BC Hydro 9-13-2010x - PQ Systems Ltd.

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5 Νοε 2013 (πριν από 3 χρόνια και 9 μήνες)

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Exlar Corporation

Energy Efficient Electric
Actuation

Exlar Corporation


The World’s leading
manufacturer of Industrial
Grade Linear Actuators.


Provider of true Electro
-
Mechanical alternatives to
Pneumatics & Hydraulics


Broad product line of Linear
and Rotary Actuators


Installed base of over
50,000 actuators


Global Support

Achieve and Maintain Market Leadership Position


Industrial Grade Electric Actuation Focus


Business Model that provides solutions for our
Customers’ Specific Needs


Worldwide Support


Quality Assurance


Focus on Target Industries and Growth Markets


Provide a broad standard product line from which to
develop customer solutions


New Product Development


Continuous Cost Reduction


Intellectual Property Protection



Focus on Quality


An Environment of Continuous Improvement


Management involvement/review


Field failure root
-
cause analysis and corrective action


Non
-
conformance root cause analysis and corrective action


Process improvement teams


Document/Record control


Employee training


Design control


Process control & qualification


Inspection/Test


Performance measurement


Customer & employee feedback


Internal Audits


Supplier Management

Agency Approvals



ISO 9001
-
2008


ATEX


CE


UL


CSA


FAA


Audited and certified by multiple customers
including US Military branches, Tier 1 Automotive
Suppliers and Medical Customers requiring FDA
approval of their equipment



Global Support

Industries Served

Automotive

Packaging

Food &
Beverage

Forestry

Industrial

Automation

Process

Control

Test &
Simulation

Military and
Aerospace

Focus on Target Markets

Energy/Process Control


Defense


Test, Simulation, & Entertainment


Life Sciences


Mobile Equipment

Industrial Automation

Food Processing & Packaging

Automotive

Construction Materials

Steady

Growth

Recovering

By focusing on target markets, Exlar is able to leverage our technology

and application expertise to provide ideal solutions exactly suited to our

customers needs

Energy/Process Control


Modulating Valve Control


Damper Control


Turbine Control


Wind Turbines Blade Pitch
Control


Production of Metals


Production of Chemicals


Formulation


Pipeline


Power Generation


Energy/Process Customers

Defense


Munitions handling


Weapons positioning


Magazine control


Valve control


Hatch opening/closing


Turret control


Gun/camera mount

Defense Customers

Test, Simulation, & Entertainment


Lifelike Motion


Product Testing


Animatronics


Quality Assurance


Simulation


Entertainment

Test, Simulations, & Entertainment Customers

Life Sciences


Patient Positioning


Dispensing


Fluid Pressurization


Rehabilitation


Sport Medicine


‘Robotic’ Surgery


Mobility


Assists & Lifts


Life Sciences Customers

Mobile Equipment


Steering


Brakes


Lifts


Dumping Systems


Door/gate Operators

Mobile Equipment Customers

Industrial Automation


Forming


Material Handling


Molding


Winding


Filling


Fastening


Packaging

Industrial Automation

Food Processing & Packaging



Volumetric Filling



Dispensing



Packaging



Cheese Processing



Meat Injection



Butchering



Meat Forming & Slicing



Pizza Assembly



Container Filling



Slicing

Food Processing and Packaging Customers

General Manufacturing/Automotive



Pressing



Fastening



Assembly



Welding



Robotics



Material handling



Lifts



Clamping



Boring

General Manufacturing/Automotive Customers

Construction Materials


Sawmill


Lumber & Plywood
Processing


Textiles


Insulation/Roofing


Construction Materials Customers

“Traditional” Actuator with ball
screw converter and “bolt on”
Servo Motor

Exlar’s
INVERTED ROLLER SCREW
design



Planetary Roller Screw Driven


T
-
lam Brushless Servo Motor


Compact


Hydraulic form factor


Light weight


Longer Life than other EMAs


Robust

Original Actuator Development Strategy

Technology Goal


Provide electromechanical actuation solutions with
precise motion capabilities with the form factor,
size and weight of hydraulics


Rotary to Linear Converter

Ball Screw Technology



Short service life



Low shock resistance



Unsuitable for “inverted”

design



Tricky disassembly


Nearly impossible to clean

and
regrease



Rotational speeds limited

to
~ 1,000 rpm


Noisy



Rotary to Linear Converter

Roller screw Technology


Up to 15x the travel life of a
(equivalent size) ball screw


High Shock Resistance


Allows “inverted” design


Easy disassembly


Easy cleaning and re
-
greasing


Rotational speeds up to
6,000 rpm


Quiet operation

Superior to ball screws

Ball Screw

Roller Screw

Load Points ( )

More Contact Area

No Conflicting Friction

No Ballistic Effect

No Recirculation Required

T
-
LAM Segmented Lamination Brushless Motor Technology

Features:


Slot fill of 90% (50% for traditionally
wound motors)


Minimized end
-
turns


Epoxy encapsulation for efficient heat
removal


Class 180(H) insulation


Up to 460 Vrms operation


Windings are readily optimized to
specific application


Highest possible power density


Neodymium Iron Boron magnets for high
magnetic strength


Low cogging torque through magnet
geometry


Magnets bonded directly to roller screw
cylinder for highest possible torsional
rigidity


Integrated Motor Linear Actuators

Highlights:


Inverted Planetary Roller Screw


T
-
Lam brushless servo motor


Operation on any Servo Drive


Modified or customized to meet

Customer needs






GS Linear Actuators

Rotary Actuators

Highlights:


T
-
Lam brushless servo motor


Servo grade planetary gears


Operation on any Servo Drive


Modified or customized to meet

Customer needs






SLM & SLG

Explosion Proof Actuators

Highlights
:


CSA rated Class I, Div. 1, Groups B, C, and D

Rotary

Linear

EL & ER

EL100


ATEX approved

Tritex

Integrated Electronics Actuators

Highlights:


Up to 4,000 lbs (17.79 KN) continuous force,
7,900 lbs (35 KN) peak


Includes embedded servo drive


Roller Screw Actuated


Position/Force Control

I Series Universal Actuators


Rollerscrew

Actuated


Accepts any “bolt on” motor


Roller Screw Actuated


Up to 4,000 lbs (17.79KN) Force


Velocity up to 37.5 in/sec (.95 m/sec)

Highlights
:



FT Series High Force Universal Actuators

Highlights:


Roller Screw Actuated


Strokes to 10ft (3.0m)
length


40,000lbf (180kN) Force


Velocity up to 60in/sec
(1.5 m/sec)

Rotary and Linear Features:


Eliminates: external servo amplifier,
cables, electrical cabinet


Easy programming


Very compact


Extremely robust to shock/vibration


Use of roller screw or planetary gears
for extremely long life


Controlled by discrete I/O or serial
communications

Tritex

Integrated Electronics Actuators

EXLAR Product Line

GS20

GS30

GS40

GS60

SLM060

SLM090

SLM115

FT35

FT60

FT80

GS50

SLG060

SLG090

SLG115

I20

I30

I40


TLM20 TLM30 Tritex II

RTM/G 060 RTM/G 090 RTM/G115

RM/LM3 RM/LM4 RM/LM5

SLM142

SLM180

SV2008/15 SV2035/SV4024 SV4075

Why
Exlar
?

Energy Efficiency


↓ Energy consumption of
Production Equipment



↑ Efficiency of Industrial
Processes



↑ Efficiency in Power
Generation Process



↓ CO
2

Emissions

Production Equipment

Oil/Air Actuator replacement


Pneumatic Actuators are only 10%
-

25% efficient


Hydraulic Actuators roughly 65%
-
80%
efficient


Both sized with 50% to 100% “safety
factor”


Both require large compressors or
pumps


Both difficult to maintain

Source: Compressed Air Challenge.
Assusmes

$0.05

per kWh, constant operation, 100 psig, and a typical

compressor.

Typical Air
Compressor Usage

Production Equipment

Oil/Air Actuator replacement


Exlar

Actuators are 85% efficient


Servo technology only requires 10%
-
25% sizing safety factor


Actuators controlled by small
independent amplifiers


Precisely controlled, no wasted motion


Uses minimum amount of energy to
complete motion.


Electric vs. Pneumatic


Sample Application Details:


Horizontal Point to Point move


400 mm (15.75 in) stroke


15 kg (33 lb) load


1 m/s max speed


10 m/s^2 max
accel
/
decel


30 cycles per minute


50% duty cycle

Electric vs. Pneumatic

Pneumatic Solution:


50 mm dia. Cylinder required


Air supply required through entire
move


Kinetic energy goes into
dampers/shock absorbers at ends


24,000 m^3 of compressed air at
6 bar, per year


3000


annual energy costs!!



Electric vs. Pneumatic

Electric Solution:


Continuous Power <100 Watts


Regen

energy can be put back on
DC bus at ends


Actuator only pulls power when
needed


Draws minimum power required to
complete the commanded move


< 100


annual energy costs!!



Electric vs. Pneumatic

Summary:


Large initial cost difference
becomes insignificant over 1
-
2
years


Energy consumption/costs
dominate life cycle costs




This information apply to a calculation done by Company
NTI AG
-

LinMot

&
MagSpring

in Switzerland and was published in the magazine “motion & drives” in 2009
.

Industrial Process Benchmarking


80% of control loops demonstrate excessive

process variability


30% due to control valve performance

The undesirable
behavior of
control valves
in the biggest
contributor to
poor loop
performance


Control Valve

Performance

Tuning

Design

Increases

Variability

20%

30%

30%

20%

Source:


Entech

---
Results

from audits of over 5000

loops in Pulp & Paper Mills

Loops

Binder Board Control


Rock
-
Tenn Paperboard
-
Aurora Mill


Basis Weight Valve on a
Beloit Paper Machine


Accurately controls water
content of binder board


Fisher Ball Valve/
Tritex

II
Rotary


R2G090


Installation is expected to
save thousands of energy
dollars per year due to less
drying time of binder board.


Example of headbox spraying water/pulp on screen

Paperboard Control

Neumann Company


Paperboard Basis Weight


Controls slurry spread on
wire


Feedback from dry end of
machine


Response time is critical


SR31 and SV


Paid for in 1 month

Industrial Turbine Pilot Valve

Canfor Pulp Mill


ASEA Steam
Turbine


Replaced hydraulic
actuator on spool
(Pilot) valve


GSX20/SV


Before

After

Fulcrum Rack Drive Retrofits


The operating cylinder,
pilot, and related
linkage devices are
replaced with a single
Exlar actuator mounted
to a cover plate
installed over the
former hydraulic
operator footprint


Before

After

Power Turbine Service Ltd.


“The actuator is in service it is giving us excellent
stability at speed/load control. While with the
hydraulic we can see fluctuations of 0.1
-
0.2Hz at
generator synchronizing speed we now can control
as narrow as 0.02Hz.

Carlo Nobus Power Turbine Services



Damper Applications


Low
-
NOx (nitrous oxide) burners
need accurate air flow


Reliant Energy Windbox Dampers


44 GSM30’s and SV positioners


4 or 8 ‘corners’ retrofitted


Replaced failing electric RACO
actuators


Damper Applications include:


Windbox dampers


Burner Tilts


Hot air dampers


EdeA Energy
-

Europe


Power Industry


Scrubber damper


Production and distribution of steam, electricity, water,
air and gasses on behalf of the DSM and Sabic


3 GSX40’s will regulate the gas
-
outfeed by positioning
the dampers



Questions?

THANK YOU!