Drive-Based Hydraulics Presented by Jeff Reese Manufacturing in America March 14-15, 2018
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Why use hydraulics to begin with? Advantages High force density (even at low velocities) Compact design possible Fast direction reversal (even at full load) Simple and robust control Simple overload protection (pressure release valve) Many standardized components Disadvantages Relatively poor efficiency Leakages (environmental, oil on glass) Compressibility of the hydraulic fluid (delay time) Noisy Strong temperature dependence High manufacturing costs (extremely precise fits)
You might know already that by using drive-based hydraulics You could you save up to 70% of the energy in each of these pictures?
Cost in $US You might know already that by using drive-based hydraulics You could you save up to 70% of the energy in each of these pictures? Conventional VFD-based Cost savings with servo pump Machine Machine Conventional hydraulic solution Servo pump solution 0 1 2 3 4 Asynchronous Motor Synchronous Servo Motor Variable Frequency Drive Time in years
But did you also know That you could be experiencing Improved energy management? Able to control peak load and reduce electrical component size Greater machine flexibility? Networking, advanced automation, digitalization Smaller machine footprint? Reduced cooling requirements, smaller components Increased precision? Reduced fluid compression with shorter hoses and cooler fluid Improved machine uptime? Remote monitoring, less vibration, reduced impact of contaminants Quieter operation? Quieter pumps, reduced pump operating time
Common configurations Doing the same thing different ways Configuration Constant pump using control valves Variable displacement pump (load sensing) Variable displacement pump (electronic) Variable speed pump (open system) Variable speed pump (closed system) Diagram Controller Controller M M M M M Benefits Tried and tested Higher productivity Higher efficiency Higher flexibility Monitoring capability Easier system design That s why we re here Technological development
Variable speed pump hydraulics benefits Reductions / enhancements Reduces Enhances Benefits Demand-oriented pressure and flow rate adaptation Energy management Servo or reluctance instead of induction motors Directional instead of proportional valves Smaller or no cooling system needed Constant instead of variable displacement pump 100% electronic control with easy integration in machine automation That s why we re here
Variable speed pump hydraulics benefits Demand-oriented pressure and flow rate adaptation A drive-based hydraulic system consumes only the required power Cycle: Process Valve control Drive control 1. Positioning 2. Forming 3. Holding M M Q x Δp = P Q (Flow rate) Δp (Pressure) P (Power) P loss (Power loss) Q Δp P 1 2 3 Q 1 2 3 Q 1 2 3 t t t Δp P P loss t t t t! Δp P P loss t t t t *Efficiency and dynamic factors neglected
Variable speed pump hydraulics benefits Servo or reluctance instead of standard induction motors Standard induction motors Continuously magnetized continuous losses heating up The power is the combination of pressure and flow rate HP (kw) 7.5 (5.5) 10 (7.5) 15 (11.0) 20 (15.0) 25 (18.5) 30 (22.0) 40 (30.0) Most hydraulic systems work mainly in partial load Reluctance 91.9 92.6 93.5 93.9 94.2 94.5 94.9 IE4 90.7 91.5 92.3 93.0 93.3 93.7 94.1 IE3 88.0 89.0 90.1 91.9 91.5 92.0 92.6 System with servo or reluctance motor and drive IE2 85.9 87.0 88.4 89.2 89.9 90.3 91.1 Minimum efficiency acc. IEC 60034-30-1. Converted to drive operation acc. DIN EN 50598-2 (chapter 5.3.2.6: additional looses depending on harmonics) Rated load Partial load System with Standard Induction Motor with or without drive
Variable speed pump hydraulics benefits Directional instead of proportional valves Directional valve Switching valve that s used to control flow direction Simple construction Less expensive Robust Proven Technology Proportional / Servo valve Variable positioning valve used to control direction and flow volume Expensive- especially a servo valve Sensitive to fluid contaminants Increased filtration requirements Increases fluid temperature Produce pressure losses Proven Technology
Variable speed pump hydraulics benefits A few changes / a lot of advantages Energy Mgmt. Benefits Demand-oriented pressure and flow rate adaptation Energy management HMI PLC Servo or reluctance instead of induction motors Variable Speed Drive Directional instead of proportional valves Smaller or no cooling system needed Constant instead of variable displacement pump Reluctance Induction or Servo M Var. Constant Pump Disp. Pump Cooling System M 100% electronic control with easy integration in machine automation Smaller Oil Tank Oil Tank
Variable speed pump hydraulics benefits 100% electronic control with easy integration in machine automation Benefits Demand-oriented pressure and flow rate adaptation Energy management Servo or reluctance instead of induction motors Directional instead of proportional valves Smaller or no cooling system needed HMI PLC Distributed IO Safety failsafe Industrial Ethernet PROFINET PROFISafe HMI Motion control / Servo drive with Integrated safety Internet Plant Network Sensor and cam functionality Remote diagnostics via browser Basic operating panel via browser Distributed IO for other peripherals Constant instead of variable displacement pump 100% electronic control with easy integration in machine automation Safety system Light curtain Protection doors E-stop Transfer system Induction Servo motor motor pump Hydraulics
From valve-based to drive-based control Implementation steps A stepwise approach is possible The first step being the most important Constant pump using control valves Step 1 Eliminate by-pass Step 2 Eliminate choke Drive-based hydraulics Step 3 Eliminate directional valve M M M M Pressure control Eliminate energy losses of by-pass Desired pressure is reached faster (motor can turn faster) Optimized pressure control (adaptations possible) Flow rate control Eliminate choke valve and pressure compensators (less energy losses) Easy realization of precise speed changes Position control Higher precision Relieves the PLC processor Direction control Eliminate directional valve (less energy loses) Highest Dynamic Very compact system
Different systems Any configuration is possible System with one actuator per pump One pump per motor Several pumps per motor Several one pump per motor M M M M Control of pressure, flow rate and position Control of pressure, flow rate and position Plus higher flow rate Control of pressure, flow rate and position Plus higher flow power System with several actuators per pump Independent movement of cylinders One-by-one movement of cylinders M M Control of pressure (fixed value or digital load-sensing) Pressure holding needs little energy Shifting of control parameters and position values possible
Siemens drive technology meets your hydraulics A smart drive, an efficient motor, any pump SINANICS drives SINAMICS V20 basic performance SINAMICS G120 modular general performance SINAMICS S120 high performance If the machine already uses SINAMICS S120, just add a motor module Electronic control Pressure Flow rate Position Tools SIZER chooses the correct pump size, motor and drive for your application SIMOTICS motors SIMOTICS S synchronous 1FK7, 1FT7, 1PH8 SIMOTICS M induction 1PH8 SIMOTICS GP / reluctance 1FP1, 1LE1 Pumps by 3 rd party Compatible with pumps of well-known manufacturers Voith, Rexroth, Eckerle, Bucher, Parker, Vickers just needs to allow variable speed operation internal gear axial piston vane pump Coupling components
Siemens drive technology meets your hydraulics Flexibility to address all hydraulics applications Example topologies Basic solution Efficient, general performance Flexible, high performance Drive control method V / Hz Vector, with / without encoder Vector / servo Dynamics Average Moderate Superior Efficiency High High Utmost Precision Moderate Moderate Highest Pressure and volume Technology controller Technology controller via Drive Control Chart (DCC) flow control Setup / programming Simple Simple Computer or HMI / templates Example application Clamping for CNC machines Channel-bailer Metal press, Injection Molding
SINAMICS SIZER tool Correct selection and sizing of components Pumps of Voith Turbo are used, but the results can also be used for Bucher, Eckerle, Bosch-Rexroth, Parker or other providers
DCC application Ready-to-use free templates DCC (Drive Control Chart) application for SINAMICS S120 high-performance/servo drives Standard application program Feedforward leakage compensation Q compensation Q max,set p max,set Simple Advanced Δp overshoot overshoot Q controller Q limited Q set n set On / n set control PI control 1 / q + - + + + + Off Extended application program D n-controller Motor Pump Cylinder Q actual p actual s actual s set + - Δs P Q position controller p max,set Feedforward leakage compensation Q compensation Simple Advanced Δp overshoot overshoot Q controller Q limited Q set n set On / n set control PI control 1 / q + - + + + + Off n-controller Motor Pump Cylinder Q actual p actual s actual D
DCC-Application / PID-Technology: controller reaction Speed and pressure traces Example trace of a set pressure step inputs Controller works in positive and Speed [rpm] negative directions turning pump backwards to diminish pressure Overshoot can be diminished / eliminated Set pressure [bar] Actual pressure [bar]
Servo pump customer success 100 tons and 100% increase in productivity Retrofit on a 100-metric-ton hydraulic press results in 100% increase in stroke rate Hydraulic drive concept was replaced by a modern servo drive concept Basic commissioning period of just three days Before retrofit the press managed 20 strokes per minute; after = 40 strokes per minute Accompanied by a significant reduction in energy consumption as well as a reduction in heat transfer to the structure Compared to conventional throttle control, the new drive concept calls for pumping of oil only when it is really necessary and demanded by the process this is the source of the greatest saving potential SINAMICS S120 Single-axis SIMOTICS M- 1PH8 servo motor Benefits realized Considerable reduction in energy consumption Less heat transfer to the structure Enhanced control quality (overshoot behavior) Reduced vibration
Servo pump customer success SINAMICS drives bring hydraulic elevators to the next level Faster commissioning, lower energy costs, reduced noise emissions SINAMICS S120 drive integrated into the hydraulic elevator system Plug-and-play system reduces installation time, noise and energy consumption Energy costs reduced up to 50 percent Motor runs only when hydraulic power is needed System is quieter More precise Eliminates necessity of installing a cooling system Old New
Servo pump customer success Hydraulic glass press energy consumption drops by up to 50% With a significantly more compact design, higher flexibility, and higher yield Motivation: to comply with glass manufacturers demands for significant energy savings System configuration SIMATIC S7-300 PLC SIMATIC HMI SIMOTICS S synchronous servomotor SINAMICS S120 drive system If an infeed unit with energy recovery capability is selected, the energy released from the press ram brakes can be retrieved, thus further boosting the efficiency Old The compact system can be located directly at the machine It sets itself apart as a result of minimum pipe lengths and oil quantities, hardly any pulsations and therefore the highest degree of stiffness and control quality New
Servo pump customer success Modernizing hydraulic injection molding machines Results Energy consumption slashed by 48% Old swivel-angle and fixed displacement pumps with induction motors which had proven themselves for over 20 years, were replaced by new controlled servomotors from Siemens Servo pump configuration SINAMICS S120 drive system with CU310 control unit SIMOTICS M-1PH8 compact synchronous motor Internal gear pump from the IPVP series Modernized system uses only as much energy as actually required by the injection molding process closing, injecting, post-pressure, dosing, cooling, opening, ejecting Servo-driven pumps are essentially at a standstill using little energy; previously they had to continuously operate at 15 20% reduced power Hydraulic oil temperature reduced from 113 to 95 F (45 to 35 C) Retrofit paid for itself within just a few years
Drive-based hydraulics For developing state-of-the-industry hydraulic systems Higher energy efficiency Pressure and volume flow not controlled by valves, but by servomotor torque and rotation speed Greater machine flexibility Networking, advanced automation, digitalization Smaller machine footprint Reduced cooling requirements, smaller components Increased precision Reduced fluid temperature, less compression Improved machine uptime Remote monitoring, less vibration, reduced impact of contaminants Quieter operation Quieter pumps, reduced pump operating time usa.siemens.com/drives-hydraulics
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Questions? Jeff Reese US Drive-based Hydraulics Business Development Siemens Industry, Inc. Phone +1 336 521-1624 E-Mail: jeffrey.reese@siemens.com