LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Replacing Pneumatics

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 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 Tubes Valve Reduction Valves Damper Limit Switches Piston Fittings Noise Filter Solenoid 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 Flexibility: Free Positioning + Simple programming over Teach-In Higher Flexibility …Savings in setup and product changeover costs

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Flexibility, Process Stability and Reliability Air Cylinder: - with air damping (1) - standard cylinder (2 ) Linear motors: free programmable velocity, acceleration force, motion profiles with monitoring Programmable, constante and Production stability & monitoring monitored motions… lower product waste costs

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Last D Higher Productivity Hub [mm] 8,0 kg 6,0 kg 4,0 kg 2,0 kg 0,0 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 timeslower production costs

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Lower maintenance costs: Life Expectancy LinMot: Pneumatic: Months Years Higher economic life-timeSavings in service and maintenance costs

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Efficiency & Energy Costs Analyzing linear motions with cycles/min

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Application example with 30 cycles/minute Backward motion- 400mm 500msec Standstill time 500msec Total cycle time 2‘000msec Standstill time 500msec Forward motion400mm 500msec 15kg v [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 Application example with 30 cycles/minute Motion Sequence Position over Time Required Motor Force Acceleration Deceleration

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Power Power Losses P v = I 2 *R Servo Controllers with DC Link Capacitors Acceleration Deceleration Ideal Linear Motion: Power & Energy

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Motor Sizing with LinMot Designer V max = 1m/s Motor Power < 100W Energy Costs: 100W x 8‘000h = 800kWh 800kWhx 0.12 EUR = 96.- EUR

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Power measurement with linear motor 30 cycles/minute, load 15kg, stroke 400mm: Measured nominal power: 92W

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Pneumatics: Power, Energy & Losses Compressor Motion Losses Power

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 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 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 Air consumption Quelle: IMI Nogren Air consumption at 30 cycles per minute with air cylinder d=50mm, stroke 400mm per cycle: 400mm x dm 3 /mm = 10.37dm 3 per minute: 30 Takte/Minute x 10.37dm 3 = dm 3 = 0.311m 3 per hour:0.311m 3 x 60 Minuten = 18.68m 3 Per year:18.68m 3 x 8‘000h = 150‘000 Nm 3

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt The compressors energy consumption to produce 1m 3 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 1Nm 3 air to a pressure of 6 bar. Motor Power: 750 kW Air Flow: 125 Nm 3 /min 7‘500 Nm 3 /h El. Energy 750 kWh. per Volume: 7‘500 Nm 3 /h = 0.10 kWh/Nm 3

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 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 Valves Leakage Losses 20%...25% Including these losses in our example, more than 190‘000Nm 3 air must be compressed to 6 bar. To compress 1Nm 3 to 6 bar the compressor consumes kWh electrical energy.

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Compressed Air: Specific Power kWh/Nm 3 Anlayse dreier Projektpartner Druckluft Effizient Studie, Dr.-Ing. Peter Radgen Fraunhofer Institut Systemtechnik und Innovationsforschung (ISI), Karlsruhe

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Compressed Air: Average leakage 20…25% Druckluft Effizient, Abschlussbericht 2005

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Pneumatic: Losses due to Leakage Reference Conditions: 7 bar; Energy Costs 0,12 Euro/kWh, operating hours / year Hole diameter in mm Air flow at 7 Bar in l/s Energy Costs in EUR ‘ ‘ ‘ ‘ ‘800.- Quelle: Atlas Copco Average losses due to leakage in air distribution 20…25%

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Energy Costs EUROSTAT Electric Energy Costs for Industrial Customers (high volume >24GWh) incl. Taxes

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Air consumption:190‘000 Nm 3 Energy requirement:0.130 kWh/m 3 - Energy consumption:25‘000kWh - Nominal power:> 3‘000 W Energy price:0.12 EUR/kWh Energy costs:3‘ 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 Full cost calculation I Quelle: The air costs including investment and maintenance costs for the compressor are around 3‘750.- EUR per cylinder and year! Investment cost: % Maintenance cost: % Energy costs: % Annual air costs per cylinder: 3‘000.- EUR / 0.80=3‘750.- EUR

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Full cost calculation II Annual air cost per cylinder: 150‘000 Nm 3 x EUR/Nm 3 = 3‘750.- EUR Quelle: Festo Broschüre „Energy Saving Services“ Stand 2010/08 Pneumatic component manufacturers calculate with the following production costs for pressured air: EUR/Nm 3 Also according pneumatic component manufacturers the air costs in this application are around 3‘750.- EUR per cylinder and year!

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Return of Investment Higher investment costs are paid off already after 5 months of operation! 5 months12 monthsStart TCO after 5 months: Air Cylinder: 1‘480.- EUR Linear Motor: 1‘480.- EUR Savings: 0.- EUR TCO after 12 months: Air Cylinder: 3‘840.- EUR Linear Motor: 1‘540.- EUR TCO after 24 months: Air Cylinder: 7‘540.- EUR Linear Motor: 1‘640.- EUR 12 months Savings 2‘300.- EUR Savings 5‘900.- EUR

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Energy Costs Air Cylinder Cylinder d=50mm, 0.12 EUR/kWh

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt CO 2 - Emission Quelle: Fraunhofer Institut (D)

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt CO 2 – Emission: Energy mix Germany CO 2 – Emission in Germany: 12,5 tons of CO 2 per year and cylinder !!! Calculation energy mix in Germany: Nuclear plants:25’000kWh x 0.22 x 32g/kWh 176 kg Brown coal:25’000kWh x 0.22 x 1153g/kWh6’341 kg Stown coal:25’000kWh x 0.18 x 949g/kWh4’270 kg Gas:25’000kWh x 0.13 x 428g/kWh1’391 kg Renewable:25’000kWh x 0.14 x 25g/kWh 87 kg Others:? ?

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt CO 2 – Emission per cylinder Pneumatic cylinder weigth: 3 kg Annual CO 2 – Emmission over 12’500 kg

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt CO 2 – Emission per cylinder

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt or drive with your car around the world times around the world!!! times around the world! CO 2 -Emission Run the pneumatic cylinder for 1 year...

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Perspectives: CO 2 -Emission CO 2 –Emission pro Zylinder2011: 12,9t CO 2 pro Zylinder/Jahr 2030: 11,5t CO 2 pro Zylinder/Jahr Quelle: Siemens Pressebilder 07/2012

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Energy consumption of kWh/Nm 3 equals 6kW/(Nm 3 /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 [Nm 3 /min] Good Zone Bad Zone Physical Limit

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt % +??% +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 Perspectives: Increasing productivity 400mm in 270msec Vmax = 2.33m/s Motor Power < 200W Energy Costs: 200W x 8‘000h = 1‘600kWh 1‘600kWh x 0.12 EUR = EUR

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 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 Perspectives: Innovation Permanent innovation helps to become and to stay a market leader! Machine builder: Top 10 countries Sales volume without service, installation, repair

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Application Example: P&P Handling Module Pneumatic Pick & PlaceLinear Motor Pick & Place

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Application Example: P&P Handling Module PneumaticLinear Motor Introduction Sales Price100%130% Sales in % 0% Sales in % 60%

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 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 Smart solutions are…

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Pneumatic Cylinder Size Supplier 1&2 D >= 50mm Supplier 3&4 D = 40/32mm 15kg v [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 Pneumatic Cylinder Size Supplier 1&2 D >= 50mm Supplier 3&4 D = 40/(32)mm Supplier 5 D = 32/(25)mm P eff >= 3’000WP 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 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 New law for savings of 2…20% «only» Efficiency laws for rotary motors Motor Power Efficiency

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt Smart solutions are…