Mechatronic analysis improves efficiency

Source: Siemens Drive Technologies - Motion Control

Publication date: March 15, 2010

By Michael Perlman

Motors and drives can be used in conjunction with mechatronic analysis and other current technologies to increase
energy efficiency. Several essential elements are the basis of a good energy management process.

Energy management is a process, rather than a product or series of products installed on a machine, or inline, to achieve
a basic energy saving of kilowatt hour consumption. This process must be ongoing and perpetual, meaning that any
defined goal should be viewed as a momentary metric of achievement, rather than a final end. Although any vendor can
supply the right products and support services to hit a target mark of energy savings, the mindset of the customer is key in
keeping the process recurrent. This ensures a continual increase in the productivity levels achieved, defined as a factor of
the energy consumed. In many ways, it can be viewed in the same manner as an ongoing, effective but constantly
evolving quality management system at your company.

First, energy monitoring systems - including energy consumption displays, infeed/supply monitoring devices, power factor
meters - must be in place to effectively determine the current consumption.

Second, the proper calculation tools, such as a motor sizing chart or a software programs used to parameterize drives,
are needed to evaluate the life cycle costs of any investment. However, a more formal mechatronics protocol may be
beneficial to your operation. In this scenario, a thorough evaluation of both mechanical and electrical/electronic influences
on your system is conducted.

In a system with multiple motors, energy savings might be realized by the use of a drive unit with a common DC bus. The
designer can also select the most appropriate infeed solution for the machine, pump or process operation, given the
particulars of performance and required output. This may include an appropriately sized infeed unit with regenerative
capability, the ability to put unused or braking energy back on the incoming power line.

Some applications may allow the use of high efficiency standard induction motors and, in the process, realize a potential
savings of 1%-3%. The use of frequency converters (VFD) for speed control might raise this to an 8%-10% savings.

Optimizing an entire system through mechatronic analysis of the machine or process design can result in a potential
savings of 15-20% by the avoidance of over-dimensioning of motors, plus partial load optimization by means of energy-
related flow control. This analysis may also point to the ability to use controlled energy infeed and recovery.

To determine the true efficiency of any drive system, demonstrate the amount of energy required by its power
components and a corresponding examination of how the system uses energy. The way that different drive concepts used
on the same system operate under identical power load must also be considered. This latter exercise might look into
partial load efficiencies with various motor and drive combinations, straight comparisons betweens synchronous servo
versus asynchronous induction motors or direct drive versus motor/gearbox combinations, drives with braking
components versus regenerative drive technology, as well as solutions with single versus multi-drive - common DC bus
solutions.

Also consider a review of potential hydraulic/pneumatic component change outs in applications in which replacement with
an integrated package of motion control might better resolve closed loop pressure control of axes. Fewer components and
their related power consumption can lead to overall system productivity improvements, as well as ongoing enhanced
energy efficiencies. Reduced programming, diagnostic and commissioning times can also flow from such an approach,
providing even more opportunities for overall machine or process improvements. Today's sophisticated mechatronic and
virtual production protocols can be utilized to validate the real-world performance characteristics of such designs before
they are implemented.

As the emergence of new technologies has affected many of the products used in energy-efficient systems, it is equally
important to take a more holistic look at operational sequences and the overall integration scheme when designing,
retrofitting or rebuilding for improved energy utilization.
Matching Motor to Load – The first step in getting motion
systems right
May 22, 2011 by Steve Meyer
Filed under Commentary, Design, Mechanical, Motion Control,Technology
Leave a Comment
Motion control solutions are primarily mechanical in nature. If the mechanism is right for the load, the motion solution can be
designed to meet the project objectives without difficulty. The starting point for this process is the selection of the motor.
In keeping with the mechanical nature of the problem, consider that across all of the possible fields of use for electric motors, very
few of them occur at typical motor nameplate speeds. Even in large fan systems where you would think you need high rpm, 1200
to 1800 RPM is a rarity. 60 miles per hour in a car is really only 800 rpm at the rear tire, depending on the tire diameter. Most
servo systems are designed at 4000 to 8000 rpm in order to increase the energy density of the solution. Size restrictions abound
in many types of equipment, so this approach makes sense in some markets. But generally, motor speeds and load speeds do
not match up very well.
This overall situation in the motor industry make the requirement for mechanical transmission of some type a necessity, and most
often it includes gear reduction. Gear reducers have been engineered over the years in many forms, complex, simple, low and
high accuracy, low and high efficiency. There are also belt and pulley reducers, clutch systems, and recently more exotic systems
like magnetic couplings. All with the intent of matching the motor speed to the required speed of the load.
The most significant contribution of gear reducers is the multiplication of torque output of the motor, or said in reverse, the
reduction of the load torque requirement by the ratio of the reducer ( minus efficiency losses ). Due to the relatively low cost of
mechanical solutions, gear reduction is the most inexpensive way to gain torque. In high performance systems, a torque increase
comes at a relatively high price if it has to be derived directly from the motor and drive system. This is based on the cost of power
electronics and permanent magnets.
The other major effect of gear reducers is the reduction in reflected inertia of the load. The neat thing here is that the inertia is
reduced by the square of the ratio. So a 10:1 gear reducer will reduce inertia by 100 times. This is a huge advantage especially
when high performance velocity regulation, as in multi-control printing, or precise positioning are required.
The feature of “controllability” comes from a combination of dynamic response in the current and voltage regulation between the
motor and power electronics and the position feedback device. The best way to know what “zone” of performance is required is to
use the parameter “dynamic response” to gauge the behavior of the load. This is an unequivocal measure that all manufacturers
are able to reference for performance. Unfortunately, dynamic response is not always the first parameter on a spec sheet, so it
takes some digging to get to. But over a number of years of doing motion control projects, it is one of the key variables that can
clearly distinguish where an application sits in the “performance continuum”