As a system partner, Rexroth achieves energy-saving goals through a combination of multiple technologies, which complements system functionality while retaining a reliable safety loop (see Figure 1).
It has complete and reliable functions, great energy saving potential and meets high safety standards – this is the goal that Rexroth has set to increase the added value of bending machine equipment (see Figure 2). Based on this goal, Rexroth has introduced the Sytronix hybrid system with a maximum energy saving rate of 60% (depending on the operating mode and duty cycle) and a faster response and higher accuracy than the traditional CNC bending machine hydraulic system.
1. Increasing energy efficiency requirements
There are two major trends in the development of the bending machine market in the next few years.
(1) Energy saving through improved design and reduced energy consumption Today's end users are paying more and more attention to energy efficiency. Especially in the energy-intensive metal forming industry, with a small initial investment, you can achieve immediate returns by reducing energy consumption and equipment operating costs. To this end, Rexroth has proposed a universal 4EE energy efficiency concept and applies it to all aspects of transmission and control. The 4EE energy efficiency concept consists of four pillar concepts: optimized system design, improved component efficiency, energy regeneration and energy on demand. It is used throughout Rexroth's solutions to include hydraulic, electrical and linear products.
Equipment manufacturers and end users can choose from the Rexroth Sytronix hybrid system product line to meet their needs.
(2) Energy saving potential exists in each stage of the equipment life cycle. Taking the prior art as an example, the hydraulic system of a conventional CNC bending machine drives a gear pump with a standard motor through two proportional directional valves on the control valve block. The speed of the hydraulic cylinder is controlled to realize the synchronization of the bending machine skateboard, and the auxiliary functions such as the winding compensation and the clamp are also provided. Although the entire power is not required for partial loads such as low speed and low load, standby and sheet handling, the system still outputs maximum power. From the perspective of Rexroth's 4EE energy efficiency concept, such systems have enormous potential for energy savings and can exert these energy savings without any impact on the functionality and reliability of the system.
2. Rexroth Sytronix Hybrid System FcP Solution - Maximum Energy Saving Rate of 26%
End users have different requirements for equipment power and material handling. The Rexroth Sytronix Hybrid System FcP solution embodies an end-user-oriented design concept with an efficient proportional variable pump for a wide range of applications, from single-step manual feeding to automated continuous production lines for robotic feeding. Equipment manufacturers can choose the right Rexroth Sytronix hybrid system based on the actual needs of the end user.
The Rexroth Sytronix Hybrid System FcP solution is particularly suitable for single-piece production and small batch production with long lead times and long feed times. Customers with this solution need generally have smaller workshops, low levels of automation, and limited investment capabilities. With Rexroth's Sytronix Hybrid System FcP solution, customers can achieve up to 26% energy savings (depending on duty cycle and mode) with a small investment, and the payback period can be up to one year.
Customers can basically use the original bending machine model, just change the design of the hydraulic part, change the pump to A10 variable pump, and use proportional controller and variable frequency motor to achieve immediate reduction. The effect of energy consumption. This solution reduces the energy loss by maintaining the speed and bending force at different stages of work just to the level required. Its energy-saving effect comes from two aspects: one is to control the flow of the pump by selecting the appropriate motor speed; the second is to pre-select the bending force (set the pressure value of the proportional variable pump), and limit the pump by adjusting the swash plate angle. flow. Therefore, the energy loss caused by the oil return overflow under a certain pressure can be reduced to the level required to control the flow rate required for the sliding motion and the corresponding differential pressure across the proportional valve. During standby and sheet handling, the flow can even be shut off to reduce bypass flow losses.
The Rexroth drive module (see Figure 3) simplifies the procurement process and management documentation (including inventory management, etc.) by optimizing manufacturing and reducing components and interfaces while reducing failure rates and improving equipment quality and reliability. For the user, the Rexroth drive module is more convenient to install, the pipe work is small when assembling, the number of interfaces is small, and it is not easy to make mistakes.
3. Rexroth Bending Machine S ytronix Hybrid System SvP7000 - the highest energy saving rate can reach 57%
The uniquely designed Rexroth S ytronix hybrid system SvP7000 (see Figure 4) can be used not only for injection molding machines, but also for bending machine systems. The system consists of two servo pumps and a control valve block with safety function. The hydraulic pump used is a four-quadrant closed axial piston pump. The bender slides are synchronized by pump control, eliminating the need for proportional valves, further simplifying the hydraulic system, but still requiring some on-off valves related to system safety functions and operating modes. In addition, a complete range of compact solutions including press brake cylinders and fill valves are included. Since there is no fundamental design change (especially the shape and size of the frame) of the traditional CNC bending machine in terms of concept and mechanical structure, the influence of the changes involved in the new design in terms of the size and operating principle of the hydraulic cylinder Smaller.
The Sytronix Hybrid System SvP7000 can be adjusted to the actual speed required by the system, changing between the maximum speed and zero speed, so that the maximum energy saving effect can be achieved according to the actual working conditions. Under normal circumstances, the system will not be at full load for most of the time, so it can discover more energy saving potential than the traditional CNC bending machine drive scheme.
This system is especially suitable for users of bending machines with large equipment, high degree of automation, mass production, high proportion of non-full load conditions and high operating costs. Other general end users can also get huge benefits from energy savings, but the return on investment cycle may be longer.
In addition, the Sytronix Hybrid System SvP7000 incorporates Rexroth's long-standing experience in hydraulic technology and electrical drive and control technology. Communication is easily achieved through a variety of commonly used bus systems or simple analog commands. This system is open to all automation levels.
The safety function of the SvP7000 remains as part of the system in the control block consisting of the switching valve. The design concept is close to the traditional CNC bending machine and can be applied to the original organic type with a few modifications.
4. China's safety requirements standards conform to international trends
Today, domestic equipment manufacturers are also beginning to enter foreign markets, including those that require CE and UL certification, and the requirements for equipment certification and regulatory understanding are also increasing.
The bending machine will have a huge impact during the molding process, so the regulations and standards for ensuring personnel safety are higher. If manufacturers lack a clear understanding and appropriate solutions, their market expansion at home and abroad will be constrained.
As Rexroth's solutions for traditional CNC bending machines are certified by the German TUEV Nord, they comply with European safety standards. Therefore, when the equipment manufacturer using this solution performs the safety certification of the whole machine, the hydraulic part can be exempted from inspection. Due to rigorous attitude and strict safety considerations, Rexroth's professional technicians will also provide any necessary information and assistance at any time during the production process of the equipment integration manufacturer to participate in all cross-links.
As the world's leading specialist in drive and control technology, Bosch Rexroth is committed to the needs of the local market, leveraging its extensive industry experience and advanced technology to continuously develop products and solutions that provide the best value for money for Chinese customers. .
Dongguan Best Instrument Technology Co., Ltd , https://www.best-tester.com