Power Saving & Energy Efficient Servo System
Energy efficiency and dynamic response
With the servo pump, Devanshi combines the advantages of hydraulic power transmission….
- High force and power densities, low inertias
- Robust and cost-effective drive elements
….With the advantages of a controllable energy source, in the form of electrical servo drive technology
- High efficiency
- High dynamic response, high precision
- Low noise levels due to use of internal gear pumps
Profitability Analysis
- Induction Motor: 22kW
- Max. Motor Current = 39 Amps
- For Injection Molding Machine
- Average Motor Current = 30 Amps
- Power Consumption per hour = 17.25 Units
- Power Consumption per month = 10764 Units
- Electricity Charges (Approx.) = 10.00 per Unit
- Annual Electricity Charges = 12,91,680/-
- Power Saving due to Servo System = 30% (approx.)*
- Saving = 12,91,680.00 x 30% = 3,87,504.00
- Cost of Equipment Servo < Rs. 4,00,000.00
- Return of investment (ROI) = 1 year (approx.)
Notes:
The above calculations are based on the following assumptions:
- Above calculations are based on Induction Motor with Fixed Pump running on Injection Molding Machine
- Injection Molding Machine is running for 24 hours per day
- The Average Current of the Injection Molding Machine is used as 30 Amps. For calculation purpose
- Actual current may vary depending upon the mold, shape, material of the article and the quality of mechanics
Key benefits for Devanshi Customer:
- In house repairing & testing
- Competitive repair cost
- Shorter lead time on drive repairs
Apart from Power Saving, you will get the following benifits:
- Improved Accuracy with Longer life of machine
- High-response, high-precision positioning
- Position Control using a Pulse Signal
- Speed Control by Analog Voltage
- Efficiency and low heat generation of the motor
- Energy conservation on power usage
- Linear relationship between speed and electric control
- Steady state stability
- Wide range of speed control
- Fast response with low mechanical and electrical inertia
160 Bar System
| Sr.No | Flow | Pressure | Flow Cc | Drive Power | Rated Current | Peak Current | Drive Size | Motor Power | RPM | RPM Alt | Motor Current | Torque | Resistor | Choke |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | 60 | 160 | 32 | 15 | 30 | 48 | 325x210x190 | 12 | 2000 | 2000 | 24.3 | 58 | 30Ω,1kW | 46A |
| 2 | 80 | 160 | 40 | 18 | 37 | 59.2 | 325x210x190 | 18 | 2000 | 2000 | 36.7 | 87 | 30Ω,1kW | 60A |
| 3 | 100 | 160 | 50 | 22 | 45 | 72 | 325x210x190 | 20.4 | 2000 | 2000 | 40.8 | 96 | 30Ω,1kW | 75A |
| 4 | 125 | 160 | 63 | 30 | 60 | 96 | 400x250x224 | 28.3 | 2000 | 1985 | 42 | 122 | 30Ω,1kW | 95A |
| 5 | 150 | 160 | 75/63 | 37 | 75 | 120 | 400x250x224 | 36.7 | 2000 | 2000/2400 | 73.7 | 175 | 30Ω,1kW | 124A |
| 6 | 180 | 160 | 80 | 37 | 75 | 120 | 400x250x224 | 36.7 | 2000 | 2250 | 73.7 | 175 | 30Ω,1kW | 124A |
| 7 | 200 | 160 | 100 | 45 | 91 | 145.6 | 520x340x275 | 44 | 1800 | 2000 | 96.5 | 232 | 30Ω,1kW | 156A |
| 8 | 250 | 160 | 125 | 55 | 112 | 179.2 | 520x340x275 | 55 | 1700 | 2000 | 106 | 304 | 30Ω,1kW | 192A |
| 9 | 300 | 160 | 160 | 75 | 150 | 240 | 566x355x290 | 67 | 1800 | 1875 | 146.5 | 357 | 30Ω,1kW | 192A |
210 Bar System
| Sr.No | Flow | Pressure | Flow Cc | Drive Power | Rated Current | Peak Current | Drive Size | Motor Power | RPM | RPM Alt | Motor Current | Torque | Resistor | Choke |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | 60 | 210 | 32 | 18 | 37 | 59.2 | 325x210x190 | 18 | 1800 | 2000 | 36.7 | 87 | 30Ω,1kW | 60A |
| 2 | 80 | 210 | 40 | 22 | 45 | 72 | 325x210x190 | 20.4 | 1800 | 2000 | 40.8 | 96 | 30Ω,1kW | 75A |
| 3 | 100 | 210 | 50 | 30 | 60 | 96 | 325x210x190 | 28.3 | 2000 | 2000 | 42 | 122 | 30Ω,1kW | 95A |
| 4 | 125 | 210 | 63 | 37 | 75 | 120 | 400x250x224 | 36.7 | 2000 | 1955 | 73.7 | 175 | 30Ω,1kW | 124A |
| 5 | 150 | 210 | 63 | 37 | 75 | 120 | 400x250x224 | 36.7 | 2000 | 2000/2400 | 73.7 | 175 | 30Ω,1kW | 124A |
| 6 | 180 | 210 | 80 | 45 | 91 | 145.6 | 400x250x224 | 44 | 1700 | 2250 | 96.5 | 232 | 30Ω,1kW | 156A |
| 7 | 200 | 210 | 100 | 55 | 112 | 179.2 | 520x340x275 | 55 | 1700 | 2000 | 106 | 304 | 30Ω,1kW | 192A |
| 8 | 250 | 210 | 125 | 75 | 150 | 240 | 520x340x275 | 67 | 1800 | 2000 | 146.5 | 357 | 30Ω,1kW | 192A |
| 9 | 300 | 210 | 160 | 90 | 180 | 288 | 566x355x290 | 91 | 1800 | 1875 | 156 | 481 | 30Ω,1kW | 250A |
Upto 150 lpm / 160 Bar, Settima and Eckerle pump is standard. Above 150 lpm systems use Eckerle pump.
Make of pump: Eckerle / Settima | Make of motor: Phase / Devanshi
Servo System Application
| Product advantage | Customer benefit |
|---|---|
| Significant reduction in energy consumption | Amortization of initial costs for servo motor and servo drive usually within 1 year |
| Excellent response characteristics and reproducibility | Improved process and product quality |
| Minimum response time at high and low pressures | Easy replacement of variable-displacement pumps and reduction of cycle times possible |
| Noise reduction by up to 20 dB (A) | Less effort required for noise protection measures |
| Integrated closed-loop control in converter: compensation for hydraulic non-linearities | Ability to connect to machine controller without difficulty (Plug & Play) Retrofits can be made without adapting the control system |
| Close partnership with pump manufacturer for optimal system design | Optimal configuration with respect to costs, noise, energy efficiency and mechanical system |
| Servo control increases degrees of freedom in the machine design | Minimum operational and life cycle costs |
| Clearly arranged operator interface for simple parameterization | Simple commissioning, machine-specific requirements are taken into consideration |
| Significantly improved efficiency when compared to an asynchronous motor with variable displacement pump | Saving of components, such as servo valves, and other innovative concepts are made possible |
| Large range of air and water-cooled motors and converters (up to 250 kW) | Cost-effective solution adapted to the customer’s specific requirements |