ENERGY SAVING: NOT ONLY A MATTER OF NEED BUT ALSO OF ETHICS

The decision to invest in energy saving systems is quite a heavy financial commitment but also ensures a considerable competitive edge for the future, enabling companies to significantly reduce the environmental impact of production and running costs.  

 

Which energy saving solutions are best suited to the various applications on the market? What advantages are to be obtained by investing in this type of technology? With this brief introduction to the systems developed by Interfluid, we intend to provide answers to these questions along with a guide to choosing the most suitable energy saving system, not only with regard to the needs of OEM and control units manufacturers, but also for end-users of presses operating in the plastic materials, die-casting, molding and metal working industries.

Considering the stringent measures that the EU is proposing to save energy, the question should no longer be “whether” to reduce our environmental impact, but “when” and “how” to do it. The Energy Efficiency Directive establishes a 20% energy efficiency target by 2020, adding a further 10% energy efficiency target for 2030.

So, in order to increase the efficiency of manufacturing processes, companies are more and more often in search of solutions for optimizing the productivity of their machinery, with systems that are able to deliver a better performance, a minor impact on energy consumption and, consequently, also on costs, so as to operate whenever possible in a way that is more green.  

ADVANTAGES

How can production processes be improved at relatively low costs? One solution consists in the adoption of systems which are able to regulate the speed and pressure in the hydraulic circuits employed on the grounds of individual production requirements. This type of intervention enables numerous advantages: in fact, the regulation of the flow rate capacity in a hydraulic circuit enables a reduced heat production, a lower oil consumption and the use of smaller heat exchangers.

If we regulate the speed of the motor and therefore vary the speed and capacity of the system, the circuit in use may be simplified significantly. There is also a considerable advantage in terms of power unit maintenance: the use of machinery with fewer valves and components allows us to have fewer pieces in need of replacement in the case of normal mechanical wear or unexpected breakdowns. It is therefore possible to stock fewer spare parts in the warehouse, with a consequential improvement and simplification of the logistics organization.  

Last but not least, a reduction in the average operating speed of the pump leads to a significant reduction in oil temperature and, consequently, a reduction in costs and energy required to cool the hydraulic system.  

So, do energy saving measures represent a cost? They certainly do, but only in the implementation phase.

The energy saving reached thaks to Piisma allows to amortize the investment in one year.

The possibility to utilize a simpler circuit also enables a reduction in the amount of oil required to stoke the hydraulic system itself: the hydraulic oil lasts longer, thanks to a minor heat conveyance, to the advantage of both the periodic maintenance of the power unit – subject to a lower risk of mechanical wear – and environmental pollution, since the production scraps in need of disposal become consequently less impacting. Moreover, the energy savings of up to 80% achieved by our systems cuts energy costs and allows for CO2emissions to be reduced

Finally, the use of internal gear pumps and helical pumps allows for a reduction of hydraulic unit-related noise emissions of up to 20 dB, with a positive impact also on the life quality of our operators, in compliance with the increasingly strict restrictions imposed by workplace sustainability regulations.  

The resulting machine is therefore able to operate with greater energy efficiency and higher production quality, thereby guaranteeing a lower per unit production cost.

INTERFLUID ENERGY SAVING SYSTEMS

Brushless synchronous motors and asynchronous motors controlled by inverters may be combined with various types of pumps to create proper energy saving systems.  

These systems are among those primarily responsible for energy absorption in industrial machinery – a factor that may however be considerably improved – thus preventing the dispersion of energy and supplying it to the system only when actually required.

Energy saving systems developed by Interfluid.

According to the types of motor and pump employed, we can identify systems for variable P/Q control closed loop, systems for P/Q control open loop  and systems for variable flow and constant pressure.

In the installation phase, our systems are adequately regulated and fine tuned by specialized technicians so they do not require any further intervention on the part of the operator.  

SYSTEM FOR VARIABLE P/Q CONTROL CLOSED LOOP

The portfolio of solutions for closed loop and P/Q control offered by Interfluid includes PIISMA, a servo pump made up of a synchronous motor with inverter coupled with an internal gear pump, available in 2 or 4 dials, and ECOSERVO Kawasaki, also consisting of a synchronous motor with inverter but coupled to a bidirectional piston pump.

Characteristics and advantages

  • High dynamics
  • High torque even when rotor is not operating
  • Considerable energy savings
  • Single axis control

Main applications

  • Plastic and rubber injection presses
  • Hydraulic presses
  • Vertical presses for metal sheet stamping
  • Die-casting presses

SYSTEM FOR P/Q CONTROL OPEN LOOP

Systems for P/Q control open loop  are composed of an asynchronous motor not driven by an inverter, which uses a variable displacement and servoproportional control piston pump.

Caratteristiche e vantaggi

  • Medium-high response dynamics
  • High powers
  • Simultaneous control of more than one axis
  • High powers available

Main applications

  • Hydraulic presses
  • Wood processing presses
  • Recycling pressing
  • Retrofit injection presses for plastic

SYSTEM FOR VARIABLE FLOW AND COSTANT PRESSURE

Interfluid is currently developing solutions with asynchronous motors and inverters which utilize vane pumpsinternal gear pumps and helical gear pumps; the latter two are very performing in reducing noise emissions.

Characteristics and advantages

  • Medium-low response dynamics
  • Low noise emissions

Main applications

  • Power unit
  • Machine tools
  • Die-casting presses
  • Wood processing presses
  • Retrofit injection presses for plastic and rubber

In the installation phase, our systems are adequately regulated and fine tuned by specialized technicians so they do not require any further intervention on the part of the operator.

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