Automation and Drives Energy Saving Concepts with Variable Speed Drives

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