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Rexroth Sytronix –Energy-efﬁcient Hydraulicswith Variable-speedPump Drives

2 Sytronix | Energy-efﬁcient Hydraulics

Rexroth Sytronix – Powerful, Energy-efﬁcient and Cost-cutting

Investing now into the future – as a result of rising energy costs and increasingly cost-efﬁcient speed-controlled drives offered on the market, variable-speed solutions areon the advance.

Sytronix | Energy-efﬁcient Hydraulics 3

Costs of variable-speed drives

Costs

1995 until 2010 -75 %

Energy costs

Costs of

variable-speed

drives

02 Rexroth Sytronix –

Powerful, Energy-efﬁcient and

Cost-cutting

04 Energy-efﬁciency up –

Unit Costs down

05 Scalable in Power and Function

1985 1990 1995 2000 2005 2010 2015

With Sytronix variable-speed pump drives Rexroth cuts

operating costs in hydraulic systems as soon as the

machine cycle utilizes ﬂuctuating ﬂows. Using intelligent

06 Variable-speed Pump Drives

Sytronix FcP 5000 and SvP 7000

07 Pumps for FcP 5000 and SvP 7000

servo-drives, Rexroth Sytronics regulates the speed and

thus the power consumption of electric motors in line with

demand. The higher the share of part-load operation, the

greater is the saving potential. In this way, the energy

08 Variable-speed Pressure and

Flow Control System DFEn 5000

consumption can be reduced by up to 80 %.

At the same time, noise emission is reduced by up to

20 dB (A). The expenditure for noise-reducing secondary

measures is cut accordingly. The investment therefore pays

off within a few years.

In many cases, it is possible to do without cooling of the

power unit, because due to the reduced energy consump-

tion the hydraulic ﬂuid will not heat up excessively. This, in

turn, allows a compacter design, which reduces complexity

and acquisition costs.

In addition, since our pump drives achieve sustained noise

reduction, the investment into secondary measures for

personnel protection is diminished. The integration into

automation requirements becomes easier and commission-

ing times are shortened.

09 Branch-oriented System

Advantages

10 Example of Machine Tools:

Efﬁcient Energy-savers

11 Example of Plastics Processing

Machines:

Higher Dynamics with Reduced

Energy Consumption

12 Example of Diecasting Machines:

80 % More Energy-efﬁcient

13 Example of Presses:

Always the Most Effective Solution

14 Example of Woodworking and

Papermaking Machines:

Flexibly Adjusted to the Task at Hand

15 Example of Retroﬁt:

Fast Increase in Efﬁciency in

Production

4 Sytronix | Energy-efﬁcient Hydraulics

Energy-efﬁciency up – Unit Costs down

Energy consumption has a signiﬁcant effect on Total Cost of Ownership of plant andmachinery: Even with standard machines, the energy consumption represents 20 – 30% of total costs, and with particularly energy-intensive applications, this share is remarkably higher.

With energy savings of between 30 and 80 %, the invest-

ment into energy-efﬁcient hydraulics from Bosch Rexroth

Advantages:

quickly pays off. At the same time, the low energy consump-

tion reduces the emission of climate-damaging CO

₂. In this

way, we support numerous companies in signiﬁcantly

reducing their “Carbon Footprint“.

High energy-saving potential

Signiﬁcant reduction of operating costs.

Remarkable noise reduction

Sytronix variable-speed pump drives from Rexroth contrib-

Compliance with EU Directives. Fewer secondary measures.

ute to reducing operating costs. In addition, they lower the

average noise emission of hydraulic power units by up to

Clearly reduced cooling effort

20 dB (A). Complex and expensive noise insulation of the

Lower investment. Reduced space requirement.

hydraulic power units is therefore no longer required.

Reduced space requirement

Sytronix variable-speed pump drives are based on perfectly

matched mass-produced components with high availability.

Lower investment. Reduced space requirement.

The extended diagnostics options of these closed-loop

controlled drives open up additional options of preventing

expensive machine failures thanks to condition monitoring.

Hydraulic and electrical standard components

Operational reliability. High availability.

A calculation that pays off: Energy-efﬁciency up – unit costs

System safety

down.

Compliance with Machinery Directives.

Future-oriented technology

Compliance with EU Directive.

Ease of integration of ﬂexible check functions

Reduction of expensive machine failures.

Sytronix | Energy-efﬁcient Hydraulics 5

Scalable in Power and Function

Sytronix variable-speed pump drives comprise a comprehensive construction kit con- sisting of pumps, control devices and motors as well as software, which perfectly meet a wide variety of requirements. Depending on cycle characteristics and rating, Sytronix variable-speed pump drives achieve energy savings of between 30 and 80 % in manyapplications.

Sytronix

As early as at the engineering stage Rexroth supports

machine manufacturers in dimensioning and the selection

FcP 5000

basic performance

with simulation models. The ﬁne scalability in power and

function always provides optimum solutions.

basic dynamics Consume always only the amount of energy that is actually

required by the process. In contrast to non-closed-loop

basic accuracy controlled pump drives, the Sytronix variable-speed drives

operates strictly in line with demand. In the pressure-hold-

energy efﬁcient ing mode or in part-load operation, the control device

reduces speed to save energy. With the internal gear pump

DFEn 5000

advanced performance

speciﬁcally developed for variable-speed operation with

SvP 7000 and FcP 5000, speeds are reduced to signiﬁcantly

below 200 min^-1without having to make concessions on the advanced dynamics

operating pressure.

advanced accuracy

With FcP 5000, asynchronous standard motors control

internal or external gear pumps. They are suitable as con- energy efﬁcient

stant-pressure system for numerous standard power units,

for example in machine tools. The system DFEn 5000 con-

SvP 7000

high performance

sists of a variable-displacement axial piston pump that is

converter. This combination guarantees a good price/per- high dynamics

formance ratio, especially in the case of great powers.

Variable servo pump drives SvP 7000 utilize the high high accuracy

dynamics of synchronous motors and therefore achieve

substantial energy savings, for example in plastics process- energy efﬁcient

ing machines and presses.

6 Sytronix | FcP 5000 and SvP 7000

Variable-speed Pump Drives Sytronix FcP 5000 and SvP 7000

With conventional hydraulic systems, a variable displacement pump works in conjunc- tion with an electric motor at a nominal speed of, for example, 1500 min_-1. The variableoil requirement of the hydraulic system is regulated via internal adjustment mecha-nisms of the pump. In contrast to this, with FcP 5000 and SvP 7000 the ﬂow demandof the hydraulic system is fulﬁlled by means of a ﬁxed displacement pump and speedadjustment of an electric motor.

The SvP 7000 system consists of a pump that is optimized the converter. Here, the pressure controller has a limiting

for variable-speed operation, a synchronous servo-motor, effect on the pump speed. The internal gear pump used is

an appropriate converter plus accessories. For applications speciﬁcally optimized to variable-speed operation and

with less stringent demands on dynamics, an asynchronous achieves low leakage rates while featuring high overall

standard motor is used with system FcP 5000. In both efﬁciency and low noise emission. The required command

systems, an internal gear pump is powered, with the speed and actual values for pressure and ﬂow can be exchanged

and the displacement of the pump providing the ﬂow rate. with the higher-level machine control via analog signals

A pressure transducer senses the hydraulic pressure that is (0 – 10 V) or over ﬁeld bus.

controlled in a decentralized manner by special software in

e SvP 7000 system d FcP 5000 system

Sytronix | FcP 5000 and SvP 7000 7

Pumps for FcP 5000 and SvP 7000

In the open circuit for standard applications, the combina-

tion of a standard motor and a frequency converter with

internal and external gear pumps covers numerous applica-

tions. The pump families PGH, PGF und AZPF developed

speciﬁcally for variable operation always deliver the

required hydraulic power.

In conjunction with axial piston or external gear pumps,

SvP 7000 perform 4-quadrant operation in a closed circuit

and offer a multitude of electrical and electrohydraulic

control features.

SvP 7000 systems are also suitable for controlling axes

directly and therefore substitute valves that used to be

necessary in the past.

Even for very high power ratings in the ﬁeld of plant con-

struction Rexroth offers tailored solutions for increasing

energy efﬁciency. In cascading systems, several Sytronix

systems jointly generate the required displacement in line

with demand. In this way, Rexroth ensures high efﬁciency

over the entire performance range.

8 Sytronix | DFEn 5000

Variable-speed Pressure and FlowControl System DFEn 5000

The variable-speed pump drive DFEn 5000 is based on the proven pressure and ﬂowcontrol system DFE. An electrohydraulically controlled axial piston pump is controlledby a variable-speed drive. Thanks to the use of standard motors, this control systemoffers an excellent price/performance ratio.

The digital on-board electronics computes the optimum In non-cyclical machines, shortly before a greater ﬂow is

speed for the entire drive train. By swiveling the variable required (e.g. change of batch), a contact can be closed

displacement pump back in the pressure holding mode, the for accelerating to a minimum speed in order that the full

displacement and loads acting on the motor are reduced. dynamics of the pump is available when required. Identical,

The optimum speed for pressure holding ranges between mechanical interfaces allow the DFEn 5000 to be retroﬁtted

300 and 400 min^-1depending on the pressure. In cyclically as substitute for a DFEE. The control system is available for

operating machines, a teach-in process can be applied in pumps of the A10 family and can therefore be utilized for a

order that the system is speeded up in due time before the wide spectrum of applications.

ﬂow demand increases.

Sytronix | Branch-oriented System Advantages 9

Branch-oriented System Advantages

Sytronix variable-speed drives change the boundary conditions for hydraulic systemsand open up new design options for efﬁcient solutions. An important factor here isperfectly matched components and an in-depth physical understanding of hydraulics.

10 Sytronix | Branch-oriented System Advantages

Example of Machine Tools:Efﬁcient Energy-savers

Providing power only when it is needed by the process: The generation of pressure asrequired with variable-speed pump drives reduces the energy requirement of hydraulicsin machine tools by up to 70 %. But even more, the KST booster developed exclusively byRexroth transfers these advantages to the high-pressure cooling lubricant supply.

Innovative power

Especially for clamping functions, hydraulics offers a unique

advantage, for it does not need additional power for the

pressure holding function. In this phase, Sytronix variable-

speed pump drives signiﬁcantly reduce the energy require-

ment. FcP 5000 consisting of the combination of a standard

motor and a frequency converter are a particularly efﬁcient

solution to reduce the energy consumption of hydraulics by

30 to 70% depending on the cycle characteristics. At the

same time, with an unchanged displacement, pumps with a

smaller swept volume and reduced cooling capacity are

sufﬁcient.

Moreover, the combination of a KST booster from Rexroth

for the high-pressure cooling lubricant supply in line with

Frequency

converter

Sytronix variable-

speed pump drives

In-line booster

demand trims down the energy requirement of this function

by almost 90 %. In this case, the Sytronix variable-speed

pump drive generates the ﬂow for the cooling lubricant

Noise reduction Energy efﬁciency

high-pressure circuit by means of an additional cylinder

pump. The common screw pump plus electric motor are

therefore no longer necessary.

Sytronix | Branch-oriented System Advantages 11

Example of Plastics Processing Machines:Higher Dynamics with Reduced EnergyConsumption

Consistent automation, higher dynamics and high accuracy: Variable servo-pump drivescombine highest efﬁciency with remarkably lower energy consumption and noise emissionin plastics processing machines. The DFEn 5000 is based on the proven control system DFEand reduces losses in pressure holding during pauses and in part-load operation.

Thanks to its acceleration, which is twice as fast compared

with variable-displacement pumps, the SvP 7000 enhances

the dynamics of plastics processing machines, thus short-

ening cycle times for higher productivity. The digital speed

control ensures high repeatability and a stable zero point.

Pressure-related leakage losses are compensated for. With

closed-loop pressure control very short pressure change

times are possible. High dynamics and the sophisticated

controller concept allow the implementation of very precise

controls, which minimize under- or overshoots. Moreover, a

Comparison of energy consumption of plastics

machinery 50 t, 30 s

special function prevents cavitation when changing over to

low pressures.

15000

10000

5000

kWh/a

41,4%

1.3 kW

2.2 kW

Sytronix variable-speed

pump drive

Electrohydraulic variable

displacement pump with

constant speed

Energy savings

Apart from the SvP 7000, a DFEn 5000 may also be used

for plastics processing machines with medium demands on

dynamics. It offers a good price/performance ratio, espe-

cially for higher power ratings and long pressure holding

times. The SvP 7000 and DFEn 5000 are ideal as energy-

saving option for machines equipped with DFEE. 0 50 t

IMM 160 t, 15 s cycle time

In addition, they reduce the introduction of heat into the oil

and signiﬁcantly lower the average noise emission. This kWh/a

70000

60000

50000

40000

30000

20000

10000

33,1%

5.6 kW

8.4 kW

Sytronix variable-speed

pump drive

Electrohydraulic variable

displacement pump with

constant speed

Energy savings

minimizes the design effort for secondary noise insulation.

In view of energy savings of up to 70% and higher produc-

tivity, Sytronix variable-speed pump drives quickly amor-

tize.

0 160 t

12 Sytronix | Branch-oriented System Advantages

Example of Diecasting Machines:80% More Energy-efﬁcient

Variable servo-pump drives open up extremely high energy-saving potentials also in hotchamber diecasting machines and, at the same time, simplify the hydraulic circuit.

Robust hydraulics with its high power density and load-

holding capacity has proven successful under the harsh

ambient conditions of diecasting machines. Practical expe-

rience gained with series machines shows: The use of SvP

7000 with synchronous servo-motor, intelligent servo-drive,

internal gear pump as well all the required software func-

tionalities cuts the energy consumption of hydraulics in hot

chamber diecasting machines by more than 80 %.

In a closed control loop, the SvP 7000 compares command

values with actual values for pressure and speed and cor-

rects any deviations. Morerover, the associated software

provides further hydraulics-speciﬁc functionalities such as

offset calibration of the pressure sensor, leakage compen-

sation and options for multiple pump systems. In addition,

in modern diecasting machines, SvP 7000 additionally

simplify the hydraulic circuits when compared with pred-

ecessor versions. In the past, two non-closed-loop-control-

led pumps for high and for low pressure were required,

whereas now one SvP 7000 system is sufﬁcient, which,

Comparison of energy consumption of diecasting machines

Dieasting machine 50 t, 7.5 s cycle time

thanks to its functionality, can even replace some high-

response valves and, in addition, supplies an accumulator

charging circuit for the shot cylinder. kWh/a

80000

Sytronix variable-speed

pump drive

60000

40000

20000

83,2% 10.1 kW

Fixed displacement pump with

constant speed (11 kW motor)

Energy savings

1.7 kW

0 50 t

Sytronix | Branch-oriented System Advantages 13

Example of Presses:

Always the Most Effective Solution

Be it for the energy-efﬁcient generation of pressure or as control element in two- or four-quadrant operation: Our scalable systems provide signiﬁcantly increased energy efﬁciencyand consistent press automation.

Comparison of energy consumption of a press

17.6 kW: electric power

Sytronix variable-speedpump drive

0.019 kWh ca. 44%

Conventional system

Energy savings

0.034 kWh

kWh

0.000 0.005 0.010 0.015 0.020 0.025 0.030 0.035

Thanks to open interfaces to all common ﬁeld buses and In addition to achieving energy savings through speed

real-time Ethernet protocols, Sytronix variable-speed pump control, Sytronix variable-speed pump drives improve the

drives seamlessly ﬁt into the press automation concept. In efﬁciency, since throttling losses across control lands are a

the simplest variant, a FcP 5000 generates the required thing of the past, the required oil ﬂow can be precisely

ﬂow efﬁciently and as required. Nevertheless, this variant metered, and the electric motor is switched off, when the

features all proven hydraulic safety circuits. In the medium press does not require a ﬂow or a pressure function. Espe-

extension stage, the pump drive additionally performs cially in the case of retroﬁtting of existing presses, the use

intelligent axis functions. In the highest extension stage, of Sytronix can clearly improve the utilization of the

the SvP 7000 achieves extremely high dynamics and pre- machine’s capacity, while remarkably reducing energy costs

cision. and the noise level.

The innovative drive concept combines the positive proper-

ties of electric and hydraulic drive technology. Due to the

functional integration of dynamic ﬂow and pressure control

as well as controlling of dynamic processes, positions and

pressures, it opens up a higher degree of freedom for

ﬂexible and effective solutions.

14 Sytronix | Branch-oriented System Advantages

Example of Woodworking andPapermaking Machines: Flexibly Adjusted to the Task at Hand

From the fully automated sawing line through to rolling up the ready paper web:Sytronix variable-speed pump drives are also suitable for harsh ambient conditionsand continuous processes.

Especially for the continuous processes of papermaking,

Sytronix variable-speed pump drives offer particularly great

advantages with regard to energy efﬁciency. For example,

for rolling up, pressure-holding functions are prevailing.

Here, an intelligently reduced speed directly saves up to

60% electricity compared with power units with non-regu-

lated ﬁxed displacement motors. At the same time, Sytronix

variable-speed pump drives achieve higher speeds with a

smaller constructive size and reduce demands on the cool-

ing capacity. The result: Signiﬁcantly reduced operating

costs and smaller space requirement in the hall.

Also in non-cyclical processing in woodworking applica-

tions, the user can achieve clear savings: Example of sawing

operations: No tree is like the other, and a multitude of

drives in the fully automated lines ﬂexibly adapt to the

individual dimensions. With unchanged pressure, the proc-

ess requires a constantly changing ﬂow that the Sytronix

variable-speed drives can ﬂexibly provide. During produc-

tion breaks, integrated software reduces the speed down

to zero stroke, without affecting the operating pressure.

Sytronix maintains the robustness and power density of

hydraulics and combines it with the ﬂexibility of electric

drives.

Sytronix | Branch-oriented System Advantages 15

Example of Retroﬁt:

Fast Increase in Efﬁciency in Production

The high modularity of hydraulics also opens up economic options on existing plant andmachinery by substituting ﬁxed displacement power units by Sytronix variable-speed pumpdrives with little effort.

Reducing the energy consumption in production swiftly on site. Open interfaces to all common ﬁeld buses and

and lastingly without having to invest directly into new Ethernet protocols simplify the integration.

machines. Sytronix variable-speed pump drives, which are

ﬁnely scalable in function and power, allow energy-efﬁcient But even more, beyond tailored and planned retroﬁtting,

solutions to be retroﬁtted with little effort, for existing Rexroth joined forces with a worldwide leading machine

hydraulic circuits can remain unchanged in many cases. manufacturer to develop a standardized retroﬁt kit for

series machines. This reduces the effort additionally and

Rexroth supports machine operators during the entire ensures fast increases in efﬁciency in production.

retroﬁt process. Speciﬁcally developed simulation pro-

grams determine possible savings for the concrete applica-

tion in advance. After planning on the basis of comprehen-

sive application experience, specialists of the worldwide