1 Introducing Energy-saving Hydraulic Units March 2006 Fujikoshi Corporation For publication.
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Transcript of 1 Introducing Energy-saving Hydraulic Units March 2006 Fujikoshi Corporation For publication.
1
Introducing Energy-saving Introducing Energy-saving Hydraulic Units Hydraulic Units
Introducing Energy-saving Introducing Energy-saving Hydraulic Units Hydraulic Units
March 2006March 2006Fujikoshi Corporation Fujikoshi Corporation For publication
2
Features Features 40% Energy-savings Compact and Lightweight Quite, Low-surge Cool Operation Block Installation Possible Easy Maintenance
Compact Variable Volume Pump Unit
NSP Series
40% Energy Savings
Compared to Existing Model
40% Energy Savings
Compared to Existing Model
Perfect for Machine and Cutting Tools
8 cm 3/rev
10 liter tank
26 cm 3/rev30/40 liter tank
3
Pump capacity cm3/rev 8.0 16.0 26.0Maximumpressure
setting(Full cut-off)
Mpa 7.0
Electric driveoutput kW 0.75,1.5 1.5,2.2 2.2,3.7
Tank capacity Lit 30,40
Installationspace mm 340×450
Estimated dry
mass(no options)
kg63
(30L,2.2kW)43
(10L,1.5kW)
ModelItem
NSP-*-*V0A* NSP-*-*V1A* NSP-*-*V2A*
8.0
10,20
300×400
NSP Unit Series NSP Unit Series
4
NSP Unit Series NSP Unit Series
660㎜320㎜
NSP-30-37V2A3-12(NSP Unit 30-L tank)
NSP-30-37V2A3-12(NSP Unit 30-L tank)
NCP-60-3.7VD1A3-20(Existing Unit 60-L tank)
NCP-60-3.7VD1A3-20(Existing Unit 60-L tank)
Energy Savings and Cool Operation mean the NSP Unit's
tank capacity is
less than 1/2 the hydraulic fluid
capacity. (Comparable
specifications)
Energy Savings and Cool Operation mean the NSP Unit's
tank capacity is
less than 1/2 the hydraulic fluid
capacity. (Comparable
specifications)
5
Pump: Increased mechanical efficiency
Pump: Increased mechanical efficiency
Pump: Increased volumetric efficiency
Pump: Increased volumetric efficiency
Electric drive: copper loss, iron loss
reduction effectiveness ratio characteristics
modification
Electric drive: copper loss, iron loss
reduction effectiveness ratio characteristics
modification
Energy Saving Configuration Energy Saving Configuration
Plate-S oil groove
Vane pushing force reduction
Side clearance
External drain reduction
Plate-HPressure factor adjustment
Internal leakage, external drain reduction
Plate-S oil groove
External drain reduction
Increased efficiency of electric drive
6
(1) Reduced pressure losses (1) Reduced pressure losses
: Energy saving product
: Conventional product
Pushing force(Not in low-energy model)
(2) Lowered sleeve resistance (2) Lowered sleeve resistance
(1) Changed hydraulic fluid routing in vane back pressure chamber
(2) Modified plate pushing force (3) Eliminated plate impulse channel
No internal leaks from gasket
Energy savings: Increased pumping efficiency Energy savings: Increased pumping efficiency
Plate S hydraulic fluid channel through-flow Stopped
Lowered internal
resistance, reduced drain
volume.
Lowered internal
resistance, reduced drain
volume.
(3) Stopped internal leaks (3) Stopped internal leaks
7
Energy savings: Increased pumping efficiency Energy savings: Increased pumping efficiency
"Internal leaks" cause losses. However, they are necessary to lubricate the pump.Too much Losses (overheating, electrical power consumption) Too little Burn out (sleeve resistance)
"Internal leaks" cause losses. However, they are necessary to lubricate the pump.Too much Losses (overheating, electrical power consumption) Too little Burn out (sleeve resistance)
About the drain...
Conventional unit's pump generated 2 l/min
NSP unit's pump generates 0.5 l/min
Pump pressure
Drain volume
Hydraulic pressure symbol
(pump)
Dwelling
1/4 drain volume
8
50
55
60
65
70
75
80
0 25 50 75 100 125
Teeth
Slot shape Open Closed
Accumulated
thickness
TeethCore back
Hoop width
Electric drive-polarity: 2.2 kW-4P Voltage-cycles: AC 200 V, 60 Hz
When pump is fully cut off (dwelling time load ratio)
Conventional model
Electric drive load ratio (%)
Electric drive efficiency
Energy saving model
(%)
Stator Stator
Energy savings: Increased electric drive efficiency Energy savings: Increased electric drive efficiency
1) Accumulated thickness reduced and iron loss suppressed. (Rotor) 2) Hoop width changed to stabilize magnetic field. (Stator)
10%Increased efficiency
10%Increased efficiency
Rotor Rotor Energy savings
9
0.0
0.5
1.0
1.5
2 4 6 8
Conditions (dwelling)
Electric drive-polarity 2.2 kW-4P
Voltage-cycles: AC 200 V, 60 Hz
Voltage 6.0 Mpa
Energy savings: Increased electric drive efficiency Energy savings: Increased electric drive efficiency
Dwelling pressure - power consumption characteristics
40% down
Conventional hydraulic unit
NCP-60
NSP Unit
NSP-20
Reduced dwell time power consumption 40%.
Reduced dwell time power consumption 40%.
Dwell pressure (MPa)
Po
wer
co
nsu
mp
tio
n (
kW)
10
0
4
8
12
0 30 60 90 120 150 180 210 240 270 300
Time (sec)
Pow
er c
onsu
mpt
ion
(kW
)
15% energy(Comparison of all machines)
40% energy savings(Comparison of hydraulic units)
All machinesWhen using the
conventional hydraulic unit
All machinesWhen using the NSP
unit
NSP Unit
Conventionalhydraulic unit
Nachi Machine Evaluation (Machining Center) Nachi Machine Evaluation (Machining Center)
11
0.0
1.0
2.0
3.0
4.0
0 10 20 30 40 50 60
Time (sec)
Pow
er c
onsu
mpt
ion
(kW
)
INV UnitNSP Unit
Discharging
2 sec
8 sec
Dwelling
Approximately 20% energy
savings during discharge
Approximately 5% energy
savings during dwell
Energy savings during cyclic
operation: 12%
(1) Power consumption comparison
* Hydraulic fluid used: ISO VG32* Hydraulic fluid temperature: 40 to 50˚C* Electricity: 2.2 kW * Voltage - frequency: AC 200 V - 60 Hz* Operating cycles: 2 seconds 8 seconds <Discharge> <Dwell> * Discharge settings: 28 L/min, 2.0 MPa(NSP Unit: 16 cm 3/rev)* Dwell settings: 0 L/min, 6.0 MPa
[Operating conditions]
Compared with inverter unit produced by other company 1Compared with inverter unit produced by other company 1
NSP Unit Saves More Energy NSP Unit Saves More Energy
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Description INV Unit NSP Unit Energysavings
Discharging(2.0 MPa) 1896 1490 406Dwelling(6.0 MPa) 615 550 65
Power consumption: W
1896 W1490 W
Power consumption compared with inverter unit produced by other company
Power consumption compared with inverter unit produced by other company
615 W550 W
Discharging
Dwelling
NSP Unit NSP Unit INV Unit INV Unit
13
0
5
10
15
20
25
30
35
40
0 1 2 3 4 5 6 7 MPa)圧力 (
l/min
流量
()
0
2
4
6
8
l/min
ドレ
ン量
()
Ⅱナチッコ
INVユニット
● Ⅱ :ナチッコ 流量○ Ⅱ :ナチッコ ドレン量■ INV : ユニット流量□ INV : ユニットドレン量
[Operating conditions] * Hydraulic fluid used: ISO VG 32 * Hydraulic fluid temperature: 45C * Voltage-cycles: AC 200 V, 60 Hz
(2) P-Q characteristics comparison
: NSP Unit Flow Capacity : NSP Unit Drain Capacity : INV Unit Flow Capacity : INV Unit Drain Capacity
Compared with inverter unit produced by other company 2Compared with inverter unit produced by other company 2
INV Unit
RPMs are stable, but drain flow is small
NSP Unit
RPMs are reduced as energy is saved because drain flow is minimal.
RPMs are reduced as energy is saved because drain flow is minimal. RPMs being reduced,
but drain flow is large
Flo
w (
l/min
)
Pressure (MPa)
Dra
in f
low
(l/m
in)
14
(3) Pressure pulse
[Operating conditions]
INV Unit 3.0 MPa, when discharging INV Unit 6.0 MPa, when dwelling
NSP Unit 6.0 MPa, when dwelling NSP Unit 3.0 MPa, when discharging
0.41 MPa 0.30 MPa
0.44 MPa 1.07 MPa
Compared with inverter unit produced by other company 3Compared with inverter unit produced by other company 3
Pulse width
is small
Propagation of pulse to machine is reduced
Propagation of pulse to machine is reduced
* Hydraulic fluid: ISO VG32 *Hydraulic fluid temperature: 40 to 50˚ * Pump capacity: 16 cm3/rev*Electric drive: 2.2 kW *Voltage - frequency: AC 200 V, 60 Hz
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[Operating conditions] * Hydraulic fluid used: ISO VG 32 * Hydraulic fluid temperature: 40 to 50C * Voltage-cycles: AC 200 V, 60 Hz
Pump operatingconditions
NSP Unit INV Unit
t1Discharging
↓Dwelling (6.0 MPa)
0.002 0.002
t2Dwelling (6.0 MPa)
↓Discharging
0.020 0.100
Flow recovery time: Effects machine cycle
Compared with inverter unit produced by other company 4Compared with inverter unit produced by other company 4
(4) Response characteristics
Time
Pressure
Dwelling
Discharging
Clamp and chuck
t2
t1
The NSP unit has a quick response time for flow recovery so machines can operate at a high cycle.
The NSP unit has a quick response time for flow recovery so machines can operate at a high cycle.
16
0
20
40
60
0 1 2 3 4
Compared with inverter unit produced by other company 5Compared with inverter unit produced by other company 5
(5) Rising hydraulic fluid temperature (Over 4 hours dwelling continuously)
Unit
MeasurementNSP Unit INV Unit
Roomtemperature (℃)Temperature of
hydraulic fluid intank (℃)
37.2 43.2
Increase intemperature (℃) 11.2 17.2
26.0
It is possible to increase cutting precision because the NSP Unit's hydraulic fluid temperature increase is low so heat is not transmitted to the machinery.
It is possible to increase cutting precision because the NSP Unit's hydraulic fluid temperature increase is low so heat is not transmitted to the machinery.
[Operating conditions] * Hydraulic fluid used: ISO VG 32 * Pump capacity: 16cm3/rev * Electric drive: 2.2 kW * Voltage-cycles: AC 200 V, 60 Hz
* Room temperature: 26C
NSP Unit
INV Unit
Room temperature
Operating time (Hrs)
Be
ari
ng
Te
mp
era
ture
(℃)
17
Compared with inverter unit produced by other company 6Compared with inverter unit produced by other company 6
(6) Power consumption comparison (estimated cost for standard cycle)Standard cycle calculation conditions Discharging 5 hours/day
Dwelling 17 hours/day
Stopped 2 hours/day
Annual 8000 hours operation
Comparison of conventional unit and NSP unitConventional
unit (kW)NSP unit (kW)
Powerdifference (kW)
Hourly cost savings
(1) (2) (2)-(1) (yen)
2.0 MPaDischarging 1.50 1.50 0.00 0.00
6.0 MPaDwelling 0.90 0.55 0.35 5.25
Comparison of INV unit and NSP unit
INV unit (kW) NSP unit (kW)Power
difference (kW)Hourly cost savings
(3) (2) (2)-(3) (yen)
2.0 MPaDischarging 1.90 1.50 0.40 6.00
6.0 MPaDwelling 0.61 0.55 0.06 0.90
Effect of energy savings for one year
(Nachi comparison)
\32,400\32,400
Effect of energy savings for one year
(INV Unit comparison)
\16,500\16,500
18
Reference materialReference material
Effect of reduction in power consumption and CO2
kWh/year kWh/year
For 50 units (hypothetical)
Tons/year Tons/year
0.733kg/Wh
Other company’sINV unit
NSP Unit
Reduction of 40 tons/year
Total reduction 54,500 kWh/year
Annual powerconsumption
CO2 emissions265 225
361,000 306,500
Annual operating time8,000 hrs
Oil-fired thermal powerequivalence
19