Energy Savings & Green Considerations in Motion Control Webinar

This webinar will be available afterwards at

www.designworldonline.com

Q&A at the end of the presentation

Hashtag for this webinar: #GreenMC

Before We Start

Moderator

Miles Budimir Design World

Ken Kerns Siemens

Presenters

Jesse Henson Baldor

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

• Energy efficiency circle

o Identify

o Evaluate

o Realize

• Energy consumption and associated technologies

focus points

• VFD systems and energy efficiency in motion control

Overview

Energy Efficiency Circle

Identify — Evaluate — Realize

A comprehensive approach

Continuous

Improvement

Process

Consistently increase the productivity of the energy applied

1 — Identify

Instead of reacting to more or less haphazardly

discovered energy guzzlers, the customer consistently

and permanently observes its energy fluxes.

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.

The Siemens approach to increasing energy efficiency —

Consistent and continuous improvement

Continuous

Improvement

Process

Energy efficiency for increased productivity

Identify • Understand cost drivers

• Plant-wide / process transparency

• Efficient monitoring is essential

Step 1: ―Identify‖

Continuous

Improvement

Process

Energy efficiency for increased productivity

Step 2: ―Evaluate‖

Evaluate • Detailed analysis of electric usage

• Estimation of savings potential Continuous

Improvement

Process

Energy efficiency for increased productivity

Step 3: ―Realize‖

Realize • Seize the opportunities identified

• Primary energy savings potential

comes from Variable Frequency

Drives applicatons

Continuous

Improvement

Process

Power Quality,

Networking

Infrastructure

Lighting

Steam, Gas,

Compressed Air,

Water

VFDs and Motors

Energy Consumption and Associated Technologies

Focus Points

MCCs,

and Control

Consumption

Monitoring

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

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.

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

Energy Recovery and Energy Exchange via Intermediate Circuit

Power drain

Energy recovery

No dissipation loss

from braking X ALM Motor modules CM

Reduction of

peak demands Energy compensation

Power factor

optimization

Harmonic mitigation

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

Important Links

o Energy savings website

www.usa.siemens.com/energysavings

o VFDs products website

www.usa.siemens.com/drives

www.usa.siemens.com/motioncontrol

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

o Consolidated list of federal, state,

utility energy savings incentives

www.dsireusa.org

o Carbon offsets

www.chicagoclimatex.com

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: [email protected]

Contact Information

Going ‗Green‘

with

Motion Control Presented by

Jesse Henson

Motion Control Sales Manager

Baldor Electric

‗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

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

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) o 2, 4, & 6 Pole

o 230/460V

o 60Hz

o 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

Servo Motor comparison

DC Shared Installation savings

• $$$ Saving with DC Power o Contactors

o MCB‘s

o Cabling

o Design Time

o Build Time

o Component Count

o Save Energy Cost

o Improved Reliability

o Less Panel Space

Filter

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

Integrated Motor Technology

• Less cabling

• Smaller control cabinet

• Reduction in assembly time

• Smaller machine footprint

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

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

Thank You!!

Questions? Design World Miles Budimir [email protected] Phone: 440.234.4531 Twitter: @wtwh_Motion

Baldor Jesse Henson [email protected]

Phone: 479.648.5828 LinkedIn:…/in/hensonjesse

Siemens Ken Kerns [email protected] Phone: 770.740.3724 Twitter: @Siemens_DT_US Facebook: … /siemens.dt.us

Thank You

This webinar will be available at www.designworldonline.com & email

Tweet with hashtag #GreenMC

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