Replacing%20Pneumatics

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Replacing Pneumatics
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Advantages of Linear Motors
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System comparison Pneumatic - Linear Motor
Even more simple than pneumatics ... Savings
in logistic- and installation costs
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Flexibility Free Positioning

Higher Flexibility Savings in setup and
product changeover costs
Simple programming over Teach-In
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Flexibility, Process Stability and Reliability
Air Cylinder - with air damping (1)
- standard cylinder (2)
Linear motors free programmable velocity,
accelerationforce, motion profiles with
monitoring
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Higher Productivity
Last
Position-time diagram for a LinMot Linear Modul
H01-37x240
Compared to a pneumatic system with soft stop
D25mm
D
600
8,0 kg
6,0 kg
500
4,0 kg
2,0 kg
0,0 kg
400
PSS 8.0 kg (max.)
PSS 8.0 kg (min.)
300
200
100
0
0
50
100
150
200
250
300
Hub mm
High dynamic Higher
productivity Short positioning times lower
production costs
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Lower maintenance costs Life Expectancy
LinMot
Pneumatic
Years
Months
Higher economic life-time Savings in service
and maintenance costs
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Efficiency Energy Costs
Analyzing linear motions with 6-600 cycles/min
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Application example with 30 cycles/minute
30 cycles per minute with 500ms
motion time and 500msec standstill time
v m/s a m/s²
400mm
Forward motion 400mm 500msec
Standstill time 500msec
Backward motion - 400mm 500msec
Standstill time 500msec
Total cycle time 2000msec
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Application example with 30 cycles/minute
Motion Sequence
Position over Time
Acceleration
Deceleration
Acceleration
Deceleration
Required Motor Force
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Ideal Linear Motion Power Energy
Power Losses Pv I2R
Power
Servo Controllers with DC Link Capacitors
Power
Acceleration
Deceleration
Acceleration
Deceleration
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Motor Sizing with LinMot Designer
Vmax 1m/s
Motor Power lt 100W
Energy Costs 100W x 8000h
800kWh800kWh x 0.12 EUR 96.- EUR
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Power measurement with linear motor
30 cycles/minute, load 15kg, stroke 400mm
Measured nominal power 92W
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Pneumatics Power, Energy Losses
Losses
Power
Losses
Power
Compressor
Power
Motion
Motion
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Pneumatics Energy Efficiency
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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.
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Air consumption
Air consumption at 30 cycles per minute with air
cylinder d50mm, stroke 400mmper cycle
400mm x 0.02529dm3/mm 10.37dm3per minute
30 Takte/Minute x 10.37dm3 311.35dm3
0.311m3per hour 0.311m3 x 60 Minuten
18.68m3 Per year 18.68m3 x 8000h
150000 Nm3
Quelle IMI Nogren
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Energy required for compressed air production
Motor Power 750 kW Air Flow 125 Nm3/min
7500 Nm3/h El. Energy 750 kWh .per
Volume 7500 Nm3/h 0.10 kWh/Nm3
The compressors energy consumption to produce
1m3 compressed air at 6 Bar, is around 0.60 kWh.
In an optimal process, 0.100kWh elektric energy
is needed to compress 1Nm3 air to a pressure of
6 bar.
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Compressed Air Losses
100 Power
Compressor Start-and Stop losses 25 ...
35 Pressure Losses,Reduction ValvesLeakage
Losses 20 ...25
10 Motor Losses
25 Compressor Losses
20 Start- Stop Losses
To compress 1Nm3 to 6 bar the compressorconsumes
0.130 kWh electrical energy.
5 Air Treatment Losses
20 Pressure Losses, Red. Valves
5 Leakage
5 Transformation Losses
5 Power at the Pneumatic Tool/Cylinder

Air consumption profile
Including these losses in our example, more than
190000Nm3 airmust be compressed to 6 bar.
Additional Energy Losses
Quelle Atlas Copco
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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
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Compressed Air Average leakage 2025
Druckluft Effizient, Abschlussbericht 2005
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Pneumatic Losses due to Leakage
Hole diameterin mm Air flow at 7 Barin l/s Energy Costs in EUR
1 1.2 480.-
2 5.0 2160.-
3 11.2 4800.-
4 19.8 8400.-
6 44.6 18690.-
10 124.0 52800.-
Reference Conditions 7 bar Energy Costs 0,12
Euro/kWh, 8.000 operating hours / year
Quelle Atlas Copco
Average losses due to leakage in air distribution
2025
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Energy Costs
EUROSTAT Electric Energy Costs for Industrial
Customers (high volume gt24GWh)
incl. Taxes
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Energy Costs Air Cylinder
Air consumption 190000 Nm3 Energy
requirement 0.130 kWh/m3 - Energy
consumption 25000kWh- Nominal power gt 3000
W Energy price 0.12 EUR/kWh Energy
costs 3000.00 EUR
Energy costs to move 15kg with 30 cycles per
minute with a stroke of 400mm 3000.- EUR per
year!
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Full cost calculation I
Investment cost 10 - 15 Maintenance
cost 10 - 15 Energy costs 70 -
80 Annual air costs per cylinder 3000.-
EUR / 0.80 3750.- EUR
Quelle www.druckluft.ch
The air costs including investment and
maintenance costs forthe compressor are around
3750.- EUR per cylinder and year!
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Full cost calculation II
Pneumatic component manufacturerscalculate with
the following productioncosts for pressured air
0.025 EUR/Nm3
Quelle Festo Broschüre Energy Saving Services
Stand 2010/08
Annual air cost per cylinder150000 Nm3 x
0.025 EUR/Nm3 3750.- EUR
Also according pneumatic component manufacturers
the air costsin this application are around
3750.- EUR per cylinder and year!
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Return of Investment
TCO after 24 months Air Cylinder 7540.-
EURLinear Motor 1640.- EUR
TCO after 12 months Air Cylinder 3840.-
EURLinear Motor 1540.- EUR
Savings5900.- EUR
TCO after 5 months Air Cylinder 1480.-
EURLinear Motor 1480.- EURSavings
0.- EUR
Savings2300.- EUR
5 months
12 months
Start
12 months
Higher investment costs are paid off already
after 5 months of operation!
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Energy Costs Air Cylinder Cylinder d50mm, 0.12
EUR/kWh
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CO2 - Emission
Quelle Fraunhofer Institut (D)
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CO2 Emission Energy mix Germany
Calculation energy mix in Germany Nuclear
plants 25000kWh x 0.22 x 32g/kWh 176
kgBrown coal 25000kWh x 0.22 x
1153g/kWh 6341 kgStown coal 25000kWh x 0.18
x 949g/kWh 4270 kgGas 25000kWh x 0.13 x
428g/kWh 1391 kgRenewable 25000kWh x 0.14 x
25g/kWh 87 kgOthers ? ?
http//www.co2-emissionen-vergleichen.de
CO2 Emission in Germany 12,5 tons of CO2 per
year and cylinder !!!
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CO2 Emission per cylinder
Pneumatic cylinderweigth 3 kg
AnnualCO2 Emmissionover 12500 kg
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CO2 Emission per cylinder
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CO2 -Emission
Run the pneumatic cylinder for 1 year ...
...or drive with your car around the world
... 3.3 - 6 times around the world!!! 0.6
... 1 timesaround the world!
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Perspectives CO2 -Emission
Quelle Siemens Pressebilder 07/2012
CO2 Emission pro Zylinder 2011 12,9t CO2
pro Zylinder/Jahr 2030 11,5t CO2 pro
Zylinder/Jahr
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Perspectives Efficiency
Electric Power kW per Nm3/min
Bad Zone
Good Zone
Physical Limit
Compressed air pressure bar
Energy consumption of 0.100 kWh/Nm3 equals
6kW/(Nm3/min) and is a valueclose to the
physical limit (yellow zone)
Quelle Bundesamt für Energie
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Perspectives Rising costs for electric energy
EUROSTAT Electric Energy Costs for Industrial
Customers (high volume gt24GWh)
??
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Since 2004 the costs for electric energy almost
doubled within a seven years.
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Perspectives Increasing productivity
400mm in 270msec
Vmax 2.33m/s
Energy Costs 200W x 8000h
1600kWh1600kWh x 0.12 EUR 192.- EUR
Motor Power lt 200W
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Perspectives Aditional functionallity
Precise and Dynamic Force Control with down to
0.1N Force Resolution. Closed Loop Control with
external force transducer.
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Perspectives Innovation
Machine builder Top 10 countriesSales volume
without service, installation, repair
Permanent innovation helps to become and to stay
a market leader!
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Application Example PP Handling Module
Pneumatic Pick Place
Linear Motor Pick Place
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Application Example PP Handling Module
Pneumatic
Linear Motor
Introduction 1997 2008 Sales
Price 100 130 Sales in 2008 100
0 Sales in 2010 40 60
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Advantages Linear Motor
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Smart solutions are
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Pneumatic Cylinder Size
30 cycles per minute with 500ms
motion time and 500msec standstill time
v m/s a m/s²
400mm
Supplier 12
Supplier 34
Supplier 5
D gt 50mm
D 40/32mm
D 32/25mm
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Pneumatic Cylinder Size
Supplier 12
Supplier 34
Supplier 5
D gt 50mm
D 40/(32)mm
D 32/(25)mm
P eff gt 3000W
P eff 2000W (1250W)
P eff 1250W (750W)
Power/Energy consumption compared to a linear
motor (P eff 100W)
x30 times 3000
x20 (12.5) times 2000
x12.5 (7.5) times 1250
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Efficiency laws for rotary motors
! Banned !
From 2011 rotary motors must correspond to
efficiency class IE2. From 2015 rotary motors
gt375kW must correspond to efficiency class IE3,
or IE2 with FC. From 2017 rotary motors lt375kW
must correspond to efficiency class IE3, or IE2
with FC.
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Efficiency laws for rotary motors
Efficiency
Motor Power
New law for savings of 220 only
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Smart solutions are