Integrated Shaker Manager The Future of Vibration Testing Dr John Goodfellow IMV Europe Ltd Copyright IMV IMV CORPORATION 2012 2009 All All right right reserved reserved
Overview Integrated Shaker Manager Energy Manager Service Manager User Benefits Questions 2
ISM Integrated Shaker Manager 3
Integrated Shaker Manager (ISM) Vision Start of a journey to make a step change in Vibration Test Systems (VTS) Each technology building block has been developed with the goal of ISM Power Module, Field Power Supply, Cooling blower supply.. Traditionally the parts of VTS have been developed by separate departments ISM aims to bring all components of VTS together into one, easy to use Customer interface To add additional functionality to a VTS that brings significant benefit to Customers over and above vibration testing For example Diagnostics, Service Support To increase the return on investment for Customers through energy saving and increased system availability 4
ISM System philosophy and architecture non-ism Test Engineer Controller Amplifier Shaker 5
ISM System philosophy and architecture ISM Test Engineer ISM Controller Amplifier Shaker 6
ISM System philosophy and architecture ISM Test Engineer Vibration Test System ISM Energy Manager Test Diagnostics Service Manager 7
Energy Manager Energy Manager 8
Energy Manager Energy Manager Power Management Automatically controls the power needed to run a test Energy Manager calculates CO 2 Emissions savings for each test Cost savings of power to run the test is automatically calculated Eliminates wasting power when the system is in pre test mode Reduction in noise pollution is a major benefit 9
ISM Architecture Energy Manager ISM-EM panel Vibration Controller (K2) Acceleration pick up Test Specimen ISM-EM controller PA interface Control Power Amplifier Armature current Shaker Cooling air Temperature sensors Thermal Model Control field current Signal Monitoring Control blower speed Control Control Variable Field Power Supply Variable Blower Power Supply Field current Cooling air Cooling Blower Air-flow sensor Hose
Energy Saving Comparison of Operating Methods Figures below show the power consumption at each method of operation for a Random vibration test. Conventional System ISM-EM (Eco-Shaker) 25 Model : i240/sa3m 25 Model : i240/sa3m Power Consumption (kw) 20 15 10 5 Amplifier Field [ Rated power ] Power Cnsumption(kW) 20 15 10 5 Amplifier Blower [ Rated speed ] Field Blower 0 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 20% 40% 60% 80% 100% 10% 20% 20% 30% 40% 40% 50% 60% 70% 80% 90% 100% Output Force Ratio (%) Outout Force ratio(%)
Energy Saving Optimum value for Armature and Field coil Power consumption of Armature and Field coil calculated at i240 output 30% force 8 Armature coil limit Field coil limit Power consumption(kw) 7 6 5 4 3 2 Armature Armature + Field Minimum Field 1 0 0% 20% 40% 60% 80% 100% 120% Ratio of Field current(%)
Energy saving Eco-Shaker achieves 55% reduction of power consumption at 50% output force, and 73% reduction at 30% output force!! 70 Measurement Comparison of an ISM-EM system and a Conventional System IMV Model EM2601 60 Power Consumption (kw) 50 40 30 20 73% reduction 55% reduction Conventional System ECO System 10 0 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Output Force Ratio
Service Manager Service Manager 14
Service Manager Service Manager CAN BUS NETWORK 15
Service Manager Service Manager All operating parameters of the system are recorded Remote system health checking can be performed allowing predictive maintenance Problems with tests aborting can be diagnosed remotely Providing increased system availability and improved return on investment 16
User Benefits 17
Energy saving Electricity charges and CO 2 reduction The table below shows the estimated electricity savings and CO 2 reduction using the ECOpower saving for i240/sa3m(rated force : 24kN) and i260/sa7m (rated force : 54kN) Unit price of electricity : CO2 emission factor : Total hours during year : 0.15 /kwh 0.000525 tonne/kw 8760 Hours i240 i260 Average force ratio 25% 50% Power saved in ECO mode (kw) 7.0 5.3 Yearly average working ratio 25% 70% 25% 70% Saving charges ( /year) 2,299 6,439 1,741 4,875 CO 2 reduction(tonne/year) 8.1 22.5 6.1 17.1 Average force ratio 25% 50% Power saved in ECO mode (kw) 28.1 22.8 Yearly average working ratio 25% 70% 25% 70% Saving charges ( /year) 10,140 28,392 8,239 23,069 CO 2 reduction(tonne/year) 32.3 90.3 26.2 73.4 Note: CO 2 emission factor published by DEFRA (UK Government) Conversion factors 2011
User Benefits - Noise Reduction Cooling Blower Acoustic Noise Reduction The table below shows the measured sound levelsthe ECO-power saving for i240/sa3m(rated force : 2.4kN) 80 Sound level in db (A-weighting) EM2601 (i260) 0 Reduction from the conventional method Sound level in db (A-weighting) EM2601 (i260) Sound level [db] 70 60 50 Conventional ECO mode Sound level [db] -5-10 -15-20 40 0 10 20 30 40 50 60 70 80 90 Excitation Force Ratio [%] 100-25 0 10 20 30 40 50 60 70 80 Excitation Force Ratio [%] 90 100
User Benefits Reduced energy, CO2 and cost of operation Reduced operating noise Improved troubleshooting including remote diagnostics Improved system protection Increased system availability Increased return on investment 20
Amplifier Replacement Energy Manager IMV s ECO-amplifier Any blower Hybrid Thermal Model Any shaker 21