Hydraulic Drives: How to Combine Dynamics and Efficiency Bert Brahmer, 2011-04-21
Contents 1. Introduction 2. Benefits of Hydraulics in Industrial Drives 3. Challenges for Hydraulics 4. HPPC: Highly Dynamic Drive for Punch Press 2 79-0039-0023-42 2011-04-21 B. Brahmer 5. PSH: Energy Efficient Drive for Servo Press 6. CLDP: Compact and Efficient Linear Drive 7. Conclusion
1. Introduction 3 79-0039-0023-42 2011-04-21 B. Brahmer Speaker: Bert Brahmer, 1964 Engineering degree (Electronics) R&D / µc Tools and Systems R&D / automation hw / sw R&D management (hydraulics and electronics) Member of Board of Management (Voith Turbo H+L hydraulic) Company: Voith Turbo H+L Hydraulic Employees: 180 Turnover: 50 M (approx.) Member of VOITH Group: Employees: 40.000 Turnover: 5.2 B Products: - Internal gear pump - Special valves and components - Electronics -> Complete hydraulic drive solutions Markets: Machine tools, energy, automotive
2. Benefits of Hydraulics in Industrial Drives Rugged against external stress Linear force without gear or spindle 4 79-0039-0023-42 2011-04-21 B. Brahmer Highly dynamic for high forces Extreme power density at actuator HPPC: Servo: 330 kn @ 0,4 m/s Peak output: 132 kw Peak input: 17 kw Reaction time: 5 ms Motor: external Peak output: 132 kw Peak input: 132 kw Reaction time: 100 ms Spindle: huge
3. Challenges for Hydraulics Facts or hearsay about hydraulics: Low efficiency Extra space for power pack Dirty (oil leakage) Complex / non-linear control loops CLDP: Integrated Drive No external motor or power pack! 5 79-0039-0023-42 2011-04-21 B. Brahmer Challenges for hydraulic drive solutions: Clean systems no leakage! Integrated drives no power pack! Efficient systems no energy wasting! Simple control scheme or plug n play controllers! HS4 hydraulic controller: Plug n play!
4. HPPC High Dynamic Punch System Requirements for punch press drive: High speed = productivity Compact must fit into frame Energy budget: 7,5.. 17 KW Accurate: 0.01.. 0.05 mm 6 79-0039-0023-42 2011-04-21 B. Brahmer
4. HPPC High Dynamic Punch System Key features to respond to challenges: Compact drive unit, includes cylinder, valves. Separate power pack Dual pressure operation for high efficiency Servo-hydraulics for high speed and accuracy Dedicated controller HS4 with read to use firmware / PC software 7 79-0039-0023-42 2011-04-21 B. Brahmer
4. HPPC High Dynamic Punch System Hydraulic Schematic (simplified) 8 79-0039-0023-42 2011-04-21 B. Brahmer Dual-Pressure: 80 bar: high-speed nibbling 285 bar: high-load punching/forming Automatic switchover High precision servo valve Valve direct drive by highly dynamic servo motor Max. force: 330 kn Max. speed: 0.8 m/s Nibbling rate: > 1.500 h/min Marking: > 3.500 h/min Resolution: 0.01 mm Rated power: 17 kw Average consumption: 7..8 kw (typical production mode)
4. HPPC High Dynamic Punch System Evaluation of energy consumption Theoretical minimum energy Energy for single pressure system 9 79-0039-0023-42 2011-04-21 B. Brahmer HPPC energy consumption: Close to theoretical minimum!
5. PSH: Energy Efficient Drive for Servo Press Requirements for servo press: Easy scaling: 500 kn... 10.000 kn (50..1000 to) Few components: easy installation, trouble shooting, retro fit Accurate: 0.01.. 0.05 mm Full servo programmability of profile/speed Energy efficiency as always! 10 79-0039-0023-42 2011-04-21 B. Brahmer
5. PSH: Energy Efficient Drive for Servo Press Key features to respond to challenges: Operation purely by servo pumps no directional valves Separate pumps for down stroke / up stroke Rapid feed using suction valve Modular design: easy machine integration, even for retro-fit Dedicated controller PCU with read to use firmware / PC software 11 79-0039-0023-42 2011-04-21 B. Brahmer
5. PSH: Energy Efficient Drive for Servo Press Principle of PSH: Mechanical equivalent: 12 79-0039-0023-42 2011-04-21 B. Brahmer
5. PSH: Energy Efficient Drive for Servo Press Modular Design: Aux. valves A side pump B side pump 13 79-0039-0023-42 2011-04-21 B. Brahmer
5. PSH: Energy Efficient Drive for Servo Press Why is PSH so power efficient? Classical throttle control Servo displacement control 14 79-0039-0023-42 2011-04-21 B. Brahmer
6. CLDP: Compact and Efficient Linear Drives Solving the drive requirements equation: Servo: Hydraulics: 15 79-0039-0023-42 2011-04-21 B. Brahmer Plug n play Energy efficiency No hydraulics! Easy scaling: + =? 5 kn...100 kn Linear movement Rugged against wear and tear
6. CLDP: Compact and Efficient Linear Drives Key features to solve the equation: Operation purely by servo pump no directional valves Closed Loop system no tank, no directional valves Compact design no hydraulic connections No hydraulic related electronics: servo interface plug n play Rugged, crash proof actuator 16 79-0039-0023-42 2011-04-21 B. Brahmer
6. CLDP: Compact and Efficient Linear Drives Principle of CLDP: Mechanical equivalent: 17 79-0039-0023-42 2011-04-21 B. Brahmer CLDP function is that of a hydrostatic spindle.
6. CLDP: Compact and Efficient Linear Drives Control loops: Classic servo (electromechanical): 18 79-0039-0023-42 2011-04-21 B. Brahmer CLDP: hybrid servo / hydraulic:
6. CLDP: Compact and Efficient Linear Drives How about CLDP energy efficiency? Throttle control Displacement control Hydraulically speaking, CLDP has the same advantages like PSH! 19 79-0039-0023-42 2011-04-21 B. Brahmer Comparison: CLDP vs. Servo + gear/spindle Servo + Gear/Spindle: gear/spindle friction CLDP: pump efficiency (>95%), cylinder friction
6. CLDP: Compact and Efficient Linear Drives Summary: No hydraulics: purely electrical interface. No hydraulics: no external hydraulic connections. Modular design: can easily scale speed / force of actuator 20 79-0039-0023-42 2011-04-21 B. Brahmer Easy control: no hydraulic-specific hardware / software Rugged against wear and tear No spindle / gear for linear movement Suitable for 5 kn..100kn, up to 1 m/s
7. Conclusion Electromechanical (servo) drives are competing hydraulics in more and more applications. Servo drives are fashionable: clean, energy efficient, easy to use (?) 21 79-0039-0023-42 2011-04-21 B. Brahmer Hydraulics have built-in advantages: Suitable for high forces Linear movement without gear / spindle Rugged aggainst crash or wear and tear Modern hydraulics can offer many user benefits: Long lifetime lower lifetime cost Energy saving through application concepts: - Dual pressure systems - Servo pump application Easy application and machine integration
7. Conclusion Contact information: Voith Germany: R & D Mr. Bert Brahmer Bert.Brahmer(at)voith.com Int l sales Mr. Bernd Schreiber Bernd.Schreiber(at)voith.com 22 79-0039-0023-42 2011-04-21 B. Brahmer Voith Taiwan: Sales Mr. Angus Lai Angus.Lai(at)voith.com
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