Motion control solution lowers energy consumption in hydraulic molding machines by 30%

08-Nov-10
Moog has unveiled a new pump system at K-2010 that will provide injection molding and blow molding machine builders with a motion control solution that can lower energy consumption in hydraulic machines by 30% or more when compared to traditional approaches and ultimately reduce the total cost of ownership. The complete integrated system called the Moog Speed Controlled Pump System is based on three of Moog's proven products. The system includes a fixed displacement Radial Piston Pump (RKP), a Maximum Dynamic Brushless Servo Motor and a Modular Multi-axis Programmable Motion Control Servodrive (MSD). The unique functionality of this system is the ability to allow users to change the speed of the motor and pump thereby controlling the fluid flow. The resulting machine is more energy efficient and this new system also provides optimized system performance and easier setup for operators. The primary advantage of the Speed Controlled Pump System is the impressive energy savings that is not typically available with the traditional hydraulic technology used in injection molding and blow molding machines. The overall energy efficiency of Moog Speed Controlled Pump (SCP System) is significantly higher than traditional hydraulic systems for a few key reasons. In a normal hydraulic application, the machine experiences partial, medium and full loads as part of the cycles. In tests conducted by Moog with customers, the efficiency of the SCP with a medium load has reached 20-30% higher when compared to the conventional system. If a machine is running without load, or in a standby mode, energy consumption can be 90% less. Under full load conditions, the performance compared to the traditional system is nearly identical. This offers the user the opportunity to optimize the energy efficiency based on the needs of the application, but without loosing performance. "We see significant potential for market penetration with the new system, as machine builders place more emphasis on total cost of ownership and energy savings as a design criterion," said Sheriff El Henaoui, Moog's marketing manager for Europe. "Our calculations and tests show that the total cost of ownership will be lower than traditional hydraulic technologies and the payback period for the initial investment is also shorter for operators due to the impressive energy savings," continued El Henaoui. The Moog Speed Controlled Pump System development is based on variable speed pump design. While the basic technology behind these pumps is not new, the rising price of energy encouraged the development of the new approach. In addition to energy savings and lower cost of ownership, the new Moog system is compact, enabling the overall footprint of the machine to be reduced. Moog's system, with its modular, integrated design, can be easily integrated into machines. It is also quieter for operating personnel with acoustic emissions up to 9 dB(A) lower in partial load conditions. A key part of the system is the MSD Servo Drive which provides intelligent pressure and flow functionality due to unique control algorithms. Depending on pressure and flow demand values, the MSD controls the speed setting requirements for torque and speed. Pump and servo motor characteristics are stored in the servo drive, creating an "intelligent" system that can communicate with external systems over a fieldbus. The design of the Speed Controlled Pump System is flexible to meet unique customer requirements. If required, the pump can feature a dual displacement pump design, capable of intelligently switching from one to the other displacement. This functionality enables the motor to run more efficiently and save energy. During the pressure-holding phase in an injection molding machine, low flow but high pressure is required, making real energy savings of up to 90% possible. Moog has also developed a system with a submerged installation of the motor and pump inside of a hydraulic tank to reduce the size of the motor and take advantage of the heat dissipating fluid in tank. The Speed Controlled Pump System not only has advantages over the traditional hydraulic systems but it also delivers lower maintenance and investment costs when compared to an all-electric motion system. Electromechanical devices on an all-electric machine are generally built into the framework of the machinery. When a machine needs to be rebuilt as part of routine maintenance, the electro-mechanical infrastructure needs to be totally disassembled and re-assembled. The cost of rebuilding a hydraulic machine with Moog's Speed Control Pump System is much lower because it is an integrated modular unit with all of the parts easily accessible for maintenance and upgrades.
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