Using variable speed pump drives in metallurgy and recycling
Photo: Bosch Rexroth

Completed modernization projects confirm that Sytronix variable speed drives reduce energy consumption by devices by up to 80%.

Initiatives aimed at climate protection, such as the European Union’s Green Deal, are exerting increasing pressure on machinery manufacturers. They are expected to assist their customers in achieving climate goals by offering highly energy-efficient hydraulic solutions. Bosch Rexroth’s Sytronix variable speed drives reduce electricity consumption and lower its costs by up to 80% compared to traditional technologies, while intelligent electrohydraulic systems indirectly reduce CO2 emissions to a similar extent. The company achieved these results through modernization projects.

Intelligent interaction between the inverter, electric motor, and hydraulic pump with constant or variable geometric volume enables significant energy savings. With a load-responsive control system, the Bosch Rexroth electrohydraulic solution, optimized for energy efficiency, always operates at the optimal working point. When power is not needed, the system automatically switches to standby mode.

Thanks to their high power density, Sytronix variable speed drives can be used to modernize various systems, from machine tools to machinery for the wood and paper industry, metallurgical machinery, presses, foundry machines, and injection molding machines.

Replacing traditional hydraulic drives with Sytronix drives and comparing both solutions reveals that energy consumption can be reduced by up to 80%, depending on the type of system. Energy costs and greenhouse gas emissions during electricity generation are also significantly reduced. These conclusions stem from evaluations of projects where traditional drives were replaced with appropriate Sytronix drives.

During many optimization projects, hydraulic system specialists at Bosch Rexroth compared initial solutions, including cooling systems, with the new Sytronix solution in terms of energy consumption. For example, the modernization of a plastic press reduced energy consumption by 87,000 kWh per year, or 78%, compared to the previous year. This resulted in annual operational cost savings of €15,390.

In the German energy mix in 2018, every kilowatt-hour of electricity produced resulted in the emission of 0.489 kg of various greenhouse gases. This value can be expressed in standard form, converted to CO2 equivalents. As a result of the Sytronix-driven modernization of the plastic press, 43.3 tons less CO2 equivalent were emitted in a year.

Even greater savings can be achieved with more complex systems, such as reheating furnaces. Here, variable speed drives can reduce emissions by 421 tons of CO2 equivalent and lower operational costs by €152,000, or approximately 80%. Power consumption by a foundry machine also decreased by the same amount. In this case, Bosch Rexroth enabled the operator to reduce greenhouse gas emissions by 30 tons of CO2 equivalent per year and lower electricity costs by €11,000.

Using Sytronix pump drives in metallurgy and recycling

Sytronix variable speed pump drives designed for the recycling industry significantly increase the energy efficiency of channel balers, scrap shears, and scrap compacting presses. The modular, standardized Sytronix system, consisting of an electric drive unit, inverter, and pump with constant or variable geometric volume, is combined with other standard components, creating an efficient and cost-effective device. With various control values, such as motor speed and tilt angle, Sytronix achieves optimal performance in every cycle, reducing energy consumption, operating costs, and CO2 emissions.

Unlike traditional hydraulic systems with constant input power, Sytronix variable speed drives operate on an “energy on demand” principle. Energy consumption depends on the current demand in each cycle, particularly in pressure-holding mode. Energy efficiency is further enhanced by the optimization of switching, especially when combined with Bosch Rexroth distributors with optimized flow. In such cases, pressure loss has been minimized through simulation in the design process and 3D sand core printing in production.

Meanwhile, variable axial piston pumps allow energy consumption to be reduced by controlling flow through the tilt angle, while the electric motor operates at an optimal speed range.

Furthermore, Sytronix drives enable downsizing of equipment, reducing costs. Thanks to their overload resistance, smaller pumps can handle power spikes caused by sudden increases in flow by increasing speed.

The modular design of the Sytronix drive opens up new possibilities for machine manufacturers. International companies can benefit from Bosch Rexroth’s global services and machine standardization for different markets. Sytronix drives can be used anywhere in the world regardless of power frequency.

Enhanced opportunities for networked electrohydraulic system designers in the metallurgical sector

In cases of variable energy demand or when installing single-axis solutions, designers are increasingly using Bosch Rexroth’s Sytronix variable speed pump drives. These drives can reduce hydraulic system energy consumption by up to 80%, depending on the proportional load size. They also enable manufacturers to significantly increase system flexibility as functions previously executed hydromechanically are now controlled by software.

Energy efficiency has a significant impact on the operational costs of devices, which is why customers in the metallurgical sector place great importance on it. Variable speed pump drives adjust energy consumption to current demand, directly reducing power usage in already installed systems.

Sytronix variable speed pump drives from Bosch Rexroth also offer new opportunities for equipment design. Their controller software already integrates hydraulic functions for power units and axis controllers. As compact axes, these drives directly power cylinders. In multi-axis solutions, axes are synchronized via the Multi-Ethernet connector, which supports popular real-time Ethernet communication protocols. Users can change motion sequences with a single click.

Designers can create hydraulic transmissions in combination with variable axial piston pumps. This reduces the size of the drive system, energy consumption, and space requirements. Intelligently networked Sytronix drive systems can also provide higher performance ranges within master-slave solutions.

Specialized system in under 30 minutes

Bosch Rexroth can simplify the dimensioning, configuration, and ordering processes of Sytronix intelligent products using a closed toolchain. The SytronixSize dimensioning tool intuitively guides users through the digital design process. It combines data from individual hydraulic and electrical components based on models. Bosch Rexroth’s expertise, transformed into software, optimizes the solution.

The software automatically checks the thermal load capacity of components and displays energy savings and noise emission data. Designers then define the properties of all drive system components. Ultimately, users receive a list of parts (verified for completeness), documentation, and 3D-CAD data.

Users can access Bosch Rexroth’s online store with a single click. The store selects a configured, personalized Sytronix solution and provides the registered customer with a price and expected delivery date. Thanks to the closed toolchain, Bosch Rexroth can reduce the time required to digitally design a custom, application-optimized Sytronix solution to less than 30 minutes.