DAIKIN PMC. Energy-saving Hybrid Hydraulic System SUPER UNIT. Development to General Industrial Machinery

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Albert Pierce
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1 Energy-saving Hybrid Hydraulic System SUPER UNIT Development to General Industrial Machinery

2 Development of Energy-saving Hybrid Hydraulic System to General Industrial Machinery For machining tool market: Reducing waste power in pressure-retained condition Reducing rpm in pressure-retained condition can considerably save energy consumption. For general industrial machine market: Energy saving in the whole operating range is required. Pressure range should be increased. Driving motor efficiency improvement Review of hydraulic system System and component review is required.

3 Components of Hybrid Hydraulic System and Required Characteristics Configuration of Hybrid Hydraulic System Required characteristics 1) Hydraulic system Energy saving Optimization for each application (High pressure: Dual pump system is used) Control 制御弁 valve Fixed capacity pump Variable speed motor Controller (Inverter) Pressure Rotational position 2) Pump Variable speed control Selection of optimum pump (rpm range, efficiency, sound level) Energy saving Optimization of rpm (Machine efficiency) 3) Motor Quick response Low speed, large torque Energy saving High efficiency ) P-Q characteristic Robust characteristic Smooth switching of control target (pressure, horsepower, flow rate)

4 Optimization of Hydraulic System T (Torque required for motor) = p (Control pressure) q (Pump capacity) Motor current value 2π n (Torque efficiency) (To reduce power consumption in high-pressure retained condition, the pump capacity must be reduced.) Low pressure: Single pump system High pressure: Dual pump system Discharge Discharge Pressure Combination flow/single flow switching solenoid valve Pressure Variable speed motor Rotational position Fixedcapacity pump Fixedcapacity pump Variable speed motor Rotational position Drain Intake Controller Low pressure, large capacity Drain High pressure, small capacity Intake Controller

5 High-pressure Dual Pump System Autonomous Switching between Combination Flow and Single Flow Basic switching conditions [Single Combination] switching condition Actual pressure < PL [Combination Single] switching condition Actual rpm < QH Response switching condition (F.F D.H. response) Development of surge pressure in combination output range Flow rate QL QH Combination output area Low pressure, large flow rate control High pressure, small flow rate control Single output area [Combination Single] switching is enabled even if the single switching flow rate (QH) is not reached. PL Pressure Composition of P-Q Area PH

6 Characteristics Required for Motor Required conditions Low speed, large torque output Variable speed range covering up to high speed rotation Advantage of motor effectively using reluctance torque Features: Challenge: Interior Permanent Magnet Synchronous Motor (IPM motor) Both magnet torque and reluctance torque are efficiently used. Motor characteristics can be easily customized by changing the winding. (Under mass production as compressor motor for DAIKIN energysaving air conditioner. Core diversion is enabled.) Improvement of stability in low rpm range (Air conditioner motor does not need low rpm range.) Response time improvement (Response time of air conditioner compressor motor is extremely long.)

7 Improvement of Acceleration Response (Low rpm high rpm) Air conditioner (compressor) motor does not need quick response. Sensorless control is applied. (Positioning sensor is not used.) In the range from pressure-retained condition (low rpm) to discharge at maximum flow rate (high rpm), 0.1- second order response is required. Sensorless control cannot provide such a response speed. Improvement Simplified encoder of 192P/R (without phase Z) is used. However, incorrect polarity detection affects phase weakening control in N-T area. Development Newly-developed maximum torque control ensures robust performance against magnetic polarity detection error and power supply voltage fluctuation.

8 Super Unit Outline The energy saving IPM motor drive system is used. Pursuing superior energy saving performance and advanced functions Through combination of the air conditioning motor and inverter technologies with the twin pump switching control technology, the Super Unit provides Δ50% energy saving performance (during dwelling at 21 MPa). With the highly efficient motor, the Super Unit enables energy conservation even in the field of general industrial machinery that frequently involves actuator operation as well as dwelling. Series of motors covering 7 MPa (15 L/min) to 21 MPa (60 L/min) World First The Super Unit provides a wide range of applications, covering from machining tools to general industrial machinery such as press.

9 Super Unit FEATURES [1] Energy saving performance (Δ50%: during dwelling, Δ0%: during actuator operation) Highly efficient IPM motor drive system is used. Autonomous-switching twin fixed-capacity pumps are used. Using the twin fixed-capacity pumps that provide small and large capacities together with the selector valve, the Super Unit enables autonomous control to select combination or separate use of the individual pumps according to the load pressure. When a large flow rate is required, the Super Unit selects combination use of the largecapacity and small-capacity pumps, and operates the motor at a high rpm to discharge the fluid at a large flow rate. During dwelling, the Super Unit selects use of the small-capacity pump only, and operates the motor at a low rpm, thus achieving significantly high energy saving ratio. Variable relief Fixedcapacity pump Low pressure / Large capacity Drain System configuration Fixedcapacity pump Discharge High pressure / Small capacity Intake Drives the solenoid valve to switch between combination and separate flows. IPM motor Controller Pressure sensor Rotating position

10 Super Unit [2]Multistage flow rate control/ Multistage pressure control Incorporating shock-less control function The Super Unit enables multistage pressure/flow rate control simply by receiving a PQ characteristic pattern input to the contact terminal among the four patterns registered in the controller, and by receiving a selection signal from the sequencer. The Super Unit enables shockless control through adjustment of the selection signal rise/fall time, when switching the PQ characteristic pattern. Throttle valve Special spool shock-less solenoid valve M Example of hydraulic press circuit configuration Eliminating control valve by using software-based control method Elimination of throttle valve Standardization of solenoid valve Elimination of proportional control valve Proportional relief valve Driver Controller M Combination/ separate flow selector valve General purpose solenoid valve Conventional system configuration Sequencer Super Unit system configuration [3]Low noise level 60 db (A) (during dwelling at 21 MPa) 70 db (A) or less (for entire operating area) Equipped with cover With the twin phase-differential pumps, the Super Unit can reduce pulsation and noise level.

Examples of Advanced Functions of High-pressure Super Unit

Application of advanced function Speed Advanced function

deceleration Actuator Speed control valve Pressure control

valve Unit Motor pump Total cost reduction at 2- stage or

11 Examples of Advanced Functions of High-pressure Super Unit Speed 2-stage speed only Large shock during switching Time Application of advanced function Speed Advanced function Arbitrary speed setting Time Shockless acceleration/ deceleration Actuator Speed control valve Pressure control valve Simple circuit Valve reduction Directional control valve Unit Motor pump Total cost reduction at 2- stage or more speed control (including valve reduction) Unit Conventional hydraulic unit Super Unit

12 Examples of Multi-stage Pressure Control/Shockless Control [Multi-stage pressure control] Four patterns of P-Q characteristics registered in the controller can be selected with contact input from a host. [Shockless control] Through adjustment of the P-Q characteristics selection signal rising/falling time, shockless control is enabled. P-Q characteristic 0 P-Q characteristic 1 P-Q characteristic 2 P-Q characteristic 3 P-Q mode selection: 1 Pressure: MPa P-Q mode selection: 3 Pressure: MPa P-Q mode selection: 0 Pressure: MPa P-Q mode selection: 2 Pressure: MPa Multi-stage pressure 接点入力による多段圧力選択 control using contact input (Shockless ( 加減速時間 switching 50ms 設定によるショックレス切換圧力データ pressure data with acceleration/deceleration ) time of 50 ms) Pressure 圧力 (MPa) (MPa) PQ 選択 0 PQ 選択 1 PQ 選択 2 PQ 選択 3 PQ 選択 1 PQ 選択 0 PQ 選択 3 PQ 選択 0 PQ 選択 1 PQ 選択 3 PQ 選択 2 PQ 選択 0 P-Q selection 0 P-Q selection 1 P-Q selection 2 P-Q selection 3 P-Q selection 1 P-Q selection 0 P-Q selection 3 P-Q selection 0 P-Q selection 1 P-Q selection 3 P-Q selection 2 P-Q selection Time 経過時間 elapse (sec) ( 秒 )

13 Models/Specifications Basic model SUT**S15 SUT**S30 SUT**D0 SUT**D60 SUT**D80 Maximum flow rate (L/min) Maximum operating pressure (MPa) Motor capacity (kw) Pump configuration Single gear pump Dual gear pump Pump capacity (cm 3 /rev) / / /12.5 Power supply (Motor) Power supply (Fan motor) Input/output Function Tank capacity Operating fluid Tank oil temperature Ambient temperature Ambient humidity Installation place 30 L 60 L 100 L 0 L 3φ 200/200/220V, 50/60/60Hz 2φ 200/200/220V, 50/60/60Hz 7 inputs, 7 outputs 3 inputs, 2 outputs PQ, Alarm, Warning PQ, Alarm, Warning * Tank less type( Motor pump unit ):SUT00S15 / SUT00S30 / SUT00D0 / SUT00D60 / (SUT00D80) 0 to 60 0 to 35 85% RH or less Indoor 7 inputs, 7 outputs PQ, Alarm, Warning Dedicated mineral hydraulic fluid/abrasion-proof hydraulic fluid (Water-glycol type cannot be used.) Viscosity grade: ISO VG32 to 68 Viscosity range: 15 to 00 mm2/s Pollution degree: NAS Class 10 or less

0 21.0 Q (L/MIN) 0 60 80 PQ Power 3.7Kw 5.

(SUT**S****) Single gear without Oil Tank

0Kw Kw P (Mpa) 10.0 10.0.0.0 Q (L/MIN) 15

14 SUT** series Double Gear Pump with Oil Tank (SUT**D***) Double Gear Pump without Oil Tank (SUT00D****) Power 3.7Kw 5.0Kw Kw P (Mpa) Q (L/MIN) PQ Power 3.7Kw 5.0Kw Kw 11.0Kw P (Mpa) Q (L/MIN) PQ Single Gear Pump with Oil Tank (SUT**S****) Single gear without Oil Tank (SUT00S****) Power 2.2KW 2.8KW 3.7Kw 5.0Kw Kw P (Mpa) Q (L/MIN) PQ Power 2.2KW 2.8KW 3.7Kw 5.0Kw Kw P (Mpa) Q (L/MIN) PQ

15 Comparison data between current unit and super unit machine tool 1application to automobile parts manufacturing company Energy saving of hydraulic unit : 90% Saving electric fee fee 129,960/year 消費電力量 (kwh) # Runnning time: 560 Hrs/year Power rates : 15 yen/kwh Time 時間 (Sec) (sec) 油圧その他消費電力量 (kwh) Power consumption 現状油圧ユニット消費電力 Conventional unitsuper unit Power consumption 消費電力量 (kwh) Comparison data between current unit and super unit kwh Conventional 現状油圧ユニット unit スーハーユニット置換後消費電力 Energy saving 90% 90% 0.20kwh スーハーユニット super unit Power consumption Time (sec) 時間 (Sec) スーハーユニットその他

16 2application to electric parts manufacturing company Energy saving of hydraulic unit : 66% Saving electric fee fee 2,512/year- 消費電力量 (kwh) # Runnning time: 800 Hrs/year Power rates : 15 yen/kwh Conventional unit 現状油圧ユニット消費電力 Time (sec) 時間 (Sec) Comparison data between current unit and super unit press machine Power consumption 消費電力量 (kwh) Conventional unitsuper unit Power consumption Power consumption 消費電力量 (kwh) Comparison data between current unit and super unit Energy saving 66% 66% 5.37kwh 1.85kwh 現状油圧ユニット super unit 油圧置換後消費電力 Time (sec) 時間 (Sec) スーハーユニット

INDEX INVERTER HYDRAULIC UNIT. 7 MPa. 10 MPa. 16 MPa. 21 MPa. List of Hybrid Hydraulic Unit Models. P.3 to 4. List of Super Unit Models Nomenclature

INDEX INVERTER HYDRAULIC UNIT. 7 MPa. 10 MPa. 16 MPa. 21 MPa. List of Hybrid Hydraulic Unit Models. P.3 to 4. List of Super Unit Models Nomenclature INDEX INVERTER HYDRAULIC UNIT List of Hybrid Hydraulic Unit Models P. to List of Super Unit Models Nomenclature P.5 Main Features and Functions Super Unit Hydraulic Circuits P.6 Features P. to 8 Functions