The procedure of drive sizing is described step by step Each step starts with an overview slide Afterwards, additional information is given

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1 User Manual 1

2 The procedure of drive sizing is described step by step Each step starts with an overview slide Afterwards, additional information is given 2

3 Content Page/Slice General Information 6 SytronixSize 6 Name of Software 6 Update SytronixSize 7 Help and FAQ 7 Navigation in Software 7 Start Program 8 Defaults 9 Preferred types 9 Languages 10 Addresses 10 Dimension Units 10 Other Settings 11 File Handling 12 - Difference between project and single file 13 - Open files 13 - Copy files 13 - Save files 13 3

4 Content Start Drive Sizing 14 From Home Screen 14 From Project Management Screen 15 Application Selection 16 Sample application 17 Motion Profile Data 18 Difference between Simplified, Phased and completed profile 18 Variable flow rate, constant pressure simplified profile 19 Variable Flow rate, constant pressure phased profile 21 Variable Flow rate, variable pressure completed profile 23 Transfer data in completed profile and export data 25 Import profiles and measurements 25 Phase transitions 26 Performance of phase transitions 26 Slope of phase transition 26 Usage of double pump 27 Variable displacement pump: Vg min and Vg max 29 Controllers for variable displacement pumps 29 4

5 Content 5 Mechanical Data 30 Criteria for pump selection 32 Red coloured pumps 32 Default for Coupling 33 Direct coupling 33 Drive Selection 34 Search Drives 34 Security factors 36 Defaults 37 On the selection of this drive, only preferred types have been taken into account 37 First line of drive selection list 37 Search criteria of Software 38 Colour of drive-motor combinations in the selection list 39 Column Set in selection list 39 Abbreviations 40 Which drive-motor combination should I prefer? 42 No drive-motor combination is found 42 Details Selected Set 43 Pressure of working points in pressure-flow rate diagram 44 is higher than maximum pressure of cycle DC-bus values 44 Balance of Energy

6 General Information SytronixSize SytronixSize is a license free software from Bosch Rexroth to size variable-speed pump drives The user will be able to choose the right components (pump, motor, drive) for its hydraulic application due to data of machine cycle This software is intended for use of sales representatives of Bosch Rexroth and distributors to support generating offers Name of Software E.g. SytronixSize 02 V Name of the Software 2 No. of Version (new versions in case of new functions, applications ) 3 V = Released Version; T = Test Version 4 No. of Release (new releases in case of removed bugs, smaller changes) 6

7 General Information Update SytronixSize If activated in defaults, software automatically looks for updates after starting Click on Update in the navigation bar to look for updates Help and FAQ Available in the navigation bar Navigation in Software While drive sizing it is only possible to navigate with the buttons Back and Next From home screen or project management screen it is also possible to use the navigation bar on the left side 7

8 Start Program Download SytronixSize ia/de/01_product_infos/system_loesungen/sytronix/index.jsp Extract ZIP-file in your own computer drive Start program without installation with start.exe (Recommended!) Or Install the software with setup.exe and start program from desktop or windows top menu 8

9 Defaults Preferred Types Activate use preferred types for drive sizing for a faster drive search and more explicit results Edit list of preferred motor types regulators!!!important!!! Only Preferred Types are used for drive sizing! 9

10 Defaults Languages Select between German, English, Chinese and French Addresses It is possible to enter optional customer and ordering addresses and additional information for the project Are included in the print out file Print options Choose what to print Dimension Units Choose between the imperial and metric system 10

11 Defaults Other Settings Activate and deactivate Security checks Additional motor data in table for search results Check for automatic updates on startup Enter maximum count of search results to display 11

12 File Handling Folienübersch rift 12

13 File Handling 13

14 File Handling Difference between project and single file Single file: includes one drive file extension:.dsa Project file: includes several axis file extension:.dpl Save files Save single file: Select the axis you want to copy from project list Press button Save as Drive Enter name for axis and safe it Save project file: Click on project button Press button Save Open files Go to Project Management screen Click on Project button To open Project: Click on Open To open Drive: Load Drive... Copy files Save file Open it in new project 14

15 Start Drive Sizing From Home Screen Click on Drive Sizing 15

16 Start Drive Sizing From Project Management Screen 16

17 Application Selection 17

18 Application Selection Sample Applications Trimming press, injection moulding machine or machine tool applications can be chosen If one of them is selected, a typical motion profile is pre-insert in the motion profile screen 18

19 Motion Profile Data Difference between simplified, phased and completed profile Simplified Profile Phased Profile Completed Profile Enter profile fast and simple Divided in motion-, pressure build-up- and pressure hold-phases Enter every single step of phase Accuracy Less accurate More accurate Most accurate Reference Value Phase Transition End value of previous phase Performance of phase transition can be chosen Time for phase transition is added on phase time Time for phase transition is set from program and cannot be changed Zero Performance of phase transition can be chosen Time is included in phase time Can be entered and changed End value of previous phase Can be entered and changed 19

20 Motion Profile Data Variable Flow Rate, Constant Pressure Simplified Profile 20

21 Motion Profile Data Variable Flow Rate, Constant Pressure Simplified Profile 21

22 Motion Profile Data Variable Flow Rate, Variable Pressure Phased Profile 22

23 Motion Profile Data Variable Flow Rate, Variable Pressure Phased Profile 23

24 Motion Profile Data Variable Flow Rate, Variable Pressure Completed Profile 24

25 Motion Profile Data Variable Flow Rate, Variable Pressure Completed Profile 25

26 Motion Profile Data Transfer data in completed profile and export data Transfer in completed profile: Use Transfer button in simple or phased profile Export data: Only from completed profile possible From other profiles: Transfer first Export data with Export button Import profiles and measurements Import profiles: Go to Completed profile Import data with Import button Import measurements:open and copy your data into the Import file (columns: t [s], p [bar], Q [l/min]), which you will find in the examples Start drive sizing Go to Completed profile Use the Import button Select edited file Switch between different profiles, projects and files 26

27 Motion Profile Data Phase Transitions A phase transition is the time a system needs to change from one value (pressure or flow rate) to another The length of phase transition depends on the hydraulic circuit, the Sytronix-system, etc. Performance of phase transitions Depends on application and required cycle As guideline: High (SvP) Advanced (DFEn, SvP) Basic (FcP) Slope of phase transition The faster the phase transition (steeper slope), the higher the needed torque and the shorter the cycle lasts The slower the phase transition (flatter slope), the lower the needed torque and the longer the cycle lasts 27

28 Motion Profile Data Usage of double pump (2 Opportunities) Opportunity 1: using a fixed displacement pump In the motion profile, enter the normal values for pressure and flow rate of all phases, where you will use the maximum displacement (both pumps) For phases with smaller displacement (one pump), you have to change the pressure and flow values by a reduction factor Example with two pumps of same size: (0,5 is the reduction factor in this case) While half of the displacement is required you need the double speed for the same flow Q / 0,5 (causes a double rpm for this phase) you have half of the torque for the same pressure p * 0,5 (causes half of the torque for this phase) Use a PGF/PGH or A10FZO with the purposed sum of displacement Add an additional coupling to adjust the inertia to the value of double pump J_coupling = J_doublepump J_pumpfromdatabase 28

29 Motion Profile Data Opportunity 2: using variable displacement pump Use setting Vg max for phases in which both pumps are used Use the setting Vg min for phases, only one pump is used In the mechanical data screen, set Vg max to displacement you will have with both pumps (V_doublepump = setting Vg max * V_A10VZO) Use a A10VZO with the purposed sum of displacement. Add an additional coupling to adjust the inertia to the value of double pump (J_coupling = J_doublepump J_A10VZO) Important advise: This is just a simulation of the different displacements, you will not have the exact efficiency of pump! 29

30 Motion Profile Data Variable displacement pump: Vg min and Vg max For variable displacement pumps with two-point-control electric (EZ) you have two different settings of displacement Vg max is the setting with the bigger displacement. Possible setting: 0,5 1,0 * Vgeo Vg min is the setting with the smaller displacement. Possible setting: 0,2 0,5 * Vgeo Controllers for variable displacement pumps Only the EZ (two point control, electric) is available For other available controllers see RE

31 Mechanical Data 31

32 Mechanical Data 2.1 Choose pump from list (click on it) 2.2 Reasons why pumps have been rejected: Maximum speed resulting from motion profile is greater than maximum speed of pump 2.2 Click on Apply 32

33 Mechanical Data Criteria for pump selection All displayed pumps are qualified for the motion profile, which was entered It is favourable to select a small pump, which uses a high rotational speed, to reduce the needed torque Sound level has to be considered For FcP (asynchronous motor) select a pump, so that the speed will not be higher than 2500 rpm because of reduced torque in field-weakening area Red coloured pumps Pumps would operate above maximum speed Usability has to be checked by Product Management of Bosch Rexroth 33

34 Mechanical Data Default for coupling For internal gear pumps there will be used a typical value of a known combination with MSK-motors For other pumps there will be used a default value For a different coupling enter value of inertia Direct coupling When direct coupling is possible with chosen elements, you can check the direct coupling box (line below pump type) Otherwise: The usability of coupling has always to be double checked for each combination of motor and pump! 34

35 Drive Selection Search Drives 35

36 Drive Selection Search Drives 36

37 Drive Selection Security factors Security factor for effective/maximum torque equal 1: The continuous torque of the motor is at least equal or higher than the required effective/maximum torque of application Only recommended for use, if machine cycle is known very well! Security factor for effective/maximum torque higher than 1: The continuous torque of the motor is at least higher than the required effective/maximum torque of application Security factors more than 1 are used, if there are unknown conditions in application Security factor for effective/maximum torque lower than 1: The continuous torque of the motor can be lower than the required effective/maximum torque of application Attention! Security factors less than 1 are only used to see the next smaller motors but the application will not work in reality There are no security factors included in the software! The software calculates the required torques, forces, speeds etc. according to the physical laws 37

38 Drive Selection Defaults Click on Defaults to set filter values for drive search to chosen ones in Defaults Preferred types On the selection of this drive, only preferred types have been taken into account A list of preferred types of motors and drives is set as default for search It consists of products, which are preferred to be used in Sytronix-Systems The use of preferred types could be deactivated in Defaults First line of drive selection list This is a dummy combination to show details without a result in drive search Use this line for sizing a third party motor, which is not included in database For this case, insert an additional coupling with inertia of third party motor 38

39 Drive Selection Search criteria of Software Effective torque at average speed has to be smaller or equal than the continuous torque of motor All working points of the application have to be smaller or equal than the maximum torque Is a working point required for more than the allowed time of maximum torque, this working point has to be smaller or equal than the intermittent torque Is there a succession of motion phases, which takes longer than the time tmax and the required torques are higher than the intermittent torque, this motor will be rejected The load torque of the application has to be smaller or equal than 2/3 of M0 When the whole cycle time of motion profile is smaller or equal than 600s and when there is a sequence in the motion profile, where the average speed is smaller or equal than n0 and the time is longer than tmax, the torque in this sequence has to be smaller or equal than Mkb0 When the whole cycle time of the motion profile is higher than 600 s and when there is a sequence in the motion profile, where the average speed is smaller or equal than n0 and the time is longer than tmax, the torque in this sequence has to be smaller or equal than Md0 39

40 Drive Selection Colour of drive-motor combinations in the selection list Orange: These combinations have a warning message, which can be seen in the details and in the print out Contact responsible branch (e.g. plastics) for support/ to check usability Red: These combinations include working points outside the allowed area (M > Mmax caused by high rotations per minute) They are displayed to show critical working points for smaller combinations Attention! Such combinations will not work in reality except these working points are acceleration or deceleration points Column Set in selection list For SvP-systems are completed sets available Matching combinations are named in the column Set Supported electrical combination are marked in the column Set with an asterisk * 40

41 Drive Selection Abbreviation UF M_Cont [%] UF M_Max [%] M0 Description Usage factor of continuous torque Usage factor of maximum torque Continuous torque (is available in continuous operations and depends on rotations per minute and on overtemperature of motor) Mkb ED Mmax JExt/JM J PWM SB tmmax Md0 Intermittent torque (is available for relative power on time ED and depends on rotations per minute and on overtemperature of motor) Relative power on time for short time operation torque Maximum torque (is available for the time tmmax and depends on rotations per minute) Relation of the inertia of the load to the inertia of the motor Inertia of motor Pulse width modulation Value of overload ability of drive motor combination Time, maximum torque Mmax is available Available continuous torque, if the rotations per minute are less than n0 for continuous operations 41

42 Mkb0 n0 PRS PDC nmmax Drive Selection Available intermittent torque if the rotations per minute are less than n0 for continuous operations Below this value of rotations per minute, the intermittent torque and the continuous torque are reduced, if it is sustained for continuous operations Intermittent power (is available for the relative power on time ED and depends on rotations per minute) Continuous power (is available in continuous operations and depends on rotations per minute) Maximum rotations per minute where Mmax is available Mnmax Nmax tacc Status Maximum available torque at point of maximum rotations per minute Maximum of the rotations per minute for a certain torque (is not the absolute maximum of the motor) Time the motor needs to accelerate to Nmax Shows the current status values (Vorl. means preliminary) 42

43 Drive Selection Which drive-motor combination should I prefer? Depends on application and requirements Relating to costs, always the smallest drive and motor should be chosen Helpful are the factors UF_M_Cont and UF_M_Max, which show the usage rate If the exact cycle of application is unknown, the drive should be sized with security factors, especially referring the M_Cont curve For SvP are sets available No drive-motor combination is found Is the maximum required torque within the range of products? Try to set a lower acceleration/deceleration (phase transitions) Try to use a smaller pump to reduce the inertia of the load Is the maximum required speed within the range of the products? Try to use a bigger pump to reduce the maximum speed Is it possible to reduce critical values in the motion profile? High flow rate at high pressure often causes problems to find combinations Try to increase phases with low flow rates and pressure 43

44 Drive Selection Details - Selected Set 44

45 Drive Selection Pressure of working points in pressure-flow rate diagram is higher than maximum pressure of cycle Pressure of working points is calculated out of the torque The torque of working points consists of the needed torque for pressure holding and the needed torque for acceleration/deceleration DC-bus values Software calculates power at DC-bus from torque and speed by taking into account considerations of motor and inverter efficiency and the direction of torque Difference to values of power in power-speed diagram (they do not contain efficiencies) The continuous power is the average value from the whole DC-bus power sequence The maximum power is the absolute maximum of the whole DC-bus power sequence The continuous braking power is the average value from the negative DC-bus power sequence The maximum braking power is the absolute maximum of the negative DC-bus power sequence The maximum braking energy is the area below the continuous braking power 45

46 Drive Selection Balance of Energy 46

47 Drive Selection Balance of Energy Background Calculations 1. Selection of pump constant and variable displacement pump is chosen based on motion profile and chosen power frequency With the maximum flow rate the minimum pump flow is calculated Therewith the pump is chosen 2. Selection of motor Power of each operating point is calculated based on motion profile and pump data With the greatest value of the power, the motor is selected 3. Calculation of the power values of each operating point to primary side Utilization is calculated for each operating point Calculation of the primary side power value Average power is calculated 47

48 Drive Selection 4. Calculation of energy costs Calculation based on average net power, hours of work per day, days of work per year and costs per kwh calculated for KP, DFE and Sytronix 5. Comparison of costs Costs are compared Calculation of savings 48