Energy consumption is a major factor in the total cost of ownership of machines and plants; but in energy-intensive hydraulic applications, investing in Sytronix technology from Bosch Rexroth will pay off quickly.
The Sytronix range consists of scalable, ready to install variable-speed pump drives that offer price and performance options to reduce costs in many hydraulic applications. Users of Sytronix realise immediate benefits from reduced energy consumption and cooling requirements, as well as a reduced carbon footprint.
Traditional hydraulic systems have relied on fixed-speed pump technology to generate the power required to operate a machine. Fixed-speed pumps typically rotate continuously without regard to the actual power required by the machine at any given moment. Additional potential energy savings can be realised by applying variable speed techniques.
Sytronix technology applies a variable-speed electric drive to rotate the pump at the speed optimal for efficiency, while supplying only the hydraulic power required by the process at any given moment. This enables Sytronix systems to achieve energy savings of up to 80%. They can also be integrated into existing systems and so are suitable for installed machines. Bosch Rexroth supports machine users over the entire retrofitting process. Simulation programs determine in advance any possible savings in the specific application.
The family of variable-speed pump drives currently consists of the base variant, Sytronix FcP 5000; the Sytronix DFEn 5000 control system; and the high performance variant, Sytronix SvP 7000.
The Sytronix FcP 5000 consists of an asynchronous standard motor and a frequency inverter. Used primarily in constant pressure systems, its benefits include:
* Maintaining system pressure at a constant level by providing a flow rate in line with demand.
* Optimising pumps specifically for variable-speed operation that covers a large speed range with high efficiency.
* Reducing the speed to considerably less than 200 rpm without limitations on the operating pressure.
* Reducing the noise level of the hydraulic power units by up to 20 dB(A).
* Eradicating the need for any secondary noise protection measures.
* Decreasing the energy consumption in existing hydraulic systems by between 30% to 80% by reducing the average discharge flow over the entire machine cycle.
* Decreasing the heat input into the oil, thus reducing the energy needed to cool the power unit.
The Sytronix DFEn 5000 variable-speed pump drive is based on the proven pressure and flow rate control system, the direct front end (DFE). An electro-hydraulic driven axial piston pump is controlled by a variable-speed drive. Sensors detect the current system pressure as well as the current motor speed and transfer these values to the pump-integrated digital on-board electronics. After matching actual values with the target values transmitted by the control, the integrated control calculates the optimal speed for the entire drive system.
The destroking of the variable displacement pump lowers the flow rate and reduces the motor load. The optimum speed for maintaining pressure is between 300 and 400 l/min, depending on the pressure. With machines that work on a cyclical basis, a teach-in process can be used to bring the system back up to speed just before an increase in flow rate. With non-cyclical machines, a contact can be closed to raise the speed to the required minimum shortly before an increase in flow rate is required. In this way, the full dynamic of the control pump is available as and when needed.
Other benefits of the Sytronix DFEn 5000 include:
* Reduced noise levels and less effort for secondary measures.
* Reduced cooling costs and short amortisation period.
* Compact design space.
* Increased machine performance.
* Lower installation and start-up expenses.
* High machine availability.
The Sytronix SvP 7000 servo-variable pump drive offers maximum performance among variable-speed pump drives with regard to dynamics and control precision. It utilises the high dynamics of permanently excited synchronous motors, thus achieving efficiency increases in plastics processing machines, die casting machines and presses, even during short cycle times.
The Syntronix SvP 7000’s benefits include:
* High energy savings of between 30% and 80% and reduced operational costs.
* Reduced noise level and less effort for secondary measures.
* Reduced cooling costs and a short amortisation period.
* Increased machine performance while downsizing.
* Lower installation and start-up expense.
* High machine availability.
* Easy integration of flexible control functions.
With the control loop closed in a decentralised form, the Sytronix SvP 7000 also offers far-reaching possibilities for simplifying hydraulic circuits. The precise flow rate control allows for direct control of cylinder movements, without the valve technology that has previously been necessary.
Sytronix pump drives comply with EC Directive No. 640/2009. They fit seamlessly into various automation structures via fieldbus or Ethernet protocols.
With the drive-based IndraMotion MLD control, Bosch Rexroth combines several servo-variable pump drives into one cascading system to generate very high performance in line with demand. The Ethernet-based real-time cross-communication of several controls when using SERCOS III allows users to synchronise an almost unlimited number of SvP 7000s in line with demand.
For more information contact Georg Venter, Tectra Automation, +27 (0)11 971 9400, [email protected], www.tectra.co.za
| Tel: | +27 11 971 9400 |
| Fax: | +27 11 971 9440 |
| Email: | [email protected] |
| www: | www.boschrexroth.africa |
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