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Automation and Drives Energy Saving Concepts with Variable Speed Drives

Automation and Drives Energy Saving Concepts with Variable Speed Drives. Presentation of Lenze. Solutions for drives and automation technologies for manufacturing machines and logistics facilities with: Frequency inverters Servo drives Geared motors Decentralized drives Automation

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Automation and Drives Energy Saving Concepts with Variable Speed Drives

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  1. Automation and Drives Energy Saving Concepts with Variable Speed Drives

  2. Presentation of Lenze • Solutions for drives and automation technologies for manufacturing machines and logistics facilities with: • Frequency inverters • Servo drives • Geared motors • Decentralized drives • Automation • 3.200 employees worldwide, thereof approx. 1.900 in Germany • Revenue of 505 mEUR in 2008/09 • Established in 1947 in Hameln

  3. Overview • Presentation of Lenze • Motivation for higher energy efficiency • The role of drive technology • Three ways to increase energy efficiency in drives • Evaluation by life cycle costs • Path breaking drive solutions to save energy

  4. Lenze‘s markets • Machine building with focus on: • Conveyor techniques • Robotics/Automotive • Material Handling • Packaging • Printing • Highly automated manufacturing and logistics systems • especially for consumer goods

  5. Motivation for higher energy efficiency • Two motivations for a higher energy efficiency • reduction of CO2 emissions due to the climate change • rising energy costs due to limited resources and worldwide rising energy consumption (industrialization of emerging countries) • Energy production from renewable sources (wind, solar, biofuel) needs high invests and political decisions • Compared to this, saved (not-used) energy is the most cost effective energy source • Actions towards a higher energy efficiency can be adopted by everyone, products and concepts are already available

  6. The role of drive technology • Drives convert two thirds of electrical energy in industry • A reduction of >20 percent can be achieved by energy saving solutions • Here, the whole drive system must be considered

  7. Three ways to increase energy efficiency in drives Designing and dimensioning drive systems

  8. 1. Intelligently using energy • Energy efficiency = as little energy as necessary • Ways to increase energy efficiency • dimensioning as required • inverter controlled operation • energy saving motion control and control systems • An exact analysis of the application is required to intelligently use energy • The intelligent use of energy in a drive application has the highest energy savings potential by far

  9. 1.1 Exact dimensioning saves money and energy • Today‘s usual practice: over dimensioning for fear of malfunctioning • This happens although engineers ought to develop solutions in a cost-efficient way • In partial load operation, drives often have a low level of efficiency. Example: • 0,75 • PN → η = 75% • 0,35 • PN → η = 45% • Therefore, dimensioning as required saves money and energy from the first moment • Lenze’s Drive Solution Designer and its “Energy Performance Certificate” result in an exact drive dimensioning

  10. 1.2 Inverter controlled operation • The energy consumption of most processes depends on the current ambient and operating conditions • e.g. cooling/heat requirements is dependent on the ambient temperature • e.g. conveying speed is dependent on the rate of production • An uncontrolled motor can only adjust its torque • A speed controlled drive including an inverter can adjust speed and torque (= power) • An inverter can optimize the operating point and the motion profile of the drive • Almost every process benefits from using an inverter • In 10 to 15 years from now, every drive will be driven by inverters

  11. 1.3 Energy efficient control and motion The use of an inverter offers further savings potential: • Voltage reduction under partial load operation • Acceleration adjustment to the required dynamics

  12. Degree of efficiency in % Motor output in kW 2. Convert energy at a high level of efficiency • Inverters already have a high level of efficiency of 94% to 97% • Level of efficiency of standard three-phase AC motors of the EFF2 efficiency class (IE1): 75% to 85% at 1…10 kW • Losses can be reduced by one third by using motors of the EFF1 efficiency class (IE2) • Useful in applications with long operating times and high continuous loads

  13. 2.1 New standard for efficiency classes for electric motors • A world-wide standard for efficiency classes for motors was created (including CEMEP, EPAct, NEMA) • Standard IEC60034-30, valid since 2009 • Efficiency classes and measurement methods have been harmonized • IE1≈eff2 • IE2≈eff1 • IE3≈Premium (EPAct) • Scope of the standard: • 2-/4-/6-pole standard induction motors, 50 und 60 Hz operation • 0,75…375 kW • continuous duty cycle (S1) • also valid for geared motors

  14. 2.2 Minimum efficiency classes for motors • Implementation of EUP directive • Will get pre-condition for CE marking for electric motors • Minimum efficiency class IE2 from 16.6.2011 for 0,75 … 375 kW • Minimum efficiency class IE3 orIE2 + inverter operation from 1.1.2015 for7,5 kW … 375 kW • Minimum efficiency class IE3 or IE2 + inverter operation from 1.1.2017 for0,75 kW … 375 kW • From 2015/2017 IE2 motors are only allowed to be operated by frequency inverters

  15. 2.3 Components with a high level of efficiency • Synchronous motors instead of asynchronous motors • No magnetizing current required • Lower currents and losses • A smaller inverter can be selected • Particularly useful in servo drives • Bevel gearboxes instead of worm gearboxes • Worm gearboxes have a very low level of efficiency • Due to the higher level of efficiency of the bevel gearbox, smaller motors and inverters can be selected

  16. 3. Using the feedback of braking energy • Many drives are moving material: • Accelerating and braking • Lifting and lowering • If a lot of braking energy is generated, it is worth while using the feedback of the braking energy • Frequent acceleration/braking of large masses • Lifting and lowering of large masses • Drives that are permanently operated in generator mode (e.g. unwinders, load drives) • Using braking energy by: • Power regeneration to the mains • Exchange of energy between two drives by DC link • Storing energy in a capacitor

  17. Evaluation by life cycle costs (LCC) • After a few years, the energy costs will be equal to the acquisition costs • Concepts with a higher level of energy efficiency are often amortized after two or three years • Evaluation by life cycle costs (LCC) is necessary • The following must act jointly • Component suppliers • Machine manufacturers • Machine operators

  18. The 12 drive solutions…

  19. …path breaking solutions to increase energy efficiency

  20. Flyer „Energy saving drive solutions“ • Motivation for higher energy efficiency • The role of drive technology • Three ways to increase energy efficiency in drives • Evaluation by life cycle costs • The 12 drive solutions as path breaking solutions to increase energy efficiency (Chart with 12 solutions and 3 ways to increase energy efficiency)

  21. Summary • Energy efficiency is the most cost effective energy source • Electrical drives are the most important consumers of electrical energy in manufacturing. A high energy saving potential of >20% can be achieved • There are three ways to increase energy efficiency in drives • Using electrical energy intelligently (75%) • Converting energy with a high degree of efficiency (15%) • Using the recovered braking energy (10%) • The evaluation of concepts with a higher level of energy efficiency is being carried out by life cycle costs • The 12 drive solutions are path breaking solutions to increase energy efficiency • Intelligent drive concepts can treat both environment and budget with care

  22. Thank you for your attention. Fabio Trindade Paes Fabio.paes@lenze.com.br ++ 55 11 23486579 São Paulo – Brasil www.lenze.com.br

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