BlueHydraulics solutions from Bosch Rexroth can save energy and increase efficiency while reducing emissions.
Machine manufacturers and end users are under pressure to reduce emissions without compromising on performance levels. To meet this need, Bosch Rexroth, locally represented by the Hytec Group, has implemented its new BlueHydraulics programme. This is a series of efficiency-optimised components, innovative modules and networked system solutions. When applied to factory automation and plant equipment they enable system designers to make a huge difference in the energy efficiency curve, even at the project planning stage. The concept has been exhibited at two of the world’s foremost technology events, Hannover Messe and BAUMA.
Mobile applications
BlueHydraulics solutions facilitate the downsizing of diesel motors or reduction of engine rpm in order to lower diesel consumption while maintaining at least the same performance levels as before. The diesel hydraulic control (DHC) solution combines motor management with controls for implementation and travel drive hydraulics. Through the combined demand control, DHC can reduce diesel consumption by up to 20% without impacting on the power available to a machine.
The hydrostatic regenerative brake (HRB) system exploits the braking process to allow the hydraulic storage unit to recover deceleration energy and make it available for the next acceleration. In practice, HRB can reduce fuel consumption by up to 25%. In addition to enabling energy recovery, Hydraulic fly wheel technology can be implemented for power smoothing or booster functions, or can clear the way for downsizing of the diesel engine.
BlueHydraulics brings in the functional properties of components in innovative ways. Load-holding and lowering valves, or green valves, utilise the force of gravity rather than a diesel engine’s energy, thus reducing power requirements and freeing up a higher volume flow for functions working in parallel.
Stationary applications
BlueHydraulics also gives increased efficiency to factory automation and plant equipment. For instance the use of variable speed pump drives cuts energy consumption by 30% to 70%, translating to lower operating costs and a return on investment which can be less than a year.
The innovative, patented cooling and lubrication KST-booster integrates the pressure supply of a high pressure cooling oil circuit into the hydraulic power unit. An additional linear pump replaces the conventional screw spindle pump, reducing the energy requirements of the high-pressure cooling oil circuit by almost 90% compared to conventional solutions. Energy costs for machine tools are about 15% of total lifecycle costs. By combining variable speed pump drives and the KST-booster, users can profit from cumulative savings.
BlueHydraulics solutions can be integrated perfectly into any automation environment via analog, fieldbus or industrial Ethernet. Commissioning is also simplified by pre-parametered software. The finely scaled lineup of speed variable pump (SVP) drives covers a wide range of applications, including machine tools, injection moulding machines, presses and all types of cyclically working equipment. In addition, SVP drives lower mid-range noise levels significantly, often alleviating the need for special sound damping enclosures. Demand control also reduces the amount of heat transfer to the hydraulic oil, and thus the energy required for cooling.
Increased efficiency at component level
At the component level, BlueHydraulics means increased energy efficiency. For instance the new internal gear pump, PGH-3X, has been optimised to support SVP drives and can now achieve up to 3000 rpm across the entire speed range.
For more information contact Willem Gijzelaar, Hytec, +27 (0)11) 979 4630, [email protected], www.hytec.co.za
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