linmot® 2012 linmot pneumatic replacement_e.ppt 15.11.2012 1 replacing pneumatics
TRANSCRIPT
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 1
Replacing Pneumatics
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 2
Advantages of Linear Motors
Flexibility
Dynamics
Duration
Process stability
Installation & setup
Energy & service costs
Perspectives for the future
Simple solution
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 3
Tubes Valve
Reduction Valves
Damper
Limit Switches
Piston
Fittings
Noise Filter
Solenoid
Cable
Cable
Cable
System comparison: Pneumatic - Linear Motor
Even more simple than pneumatics ... Savings in logistic-and installation costs
Linear Motor
Cable
Drive
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 4
Flexibility: Free Positioning
+
Simple programming over Teach-In
Higher Flexibility … Savings in setup and product changeover costs
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 5
Flexibility, Process Stability and Reliability
Air Cylinder: - with air damping (1) - standard cylinder (2)
Linear motors: free programmable velocity, accelerationforce, motion profiles with monitoring
Programmable, constante and Production stability & monitoring monitored motions… lower product waste costs
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 6
Last
D
Higher Productivity
0
100
200
300
400
500
600
0 50 100 150 200 250 300Hub [mm]
8,0 kg6,0 kg4,0 kg2,0 kg0,0 kg
PSS 8.0 kg (max.)PSS 8.0 kg (min.)
Position-time diagram for a LinMot Linear Modul H01-37x240
Compared to a pneumatic system with soft stop D=25mm
High dynamic & Higher productivity & Short positioning times lower production costs
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 7
Lower maintenance costs: Life Expectancy
LinMot:Pneumatic:
Mo
nth
s
Yea
rs
0.0
2.0
4.0
6.0
8.0
10.0
12.0
1 2 3 4 5 6 7 8 9 10
Cycles per Second
MO
NT
HS
Air Cylinder 10 Mio.
Air Cylinder 20 Mio.
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
1 2 3 4 5 6 7 8 9 10
Cycles per SecondY
EA
RS
S
LinMot 500 Mio.
LinMot 1'000 Mio.
Higher economic life-time Savings in service and maintenance costs
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 8
Efficiency & Energy Costs
Analyzing linear motions with 6-600 cycles/min
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 9
Application example with 30 cycles/minute
Backward motion - 400mm 500msec
Standstill time 500msec
Total cycle time 2‘000msec
Standstill time 500msec
Forward motion 400mm 500msec
15kg 15kgv [m/s] a [m/s²]
400mm
30 cycles per minute with 500ms motion time and 500msec standstill time
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 10
Application example with 30 cycles/minute
Motion Sequence
Position over Time
Required Motor Force
Acceleration
Acceleration
Deceleration
Deceleration
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 11
Power
Power
Power Losses Pv = I2*R
Servo Controllers with DC Link Capacitors
Acceleration
Acceleration
Deceleration
Deceleration
Ideal Linear Motion: Power & Energy
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 12
Motor Sizing with LinMot Designer
Vmax = 1m/s
Motor Power < 100W Energy Costs:
100W x 8‘000h = 800kWh800kWh x 0.12 EUR = 96.- EUR
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 13
Power measurement with linear motor
Linear Movement with P01-48x240 (400mm, 15kg, 30 cycles/min): measured mean power 92W
-300
-150
0
150
300
450
600
750
900
1'050
1'200
1'350
1'500
0 500 1'000 1'500 2'000 2'500 3'000 3'500 4'000
Time [msec]
Po
wer
[W
]
-10
0
10
20
30
40
50
60
70
80
90
Su
pp
ly V
olt
age-
Cu
rren
t [V
-A]
Power [W]
Supply Voltage [V]
Supply Current [A]
30 cycles/minute, load 15kg, stroke 400mm: Measured nominal power: 92W
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 14
Pneumatics: Power, Energy & Losses
Compressor
Motion Motion
Losses
Losses Power
Power
Power
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 15
Pneumatics: Energy Efficiency
100% Power
10% Motor Losses
25% Compressor Losses
20% Start- Stop Losses
5% Air Treatment Losses
20% Pressure Losses, Reduction Valves
5% Leakage 5% Transformation Losses
5% Power at the Pneumatic Tool/Cylinder
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 16
Pneumatics: Cylinder sizing
The minimal required velocity in this application to move 400mm forward within 500msec is 1m/s.
The pneumatic cylinder required to move 15kg payload with a speed of 1m/s has a minimal diameter of 50mm.
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 17
Air consumption
Quelle: IMI Nogren
Air consumption at 30 cycles per minute with air cylinder d=50mm, stroke 400mm
per cycle: 400mm x 0.02529dm3/mm = 10.37dm3
per minute: 30 Takte/Minute x 10.37dm3
= 311.35dm3 = 0.311m3
per hour: 0.311m3 x 60 Minuten = 18.68m3
Per year: 18.68m3 x 8‘000h
= 150‘000 Nm3
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 18
The compressors energy consumption to produce 1m3 compressed air
at 6 Bar, is around 0.60 kWh.
Energy required for compressed air production
In an optimal process, 0.100kWh elektric energy is needed to compress
1Nm3 air to a pressure of 6 bar.
Motor Power: 750 kW
Air Flow: 125 Nm3/min 7‘500 Nm3/h
El. Energy 750 kWh .per Volume: 7‘500 Nm3/h
= 0.10 kWh/Nm3
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 19
Compressed Air: Losses
Quelle: Atlas Copco
100% Power
10% Motor Losses
25% Compressor Losses
20% Start- Stop Losses
5% Air Treatment Losses
20% Pressure Losses, Red. Valves
5% Leakage
5% Transformation Losses
5% Power at the Pneumatic Tool/Cylinder
Air consumption profile
Additional Energy Losses
Compressor Start-and Stop losses: 25% ... 35%
Pressure Losses,Reduction ValvesLeakage Losses 20% ...25%
Including these losses in our example, more than 190‘000Nm3 air
must be compressed to 6 bar.
To compress 1Nm3 to 6 bar the compressorconsumes 0.130 kWh electrical energy.
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 20
Compressed Air: Specific Power 0.12-0.16kWh/Nm3
Anlayse dreier Projektpartner Druckluft Effizient Studie, Dr.-Ing. Peter RadgenFraunhofer Institut Systemtechnik und Innovationsforschung (ISI), Karlsruhe
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 21
Compressed Air: Average leakage 20…25%
Druckluft Effizient, Abschlussbericht 2005
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 22
Pneumatic: Losses due to Leakage
Reference Conditions: 7 bar; Energy Costs 0,12 Euro/kWh, 8.000 operating hours / year
Hole diameterin mm
Air flow at 7 Barin l/s
Energy Costs in EUR
1 1.2 480.-
2 5.0 2‘160.-
3 11.2 4‘800.-
4 19.8 8‘400.-
6 44.6 18‘690.-
10 124.0 52‘800.-
Quelle: Atlas Copco
Average losses due to leakage in air distribution 20…25%
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 23
Energy Costs
EUROSTAT Strompreise für industrielle Grossverbraucher 24 GWh
0.04
0.05
0.06
0.07
0.08
0.09
0.1
0.11
0.12
0.13
0.14
2002
s01
2002
s02
2003
s01
2003
s02
2004
s01
2004
s02
2005
s01
2005
s02
2006
s01
2006
s02
2007
s01
2007
s02
EU
R/K
Wh
.
EU (27 Länder)
EU (25 Länder)
EU (15 Länder)
Deutschland
Italien
UK
Slowakei
Rumänien
Tschechien
EUROSTAT Electric Energy Costs for Industrial Customers (high volume >24GWh)incl. Taxes
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 24
Air consumption: 190‘000 Nm3
Energy requirement: 0.130 kWh/m3
- Energy consumption: 25‘000kWh- Nominal power: > 3‘000 W
Energy price: 0.12 EUR/kWh
Energy costs: 3‘000.00 EUR
Energy Costs Air Cylinder
Energy costs to move 15kg with 30 cycles per minute with a stroke of 400mm: 3‘000.- EUR per year!
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 25
Full cost calculation I
Quelle: www.druckluft.ch
The air costs including investment and maintenance costs forthe compressor are around 3‘750.- EUR per cylinder and year!
Investment cost: 10 - 15%Maintenance cost: 10 - 15%Energy costs: 70 - 80%
Annual air costs per cylinder: 3‘000.- EUR / 0.80 = 3‘750.- EUR
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 26
Full cost calculation II
Annual air cost per cylinder:150‘000 Nm3 x 0.025 EUR/Nm3 = 3‘750.- EUR
Quelle: Festo Broschüre „Energy Saving Services“ Stand 2010/08
Pneumatic component manufacturerscalculate with the following productioncosts for pressured air:
0.025 EUR/Nm3
Also according pneumatic component manufacturers the air costsin this application are around 3‘750.- EUR per cylinder and year!
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 27
Return of Investment
Higher investment costs are paid off already after 5 months of operation!
5 months 12 months Start
TCO after 5 months:
Air Cylinder: 1‘480.- EURLinear Motor: 1‘480.- EURSavings: 0.- EUR
TCO after 12 months:
Air Cylinder: 3‘840.- EURLinear Motor: 1‘540.- EUR
TCO after 24 months:
Air Cylinder: 7‘540.- EURLinear Motor: 1‘640.- EUR
12 months
Savings2‘300.- EUR
Savings5‘900.- EUR
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 28
Frequenz Energiekosten in EUR pro Jahr bei Hub in mm[Hz] Takte/min pro Tag pro Monat pro Jahr 25 50 75 100 150 200 250 300 350 400 500 600 700
0.10 6 8'640 259'200 3'153'600 40 79 119 159 238 317 397 476 555 635 794 952 1'111
0.25 15 21'600 648'000 7'884'000 99 198 298 397 595 794 992 1'190 1'389 1'587 1'984 2'381 2'777
0.50 30 43'200 1'296'000 15'768'000 198 397 595 794 1'190 1'587 1'984 2'381 2'777 3'174 3'968 4'761 5'555
0.75 45 64'800 1'944'000 23'652'000 298 595 893 1'190 1'785 2'381 2'976 3'571 4'166 4'761 5'952 7'142 8'332
1.00 60 86'400 2'592'000 31'536'000 397 794 1'190 1'587 2'381 3'174 3'968 4'761 5'555 6'348 7'935 9'522 11'110
1.50 90 129'600 3'888'000 47'304'000 595 1'190 1'785 2'381 3'571 4'761 5'952 7'142 8'332 9'522 11'903 14'284 16'664
2.00 120 172'800 5'184'000 63'072'000 794 1'587 2'381 3'174 4'761 6'348 7'935 9'522 11'110 12'697 15'871 19'045 22'219
2.50 150 216'000 6'480'000 78'840'000 992 1'984 2'976 3'968 5'952 7'935 9'919 11'903 13'887 15'871 19'839 23'806 27'774
3.00 180 259'200 7'776'000 94'608'000 1'190 2'381 3'571 4'761 7'142 9'522 11'903 14'284 16'664 19'045 23'806 28'567 33'329
3.50 210 302'400 9'072'000 110'376'000 1'389 2'777 4'166 5'555 8'332 11'110 13'887 16'664 19'442 22'219 27'774 33'329 38'883
4.00 240 345'600 10'368'000 126'144'000 1'587 3'174 4'761 6'348 9'522 12'697 15'871 19'045 22'219 25'393 31'742 38'090 44'438
4.50 270 388'800 11'664'000 141'912'000 1'785 3'571 5'356 7'142 10'713 14'284 17'855 21'426 24'997 28'567 35'709 42'851 49'993
5.00 300 432'000 12'960'000 157'680'000 1'984 3'968 5'952 7'935 11'903 15'871 19'839 23'806 27'774 31'742 39'677 47'612 55'548
5.50 330 475'200 14'256'000 173'448'000 2'182 4'364 6'547 8'729 13'093 17'458 21'822 26'187 30'551 34'916 43'645 52'374 61'103
6.00 360 518'400 15'552'000 189'216'000 2'381 4'761 7'142 9'522 14'284 19'045 23'806 28'567 33'329 38'090 47'612 57'135 66'657
6.50 390 561'600 16'848'000 204'984'000 2'579 5'158 7'737 10'316 15'474 20'632 25'790 30'948 36'106 41'264 51'580 61'896 72'212
7.00 420 604'800 18'144'000 220'752'000 2'777 5'555 8'332 11'110 16'664 22'219 27'774 33'329 38'883 44'438 55'548 66'657 77'767
7.50 450 648'000 19'440'000 236'520'000 2'976 5'952 8'927 11'903 17'855 23'806 29'758 35'709 41'661 47'612 59'516 71'419 83'322
8.00 480 691'200 20'736'000 252'288'000 3'174 6'348 9'522 12'697 19'045 25'393 31'742 38'090 44'438 50'787 63'483 76'180 88'877
8.50 510 734'400 22'032'000 268'056'000 3'373 6'745 10'118 13'490 20'235 26'980 33'725 40'471 47'216 53'961 67'451 80'941 94'431
9.00 540 777'600 23'328'000 283'824'000 3'571 7'142 10'713 14'284 21'426 28'567 35'709 42'851 49'993 57'135 71'419 85'702 99'986
9.50 570 820'800 24'624'000 299'592'000 3'769 7'539 11'308 15'077 22'616 30'155 37'693 45'232 52'770 60'309 75'386 90'464 105'541
10.00 600 864'000 25'920'000 315'360'000 3'968 7'935 11'903 15'871 23'806 31'742 39'677 47'612 55'548 63'483 79'354 95'225 111'096
12.00 720 1'036'800 31'104'000 378'432'000 4'761 9'522 14'284 19'045 28'567 38'090 47'612 57'135 66'657 76'180 95'225 114'270 133'315
25 Mio Zyklen Mehrkosten amortisiert nach max. 12 Monaten (8'000 Betriebstunden/Jahr)
Anzahl Zyklen (Doppelhübe)
Energy Costs Air Cylinder Cylinder d=50mm, 0.12 EUR/kWh
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 29
CO2 - Emission
Quelle: Fraunhofer Institut (D)
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 30
CO2 – Emission: Energy mix Germany
CO2 – Emission in Germany:
12,5 tons of CO2 per year and cylinder !!!
Calculation energy mix in Germany:
Nuclear plants: 25’000kWh x 0.22 x 32g/kWh 176 kgBrown coal: 25’000kWh x 0.22 x 1153g/kWh 6’341 kgStown coal: 25’000kWh x 0.18 x 949g/kWh 4’270 kgGas: 25’000kWh x 0.13 x 428g/kWh 1’391 kgRenewable: 25’000kWh x 0.14 x 25g/kWh 87 kgOthers: ? ?
http://www.co2-emissionen-vergleichen.de
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 31
CO2 – Emission per cylinder
Pneumatic cylinderweigth:
3 kg
AnnualCO2 – Emmission
over 12’500 kg
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 32
CO2 – Emission per cylinder
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 33
...or drive with your car around the world ...
3.3 - 6 times around the world!!!
0.6 ... 1 timesaround the world!
CO2 -Emission
Run the pneumatic cylinder for 1 year ...
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 34
Perspectives: CO2 -Emission
CO2 –Emission pro Zylinder 2011: 12,9t CO2 pro Zylinder/Jahr
2030: 11,5t CO2 pro Zylinder/Jahr
Quelle: Siemens Pressebilder 07/2012
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 35
Energy consumption of 0.100 kWh/Nm3 equals 6kW/(Nm3/min) and is a value
close to the physical limit (yellow zone)
Perspectives: Efficiency
Quelle: Bundesamt für Energie
Compressed air pressure [bar]
Electric Power [kW] per [Nm3/min]
Good Zone
Bad Zone
Physical Limit
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 36
EUROSTAT Strompreise für industrielle Grossverbraucher 24 GWh
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
2002
s01
2002
s02
2003
s01
2003
s02
2004
s01
2004
s02
2005
s01
2005
s02
2006
s01
2006
s02
2007
s01
2007
s02
2008
s01
2008
s02
2009
s01
2009
s02
EU
R/K
Wh
.
EU (27 Länder)
EU (25 Länder)
EU (15 Länder)
Deutschland
Italien
UK
Slowakei
Rumänien
Tschechien
+40%
+??%
+33%
Perspectives: Rising costs for electric energy
Since 2004 the costs for electric energy almost doubled within a seven years.
EUROSTAT Electric Energy Costs for Industrial Customers (high volume >24GWh)
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 37
Perspectives: Increasing productivity
400mm in 270msec
Vmax = 2.33m/s
Motor Power < 200WEnergy Costs:
200W x 8‘000h = 1‘600kWh1‘600kWh x 0.12 EUR = 192.- EUR
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 38
Perspectives: Aditional functionallity
Precise and Dynamic Force Control with down to 0.1N Force Resolution.Closed Loop Control with external force transducer.
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 39
Perspectives: Innovation
Permanent innovation helps to become and to stay a market leader!
Machine builder: Top 10 countriesSales volume without service, installation, repair
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 40
Application Example: P&P Handling Module
Pneumatic Pick & Place Linear Motor Pick & Place
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 41
Application Example: P&P Handling Module
Pneumatic Linear Motor
Introduction 1997 2008
Sales Price 100% 130%
Sales in 2008 100% 0%
Sales in 2010 40% 60%
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 42
Advantages Linear Motor
Flexibility
Dynamics
Duration
Process stability
Installation & setup
Energy & service costs
Perspectives for the future
Simple solution
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 43
Smart solutions are…
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 44
Pneumatic Cylinder Size
Supplier 1&2
D >= 50mm
Supplier 3&4
D = 40/32mm
15kg 15kgv [m/s] a [m/s²]
400mm
Supplier 5
D = 32/25mm
30 cycles per minute with 500ms motion time and 500msec standstill time
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 45
Pneumatic Cylinder Size
Supplier 1&2
D >= 50mm
Supplier 3&4
D = 40/(32)mm
Supplier 5
D = 32/(25)mm
P eff >= 3’000W P eff = 2’000W (1’250W) P eff = 1’250W (750W)
Power/Energy consumption compared to a linear motor (P eff = 100W)
x30 times
3’000%
x20 (12.5) times
2’000%
x12.5 (7.5) times
1’250%
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 46
Efficiency laws for rotary motors
From 2011 rotary motors must correspond to efficiency class IE2.
From 2015 rotary motors >375kW must correspond to efficiency class IE3, or IE2 with FC.
From 2017 rotary motors <375kW must correspond to efficiency class IE3, or IE2 with FC.
! Banned !
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 47
New law for savings of 2…20% «only»
Efficiency laws for rotary motors
Motor Power
Eff
icie
nc
y
LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 48
Smart solutions are…