Everybody is talking more and more about “green” engineering these days. While its beginning to become clearer what this means in the fields of alternative energy and consumer energy usage, it’s still not at all clear what this means for the world of motion control. Some of the leading motion control companies discuss and explore your questions about “green” design principles and how they apply to applications in the motion control world. By watching this special 1-hour free webinar you will gain a better understanding of the key factors involved in “green” motion control and their relation to the projects you’re working on now and in the future.

2. Before We Start
This webinar will be available afterwards at
www.designworldonline.com
Q&A at the end of the presentation
Hashtag for this webinar: #GreenMC

3. Moderator
Miles Budimir
Design World
Presenters
Ken Kerns
Jesse Henson
Siemens
Baldor

4. Energy Efficiency in Motion Control
using Variable Frequency Drives (VFDs)
Ken Kerns
Marketing Programs Manager
Siemens Industry, Inc.
Drive Technologies Division
Motion Control and Low-Voltage Drives business

5. Overview
•
Energy efficiency circle
o Identify
o Evaluate
o Realize
•
Energy consumption and associated technologies
focus points
•
VFD systems and energy efficiency in motion control

6. Energy Efficiency Circle
Identify — Evaluate — Realize
A comprehensive approach
Continuous
Improvement
Process

7. The Siemens approach to increasing energy efficiency —
Consistent and continuous improvement
1 — Identify
Instead of reacting to more or less haphazardly
discovered energy guzzlers, the customer consistently
and permanently observes its energy fluxes.
Continuous
Improvement
Process
2 — Evaluate
Interpretation and comparative analysis of all
energy changes to recognize potential.
3 — Realize
Optimizing energy consumption and monitoring results.
The result is that energy resources are controlled
transparently and effectively.
Consistently increase the productivity of the energy applied

8. Step 1: ―Identify‖
Identify
• Understand cost drivers
Continuous
Improvement
Process
• Plant-wide / process transparency
• Efficient monitoring is essential
Energy efficiency for increased productivity

9. Step 2: ―Evaluate‖
Evaluate
• Detailed analysis of electric usage
Continuous
Improvement
Process
• Estimation of savings potential
Energy efficiency for increased productivity

10. Step 3: ―Realize‖
Realize
• Seize the opportunities identified
Continuous
Improvement
Process
• Primary energy savings potential
comes from Variable Frequency
Drives applicatons
Energy efficiency for increased productivity

11. Energy Consumption and Associated Technologies
Focus Points
Lighting
Steam, Gas,
Compressed Air,
Water
Power Quality,
Consumption
Monitoring
Networking
Infrastructure
and Control
MCCs,
VFDs and Motors

12. VFDs
and Energy Efficiency
1. Flow control optimization
o Pumps, fans, blowers,
and compressors using
mechanical flow control
2. Wasted energy recovery
o Cyclical applications
o Braking applications
• Holding Torque (regen)
applications

13. Why Use VFDs?
• Industrial electric motor-driven systems represent the
largest single category of electricity use in the country.
• Industrial electric motors represent over 65% of
power demand in industry.
• Motor-driven systems offer one of the highest potential
for energy savings in the industrial segment — 70%.
• Almost all motor lifecycle cost is expended on the
energy the motor uses (97-99%).
• Government incentives, utility rebates and savings-based
financing can provide low up-front investment and ROI in
as few as 3-6 months.
• Approximately 33% of industries report no improvements
for the pumps, fans, compressors in their facilities.

14. Benefits of Implementing
Energy Efficient VFDs
• Energy efficient VFDs save energy,
reduce utility bills, provide precise
motor speed control, improve overall
process control and reduce operating
and maintenance costs
• May require little upfront investment,
are easy to implement, and have
payback times of less than a year
• Energy efficient VFDs help reduce the
negative impacts on the environment
and can enhance corporate community
relations programs

15. Energy Recovery and Energy Exchange via Intermediate Circuit
Power drain
Reduction of
peak demands
Energy compensation
Energy recovery
No dissipation loss
from braking
X
Power factor
optimization
Harmonic mitigation
ALM
Motor modules
CM

16. Focus Areas for VFD systems in Motion Control
• Regenerative Applications (torque holding, braking)
= Energy recovery and reuse
• Ancillary systems – fans, pumps, compressors
= Energy saved normally wasted via mechanical control methods
(veins, throttles, dampers, etc.)
• Power factor monitoring and control
= Less energy consumption
• Control and monitoring systems - thin client control systems versus PCUs
= Less energy consumption
• Optimized heat dissipation for power units
= Less energy consumption
• Use of proper component sizing tools to avoid over sizing
= Less energy consumption
• Mechatronic evaluation for optimized system efficiency
= Les energy consumption and reduced system stress

17. Important Links
o Energy savings website
www.usa.siemens.com/energysavings
o Consolidated list of federal, state,
utility energy savings incentives
www.dsireusa.org
o VFDs products website
www.usa.siemens.com/drives
www.usa.siemens.com/motioncontrol
o Carbon offsets
www.chicagoclimatex.com
o Sinasave — energy savings calculator and training
www.siemens.com/sinasave
o SIZER design tool
www.siemens.com/sizer
o Financing through Siemens Financial Services
www.usa.siemens.com/finance

18. Contact Information
Ken Kerns
Marketing Programs Manager
Siemens Industry, Inc.
Drive Technologies Division
Motion Control and Low-Voltage Drives business
100 Technology Drive
Alpharetta, GA 30005
office: (770) 740-3724
Email: thomas.kerns@siemens.com

19. Going ‗Green‘
with
Motion Control
Presented by
Jesse Henson
Motion Control Sales Manager
Baldor Electric

20. ‗Green‘ Motion Control
• Induction Motor efficiency compared to PM Servo
• Impact of the Energy Independence and Security Act
• DC shared installation savings
• Trends using integrated motors and distributed power
• How Motion Controllers Save Energy

21. Today‘s Industrial Market
Challenges to compete
•
•
•
•
•
•
•
•
•
Reduce Manufacturing Cost
Increase Through put
Reduce Labor Cost / Content
Reduce Energy Cost / Content
Minimize waste
Maximize equipment life
Reduce downtime
Increase Quality
Remove things that are not productive

22. Energy Independence and
Security Act Impact
• Automakers gas mileage to 35mpg by 2020
• 25% greater efficiency for light bulbs 2012 to 2014
• 1 – 200 HP general purpose motors (December 19, 2010)
2, 4, & 6 Pole
230/460V
60Hz
General purpose motors already covered by EPAct
• Change from MG-1, Table 12-11 to Table 12-12 Premium Efficient levels
o 201 – 500 HP will comply with Table 12-11
o
o
o
o

23. Servo Motor comparison

24. DC Shared Installation
savings
• $$$ Saving with DC Power
o
o
o
o
o
o
o
o
o
Contactors
MCB‘s
Cabling
Design Time
Build Time
Component Count
Save Energy Cost
Improved Reliability
Less Panel Space
Filter

25. Today‘s typical Motion
Control system
• Traditional Control cabinet takes up a lot of space
• Wires per motor from control cabinet to each motor
• Extra expense in panel wiring and cable routing

26. Integrated Motor
Technology
•
•
•
•
Less cabling
Smaller control cabinet
Reduction in assembly time
Smaller machine footprint

27. Going ‗Green‘ with
Motion Controllers
•
•
•
•
•
•
•
•
•
Reduced carbon footprint
Advanced diagnostics
Reduced downtime
Real-time Ethernet connectivity
Complete machine visibility (Remote diagnostics)
Energy to a motor only when needed
Advanced software reducing mechanics on the machine
Increased Productivity reduces cost
Increased accuracy / reducing waste

28. Industrial Market
Challenges to compete
•
•
•
•
•
•
•
•
•
Reduce Manufacturing Cost
Increase Through put
Reduce Labor Cost / Content
Reduce Energy Cost / Content
Minimize waste
Maximize equipment life
Reduce downtime
Increase Quality
Remove things that are not productive

29. Thank You!!

30. Questions?
Design World
Miles Budimir
mbudimir@wtwhmedia.com
Phone: 440.234.4531
Twitter: @wtwh_Motion
Siemens
Ken Kerns
thomas.kerns@siemens.com
Phone: 770.740.3724
Twitter: @Siemens_DT_US
Facebook: … /siemens.dt.us
Baldor
Jesse Henson
JHenson@baldor.com
Phone: 479.648.5828
LinkedIn:…/in/hensonjesse

31. Thank You
 This webinar will be available at
www.designworldonline.com & email
Tweet with hashtag #GreenMC
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