Energy-efficient application advice

While best practice energy efficiency tips are always helpful in identifying steps to energy management improvements, it can often be more helpful to look at specific processes within a plant to identify the low-hanging, energy savings fruit.


While best practice energy efficiency tips are always helpful in identifying steps to energy management improvements, it can often be more helpful to look at specific processes within a plant to identify the low-hanging, energy savings fruit. Peter P. Fischbach, manager of component sales for Bosch Rexroth Corp., offers the following specific suggestions for three common applications:

  • Converting/Printing: In continuous web applications, direct drive motors and electronic line shafting controls help eliminate inefficient mechanical shafts, transmissions, and tensioning brakes. “By replacing the inefficient induction motor, mechanical drive train, and tensioning systems of a printing machine with a multi-axis servo drive system, users can reasonably expect to achieve around 30% savings in energy,” Fischbach says. How? The common dc Bus of the drive system distributes the regenerative energy from the tensioning axis to the driving axis, lowering the net power consumed from the grid (see “Reusing energy via a common DC bus” sidebar in the January 2009 article).

  • Packaging/Handling: In production lines with fast, cyclical motion and repetitive start/stop operations, DC capacitor modules can be used to store excess energy from slowing or stopping until the next acceleration phase of the motion axis. “This reduces the net power used by the packaging/handling system,” says Fischbach. ”It is possible to reduce energy usage in such applications by up to 20% by replacing mechanical cams, induction motors, and variable frequency drives with a common dc bus servos system and capacitor modules.”

  • Hoisting/ Lifting/Palletizing: Regenerative energy is created during an application where the load possesses more energy than the motor, as is often the case when lowering or stopping heavy loads like pallets, hoists, or centrifuges. While motors are used to convert electrical power into mechanical power for the machine, servo motors have the potential to generate electricity, too. “As a heavy load decelerates or stops, the braking motor turns into a generator converting mechanical power back into electrical power, which needs to be removed,” says Fischbach. “Traditionally, most motor systems would take this excess energy and burn it off using a brake resistor or other mechanical ways, which generate heat and in many cases uses even more energy for cooling off the control cabinet and building. Servo drives connected via a common dc bus to a regenerative power supply can convert the excess energy back to ac power, which then can be reused by other equipment in plant.”

For more energy efficiency tips, see the two-part energy management articles in the January and February 2009 issues of Control Engineering, online at .
Control Engineering News Desk
Register here .

No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Safety for 18 years, warehouse maintenance tips, Ethernet and the IIoT, GAMS 2016 recap
2016 Engineering Leaders Under 40; Future vision: Where is manufacturing headed?; Electrical distribution, redefined
Strategic outsourcing delivers efficiency; Sleeve bearing clearance; Causes of water hammer; Improve air quality; Maintenance safety; GAMS preview
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
Safety at every angle, Big Data's impact on operations, bridging the skills gap
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Driving motor efficiency; Preventing arc flash in mission critical facilities; Integrating alternative power and existing electrical systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role of plant safety and offers advice on best practices.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me