Terugleveren remenergie - Energieefficiëntie op machineniveau
Bremsenergie managen IE Motoren EVENT 2015
Holger Barth Michael Koch GmbH Sales
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Fabian Hofmann Michael Koch GmbH Prokurist Holger Barth Michael Koch GmbH Sales Hans Zijlstra Elincom electronics B.V. Owner 15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Why do I talk about DC-link?
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Electric Drives Brake-Chopper Frequency-Inverter Frequenzumrichter
DC-Link Capacitor
M
L
3
Mains
Motor Load Last Umrichterendstufe
Rectifier 15.09.2015
www.bremsenergie.de
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IE Motoren EVENT 2015
Results when using features of DC-Link
increasing the energy efficiency
increasing the performance of a machine
supporting the grid
extending the service live of the drive controller by avoiding ups and downs in the DC-link
avoiding power peaks by supporting the power supply from the mains
handling break energy without creating heat
Perfectly suitable for different needs
15.09.2015
www.bremsenergie.de
6
IE Motoren EVENT 2015
How? Storing break energy in a Dynamic Energy Storage that is connected to the DC-link -> Intelligent and active expansion of the DC-link capacity -> efficient way to deal with regen energy (instead of using a break resistor)
15.09.2015
www.bremsenergie.de
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IE Motoren EVENT 2015
Frequenzumrichter
M
L
3
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Energy-flow in controlled electric drives Drive: Main Drive control system Motor as current-consumer Gearing mechanism Machine
Brake: Drive control system Motor as generator Gearing mechanism Machine
15.09.2015
www.bremsenergie.de
9
IE Motoren EVENT 2015
Succesfully implemented in machines Bending machine: result: improved dynamic and increased energy efficiency
Screen printing machine: result: drive failures are avoided, clock rate is being improved, energy efficiency is increased
Press feeding robot: result: improved clock rate, energy savings up to 24% in comparison to the old system
Portioning machine: result: number of cuts were raised by 47%
15.09.2015
www.bremsenergie.de
10
Bremsenergie managen IE Motoren EVENT 2015
Handling electric braking-energy Solutions without re-utilisation from brake-energy: Let drive coast freely
Brake resistor (convert electric energy into heat) Internal resistor in drive If applicable, additional external brake resistor
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
DC-Link coupling Frequenzumrichter
Advantages
M
L
M
L
3
cheap Frequenzumrichter
3
Disadvantages
The concept is limited through the pre-loading circuit of the frequency inverter The concept is limited through the permissible sub-harmonic-load The concept is an improvement, but rarely the solution Rectifiers may be loaded asymmetrically
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Regenerative feedback (Active Front End) Advantages Energy is directly fed back into the mains (Storage not required)
Disadvantages Time-consuming / expensive Concept does not work during mains-power-failure Danger due to EMC problems
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Passive DC-Link expansion Advantages
Frequenzumrichter
cheap M
L
3
Disadvantages Possible saturation of the capacitors Concept is limited through the pre-loading-circuit of the frequency inverter Concept is limited through the permissible sub-harmonic-load
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Rectifying alternating current
15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Active DC-Link expansion (DES) Frequenzumrichter
M
L
3
Devices can be connected in parallel Expandable storage Good exploitation of the capacitor No limititations due to the preloading circuit of the frequency inverter Relieving load on the DC-Link capacitor No limitations due to the permissible sub-harmonic-load 15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Concept of operation Automatic mode with brake-chopper detection
UDC [V] 950
Safety shut off
~ 700
Brems-Chopper switch-on-threshold Brems-Chopper switch-off-threshold Energy storage
660 UZR = 620 V Peak rectification 3 x 400 V~
566
Feedback in the Drive control system
~
Zeit 15.09.2015
www.bremsenergie.de
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Bremsenergie managen IE Motoren EVENT 2015
Oscillogram – charging and discharging of energy Legende: Capacitor voltage DC-Link voltage Current (inverse)
15.09.2015
www.bremsenergie.de
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2015 Bremsenergie managen IE Motoren EVENT
- Relieve the load on the DC-Link capacitor 900 800 700
Spannung [V]
600
500 Uz BC
400
Uz DES 300 200 100 0 0
0,02
0,04
0,06
0,08
0,1
0,12
0,14
0,16
0,18
0,2
Time [s]
www.bremsenergie.de
19
IE Motoren EVENT 2015
Further features of smart DC-link expansion Short-term UPS to compensate voltage fluctuation or power failures:
Avoids damage of the machine by supporting it with energy to reach a defined stopping position
Identifies irregularities of the voltage supply and supports the drive immediately when needed
Helps to safe time, ressources, money and trouble
Perfect solution for contries with weak and instable power supply
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Relieve load on the break-chopper's IGBTs → Higher Performance and longer service life Relieve load on the internal brake-resistor
