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LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 1 Replacing Pneumatics.

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Presentation on theme: "LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 1 Replacing Pneumatics."— Presentation transcript:

1 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 1 Replacing Pneumatics

2 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

3 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 3 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

4 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

5 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, acceleration force, motion profiles with monitoring Programmable, constante and Production stability & monitoring monitored motions… lower product waste costs

6 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 6 Last D Higher Productivity 0 100 200 300 400 500 600 050100150200250300 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

7 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 7 Lower maintenance costs: Life Expectancy LinMot: Pneumatic: Months Years Higher economic life-timeSavings in service and maintenance costs

8 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 8 Efficiency & Energy Costs Analyzing linear motions with 6-600 cycles/min

9 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 motion400mm 500msec 15kg v [m/s] a [m/s²] 400mm 30 cycles per minute with 500ms motion time and 500msec standstill time

10 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 Deceleration

11 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 11 Power Power Losses P v = I 2 *R Servo Controllers with DC Link Capacitors Acceleration Deceleration Ideal Linear Motion: Power & Energy

12 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 12 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

13 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 13 Power measurement with linear motor 30 cycles/minute, load 15kg, stroke 400mm: Measured nominal power: 92W

14 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 14 Pneumatics: Power, Energy & Losses Compressor Motion Losses Power

15 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

16 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.

17 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 0.02529dm 3 /mm = 10.37dm 3 per minute: 30 Takte/Minute x 10.37dm 3 = 311.35dm 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

18 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 18 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

19 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 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 0.130 kWh electrical energy.

20 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 20 Compressed Air: Specific Power 0.12-0.16kWh/Nm 3 Anlayse dreier Projektpartner Druckluft Effizient Studie, Dr.-Ing. Peter Radgen Fraunhofer Institut Systemtechnik und Innovationsforschung (ISI), Karlsruhe

21 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 21 Compressed Air: Average leakage 20…25% Druckluft Effizient, Abschlussbericht 2005

22 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 diameter in mm Air flow at 7 Bar in l/s Energy Costs in EUR 11.2480.- 25.02‘160.- 311.24‘800.- 419.88‘400.- 644.618‘690.- 10124.052‘800.- Quelle: Atlas Copco Average losses due to leakage in air distribution 20…25%

23 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 23 Energy Costs EUROSTAT Electric Energy Costs for Industrial Customers (high volume >24GWh) incl. Taxes

24 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 24 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‘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!

25 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 for the 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

26 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 26 Full cost calculation II Annual air cost per cylinder: 150‘000 Nm 3 x 0.025 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: 0.025 EUR/Nm 3 Also according pneumatic component manufacturers the air costs in this application are around 3‘750.- EUR per cylinder and year!

27 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 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

28 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 28 Energy Costs Air Cylinder Cylinder d=50mm, 0.12 EUR/kWh

29 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 29 CO 2 - Emission Quelle: Fraunhofer Institut (D)

30 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 30 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:? ? http://www.co2-emissionen-vergleichen.de

31 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 31 CO 2 – Emission per cylinder Pneumatic cylinder weigth: 3 kg Annual CO 2 – Emmission over 12’500 kg

32 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 32 CO 2 – Emission per cylinder

33 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 times around the world! CO 2 -Emission Run the pneumatic cylinder for 1 year...

34 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 34 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

35 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 35 Energy consumption of 0.100 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

36 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 36 +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)

37 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 37 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 = 192.- EUR

38 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.

39 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 countries Sales volume without service, installation, repair

40 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 40 Application Example: P&P Handling Module Pneumatic Pick & PlaceLinear Motor Pick & Place

41 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 41 Application Example: P&P Handling Module PneumaticLinear Motor Introduction 19972008 Sales Price100%130% Sales in 2008100% 0% Sales in 2010 40% 60%

42 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

43 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 43 Smart solutions are…

44 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 v [m/s] a [m/s²] 400mm Supplier 5 D = 32/25mm 30 cycles per minute with 500ms motion time and 500msec standstill time

45 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 >= 3’000WP 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%

46 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 !

47 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 Efficiency

48 LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 48 Smart solutions are…

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