linmot® 2012 linmot pneumatic replacement_e.ppt 15.11.2012 1 replacing pneumatics

LinMot® 2012 LinMot Pneumatic Replacement_e.ppt 15.11.2012 1

Replacing Pneumatics


Advantages of Linear Motors

Flexibility

Dynamics

Duration

Process stability

Installation & setup

Energy & service costs

Perspectives for the future

Simple solution


Tubes Valve

Reduction Valves

Damper

Limit Switches

Piston

Fittings

Noise Filter

Solenoid

Cable

Cable

Cable

System comparison: Pneumatic - Linear Motor

Even more simple than pneumatics ... Savings in logistic-and installation costs

Linear Motor

Cable

Drive


Flexibility: Free Positioning

+

Simple programming over Teach-In

Higher Flexibility … Savings in setup and product changeover costs


Flexibility, Process Stability and Reliability

Air Cylinder: - with air damping (1) - standard cylinder (2)

Linear motors: free programmable velocity, accelerationforce, motion profiles with monitoring

Programmable, constante and Production stability & monitoring monitored motions… lower product waste costs


Last

D

Higher Productivity

0

100

200

300

400

500

600

0 50 100 150 200 250 300Hub [mm]

8,0 kg6,0 kg4,0 kg2,0 kg0,0 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 times lower production costs


Lower maintenance costs: Life Expectancy

LinMot:Pneumatic:

Mo

nth

s

Yea

rs

0.0

2.0

4.0

6.0

8.0

10.0

12.0

1 2 3 4 5 6 7 8 9 10

Cycles per Second

MO

NT

HS

Air Cylinder 10 Mio.

Air Cylinder 20 Mio.

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

1 2 3 4 5 6 7 8 9 10

Cycles per SecondY

EA

RS

S

LinMot 500 Mio.

LinMot 1'000 Mio.

Higher economic life-time Savings in service and maintenance costs


Efficiency & Energy Costs

Analyzing linear motions with 6-600 cycles/min


Application example with 30 cycles/minute

Backward motion - 400mm 500msec

Standstill time 500msec

Total cycle time 2‘000msec

Standstill time 500msec

Forward motion 400mm 500msec

15kg 15kgv [m/s] a [m/s²]

400mm

30 cycles per minute with 500ms motion time and 500msec standstill time


Application example with 30 cycles/minute

Motion Sequence

Position over Time

Required Motor Force

Acceleration

Acceleration

Deceleration

Deceleration


Power

Power

Power Losses Pv = I2*R

Servo Controllers with DC Link Capacitors

Acceleration

Acceleration

Deceleration

Deceleration

Ideal Linear Motion: Power & Energy


Motor Sizing with LinMot Designer

Vmax = 1m/s

Motor Power < 100W Energy Costs:

100W x 8‘000h = 800kWh800kWh x 0.12 EUR = 96.- EUR


Power measurement with linear motor

Linear Movement with P01-48x240 (400mm, 15kg, 30 cycles/min): measured mean power 92W

-300

-150

0

150

300

450

600

750

900

1'050

1'200

1'350

1'500

0 500 1'000 1'500 2'000 2'500 3'000 3'500 4'000

Time [msec]

Po

wer

[W

]

-10

0

10

20

30

40

50

60

70

80

90

Su

pp

ly V

olt

age-

Cu

rren

t [V

-A]

Power [W]

Supply Voltage [V]

Supply Current [A]

30 cycles/minute, load 15kg, stroke 400mm: Measured nominal power: 92W


Pneumatics: Power, Energy & Losses

Compressor

Motion Motion

Losses

Losses Power

Power

Power


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


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.


Air consumption

Quelle: IMI Nogren

Air consumption at 30 cycles per minute with air cylinder d=50mm, stroke 400mm

per cycle: 400mm x 0.02529dm3/mm = 10.37dm3

per minute: 30 Takte/Minute x 10.37dm3

= 311.35dm3 = 0.311m3

per hour: 0.311m3 x 60 Minuten = 18.68m3

Per year: 18.68m3 x 8‘000h

= 150‘000 Nm3


The compressors energy consumption to produce 1m3 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

1Nm3 air to a pressure of 6 bar.

Motor Power: 750 kW

Air Flow: 125 Nm3/min 7‘500 Nm3/h

El. Energy 750 kWh .per Volume: 7‘500 Nm3/h

= 0.10 kWh/Nm3


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 ValvesLeakage Losses 20% ...25%

Including these losses in our example, more than 190‘000Nm3 air

must be compressed to 6 bar.

To compress 1Nm3 to 6 bar the compressorconsumes 0.130 kWh electrical energy.


Compressed Air: Specific Power 0.12-0.16kWh/Nm3

Anlayse dreier Projektpartner Druckluft Effizient Studie, Dr.-Ing. Peter RadgenFraunhofer Institut Systemtechnik und Innovationsforschung (ISI), Karlsruhe


Compressed Air: Average leakage 20…25%

Druckluft Effizient, Abschlussbericht 2005


Pneumatic: Losses due to Leakage

Reference Conditions: 7 bar; Energy Costs 0,12 Euro/kWh, 8.000 operating hours / year

Hole diameterin mm

Air flow at 7 Barin l/s

Energy Costs in EUR

1 1.2 480.-

2 5.0 2‘160.-

3 11.2 4‘800.-

4 19.8 8‘400.-

6 44.6 18‘690.-

10 124.0 52‘800.-

Quelle: Atlas Copco

Average losses due to leakage in air distribution 20…25%


Energy Costs

EUROSTAT Strompreise für industrielle Grossverbraucher 24 GWh

0.04

0.05

0.06

0.07

0.08

0.09

0.1

0.11

0.12

0.13

0.14

2002

s01

2002

s02

2003

s01

2003

s02

2004

s01

2004

s02

2005

s01

2005

s02

2006

s01

2006

s02

2007

s01

2007

s02

EU

R/K

Wh

.

EU (27 Länder)

EU (25 Länder)

EU (15 Länder)

Deutschland

Italien

UK

Slowakei

Rumänien

Tschechien

EUROSTAT Electric Energy Costs for Industrial Customers (high volume >24GWh)incl. Taxes


Air consumption: 190‘000 Nm3

Energy requirement: 0.130 kWh/m3

- 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!


Full cost calculation I

Quelle: www.druckluft.ch

The air costs including investment and maintenance costs forthe 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


Full cost calculation II

Annual air cost per cylinder:150‘000 Nm3 x 0.025 EUR/Nm3 = 3‘750.- EUR

Quelle: Festo Broschüre „Energy Saving Services“ Stand 2010/08

Pneumatic component manufacturerscalculate with the following productioncosts for pressured air:

0.025 EUR/Nm3

Also according pneumatic component manufacturers the air costsin this application are around 3‘750.- EUR per cylinder and year!


Return of Investment

Higher investment costs are paid off already after 5 months of operation!

5 months 12 months Start

TCO after 5 months:

Air Cylinder: 1‘480.- EURLinear Motor: 1‘480.- EURSavings: 0.- EUR

TCO after 12 months:

Air Cylinder: 3‘840.- EURLinear Motor: 1‘540.- EUR

TCO after 24 months:

Air Cylinder: 7‘540.- EURLinear Motor: 1‘640.- EUR

12 months

Savings2‘300.- EUR

Savings5‘900.- EUR


Frequenz Energiekosten in EUR pro Jahr bei Hub in mm[Hz] Takte/min pro Tag pro Monat pro Jahr 25 50 75 100 150 200 250 300 350 400 500 600 700

0.10 6 8'640 259'200 3'153'600 40 79 119 159 238 317 397 476 555 635 794 952 1'111

0.25 15 21'600 648'000 7'884'000 99 198 298 397 595 794 992 1'190 1'389 1'587 1'984 2'381 2'777

0.50 30 43'200 1'296'000 15'768'000 198 397 595 794 1'190 1'587 1'984 2'381 2'777 3'174 3'968 4'761 5'555

0.75 45 64'800 1'944'000 23'652'000 298 595 893 1'190 1'785 2'381 2'976 3'571 4'166 4'761 5'952 7'142 8'332

1.00 60 86'400 2'592'000 31'536'000 397 794 1'190 1'587 2'381 3'174 3'968 4'761 5'555 6'348 7'935 9'522 11'110

1.50 90 129'600 3'888'000 47'304'000 595 1'190 1'785 2'381 3'571 4'761 5'952 7'142 8'332 9'522 11'903 14'284 16'664

2.00 120 172'800 5'184'000 63'072'000 794 1'587 2'381 3'174 4'761 6'348 7'935 9'522 11'110 12'697 15'871 19'045 22'219

2.50 150 216'000 6'480'000 78'840'000 992 1'984 2'976 3'968 5'952 7'935 9'919 11'903 13'887 15'871 19'839 23'806 27'774

3.00 180 259'200 7'776'000 94'608'000 1'190 2'381 3'571 4'761 7'142 9'522 11'903 14'284 16'664 19'045 23'806 28'567 33'329

3.50 210 302'400 9'072'000 110'376'000 1'389 2'777 4'166 5'555 8'332 11'110 13'887 16'664 19'442 22'219 27'774 33'329 38'883

4.00 240 345'600 10'368'000 126'144'000 1'587 3'174 4'761 6'348 9'522 12'697 15'871 19'045 22'219 25'393 31'742 38'090 44'438

4.50 270 388'800 11'664'000 141'912'000 1'785 3'571 5'356 7'142 10'713 14'284 17'855 21'426 24'997 28'567 35'709 42'851 49'993

5.00 300 432'000 12'960'000 157'680'000 1'984 3'968 5'952 7'935 11'903 15'871 19'839 23'806 27'774 31'742 39'677 47'612 55'548

5.50 330 475'200 14'256'000 173'448'000 2'182 4'364 6'547 8'729 13'093 17'458 21'822 26'187 30'551 34'916 43'645 52'374 61'103

6.00 360 518'400 15'552'000 189'216'000 2'381 4'761 7'142 9'522 14'284 19'045 23'806 28'567 33'329 38'090 47'612 57'135 66'657

6.50 390 561'600 16'848'000 204'984'000 2'579 5'158 7'737 10'316 15'474 20'632 25'790 30'948 36'106 41'264 51'580 61'896 72'212

7.00 420 604'800 18'144'000 220'752'000 2'777 5'555 8'332 11'110 16'664 22'219 27'774 33'329 38'883 44'438 55'548 66'657 77'767

7.50 450 648'000 19'440'000 236'520'000 2'976 5'952 8'927 11'903 17'855 23'806 29'758 35'709 41'661 47'612 59'516 71'419 83'322

8.00 480 691'200 20'736'000 252'288'000 3'174 6'348 9'522 12'697 19'045 25'393 31'742 38'090 44'438 50'787 63'483 76'180 88'877

8.50 510 734'400 22'032'000 268'056'000 3'373 6'745 10'118 13'490 20'235 26'980 33'725 40'471 47'216 53'961 67'451 80'941 94'431

9.00 540 777'600 23'328'000 283'824'000 3'571 7'142 10'713 14'284 21'426 28'567 35'709 42'851 49'993 57'135 71'419 85'702 99'986

9.50 570 820'800 24'624'000 299'592'000 3'769 7'539 11'308 15'077 22'616 30'155 37'693 45'232 52'770 60'309 75'386 90'464 105'541

10.00 600 864'000 25'920'000 315'360'000 3'968 7'935 11'903 15'871 23'806 31'742 39'677 47'612 55'548 63'483 79'354 95'225 111'096

12.00 720 1'036'800 31'104'000 378'432'000 4'761 9'522 14'284 19'045 28'567 38'090 47'612 57'135 66'657 76'180 95'225 114'270 133'315

25 Mio Zyklen Mehrkosten amortisiert nach max. 12 Monaten (8'000 Betriebstunden/Jahr)

Anzahl Zyklen (Doppelhübe)

Energy Costs Air Cylinder Cylinder d=50mm, 0.12 EUR/kWh


CO2 - Emission

Quelle: Fraunhofer Institut (D)


CO2 – Emission: Energy mix Germany

CO2 – Emission in Germany:

12,5 tons of CO2 per year and cylinder !!!

Calculation energy mix in Germany:

Nuclear plants: 25’000kWh x 0.22 x 32g/kWh 176 kgBrown coal: 25’000kWh x 0.22 x 1153g/kWh 6’341 kgStown coal: 25’000kWh x 0.18 x 949g/kWh 4’270 kgGas: 25’000kWh x 0.13 x 428g/kWh 1’391 kgRenewable: 25’000kWh x 0.14 x 25g/kWh 87 kgOthers: ? ?

http://www.co2-emissionen-vergleichen.de


CO2 – Emission per cylinder

Pneumatic cylinderweigth:

3 kg

AnnualCO2 – Emmission

over 12’500 kg


CO2 – Emission per cylinder


...or drive with your car around the world ...

3.3 - 6 times around the world!!!

0.6 ... 1 timesaround the world!

CO2 -Emission

Run the pneumatic cylinder for 1 year ...


Perspectives: CO2 -Emission

CO2 –Emission pro Zylinder 2011: 12,9t CO2 pro Zylinder/Jahr

2030: 11,5t CO2 pro Zylinder/Jahr

Quelle: Siemens Pressebilder 07/2012


Energy consumption of 0.100 kWh/Nm3 equals 6kW/(Nm3/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 [Nm3/min]

Good Zone

Bad Zone

Physical Limit


EUROSTAT Strompreise für industrielle Grossverbraucher 24 GWh

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0.18

2002

s01

2002

s02

2003

s01

2003

s02

2004

s01

2004

s02

2005

s01

2005

s02

2006

s01

2006

s02

2007

s01

2007

s02

2008

s01

2008

s02

2009

s01

2009

s02

EU

R/K

Wh

.

EU (27 Länder)

EU (25 Länder)

EU (15 Länder)

Deutschland

Italien

UK

Slowakei

Rumänien

Tschechien

+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)


Perspectives: Increasing productivity

400mm in 270msec

Vmax = 2.33m/s

Motor Power < 200WEnergy Costs:

200W x 8‘000h = 1‘600kWh1‘600kWh x 0.12 EUR = 192.- EUR


Perspectives: Aditional functionallity

Precise and Dynamic Force Control with down to 0.1N Force Resolution.Closed Loop Control with external force transducer.


Perspectives: Innovation

Permanent innovation helps to become and to stay a market leader!

Machine builder: Top 10 countriesSales volume without service, installation, repair


Application Example: P&P Handling Module

Pneumatic Pick & Place Linear Motor Pick & Place


Application Example: P&P Handling Module

Pneumatic Linear Motor

Introduction 1997 2008

Sales Price 100% 130%

Sales in 2008 100% 0%

Sales in 2010 40% 60%


Advantages Linear Motor

Flexibility

Dynamics

Duration

Process stability

Installation & setup

Energy & service costs

Perspectives for the future

Simple solution


Smart solutions are…


Pneumatic Cylinder Size

Supplier 1&2

D >= 50mm

Supplier 3&4

D = 40/32mm

15kg 15kgv [m/s] a [m/s²]

400mm

Supplier 5

D = 32/25mm

30 cycles per minute with 500ms motion time and 500msec standstill time


Pneumatic Cylinder Size

Supplier 1&2

D >= 50mm

Supplier 3&4

D = 40/(32)mm

Supplier 5

D = 32/(25)mm

P eff >= 3’000W P 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%


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 !


New law for savings of 2…20% «only»

Efficiency laws for rotary motors

Motor Power

Eff

icie

nc

y


Smart solutions are…

linmot® 2012 linmot pneumatic replacement_e.ppt 15.11.2012 1 replacing pneumatics

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