraulaggregat
Ingen möjlighet till att spara
energi med fast pump o varvtal
där energin går över en
tryckbegränsningsventil.
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix – Motivation
Energy Saving Potential
 Variable Speed Pump Drives Sytronix
Sytronix SvP5000
 Inga strypförluster.
 40-70% reduktion av hastighet
under dellaster.
 Reducering av avgiven värme
från motor.
20%
 Mindre förluster i en Servoförstärkare.
Potential att spara upp till 80%
av energiförbrukningen jmf. med
en klassiskt hydraulaggregat
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix optioner
Sytronix
Varvtalsreglerade pumpsystem
Tre principkonfigurationer
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Sytronix FcP 5010
Sytronix FcP 7010
Sytronix SvP 7010
Asynkron motor och frekvensomriktare.
Reglering med konstant pump av
• Tryck och flöde
Synkron motor och servoförstärkare
Reglering med konstant eller variabel
pump av
• Tryck- och flöde
• Positionering
Asynkron motor och servoförstärkare
Reglering med konstant eller variabel
pump av
• Tryck- och flöde
• Positionering
• Effekt och hastighet
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Bosch Rexroth – energi och smarta lösningar – Sytronix
Exempelsystem
Servoförstärkare/frekvensomriktare
Konstant/variabel
Analog
ProfiNet
SercosIII
Profibus
EtherCat
EtherNet/IP
m.fl.
Servomotor/asynkron
Tryck-/
flödessensor
Sytronix
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2015-04-20 | DC-IA/SET5 Bjarne Restedt | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Hydraulik 2015 och framåt
Hydraulisk “Compac axis”
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Hydraulik 2015 och framåt
Elektrisk “Compac axis”
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2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix – pumpval
Innerkugghjuls / axialkolv pumpar - Systemet huvudkomponenter
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PGF2
PGH2,3,4,5
A10 VZO
A4 VSO
Proven pump for
small systems
Proven for high
pressure range
Variable speed
variant of proven
A10VSO
High pressure
pump for heavy
duty applications
Silent internal gear pumps with fixed
displacement
Variable axial piston pumps reduce
displacement ( motor torque)
during part-load operation
Cont. pressure
until 144 bar
until 305 bar
until 260 bar
until 313 bar
Max. pressure
250 bar
350 bar
350 bar
400 bar
Max. flow
68 l/min
750 l/min
324 l/min
750 l/min
Data sheet
RE 10213
RE 10227
RE 91485
RE 92050
05.05.2014
Product
Management
Bosch
AG
2014. Alle
Rechte
vorbehalten,
auch exploitation,
bzgl. jeder Verfügung,
Verwertung,
Reproduktion,
2015-04-20 || Sytronix
Jan Tegevall
| © Bosch
Rexroth| ©
AG
2012.Rexroth
All rights
reserved,
also
regarding
any disposal,
reproduction,
editing, distribution,
as well as
Bearbeitung,
sowie
für den Fall
von Schutzrechtsanmeldungen.
in
the event ofWeitergabe
applications
for industrial
property
rights.
Var går detta att applicera?
Focus applications
Machine
Tools
27
Wood & Paper
Metallurgy
Presses
Sytronix
Sytronix
Sytronix
Sytronix
FcP
FcP
FcP
FcP
Basic
Dynamics
Basic
Dynamics
Basic
Dynamics
Basic
Dynamics
Die Casting
machines
Plastic Machines
Sytronix
Sytronix
Sytronix
SvP
SvP
SvP
High Dynamics
High Dynamics
High Dynamics
Sytronix
Sytronix
Sytronix
Sytronix
Sytronix
DFE
DFE
DFE
DFE
DFE
High Dynamics
&
High Dynamics
&
High Dynamics
&
High Dynamics
&
High Dynamics
&
High Power
High Power
High Power
High Power
High Power
05.05.2014
Product
Management
Bosch
AG
2014. Alle
Rechte
vorbehalten,
auch exploitation,
bzgl. jeder Verfügung,
Verwertung,
Reproduktion,
2015-04-20 || Sytronix
Jan Tegevall
| © Bosch
Rexroth| ©
AG
2012.Rexroth
All rights
reserved,
also
regarding
any disposal,
reproduction,
editing, distribution,
as well as
Bearbeitung,
sowie
für den Fall
von Schutzrechtsanmeldungen.
in the event ofWeitergabe
applications
for industrial
property
rights.
Bosch Rexroth - Sytronix Exempel
 Exempel - Verktygsmaskin:
 Installerad effekt 5,5 kW – konstant trycksystem 100 bar, max. flöde 32 l/min
 Standard maskincykeltid 45s
Standard
lösning
Sytronix
Sytronixfördelar
Enhet
Effektförbrukning – maskincykel
3,7
2,2
- 40%
kW
Effektförbrukning – standby
2,3
0,7
- 70%
kW
Uppvärmning hydraulolja
1,3
0,2
- 85%
kW
Kylare
nödvändig
T = 45°C
t = 8-9h
Ingen eller
mindre behov
€
72
62
-10
dB(A)
Kylbehov hydraulolja
Ljud – genomsnitt
28
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Bosch Rexroth Sytronix – Best Practices
Hydraulaggregat med Sytronix
Ursprunglig lösning
 22kW Asynkronmotor
 Fastpump, 97 cm3 / 80 bar
 Ackumulator (75-90bar) 50l, p0=30bar
Energiförbrukning
21.600 kWh/år
Bosch Rexroth Sytronix
 Synkronmotor
 2* 20 cm3 Fastpump
Energy
System Design
Efficient
Components
Energiförbrukning
6.000 kWh/år
Besparing
15.600 kWh/år
2.184 €/år **
7,8 t/år
Sytronix SvP 7000
CO2-reducering*
* Energiemix, Deutschland gemäß GEMIS Version 4.2 im Vergleichsjahr 2004: 0,5 kg CO2/kWh
** Strompreis 0,14 €/KWh inkl. 3,592 ct/KWh EEG-Umlage
29
2015-04-20 | DC-IA/SET5 Bjarne Restedt | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Energy
on Demand
– 70 %
Sytronix – Best Practice (Sverige)
Sytronix – Variabel pump control
Bosch Rexroth Sytronix
 37kW Asynchronous motor
 Variable axial piston pump A10-DRG, 71 cm3
 IndraDrive – with special MLD software (AVP) for variabel pumps.
Energy
System Design
Efficient
Components
Energy
on Demand
Energy saving, more than 50%*)
http://www.youtube.com/watch?v=NBrK9C28Ufw
>50 %
*) Long time field test at an end customer in Spain and Great Britain
31
2015-04-20 | DCSE/IA Bjarne Restedt | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,
as well as in the event of applications for industrial property rights.
Sammanfattning Sytronix
 Energieffektivitet
 Energibesparing upp till 80%
 Återbetalningstid 6 månader till 3 år
 Reducering av ljudnivå
 Installation även i befintliga anläggningar
 Ökat konkurrenskraft för våra kunder!
 Slutförbrukare sparar energi
- Energieffektivisering hos många kunder
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2015-04-20 | DC-IA/SET5 Bjarne Restedt | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Hur kommer vi vidare ?
33
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix
picture(s)
hydraulic scheme
environment
34
p/Q/t - profile
Hur kommer vi vidare ?
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.
Sytronix
Sytronix testskåp
 HMV-R, HMS-W210 (65kW)
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HCS03-W070 (20kW)
2015-04-20 | DC-IA/SET5 Bjarne Restedt | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
HCS02 (1-15kW)
Bosch Rexroth - Sytronix
36
2015-04-20 | DCSE-Bosch Rexroth | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as
well as in the event of applications for industrial property rights.
Hydraulik 2015 och framåt
Tackar för er uppmärksamt.
37
2015-04-20 | Jan Tegevall | © Bosch Rexroth AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as
in the event of applications for industrial property rights.