Energy Savings with Pneumatics

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Energy Savings with Pneumatics

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

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