energy efficient actuation - schaedler yesco€¦ · the global leader in actuator technology...

The Global Leader in Actuator Technology

Energy Efficient Actuation

Good for the Environment. Good for Business.


NEED FOR CHANGE

ACTUATION TECHNOLOGIES

COMPARISON OF EFFICIENCIES

APPLICATION EXAMPLES

CONCLUSION

AGENDA:


Energy Efficiency…

￭ Not just about being “green” or environmentally friendly

￭ Can produce significant cost savings to the business

￭ Can address increasing regulatory mandates (cost avoidance)

￭ Can lead to benefits beyond energy cost savings

The Need for Change


The Need for Change

Industrial Sector ￭ Account for over 20% of US energy

consumption (41% world-wide)

￭ And, uses 25% + of the Electric

Power generated

Transportation / Mobile

Equipment Sector ￭ Addressing EPA Tier IV regulations

￭ Concerned about cost & availability of

fossil and alternative fuel sources

Source: U.S. Energy Information Administration

0 10 20 30 40 50

Residential/Commercial

Industrial

Transportation

Electric Power Generation

US Energy Consumption by Sector


90.0%

92.0%

94.0%

96.0%

98.0%

100.0%

2HP 150HP

Electric Motor TCO

Purchase Price

Installation/Maintenance

Energy Cost

The Need for Change

Energy Costs Represent the

Largest Portion of Equipment

Total Cost of Ownership (TCO)

for Many Industrial

Applications*

Other factors driving the move to electric

actuation:

￭ Environmental Concerns (oil leaks, disposal,

etc.)

￭ Operator Safety (noise)

￭ Performance (precision and repeatability)

￭ Down Time (maintenance and support)

*Source: U.S. Energy Information Administration


The Need for Change

Efficiency-focused Investment Increasing

US DOE indicates:

￭ 40% of industrial applications lacking in use of energy efficient technologies

￭ 50% of industrial applications not using some form of control to mange

motor-based applications

Source: Energy Efficiency & Technology Magazine & DOE web site

Yes 43%

No 57%

Are You Engaged in an Energy Efficiency Engineering Program?

6%

41%

37%

16%

Do You Anticipate More Energy Savings Programs?

No More Projects

More Projects in 6Months




Typical Actuation Technologies

HYDRAULIC PNEUMATIC ELECTRIC


Hydraulic Actuation

Pro’s ￭ High power density

￭ Low component acquisition cost

￭ Moderate to high stiffness

￭ Moderate speed

￭ Mature, well understood technology

￭ Numerous suppliers

http://www.google.com/url?sa=i&rct=j&q=hydraulic+cylinder&source=images&cd=&cad=rja&docid=QZxxsMB2F1nmAM&tbnid=ug69A9RNlBtGWM:&ved=0CAUQjRw&url=http://dutaflow.com/showequipment.php?merk=Vickers&type=Hydraulic Cylinders&ei=FKk4UcuWKKmuyQHSlICwBw&psig=AFQjCNE9ew6qEa7VJebPQQB1BgjkKOppRg&ust=1362754184550102


Hydraulic Actuation

Con’s ￭ Moderate accuracy / repeatability

￭ Installation / maintenance complexity

￭ High installation cost (labor)

￭ Time to commission

￭ Expensive (TCO)

￭ High maintenance

￭ Low energy efficiency

￭ Low scalability / modularity

￭ Messy (environmental impact)

“The annual cost of one slow leak

can amount to nearly $1,000 per year

in make-up fluid, clean-up and

disposal costs alone.” Source: www.empire-cat.com


Pneumatic Actuation

Pro’s ￭ Low component acquisition cost

￭ High speed

￭ Mature, well understood technology

￭ Numerous suppliers

Con’s ￭ Low to moderate power density

￭ Low accuracy / repeatability

￭ Low energy efficiency

￭ Low stiffness

￭ Time consuming to install

￭ Moderate scalability / modularity

￭ High maintenance

￭ High noise

http://www.google.com/url?sa=i&rct=j&q=pneumatic cylinder&source=images&cd=&cad=rja&docid=s6nhU4Tmbh-5AM&tbnid=qij1vR3CCldJAM:&ved=0CAUQjRw&url=http://www.bombayharbor.com/Product/8229/Pneumatic_Air_Cylinder.html&ei=Qqs4Ub_IJOKFywHZ54GABw&psig=AFQjCNF1dA9HOKzdpyRFrpsOR1l1cnOzZA&ust=1362754584080713


Pneumatic Actuation – Hidden Costs

Cost to Run Compressor: ￭ Installed compressor capacity = 1,500 cfm

￭ Average demand = 1,000 cfm

￭ Operates 24 x 7, 50 weeks / year

￭ Electricity cost = $0.068 / kWh

￭ Compressor duty cycle = 75%

￭ 4.5 cfm compressor capacity requires 1 compressor

HP

Total Running Cost = $107,000 / yr

Cost of Commonly Found Problems: ￭ On average, 30% of air is wasted

￭ 30% of $107,000

Cost of Wasted Energy = $32,100 / yr Source: Norgren – “How to improve energy efficiency”


Electric Actuation

Pro’s ￭ High speed + high force

￭ High accuracy / repeatability

￭ High Scalability / Modularity / Flexibility

￭ High Energy Efficiency

￭ High System Stiffness

￭ Medium to High Power Density

￭ Reduced Maintenance / Down Time

￭ Eliminates Hydraulic Fluid / Air Leaks

￭ Lower operating cost (TCO)

￭ Reduced Ambient Noise

￭ Easy to Install

Con’s ￭ Higher component acquisition cost


Actuation Technology Scorecard

Attribute Hydraulics Pneumatics Electrics

Power Density High Low Medium to High

Precision Medium Low High

Energy Efficiency Low Medium High

Cleanliness Low Medium High

Maintenance High Medium Low

Installation Costs Medium to High Medium to High Low

Scalability Low Medium High

Component Cost Medium Low Medium to High

TCO* Medium High Low


Comparison of Technology Efficiencies

Comparative Testing by University of Kassel ￭ Founded in 1971 as a multi-disciplinary teaching and research

university based in Kassel, Germany

￭ The University of Kassel is characterized by diverse and

networked competencies across the domains of nature,

technology, culture and society

￭ Over 160 research programs to date have been conducted by UNI-

Kassel

￭ Testing funded by University of Kassel

http://www.uni-kassel.de/



Test Set Up

3 Technologies

￭ Pneumatic

￭ Hydraulic

￭ Electro-mechanical (with integrated

servo motor)

Test Conditions

￭ 1000 N of force exerted by each

actuator

￭ 150 mm stroke

￭ 1.7 sec/cycle

Photo courtesy of UNI-Kassel



Results

Consumption Factors

￭ Electric = 1

￭ Pneumatic = 4.4x

￭ Hydraulic = 10.3x

Energy Conversion

(efficiency)

￭ Electric = 90%

￭ Pneumatic = 77%

￭ Hydraulic = 57% 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Hydraulic Pnuematic Electric

Energy Conversion (% Efficiency)

0.0

1000.0

2000.0

3000.0

4000.0

5000.0

6000.0

7000.0

8000.0

9000.0

Hydraulic Pnuematic Electric

Energy Consumption (Kwh)

* Study and Test Data by UNI-Kassel, 2012


Application Examples

Case Study: Fastening

Press

Challenges

￭ Provide High Production Capacity

at Lower Cost

￭ Decrease Set Up Time

￭ Reduce Environmental Impact

Results

￭ Higher Productivity at Lower Cost

￭ Lower Maintenance / More Up Time

￭ Self-contained Machine / Scalability

0

100

200

300

400

500

600

700

800

900

0

1000

2000

3000

4000

5000

Electric Hydraulic

$/y

ea

r

Un

its

/ye

ar

(00

0s

)

Machine Comparison by Technology

Production Output Energy Cost/year


Application Examples

Case Study: Injection

Molding Machine

Challenges

￭ Higher Precision

￭ Faster Cycle Times

￭ Lower Energy Cost

Results

￭ Quieter Operation

￭ Increased Uptime

￭ Scalable Solution

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

Electric Hydraulic

kw

h/k

g m

ate

ria

l

Injection Molding Machine


Benefits of Converting to Electric Actuation

Higher Efficiency Equating to:

￭ Lower Energy Consumption

￭ Lower Cost to Operate

￭ Higher Productivity

Additional Benefits:

￭ Lower Installation and Maintenance Costs

￭ Modularity / Scalability (cost to change)

￭ Reduced Environmental Impact (noise, leaks, disposal of fluids, etc.)

￭ Lower Total Cost of Ownership (install, operate, maintain, repair)

Conclusion

THANK YOU

energy efficient actuation - schaedler yesco€¦ · the global leader in actuator technology...

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