energy efficiency on hydraulics

© 2021 KEB Automation KG. Proprietary and confidential. All rights reserved.

Motion control application – A novel approach with

servo pump systems

ENERGY EFFICIENCY ON HYDRAULICS


Culture

Miss ion:

▪ The company 's miss ion is to prov ide a Mot ion Cont ro l and power t ransmiss ion technologica l cont r ibut ion to

▪ Indust r ia l OEM market

▪ Renewable energy

▪ Elect r ic mobi l i ty

prov id ing innovat ive so lut ions that respect the env i ronment and energy eff ic iency.

Market :

▪ We are serv ing

▪ customers range f rom medium to large s ize thank to qual i ty - process, long term avai lab i l i ty

▪ customers smal l s ize range thank to f lex ib i l i ty and dynamic react ions

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Corporate values

Customer satisfaction:

▪ It is what ownership and management demands to

their employees and partners. The company has

obtained quality and process certifications both in the

industrial and automotive fields (ISO 9001 - IATF).

Environment:

▪ Intended as a territory but also as a workplace

(together they contribute to people's health)

Energy - efficiency

▪ A commitment and attention to the concept of

continuous improvement designing efficient and

energy saving products and solutions

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From mechanics to electronics; our path towards mechatronics

▪ In order to contribute to the respect and care

of the environment we have analyzed for

years all the solutions whose movement can

be carried out with an electric actuator.

▪ There are applications where an electric

actuator would be a technically and

economically NOT sustainable compared to a

hydraulic solution.

▪ Combining our experience with experts in

hydraulics, we design a Mechatronic solution

to improve the performance in terms of

▪ Energy Efficiency

▪ Motion control quality4


Servo pump as efficient hydraulic Technology

▪ Generally speaking, the servo pump is a gear pump that allows to regulate the flow rate and the pressure according to the number of revolutions of the pump

▪ The use of servo pumps allows real -time control of the flow and/or pressure of a system directly from the motor, without the use of valves.

▪ Energy savings (more than 70 percent)

▪ Noise savings (up to -20dB)

▪ Thanks to the Built in Servo pump Controller algorism in a frequency inverter, it is possible to manage and reduce cycle times of a system.

▪ A permanent magnet motor operates over a wide range of speed (flow) and torque (pressure) without excessive consumption or overheating. Applications are even more dynamic.

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Conventional vs Servo Pump

09 /2021 6

3 ph

Variable

Pump

Constant

Pressure

LOADMain

Voltage

Electric

Motor

3 ph

Electric

Motor

VSD

Main

Voltage

Heat dissipation

Oil Passage

Resistance

Heat dissipation

throttling to

adjust actuator

speed

Heat dissipation

Pressure

adjustment

Energy

Consumption

Motor running

continuously @

Nominal Speed Heat extraction

by using cooling

systems

Potential energy recovery

Servo

Pump

A conventional hydraulic system for Motion

Control dissipates energy at every stage of the

cycle

while Servo Pump system regulates speed

and torque (Flow and Pressure) by using

energy only when necessary


Conventional hydraulics Motion Application

Considering a dissipative type system as

▪ Pressure and Flow in the circuit are set at the

nominal value necessary to perform any movement.

▪ To manage the speed of the actuator is necessary

throttle which means “just dissipation” instead of

“regulation”

▪ The Oil temperature reach high value. In order to

keep the Oil within certain range, an Oil colling

system is required (additional energy dissipation).

▪ The tank sizing is normally 3/5 time the pump flow

(e.g. 100L pump flow >> 300 – 500L Oil)

09 /2021 7

3 ph

Variable

Pump

Constant

Pressure

LOADMain

Voltage

Electric

Motor

Heat dissipation

Oil Passage

Resistance

Heat dissipation

throttling to

adjust actuator

speed

Heat dissipation

Pressure

adjustment

Energy

Consumption

Motor running

continuously @

Nominal Speed Heat extraction

by using cooling

systems


Servo Pump Efficient Hydraulics Motion Control

▪ In principle the system requires fewer classic valves

that’s why we can say that system is less complex.

▪ Having simpler circuit and run the pump on demand

makes Hydraulic power loss in the system is lower.

▪ The level of heat introduced into the hydraulic

system is lower so your cooling system is simpler

▪ The tank sizing is normally 0,5/1 time the pump flow

(e.g. 100L pump flow >> 50 – 100L Oil)

▪ Oil Operating temperature is lower

▪ Components longer service life

▪ Hydraulic system has high reliability and

availability with positive impact on the

productivity of your machine.

09 /2021 8

LOAD

3 ph

Electric

Motor

VSD

Main

Voltage

Potential energy recovery

Servo

Pump


Quality on Motion Control even with Hydraulics

▪ Thanks to the dedicated Servo pump Control algorism, actuator cycle times can be drastically shortened

(High bandwidth of the system).

▪ Due to Low mass moment of inertia of the internal gear pump and motors, Highly dynamic control can be

achive (Accurate pressure control) .

09 /2021 9

Easy Commissioning!!


Is energy efficiency economically sustainable?

09 /2021 10

Actuator

Cost

Hydraulic

Control Cost(Valves for regulation)

(Throttle valves)

(security)

Electrical

Cost(Control Cabinet)

(Motor)

(Pump)

Energy

Cost

Hydraulic

circuit cost(Tank)

(Pipes)

(Connections)

(Heat exchanger)

(Accessories)

Life-time

Cost(filtering system)

(fire hazard - cooling)

(Oil life-time)

(Frequency)

OEM End User

Considering a system which

needs an Actuator who runs

100L/min with a pressure

100 bar

Conventional

Servo Pump

28% 60% 4%

Same

50%30%

cost estimates based on the examples given. for the same application, there could be numerous technical solutions that would definitely have an impact on costs

PQ Control shift Easier circuit Easier Circuit

Component life-time


Video

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Application example

▪ Injection molding machine

▪ Blow molding machine

▪ Die-casting machine (Al & Mg)

▪ Metal forming presses

▪ Hydraulic presses

▪ Press feeding systems

▪ Trimming presses

▪ Sheet processing machine

▪ Punching machines

▪ Nibbling machine

▪ Notching machine

▪ Sheet shears

▪ Recycling presses

▪ Fuel pumps for gas turbine

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KEB Automation KG | Südstraße 38 | 32683 Barntrup | Germany

Tel. +49 (0) 5263 401-0 | Fax +49 (0) 5263 401-116 | E-Mail: [email protected]

www.keb.de

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If you have any further questions, please do not hesitate to contact us.

Contact: Marco Sala

Business Strategy Manager KEB Group

KEB thanks for your attention

energy efficiency on hydraulics

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