Energy Savings with Pneumatics
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Energy Savings with Pneumatics

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A great PowerPoint presentation on using pneumatics to save energy by Phil O'Neil of Bosch Rexroth

A great PowerPoint presentation on using pneumatics to save energy by Phil O'Neil of Bosch Rexroth

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Energy Savings with Pneumatics Presentation Transcript

  • 1. Fluid Power Expo Phil O’Neill Bosch Rexroth Pneumatics Cleveland, OH 10/26/2011 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 2. Global Trends
    • Reduce costs
      • Consider total cost of ownership
        • Not just acquisition costs
    • Increase efficiency
      • Improve throughput
      • Reduce cycle times
      • Minimise waste
      • Reduce power consumption
    • Environmental awareness
      • Carbon emissions
    • Has to have a short payback period
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 3. So what’s the problem ?
    • Pneumatics has a bad name
    • Inefficiency
      • Inefficient design by rule of thumb
        • Using higher pressures than necessary
        • Using higher wattage coils than necessary
        • Oversized valves
        • Oversized actuators
        • Not minimizing pressure drops
          • Long tube runs
          • Undersized tubes
    • Leakage
      • Poor connections
      • Worn seals
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 4. Why do we care ?
    • Because it’s expensive
      • More expensive than it needs to be
    • Where’s the problem ?
      • After all, air is free !!
    • Compressed air isn’t free.
    • One of the most expensive energy storage media
      • What does it cost to run your compressor ?
    • There is a need for a TCO balance
      • Operating costs (approx. 70%)
      • Initial investment (30%)
        • Acquisition cost
        • Installation & commissioning
        • Maintenance
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 5. How big is the problem ?
    • Source - www.energystar.gov
    • “ Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 20-30% of the compressor’s output.
    • Compressed air leaks can also contribute to problems with system operations, including:
      • Fluctuating system pressure, which can cause air tools and other air-operated equipment to function less efficiently, possibly affecting production
      • Excess compressor capacity, resulting in higher than necessary costs
      • Decreased service life and increased maintenance of supply equipment (including the compressor package) due to unnecessary cycling and increased run time.”
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 6. Google “Compressed air leak” 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 7. What can we do about it ?
    • Establish a baseline
    • Measure air consumption at no-load
      • Leakage
      • How to measure leakage ?
        • Hearing ?
        • More sophisticated ?
          • Totalising mass flow meters
            • Measure overall leakage
          • Ultrasonic leak detectors
            • Locate leak points
    • Quantify the cost
      • That gets attention !
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics Source - www.airbestpractices.com/
  • 8. What can we do about it ?
    • Optimise work cycles
    • Minimise cycle times
      • More than cylinder speed
        • Minimise bounce at end of stroke
        • Reduce off-cushion time delays
          • Minimum time between valve switching and cylinder moving
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 9. Totalising Mass Air Flow Sensors
    • Sensor emits an electrical pulse after a certain volume of air is flowed
    • Count the pulses over time
      • Calculate the average flow
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 10. Ultrasonic leak detectors
    • Air leaks “Hiss”
      • Broad spectrum white noise
      • Contains an ultrasonic components
      • Leak detectors “listen” for this ultrasonic component
      • Loudest at the source
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 11. Ultrasonic leak detectors 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 12. Reduce leakage
    • Best practices for tube connections
      • Square cuts on tube for push connect fittings
    • Reusable fittings
        • ISO “G” threads seal on a spot face with “O” ring
        • Don’t re-use tapered thread fittings
          • Seal by deforming threads
          • PTFE tape
    • Low leakage valves
        • Elastomeric seals
        • Preferable to lapped spools
          • Leakage increases over time
    • Take advantage of air-pilot valve technology
        • Lower wattage solenoid coils
          • 0.35 W, not 3.5W
        • Especially important for spring return valves
          • Where coil voltage needs to be maintained
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 13. Size actuators correctly for the application
    • Very common to guesstimate on the high side
        • Just in case
    • How fast ?
    • How much load ?
    • Orientation ?
    • Web-based calculation tools are available
      • Optimize the actuator based on application parameters
        • Load
        • Speed
        • Line pressure
        • Tube lengths
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 14. Pressure drops in tube
    • Easy win
      • Match tube diameter and length to needed flow
      • Example – 3/8” tube (10mm)
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics 2400 Nl/min / 85 cfm 1700 Nl/min / 60 cfm 1300 Nl/min / 46 cfm
  • 15. Web-based calculation tools 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 16. Size actuators correctly for the application 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 17. Size actuators correctly for the application 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 18. Size actuators correctly for the application 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 19. Reduce distances between valves and actuators
    • Decentralised pneumatics
      • Fieldbus
        • Minimal wiring
      • Avoid larger valve manifolds
        • Multiple smaller manifolds
      • Lets you keep valves and actuators closer together
        • Reduce tube lengths
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 20. Valve / Cylinder combinations
      • Valve mounted on cylinder
        • Best case to minimise tube lengths
          • Minimises dead volumes
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 21. Reduce your pressures
    • Force = Pressure x Area
      • More force if more pressure – Right ?
        • Not the whole story
    • Net force =
      • Pressure x piston area – Pressure x (piston area – rod area)
    • What about double rod cylinders ?
    • What about rodless cylinders ?
    • Need to control the DIFFERENTIAL pressure across the piston
      • Speed controlled by exhaust rate of second chamber
        • Exhaust rate slower the higher the pressure
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 22. Simple application, one pressure
    • One valve
      • Same pressure for extend and retract
      • Speed limited by amount of air to be exhausted
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 23. Different pressures
    • High pressure to extend
    • Lower pressure for return stroke
    • Insert pressure regulator in retract line
      • Needs check valve for exhaust line
      • Saves energy
      • Unexpected benefit
        • Increases extend speed
        • Easy retrofit for existing applications
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 24. Stroke time with 6 bar main, different “no-load” pressures 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 25. Cycle time reduction for different strokes: 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics 2 bar “no-load stroke”
  • 26. Application example
    • Lab exercise
    • Rodless cylinder
    • Two ISO size 2, 3/2 valves
    • Multiple ports
    • 4.4 lb
    • 36 ft / sec
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 27. Case study
    • Press fit application
      • Rexroth in-house production
      • 6 inch bore cylinder
      • 100 psi
      • 2800 lbf
    • Regulator added for return stroke
      • 10 psi
      • Air pressure reduced 90%
    • 38% energy savings
    • ROI 2100 cycles
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 28. High air consumption devices
    • Vacuum generators
      • Venturi effect requires a constant air supply
      • Not needed after required vacuum level achieved
    • Air Economiser technology
      • Vacuum switch to sense vacuum level
      • Turns off venturi air supply while vacuum is sufficient
      • Turns venturi air supply back on after vacuum level degrades
    • Needs NO controls logic
      • Vacuum switch and on/off circuitry onboard
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 29. But what does it cost ?
    • HOW MUCH air am I using ?
      • Need to know cylinder internal volumes
        • Extend
        • Retract
        • Single or double acting ?
          • Do I use air on 1 or 2 strokes ?
      • Tube dimensions
          • ID
          • Length
      • Air pressure
        • Compression ratio
      • Compressor efficiency
      • Cost per kW-hour
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 30. You could do it in Excel . . . 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 31. Or you can use online tools 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 32. Air costs with differential pressures 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 33. Conclusions
    • If you want to be efficient and economical -
      • Don’t tolerate leakage
        • Poor installation
        • Aging, worn components
        • Fix leaks - ongoing
      • Size components correctly
        • Don’t neglect the tube size – very important
        • Take advantage of online tools
      • Use minimum pressure to do the work
        • Is the return stroke a “No-Load” stroke ?
        • Also increases speed
          • Reduces cycle times
    • Bigger isn’t always better
    13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics
  • 34. Thank You 13/10/2011 | Phil O'Neill, Bosch Rexroth Pneumatics | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Energy Savings with Pneumatics Fluid Power Expo Phil O’Neill Bosch Rexroth Pneumatics Cleveland, OH 10/26/2011