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Introducing Energy-saving Hydraulic Units

Introducing Energy-saving Hydraulic Units . March 2006. Fujikoshi Corporation . For publication . Compact Variable Volume Pump Unit NSP Series. Features  40% Energy-savings  Compact and Lightweight

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Introducing Energy-saving Hydraulic Units

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  1. Introducing Energy-saving Hydraulic Units March 2006 Fujikoshi Corporation For publication

  2. Compact Variable Volume Pump Unit NSP Series Features  40% Energy-savings  Compact and Lightweight  Quite, Low-surge  Cool Operation Block Installation Possible  Easy Maintenance Perfect for Machine and Cutting Tools 26 cm 3/rev 30/40 liter tank 8 cm 3/rev 10 liter tank 40%Energy Savings Compared to Existing Model

  3. NSP Unit Series

  4. NCP-60-3.7VD1A3-20 (Existing Unit 60-L tank) NSP-30-37V2A3-12 (NSP Unit 30-L tank) ３２０㎜ NSP Unit Series Energy Savings and Cool Operationmean the NSP Unit's tank capacity is less than 1/2 the hydraulic fluid capacity. (Comparable specifications) ６６０㎜

  5. Energy Saving Configuration Increased efficiency of electric drive Plate-S oil groove External drain reduction Pump: Increased mechanical efficiency Plate-H Pressure factor adjustment Internal leakage, external drain reduction Pump: Increased volumetric efficiency Electric drive: copper loss, iron loss reduction effectiveness ratio characteristics modification Plate-S oil groove Side clearance Vane pushing force reduction External drain reduction

  6. : Energy saving product : Conventional product Pushing force (Not in low-energy model) Energy savings: Increased pumping efficiency (1) Changed hydraulic fluid routing in vane back pressure chamber (1) Reduced pressure losses Lowered internal resistance, reduced drain volume. (3) Eliminated plate impulse channel (2) Modified plate pushing force (3) Stopped internal leaks (2) Lowered sleeve resistance Plate S hydraulic fluid channel through-flow  Stopped No internal leaks from gasket

  7. Energy savings: Increased pumping efficiency About the drain... "Internal leaks" cause losses. However, they are necessary to lubricate the pump. Too much Losses (overheating, electrical power consumption) Too little Burn out (sleeve resistance) Hydraulic pressure symbol (pump) Conventional unit's pump generated 2 l/min 1/4 drain volume Drain volume NSP unit's pump generates 0.5 l/min Dwelling Pump pressure

  8. Teeth Energy saving model Slot shape Open  Closed Accumulated thickness Teeth Core back Conventional model Hoop width Energy savings: Increased electric drive efficiency Rotor Energy savings Stator Electric drive efficiency (%) 10% Increased efficiency Electric drive-polarity: 2.2 kW-4P Voltage-cycles: AC 200 V, 60 Hz When pump is fully cut off (dwelling time load ratio) 1) Accumulated thickness reduced and iron loss suppressed. (Rotor) 2) Hoop width changed to stabilize magnetic field. (Stator) Electric drive load ratio (%)

  9. Energy savings: Increased electric drive efficiency Dwelling pressure - power consumption characteristics Conditions (dwelling) Electric drive-polarity 2.2 kW-4P Voltage-cycles: AC 200 V, 60 Hz Voltage 6.0 Mpa Conventional hydraulic unit NCP-60 Reduced dwell time power consumption 40%. 40% down Power consumption (kW) NSP Unit NSP-20 Dwell pressure (MPa)

  10. Nachi Machine Evaluation (Machining Center)

  11. Compared with inverter unit produced by other company 1 (1) Power consumption comparison NSP Unit Saves More Energy [Operating conditions] Approximately 20% energy savings during discharge * Hydraulic fluid used: ISO VG32* Hydraulic fluid temperature: 40 to 50˚C * Electricity: 2.2 kW * Voltage - frequency: AC 200 V - 60 Hz * Operating cycles: 2 seconds  8 seconds <Discharge> <Dwell> * Discharge settings: 28 L/min, 2.0 MPa (NSP Unit: 16 cm 3/rev) * Dwell settings: 0 L/min, 6.0 MPa Energy savings during cyclic operation:12% Approximately 5% energy savings during dwell

  12. Power consumption compared with inverter unit produced by other company Power consumption: W Dwelling Discharging 1896 W 615 W 550 W 1490 W NSP Unit NSP Unit INV Unit INV Unit

  13. Compared with inverter unit produced by other company 2 (2) P-Q characteristics comparison [Operating conditions] 　* Hydraulic fluid used: ISO VG 32 　* Hydraulic fluid temperature: 45C 　* Voltage-cycles: AC 200 V, 60 Hz : NSP Unit Flow Capacity : NSP Unit Drain Capacity : INV Unit Flow Capacity : INV Unit Drain Capacity NSP Unit RPMs are reduced as energy is saved because drain flow is minimal. Drain flow (l/min) Flow (l/min) INV Unit RPMs being reduced, but drain flow is large RPMs are stable, but drain flow is small Pressure (MPa)

  14. Compared with inverter unit produced by other company 3 (3) Pressure pulse NSP Unit 3.0 MPa, when discharging NSP Unit 6.0 MPa, when dwelling 0.30 MPa 0.41 MPa Pulse width is small Propagation of pulse to machine is reduced INV Unit 3.0 MPa, when discharging INV Unit 6.0 MPa, when dwelling 0.44 MPa 1.07 MPa * Hydraulic fluid: ISO VG32 *Hydraulic fluid temperature: 40 to 50˚ * Pump capacity: 16 cm3/rev*Electric drive: 2.2 kW *Voltage - frequency: AC 200 V, 60 Hz [Operating conditions]

  15. t1 Clamp and chuck t2 Dwelling Pressure Discharging Time Compared with inverter unit produced by other company 4 (4) Response characteristics Flow recovery time: Effects machine cycle [Operating conditions] 　* Hydraulic fluid used: ISO VG 32 　* Hydraulic fluid temperature: 40 to 50C 　* Voltage-cycles: AC 200 V, 60 Hz The NSP unit has a quick response time for flow recovery so machines can operate at a high cycle.

  16. Compared with inverter unit produced by other company 5 (5) Rising hydraulic fluid temperature (Over 4 hours dwelling continuously) [Operating conditions] 　* Hydraulic fluid used: ISO VG 32 　* Pump capacity: 16cm3/rev 　* Electric drive: 2.2 kW * Voltage-cycles: AC 200 V, 60 Hz* Room temperature: 26C INV Unit It is possible to increase cutting precision because the NSP Unit's hydraulic fluid temperature increase is low so heat is not transmitted to the machinery. Bearing Temperature （℃） Room temperature NSP Unit Operating time (Hrs)

  17. Compared with inverter unit produced by other company 6 (6) Power consumption comparison (estimated cost for standard cycle) Effect of energy savings for one year (Nachi comparison) \32,400 Effect of energy savings for one year (INV Unit comparison) \16,500

  18. Reference material Effect of reduction in power consumption and CO2

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